CN1776844A - 电介体陶瓷组合物和电子部件 - Google Patents

电介体陶瓷组合物和电子部件 Download PDF

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CN1776844A
CN1776844A CNA2005101136160A CN200510113616A CN1776844A CN 1776844 A CN1776844 A CN 1776844A CN A2005101136160 A CNA2005101136160 A CN A2005101136160A CN 200510113616 A CN200510113616 A CN 200510113616A CN 1776844 A CN1776844 A CN 1776844A
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accessory ingredient
mole
dielectric
mentioned
ceramic composition
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CN1776844B (zh
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伊东和重
佐藤阳
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TDK Corp
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TDK Corp
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Abstract

本发明提供一种确保高介电常数和良好的温度特性、并且改善了TC偏压特性的多层陶瓷电容器。通过本发明，提供一种多层陶瓷电容器1，其具有由电介体陶瓷组合物构成的电介体层2和内部电极层3交替层压而成的电容器元件主体10，上述电介体陶瓷组合物是含有多个具有壳24a的电介体粒子2a的电介体陶瓷组合物，上述壳24a是在基本上由主成分构成的芯22a周围、副成分扩散至主成分而形成的；以显示平均粒径值的电介体粒子为对象时，上述壳24a的最大厚度t1和最小厚度t2之差(t1－t2)被控制为上述电介体粒子半径R的6～60％。

Description

电介体陶瓷组合物和电子部件
技术领域
本发明涉及一种例如用作多层陶瓷电容器的电介体层等的电介体陶瓷组合物，以及将此电介体陶瓷组合物用作电介体层的多层陶瓷电容器等电子部件。
背景技术
一直以来，为了确保高介电常数和良好的温度特性，认为有效方法为用电介体粒子形成作为电子部件之一例的多层陶瓷电容器的电介体层，此电介体粒子(晶粒)具有芯-壳结构，该芯-壳结构为在副成分不扩散的、基本上由钛酸钡构成的芯表面存在有副成分扩散至作为主成分的钛酸钡的区域形成的壳的结构。对于使晶粒中具有芯-壳结构的技术，一直以来提出了很多方案。
例如，专利文献1(特开平10-308321号公报)中提出了下述技术方案，向作为主成分的钛酸钡中加入作为副成分的Mg，通过调整烧结温度和烧结时间，将Mg从结晶表面向内部扩散的深度(即壳的厚度)控制在一定的范围内。
然而，采用专利文献1的技术，由于构成电介体层的电介体粒子的粒径基本一致，且在这些电介体粒子中存在的壳厚度一致，因此静电电容的温度特性良好，但是介电常数有变小的趋势。
因此，为了解决这个问题，在专利文献2(特开2004-111951号公报)中公开了下述技术方案，即，使壳的厚度因电介体粒子的粒径而异。另外，在专利文献2中记载了以下内容，即，存在的电介体粒子可以不必将芯表面用壳完全覆盖，也可以存在芯部分剥露的电介体粒子。
