CN1713308A - 电介质瓷器组合物和其制造方法以及层叠陶瓷部件 - Google Patents

电介质瓷器组合物和其制造方法以及层叠陶瓷部件 Download PDF

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CN1713308A
CN1713308A CNA2005100790434A CN200510079043A CN1713308A CN 1713308 A CN1713308 A CN 1713308A CN A2005100790434 A CNA2005100790434 A CN A2005100790434A CN 200510079043 A CN200510079043 A CN 200510079043A CN 1713308 A CN1713308 A CN 1713308A
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dielectric
composition
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porcelain composition
glass
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梅本卓史
野野上宽
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三洋电机株式会社
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Abstract

本发明提供一种电介质瓷器组合物,是将含有用组成式a·Li2O-b·(CaO1-X-SrOX)-c·R2O3-d·TiO2 (其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的电介质成分和玻璃成分的混合物进行烧成而得到的电介质瓷器组合物,其特征在于,电介质成分是通过对原料进行煅烧而调制的;作为玻璃成分,至少含有铋系玻璃;在烧成后的X射线衍射中,含有稀土元素的第2相的峰强度相对于具有钙钛矿构造的主相即第1相的峰强度的比(第2相/第1相)为20%以下。

Description

电介质瓷器组合物和其制造方法以及层叠陶瓷部件
技术领域
本发明涉及用于层叠陶瓷部件等的电介质瓷器组合物(dielectricceramic composition)和其制造方法以及使用该组合物的层叠陶瓷部件。
背景技术
近年来,随着电子部件的小型化、薄型化,对层叠陶瓷部件的需要急速增加。作为层叠陶瓷部件的代表性例子,可以举出使用可以与Ag等导电材料同时烧成的低温烧成材料(LTCC)并在各层上形成了感应器或电容器回路的部件。作为用于该层叠陶瓷部件的低温烧成材料,通常使用将氧化铝等陶瓷填充剂和玻璃混合而成的电介质瓷器组合物。不过,像这样的组合物其介电常数为10以下,较低,其介电特性在应用于LC过滤器方面不够充分。
为了适用于LC过滤器,要求介电常数高且介质损失少同时温度系数τf接近于0。作为满足这些特性的电介质瓷器组合物,在特开平5-211007号公报中,公开了具有Li2O-CaO-Sm2O3-TiO2的组成的电介质瓷器组合物。
另外,在特开2003-146742号公报中,公开了在(Li0.5(Nd,Sm)0.5TiO3)-(Ca1-XNd2X/3)TiO3中含有ZnO-B2O3-SiO2系玻璃粉和Li2O-B2O3-SiO2系玻璃粉当中的任何一种玻璃粉3~15重量%的电介质瓷器组合物。
不过,在特开平5-211007号公报中的公开的电介质瓷器组合物是在1300℃左右的高温下被烧成,因而以该组成是难以适用于在900℃左右的低温下烧成的层叠陶瓷部件。
另外,对于在特开2003-146742号公报中公开的电介质瓷器组合物,为了改善在900℃左右的低温下的烧结性,必须增加玻璃的添加量。如果增加玻璃的添加量,则存在介质特性劣化的问题。
另外,在Jpn.J.Appl.Phys.Vol.32(1993)pp.4319-4322中,报告了对于CaO-Li2O-Ln2O3-TiO2陶瓷,当Ln是Tb时,除了析出作为主相的钙钛矿相之外,作为第2相还析出Ln2Ti2O7。该第2相成为Qf值减小的原因。这里公开的陶瓷不含有玻璃成分,也不是可以在低温下烧成的电介质瓷器组合物。
发明内容
本发明的目的在于,提供一种可以在1000℃的低温下烧结且介质特性优异的电介质瓷器组合物及其制造方法以及使用该组合物的层叠陶瓷部件。
本发明提供将含有用组成式a·Li2O-b·(CaO1-X-SrOX)-c·R2O3-d·TiO2(其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的电介质成分和玻璃成分的混合物烧成而得到的电介质瓷器组合物,其特征在于,电介质成分是通过将原料煅烧而调制;作为玻璃成分,至少含有铋系玻璃;在烧成后的X射线衍射中,含有稀土元素的第2相的峰强度相对于具有钙钛矿构造的主相即第1相的峰强度的比(第2相/第1相)为20%以下。
按照本发明,通过使在烧成后的X射线衍射中的峰强度比(第2相/第1相)为20%以下,可以制成介质特性优异的电介质瓷器组合物。
在本发明中,电介质成分是通过将原料煅烧而调制的。作为煅烧的温度,优选为1000℃以上,进一步优选在1100~1300℃的范围内。另外,作为煅烧时间,优选为2~10小时,对原料混合方法没有特别限制,但可以举出使用醇并基于球磨机的湿式混合方法等。优选在煅烧之后,再次采用使用醇并基于球磨机的湿式粉碎法实施粉碎处理。
作为本发明中的玻璃成分,至少含有铋系玻璃。作为铋系玻璃,优选使用Bi2O3含量为30~80重量%的玻璃。
在本发明的电介质瓷器组合物中,优选玻璃成分含量为1~10重量%。当玻璃成分的量少时,有时难以进行低温烧成,当玻璃成分的量多时,因为电介质成分的量相对较少,所以介质特性降低。
本发明中的电介质成分是用组成式a·Li2O-b·(CaO1-x-SrOx)-c·R2O3-d·TiO2(其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的成分。组成式中的R表示稀土元素,在稀土元素中包括La和Y。本发明中的电介质成分只要是用上述组成式表示的成分,就没有特别限制,例如可以优选使用在特开平5-211007号公报中所述的成分。