关于含有芯部分剥露的电介体粒子，在专利文献3(特开2001-313225号公报)中也有所公开。专利文献3中记载了以下内容，即，含有芯部分剥露的电介体粒子与用壳将芯全部覆盖的电介体粒子相比，能够减小壳的整体容积，提高陶瓷烧结体的介电常数。达到了以下的作用效果，即，在不降低静电电容的情况下，由于能够尽可能增加电介体层的厚度，因此可以兼顾薄层大容量化的要求和与其相对立的可靠性、确保寿命的要求。
然而在专利文献2、3中记载了以下内容，即，如果含有芯部分剥露的电介体粒子，则TC偏压特性恶化。其理由虽然还不清楚，但是认为是由于对作为强电介体的芯施加电压的缘故。如果TC偏压特性恶化，则在实际使用时会发生静电电容降低，使产品价值显著降低。
发明内容
本发明的目的在于提供例如用作多层陶瓷电容器的电介体层等的电介体陶瓷组合物，该电介体陶瓷组合物能够确保高介电常数和良好的温度特性，而且改善了TC偏压特性；并且提供将此电介体陶瓷组合物作为电介体层使用的多层陶瓷电容器等电子部件。
本发明人等对电介体粒子(晶粒)的芯-壳构造进行刻苦研究时，发现制成电介体粒子中的壳厚度不一致、壳无部分缺损、芯未部分外露、虽然芯被壳完全覆盖但是壳的厚度不一致的电介体粒子时，能够确保高介电常数和良好的温度特性，而且TC偏压特性有所改善，从而完成本发明。
即，通过本发明，提供一种电介体陶瓷组合物，其具有多个电介体粒子，此电介体粒子在基本上由主成分构成的芯周围具有副成分扩散至主成分形成的壳；其特征在于，以表示平均粒径值的电介体粒子为对象时，上述壳的最大厚度t1和最小厚度t2之差(t1-t2)控制为上述电介体粒子半径R的6～60％。
上述主成分优选含有钛酸钡。
上述副成分优选含有Mg的氧化物、稀土类元素的氧化物及碱土类金属元素(除Mg以外)的氧化物。
上述副成分优选含有：
从MgO、CaO、BaO及SrO中选择的至少一种的第1副成分；
氧化硅的第2副成分；
从V2O5、MoO3及WO3中选择的至少一种的第3副成分；
R1的氧化物(R1为从Sc、Er、Tm、Yb及Lu中选择的至少一种)的第4副成分；
CaZrO3或者是CaO+ZrO2的第5副成分；
R2的氧化物(R2为从Y、Dy、Ho、Tb、Gd及Eu中选择的至少一种)的第6副成分；
MnO的第7副成分；
相对于100摩尔的上述主成分，各副成分的比例为：
第1副成分：0.1～3摩尔；
第2副成分：2～10摩尔；
第3副成分：0.01～0.5摩尔；
第4副成分：0.5～7摩尔(第4副成分的摩尔数为R1单独时的比例)；
第5副成分：0＜第5副成分≤5摩尔；
第6副成分：9摩尔以下(第6副成分的摩尔数为R2单独时的比例)
第7副成分：0.5摩尔以下。
上述副成分优选含有：
第1副成分为AE的氧化物(AE为从Mg、Ca、Ba及Sr中选择的至少一种)；
第2副成分为R的氧化物(R为从Y、Dy、Tm、Ho及Er中选择的至少一种)；
第3副成分为MxSiO3(M为从Ba、Ca、Sr、Li及B中选择的至少一种；当M＝Ba时x＝1；当M＝Ca时，x＝1；当M＝Sr时，x＝1；当M＝Li时，x＝2；当M＝B时，x＝2/3)；
第4副成分为MnO；
第5副成分为从V2O5、MoO3及WO3中选择的至少一种；
第6副成分为CaZrO3或者是CaO+ZrO2。
相对于100摩尔的上述主成分，各副成分的比例为：
第1副成分：0～0.1摩尔(不包括0摩尔和0.1摩尔)；
第2副成分：1～7摩尔(不包括1摩尔和7摩尔)；
第3副成分：2～10摩尔；
第4副成分：0～0.5摩尔(不包括0)；
第5副成分：0.01～0.5摩尔；
第6副成分：0～5摩尔(不包括0和5摩尔)。
本发明所涉及的电子部件，只要是含有电介体层的电子部件即可，没有特殊的限定。例如，具有将电介体层和内部电极层交替层压形成的电容器主体的多层陶瓷电容器。在本发明中，上述电介体层由上述任一种电介体陶瓷组合物构成。作为内部电极层含有的导电材料，没有特别限定，例如Ni或者Ni的合金。
通过本发明，能够提供例如用为多层陶瓷电容器的电介体层的电介体陶瓷组合物，以及将此电介体陶瓷组合物作为电介体层使用的多层陶瓷电容器等电子部件。由于电介体粒子具有芯-壳的结构，即，在基本上由作为主成分的钛酸钡所构成的芯周围，存在副成分扩散至钛酸钡形成的壳，因此确保了高介电常数和良好的温度特性，而且改善了TC偏压特性。
作为本发明涉及的电子部件，没有特殊的限制，可以举出例如多层陶瓷电容器、压电元件、芯片感应器、芯片变阻器、芯片热敏变阻器、芯片电阻及其它表面安装(SMD)芯片型电子部件等。
附图说明
图1为本发明的一种实施方式所涉及的多层陶瓷电容器的简要剖面图。
图2为图1所示的电介体层2的要部放大剖面图。
图3为利用TEM拍摄的相当于壳厚度不一致的本发明实施例(试样4)的晶粒微细结构的照片。
图4为利用TEM拍摄的相当于壳部分缺损、芯剥露的本发明比较例(试样9)的晶粒微细结构的照片。
图5为利用TEM拍摄的相当于壳厚度均匀的本发明比较例(试样8)的晶粒微细结构的照片。
图6示出图3的TEM照片的模式图。
图7示出图4的TEM照片的模式图。
图8示出图5的TEM照片的模式图。
图9为说明实施例中壳最大厚度t1和最小厚度t2之差(t1-t2)的计算方法的概念图。
具体实施方式
本实施方式中，作为电子部件，以图1所示的多层陶瓷电容器1为例进行说明。
多层陶瓷电容器
如图1所示，作为本发明的一个实施方式涉及的电子部件的多层陶瓷电容器1，具有由电介体层2和内部电极层3交替层压而成的电容器元件主体10。在电容器元件主体10的两端，形成与在元件主体10内部交替配置的内部电极层3分别连通的一对外部电极4。层压内部电极层3，使各端面交替露出在电容器元件主体10对向的2端部表面上。一对外部电极4形成在电容器元件主体10的两端，与交替配置的内部电极层3的露出端面相接续，构成电容器电路。
电容器元件主体10的外形、尺寸没有特殊限定，可以根据用途进行适当设定。通常外形大致为长方体，尺寸通常为长(0.4～5.6mm)×宽(0.2～5.0mm)×高(0.2～1.9mm)左右。
电介体层
电介体层2的组成在本发明中没有特殊限定，例如可以由下述电介体陶瓷组合物构成。
本实施方式的电介体陶瓷组合物含有作为主成分的钛酸钡(优选结构式为(BaO)m·TiO2，前式中的摩尔比m为m＝0.990～1.035)。
本实施方式的电介体陶瓷组合物含有上述主成分及副成分。作为副成分，可以举出含有Mg的氧化物、稀土类元素的氧化物和碱土类金属元素(除Mg以外)的氧化物的物质。通过添加副成分，即使在还原气氛下进行烧结也能够得到作为电容器的特性。另外，作为杂质，可以含有0.1重量％以下的C、F、Li、Na、K、P、S、Cl等微量成分。但是，在本发明中，电介体层2的组成不受上述限制。
本实施方式中，作为电介体层2，优选使用以下组成的物质。
作为主成分含有结构式为(BaO)m·TiO2、其中上式中的摩尔比m为m＝0.990～1.035的钛酸钡，作为副成分含有：
从MgO、CaO、BaO及SrO中选择的至少一种作为第1副成分；
氧化硅作为第2副成分；
从V2O5、MoO3及WO3中选择的至少一种作为第3副成分；
R1的氧化物(R1为从Sc、Er、Tm、Yb及Lu中选择的至少一种)作为第4副成分；
CaZrO3或者是CaO+ZrO2作为第5副成分；
R2的氧化物(R2为从Y、Dy、Ho、Tb、Gd及Eu中选择的至少一种)作为第6副成分；
MnO作为第7副成分。
当将钛酸钡换算成为(BaO)0.999～1.035·TiO2时，相对于100摩尔的(BaO)0.990～1.035·TiO2，各副成分的比例为：
第1副成分：0.1～3摩尔；
第2副成分：2～10摩尔；
第3副成分：0.01～0.5摩尔；
第4副成分：0.5～7摩尔(第4副成分的摩尔数为R1单独时的比例)；
第5副成分：0＜第5副成分≤5摩尔；