本发明的电介质瓷器组合物中的第2相含有稀土元素,优选进一步含有Ti。作为在第2相中含有的稀土元素,可以举例为Sm和/或Nd。
本发明的电介质瓷器组合物可以通过将上述电介质成分和玻璃成分混合并对该混合物进行烧成而得到。作为烧成温度,优选为1000℃以下,进一步优选在850~950℃的范围内。
本发明的制造方法是将含有用组成式a·Li2O-b·(CaO1-X-SrOX)-c·R2O3-d·TiO2(其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的电介质成分和玻璃成分的混合物烧成而制造电介质瓷器组合物的方法,其特征在于,包括:在1000℃以上的温度下将电介质成分的原料煅烧以调制电介质成分的工序;混合至少含有铋系玻璃的玻璃成分和电介质成分并在1000℃以下的温度下烧成该混合物的工序。
根据本发明的制造方法,可以以较大的收缩率烧结电介质瓷器组合物,并可以改善烧结性,同时可以制造具有高介电常数的电介质瓷器组合物。
本发明的层叠陶瓷部件,其特征在于,具有将由上述本发明的电介质瓷器组合物或通过上述本发明的制造方法制造的电介质瓷器组合物构成的电介质层、和导体层层叠的构造。
图3是表示本发明的层叠陶瓷部件的立体图,图4是分解立体图。如图3和图4所示,在电介质层1的上面形成有导体层2。另外,也有在电介质层1上形成有通孔3(via holl)的电介质层。通过层叠多块这样的电介质层,构成层叠陶瓷部件。
根据本发明,可以制成即便在1000℃以下的低温下也可以烧结且介质特性优异的电介质瓷器组合物。
附图说明
图1是表示本发明的实施例1的X射线衍射图案的图。
图2是表示比较例1的X射线衍射图案的图。
图3是表示本发明的层叠陶瓷部件的一个例子的立体图。
图4是表示本发明的层叠陶瓷部件的一个例子的分解立体图。
具体实施方式
下面,根据实施例对本发明进行详细说明,但本发明并不限于以下的实施例,只要不更改其宗旨,则可以适当更改后实施。
[实施例1]称量Li2CO3、CaCO3、SrCO3、Sm2O3和TiO2并使其为Li2CO3:9mol%、CaO:15mol、SrO:1mol%、Sm2O3:12mol%、以及TiO2:63mol%,然后进行混合。用球磨机并采用醇,利用湿式混合方法将该混合物湿式混合24小时。然后,在1200℃下煅烧5小时。再次用球磨机并采用醇,利用湿式粉碎法将煅烧后的粉末粉碎处理24小时。
粉碎处理后,在得到的煅烧物中添加玻璃A(硼硅酸玻璃、日本电气硝子公司制“GA-12”,软化点:约560℃)5重量%、玻璃B(铋系玻璃,Bi2O3:75重量%,B2O3:15重量%,ZnO:10重量%,软化点:约470℃)1重量%,以醇为溶剂使用球磨机进行20小时的混合处理。将处理后的料浆干燥之后,添加聚乙烯醇等有机粘合剂进行造粒,分级之后,施加2000kg/cm2的压力,成形为规定的尺寸和形状。对该成型品,在进行500℃、2小时的脱粘合剂处理之后,在900℃下进行5小时的烧成。
[比较例1]在实施例1中,采用湿式混合方法将原料混合之后,除了使煅烧条件为900℃、5小时代替1200℃、5小时之外,和实施例1一样,制作电介质瓷器组合物的成型品。
(X射线衍射图案的测定)对实施例1和比较例1的试样进行X射线衍射图案的测定。图1是实施例1的X射线衍射图案,图2是比较例1的X射线衍射图案。
如图1和图2所示,在实施例1和比较例1中,在33.1度附近看到了作为主相的钙钛矿相的尖峰。另外,对于实施例1和比较例1的任何试样,都可以在31.4度附近看到第2相的峰。以下,有时将该第2相称为Sm-Ti-O相。在实施例1中,第2相相对于作为主相的第1相的峰强度比为11%,在比较例中为34%。
(基于TEM的第2相的分析)通过TEM(透过型电子显微镜)分析了第2相。由于在反射电子像中相对发白的部分被认为是主相以外的相,所以采用EDS分析对该部分进行分析,结果发现有检测出Ti、Sm、Ca和O的部分,以及检测出Ti、Sm、Bi、Ca、和O的部分。前部分的存在多于后部分。另外,采用限制视野衍射像(SAD)分析晶体系,结果是任何部分都与单斜晶(monoclinic)的Ca1.38Sm3.1Ti0.52O7.07的峰的位置一致。因此,认为是与此相当或类似的结晶构造。
(收缩率和介电常数ε的测定)对实施例1和比较例1的试样,使用电介质共振法(Hakki-Coleman法)测定介电常数。另外,从烧成试样前后的尺寸求出烧成时的收缩率。收缩率和介电常数ε如表1所示。
表1
由表1可知,在使煅烧温度为1200℃的实施例1中,收缩率和介电常数都升高,且烧结性得到改善,同时介电常数提高。
[实施例2和3]和实施例1一样,使用通过煅烧而制作的电介质成分,除了使用表2所示的玻璃作为玻璃成分之外,与实施例1一样制作试样。另外,玻璃C是铋系玻璃,是由Bi2O3:60重量%,B2O3:25重量%,ZnO:5重量%以及SiO2:10重量%的组成构成,软化点约为540℃。
与实施例1一样,测定X射线衍射图案中的峰强度比(Sm-Ti-O相/主相),同时测定收缩率和介电常数ε。测定结果如表2所示。
表2
由表2可知,在实施例2和3的试样中,未检测出作为第2相的Sm-Ti-O相的峰。另外,在实施例2和3中,由与表1所示的比较例1的比较可知,收缩率和介电常数都比比较例1高,并在烧结性得到改善的同时介电常数提高。
[实施例4]如上所述,本发明的层叠陶瓷部件是通过将由本发明的电介质瓷器组合物所形成的电介质层和在该电介质层的表面上形成的导体层构成的电介质生片层叠,并烧成该层叠物而获得。例如,在与上述实施例一样得到的电介质成分中添加玻璃成分和根据需要添加其他添加剂,并用球磨机对其进行混合,在得到的混合物中添加聚乙烯醇缩丁醛(PVB)系粘合剂,添加后用球磨机对其进行混合而制作料浆。接着,使用刮刀(doctor blade)装置将得到的料浆成形为片厚50~100μm的片状。将得到的薄片切断成需要的大小,并将Ag膏印刷成为需要的图案,制成电介质生片。如图3和图4所示,层叠该电介质生片8~20层,压接之后,在400℃下实施脱粘合剂处理,接着在900℃下保持2小时进行烧成,可以制成层叠陶瓷部件。