第6副成分：9摩尔以下(第6副成分的摩尔数为R2单独时的比例)；
第7副成分：0.5摩尔以下。
另外，其它组成作为主成分含有用结构式[(BaO)m·TiO2]表示的钛酸钡，其中摩尔比m为m＝0.990～1.035，作为副成分含有：
AE的氧化物(AE为从Mg、Ca、Ba及Sr中选择的至少一种)作为第1副成分；
R的氧化物(R为从Y、Dy、Tm、Ho及Er中选择的至少一种)作为第2副成分；
MxSiO3(M为从Ba、Ca、Sr、Li及B中选择的至少一种；当M＝Ba时x＝1；当M＝Ca时，x＝1；当M＝Sr时，x＝1；当M＝Li时，x＝2；当M＝B时，x＝2/3)作为第3副成分；
MnO作为第4副成分；
从V2O5、MoO3及WO3中选择的至少一种作为第5副成分；
CaZrO3或者是CaO+ZrO2作为第6副成分。
当将钛酸钡换算成为(BaO)0.990～1.035·TiO2时，相对于100摩尔的(BaO)0.990～1.035·TiO2，各副成分的比例为：
第1副成分：0～0.1摩尔(不包括0摩尔和0.1摩尔)；
第2副成分：1～7摩尔(不包括1摩尔和7摩尔)；
第3副成分：2～10摩尔；
第4副成分：0～0.5摩尔(不包括0摩尔)；
第5副成分：0.01～0.5摩尔；
第6副成分：0～5摩尔(不包括0摩尔和5摩尔)。
当具有上述组成时，静电电容的温度特性能够满足EIAJ规定的X8R特性(-55～150℃，ΔC/C＝±15％以内)。
电介体层2的层压数、厚度等诸条件可以根据目的、用途适当地决定。在本实施方式中，电介体层2的厚度优选为7.5μm以下，更优选进行薄层化达到4μm以下。在本实施方式中，即使由此将电介体层2的厚度进行薄层化，也具有电容器1的各种电特性，特别是具有足够的介电常数，TC偏压特性也得到改善。
电介体层的微细结构
如图2所示，电介体层2由多个电介体粒子(晶粒)2a和在相邻的多个电介体粒子2a之间形成的晶界相2b构成。
电介体粒子(晶粒)2a含有芯-壳的结构，即，在基本上由作为主成分的钛酸钡构成的芯22a的周围，具有副成分扩散至钛酸钡中形成的壳(副成分扩散层)24a。
所谓的电介体粒子2a的芯-壳结构是指，作为电介体粒子中心部的芯(核)22a和被覆该芯22a表面的壳(壳)24a所形成的物理性·化学性各异的相的结构。实际上认为，与电介体粒子2a的中心相比，副成分元素更多地扩散至粒子表面，进而形成了壳24a。
并且，以表示平均粒径值的电介体粒子2a为对象时，将上述壳24a的最大厚度t1和最小厚度t2之差(t1-t2)控制为电介体粒子2a的半径(相当于平均粒径一半的数值)R的6～60％，优选为10～40％。在这个范围内，通过形成壳24a，能够确保高介电常数和良好的温度特性，并且能够改善TC偏压特性。
即，本实施方式中，电介体粒子2a中的壳24b的厚度并不均匀，壳24a部分并不缺损，芯22a未部分剥露。另外，只要不影响本发明的目的，也可以少量含有上述粒子。
壳24a的最大厚度t1通常为0.01～0.1μm，优选为0.03～0.05μm，最小厚度t2通常为0.001～0.009μm，优选为0.003～0.007μm。
另外，电介体粒子2a整体的平均粒径D50(单位：μm)是指将电容器元件主体10沿着电介体层2和内部电极层3的层压方向切断，在如图2所示的断面中测定200个以上电介体粒子2a的平均面积，作为圆等效直径算出直径，其1.5倍值即是平均粒径。在本实施方式中，电介体粒子2a整体的平均粒径D50，以电介体层2的厚度为上限，优选为电介体层2厚度的25％以下，更优选为15％以下。
将上述(t1-t2)的值控制在规定范围内的方法没有特殊限定，对其中之一例如后所述。
晶界相2b通常以下述物质为成分：构成电介体材料或者内部电极材料的材质的氧化物，或另外添加的材质的氧化物，以及工序中作为杂质混入的材质的氧化物。
内部电极层
图1所示的内部电极层3由实际上作为电极起作用的贱金属的导电材料构成。作为导电材料使用的贱金属优选Ni或者Ni合金。作为Ni合金优选从Mn、Cr、Co、Al、Ru、Rh、Ta、Re、Os、Ir、Pt及W中选择的一种以上与Ni形成的合金。合金中Ni的含量优选为95重量％以上。另外，Ni或Ni合金中也可以含有0.1重量％以下的P、C、Nb、Fe、Cl、B、Li、Na、K、F、S等各种微量成分。本实施方式中，内部电极层3的厚度优选为不足2μm，更优选进行薄层化达到1.5μm以下。
外部电极
作为如图1所示的外部电极4，通常可以使用Ni、Pd、Ag、Au、Cu、Pt、Rh、Ru、Ir等中的至少一种或者它们的合金。通常使用Cu、Cu合金、Ni或者Ni合金等，Ag、Ag-Pd合金，In-Ga合金等。外部电极4的厚度可以根据用途适当地决定，但通常优选为10～200μm左右。
多层陶瓷电容器的制造方法
接下来，说明本实施方式涉及的多层陶瓷电容器1的制造方法之一例。
(1)在本实施方式中，准备电介体层用浆料和内部电极层用浆料，前者构成用于在烧结后形成图1所示电介体层2的烧结前电介体层；后者构成用于在烧结后形成图1所示内部电极层3的烧结前内部电极层。另外，还要准备外部电极用浆料。
电介体层用浆料是通过混炼电介体原料和有机载体而制成的。
(1-1)本实施方式中使用的电介体原料按照一定比例含有上述构成电介体陶瓷组合物的各种原料。因此，首先要准备作为主成分原料的钛酸钡原料和各种副成分原料。
各原料的添加量可以按照烧结后的上述电介体陶瓷组合物的组成进行决定。
(1-2)在第一种观点中，首先在钛酸钡原料中添加副成分原料的一部分，进行第一预烧结，在钛酸钡原料粒子的表面上形成较薄的壳。
在第一预烧结时添加的副成分原料量(添加量)是控制上述壳24a的最大厚度t1与最小厚度t2之差(ti-t2)的要素之一。在第一预烧结时添加的副成分原料量(添加量)优选为各副成分原料最终添加量的40％以下(不包括0％)，更优选10～30％。在第一预烧结时，副成分的添加量如果过多，则壳厚度会变得均匀，介电常数会降低；过少的话，壳会剥露出，导致TC偏压特性降低。
具体地说，例如相对于100摩尔BaTiO3的最终添加量分别为MgO 0.9摩尔，MnO 0.37摩尔，V2O5 0.1摩尔，(Ba0.6Ca0.4)SiO3 4.5摩尔，Y2O3 3摩尔，Yb2O3 1.75摩尔，CaZrO3 1.5摩尔，在添加上述添加量的30％时，在第一预烧结时添加的副成分原料分别为MgO0.27摩尔，MnO 0.111摩尔，V2O5 0.03摩尔，(Ba0.6Ca0.4)SiO3 1.35摩尔，Y2O3 0.9摩尔，Yb2O3 0.525摩尔，CaZrO3 0.45摩尔。
第一预烧结的保持温度也是控制上述壳24a的最大厚度t1及最小厚度t2之差(t1-t2)的要素之一。第一预烧结的保持温度优选600℃以上，更优选700～900℃。如果此时的预烧结温度较低，则可能无法在钛酸钡原料粒子的表面形成较薄的壳。
第一预烧结的上述保持温度的保持时间优选0.5～10小时，更优选1～4小时。如果此时的预烧结保持时间过短，则无法在钛酸钡原料粒子表面形成较薄的壳；另一方面，如果预烧结保持时间过长，则壳厚度变得均匀，介电常数降低。
第一预烧结的其他条件为，升温速度：50～400℃/小时，特别优选100～300℃/小时；烧结气氛：空气中和氮气中。
在第一预烧结后，在钛酸钡原料粒子表面形成的较薄壳的厚度通常为0.001～0.009μm，优选为0.003～0.007μm。
接下来，在第一预烧结后的钛酸钡原料粒子中添加剩余的副成分原料，通过低温进行第二预烧结形成预烧结粉末。所得到的预烧结粉末的壳厚度不均匀。
在第二预烧结时添加的副成分原料量(添加量)是各副成分原料最终添加量的剩余量。根据上面的例子，在此次预烧结中添加MgO0.63摩尔，MnO 0.259摩尔，V2O5 0.07摩尔，(Ba0.6Ca0.4)SiO3 3.15摩尔，Y2O3 2.1摩尔，Yb2O3 1.225摩尔，CaZrO3 1.05摩尔。