Claims (9)

1.一种电介质瓷器组合物,是将含有用组成式a·Li2O-b·(CaO1-x-SrOx)-c·R2O3-d·TiO2(其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的电介质成分和玻璃成分的混合物烧成而得到的电介质瓷器组合物,其特征在于,所述电介质成分是通过将原料煅烧而调制;作为所述玻璃成分,至少含有铋系玻璃;在烧成后的X射线衍射中,含有稀土元素的第2相的峰强度相对于具有钙钛矿构造的主相即第1相的峰强度的比(第2相/第1相)为20%以下。
2.如权利要求1所述的电介质瓷器组合物,其特征在于,所述第2相进一步含有Ti。
3.如权利要求1所述的电介质瓷器组合物,其特征在于,所述第2相中含有的稀土元素为Sm和/或Nd。
4.如权利要求1所述的电介质瓷器组合物,其特征在于,所述玻璃成分含量为1~10重量%。
5.如权利要求1所述的电介质瓷器组合物,其特征在于,所述煅烧的温度为1000℃以上。
6.如权利要求1所述的电介质瓷器组合物,其特征在于,所述烧成的温度为1000℃以下。
7.一种电介质瓷器组合物的制造方法,是将含有用组成式a·Li2O-b·(CaO1-x-SrOx)-c·R2O3-d·TiO2(其中,x满足0≤x<1,R是从稀土元素中选择的至少一种,a、b、c和d满足0≤a≤20mol%、0≤b≤45mol%、0<c≤20mol%、40≤d≤80mol%、以及a+b+c+d=100mol%。)表示的电介质成分和玻璃成分的混合物烧成而制造电介质瓷器组合物的方法,其特征在于,包括:在1000℃以上的温度下将所述电介质成分的原料煅烧以调制所述电介质成分的工序;混合至少含有铋系玻璃的玻璃成分和电介质成分并在1000℃以下的温度下烧成该混合物的工序。
8.一种层叠陶瓷部件,其特征在于,具有层叠了由权利要求1所述的电介质瓷器组合物构成的电介质层和导体层的构造。
9.一种层叠陶瓷部件,其特征在于,具有层叠了由利用权利要求7所述的方法制造的电介质瓷器组合物构成的电介质层和导体层的构造。
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