第二预烧结的保持温度也是控制上述壳24a的最大厚度t1及最小厚度t2之差(t1-t2)的要素之一。第二预烧结的保持温度优选800℃以下，更优选400～750℃。如果此时的预烧结温度高，则最终形成的壳24a的厚度不会变得不均匀。
第二预烧结的保持时间优选0.5～10小时，更优选1～4小时。如果此时的预烧结保持时间过短，则壳剥露出、TC偏压降低。另一方面，如果预烧结保持时间过长，则壳的厚度变得均匀、介电常数降低。
第二预烧结的其它条件为，升温速度：50～400℃/小时，特别优选100～300℃/小时；烧结气氛：空气中和氮气中。
(1-3)在第二种观点中，不进行上述第一种观点中进行的第一预烧结，在钛酸钡原料上被覆副成分原料的一部分，由此在钛酸钡原料粒子的表面形成较薄的壳。其后，进行上述第一种观点中的第二预烧结，形成预烧结粉末。所得到的预烧结粉末，和第一种观点相同，壳的厚度不均匀。
在被覆副成分原料的一部分时采用以下方法，使用有机金属等使添加物成为液相，与作为主成分的钛酸钡混合后，进行预烧结。
(1-4)接下来，将得到的预烧结粉末用铝制辊等进行粗粉碎后，根据需要，用球磨机等与纯水等分散介质混合，进而干燥，由此得到电介体原料。
由上述成分构成的电介体原料，也可以使用上述氧化物、它们的混合物、复合氧化物。另外，通过烧结成为上述氧化物、复合氧化物的各种化合物，也可以从碳酸盐、草酸盐、硝酸盐、氢氧化物、有机金属化合物等中进行适当选择并混合。
电介体原料中各化合物的含量可以根据烧结后的上述电介体陶瓷组合物的组成进行决定。
在制成涂料前的状态下，电介体原料的平均粒径优选5μm以下，更优选0.1～1μm左右。
有机载体含有粘合剂和溶剂。作为粘合剂，可以举出例如乙基纤维素、聚乙烯醇缩丁醛、丙烯酸树脂等通常使用的各种粘合剂。溶剂也没有特殊限定，可以使用松油醇、丁基卡必醇、丙酮、甲苯、二甲苯、乙醇等有机溶剂。
电介体层用浆料可以通过混炼电介体原料和在水中溶解有可溶性粘合剂的载体而形成。水溶性粘合剂没有特殊限定，可以使用聚乙烯醇、甲基纤维素、羟乙基纤维素、水溶性丙烯酸树脂、乳胶等。
内部电极层用浆料通过混炼由上述各种导电性金属或合金制成的导电材料或者烧结后成为导电材料的各种氧化物、有机金属化合物、树脂等与上述有机载体而制成。
外部电极用浆料也与内部电极用浆料同样地调制。
各浆料的有机载体含量没有特殊限定，只要为通常的含量即可，例如粘合剂1～5重量％，溶剂10～50重量％。另外，各浆料中根据需要可以含有从各种分散剂、增塑剂、介电体、绝缘体等中选择的添加物。
(2)接下来，利用含有上述电介体原料的电介体层用浆料和内部电极层用浆料，制作烧结前的电介体层和烧结前的内部电极层层压而成的生片，在经过脱粘合剂工序、烧结工序、根据需要进行的退火工序而制成的、由烧结体构成的电容器元件主体10上印刷或者转印、烧结外部电极用浆料，形成外部电极4，制造多层陶瓷电容器1。
特别是由于生片的烧结时间是控制上述壳24a的最大厚度t1与最小厚度t2之差(t1-t2)的要素之一，因此优选适当地进行控制。
本实施方式中优选在1180～1320℃、更优选在1200～1300℃的烧结保持温度下，优选保持0.5～4小时、更优选保持1～2.5小时，由此能够将上述(t1-t2)值控制在适当的范围内。如果烧结保持时间较短，则(t1-t2)值有变大(接近壳部分缺损、芯剥露出的方向)的倾向；如果时间长，则(t1-t2)值有变小(接近壳厚度变得均匀的方向)的倾向。
作为其它烧结条件，升温速度优选50～500℃/小时，更优选100～300℃/小时。降温速度优选50～500℃/小时，更优选200～300℃/小时。烧结气氛优选还原气氛。作为还原气氛中的气氛气体，优选将例如N2和H2的混合气体加湿后使用。烧结气氛中的氧气分压优选6×10-3～10-4Pa。
如上所述，通过本实施方式得到的多层陶瓷电容器1含有介电体层2，此介电体层2含有介电体粒子2a，其具有芯-壳结构，即，在基本上由作为主成分的钛酸钡构成的芯22a的周围，具有副成分扩散至钛酸钡形成的壳24a。因此，确保了高介电常数和良好的温度特性，并且在TC偏压特性得到改善的同时，可靠性也有所改善。
以上，对本发明的实施方式进行了说明，但是本发明并不限定于此，在不超过本发明宗旨的范围内，当然可以采用各种方式进行实施。
例如，上述实施方式中，作为本发明涉及的电子部件，列举了多层陶瓷电容器，但是作为本发明涉及的电子部件，并不限定于多层陶瓷电容器，只要具有由上述组成的电介体陶瓷组合物构成的电介体层，可以为任何电子部件。
以下，基于详细的实施例对本发明进行说明，但是本发明并不限定于此。
实施例1
电介体原料的制备
首先，准备钛酸钡原料和副成分原料。作为钛酸钡原料使用平均粒径0.25μm的BaTiO3(以下称为BT)。作为副成分原料，使用平均粒径0.01～0.1μm的MgO、MnO、V2O5、(Ba0.6Ca0.4)SiO3(以下也称为BCG)、Y2O3、Yb2O3、CaZrO3。BCG是用球磨机将BaCO3、CaCO3和SiO2湿式混合16个小时，干燥后，在1150℃的空气中进行烧结，再使用球磨机进行100个小时的湿式粉碎而得到。CaZrO3是用球磨机对CaCO3和ZrO3进行16个小时的湿式混合，干燥后，在1150℃的空气中进行烧结，再使用球磨机进行24个小时的湿式粉碎而得到。
称量上述原料，使烧结后的组成相对于100摩尔作为主成分的BT分别为：MgO 0.9摩尔，MnO 0.37摩尔，V2O5 0.1摩尔，BCG 4.5摩尔，Y2O3 3摩尔，Yb2O3 1.75摩尔，CaZrO3 1.5摩尔。对于各副成分原料，此处称量的量为最终添加量。
接下来，相对于100摩尔的BT，添加上述副成分原料最终添加量的30％(MgO 0.27摩尔，MnO 0.111摩尔，V2O5 0.03摩尔，BCG1.35摩尔，Y2O3 0.9摩尔，Yb2O3 0.525摩尔，CaZrO3 0.45摩尔)，以水为溶剂，用球磨机进行16个小时的湿式混合，准备第一预烧结前粉体。
之后，将得到的第一预烧结前粉体在700℃、空气中第一预烧结3小时得到第一预烧结粉体。利用电子显微镜观察第一预烧结粉体，能够证实在钛酸钡原料粒子的表面具有较薄的壳(厚度0.003μm)。
向第一预烧结粉体中添加上述副成分原料最终添加量的剩余部分(MgO 0.63摩尔，MnO 0.259摩尔，V2O5 0.07摩尔，BCG 3.15摩尔，Y2O3 2.1摩尔，Yb2O3 1.225摩尔，CaZrO3 1.05摩尔)，以水为溶剂，用球磨机进行16个小时的湿式混合，准备第二预烧结前粉体。
将得到的第二预烧结前粉体，在表1所示的温度下、空气中进行3小时的第二预烧结，得到第二预烧结粉体。用电子显微镜对此第二预烧结粉体进行观察，能够证实在钛酸钡原料粒子的表面形成的壳厚度不均匀。
然后，将第二预烧结粉体用铝制辊进行粉碎，得到最终组成的电介体原料。此电介体原料相对于100摩尔的BT含有MgO 0.9摩尔，MnO 0.37摩尔，V2O5 0.1摩尔，BCG 4.5摩尔，Y2O3 3摩尔，Yb2O31.75摩尔，CaZrO3 1.5摩尔。
各种浆料的制备
接下来，在得到的电介体原料中加入聚乙烯醇缩丁醛树脂和醇类有机溶剂，再次用球磨机混合制成浆料，得到电介体层用浆料。
然后，用3辊磨将44.6重量份的Ni粒子、52重量份的松油醇、3重量份的乙基纤维素和0.4重量份的苯并三唑混合制成浆料，得到内部电极用浆料。
烧结体的制备
使用得到的电介体层用浆料，通过刮刀法在PET膜上形成生片材。在其上将内部电极用浆料用丝网印刷法进行印制。其后，将形成双层的生片材从PET膜上剥离，数张层压至厚度达到300μm，边从PET膜上剥离其上印制有内部电极用浆料的片材，边层压所希望的张数(此时为5张)，再次层压形成双层的生片材，进行压制得到生片。此时坯料状态的电介体层厚度为3.5μm。
之后，按照一定大小切断生片，按照下述条件进行脱粘合剂处理、烧结和退火，得到芯片烧结体。脱粘合剂处理条件为，升温速度：60℃/小时；保持温度：260℃；温度保持时间：8小时；气氛：空气。烧结条件为，升温速度：200℃/小时；保持温度：1240℃；温度保持时间：2小时；冷却速度：200℃/小时；烧结气氛：加湿的N2+H2混合气体。退火条件为，升温速度：200℃/小时；保持温度：1000℃；温度保持时间：2小时；冷却速度：200℃/小时；气氛：加湿后的氮气。另外，对烧结和退火时所使用的气体进行加湿使用的是水温20℃的加湿器。
得到的烧结体大小为：长3.2mm×宽1.6mm×高0.6mm，内部电极层所夹的电介体层数为5。
烧结体(电介体陶瓷组合物)的构造
将得到的烧结体加工至厚度为10μm之后，通过离子粉碎将试样进一步薄片化。其后通过扫描式透视显微镜(TEM)进行观察，证实是由晶粒2a和晶界相2b所构成。
烧结体中晶粒的平均短径
对得到的烧结体进行研磨、蚀刻后，利用扫描电子显微镜(SEM)对研磨面进行观察，利用代码法，假定晶粒2a的形状为球形，测定该晶粒的平均粒径。平均粒径是250个测定点数的平均值。结果为0.32μm。
平均粒径的晶粒的微细结构
上述平均粒径为0.32μm的晶粒的微细结构利用透射型电子显微镜(TEM)观察的照片如图3～5所示，图6～8为它们的模式图。
观察图3、6和图5、8，可以证实，任何一个电介体粒子(晶粒)都具有芯-壳结构，即在基本上由作为主成分的钛酸钡构成的芯周围，有副成分扩散至钛酸钡形成的壳结构(副成分扩散层)。与图3、6中的壳厚度不均匀相反，图5、8的壳厚度变得均匀。另外，观察图4、7，可以证实壳部分缺损、芯部分剥露。
然后，计算出壳24a的最大厚度t1和最小厚度t2，求得它们的差(t1-t2)，计算相对于表示上述平均粒径值的电介体粒子半径R(平均粒径的一半)的比例(表中用“扩散区域之差”表示)。结果如表1所示。
本实施方式中，壳24a的最大厚度t1和最小厚度t2之差(t1-t2)如下计算。如图9所示，对于具有上述平均粒径的晶粒，通过该晶粒的大致中心位置、从晶粒一端到另一端做一条直线，利用TEM进行线分析；然后偏移45度在同一粒径上进行线分析，求出扩散区域之差，以扩散区域差的最大值作为在此粒径下的扩散区域之差。此过程对10个粒子进行，计算平均值(参照图9)。
电容器试样的制备
对得到的芯片烧结体端面用砂磨机进行研磨后，作为外部电极涂布In-Ga，得到如图1所示的多层陶瓷电容器试样。
电容器试样的特性评价
对得到的电容器试样进行单位介电常数ε、静电电容温度特性(TC)、TC偏压及可靠性的评价，结果如表1所示。
对得到的电容器试样，在标准温度25℃下，用数字LCR测量仪(YHP社制4274A)，在频率为1kHz、输入信号水平(测定电压)为1.0Vrms的条件下测定静电电容，由此计算单位介电常数ε(无单位)。评价标准，以1300以上为良好。
容量温度特性(TC)是在-55℃～150℃的温度范围内测定得到的试样的静电电容。静电电容的测定利用数字LCR测量仪(YHP社制4274A)，在频率1kHz，输入信号水平1Vrms的条件下进行。然后计算在此温度范围内、容量温度特性最差的150℃温度环境中静电电容的变化率(ΔC/C，单位％)，确定是否满足X8R特性(-55℃～150℃，ΔC/C＝±15％以内)。评价标准以-15％以上为良好。
TC偏压如下评价：使用数字LCR测量仪(YHP社制4274A)，在1kHz、1Vrms、7.0V/μM的偏压电压(直流电压)下，使温度从-55℃改变至150℃，对得到的试样进行测定，计算相对于未施加25℃的偏压电压时的测定值的静电电容变化率，进行评价。另外，静电电容的测定是利用数字LCR测量仪，在频率1kHz、输入信号水平1Vrms的条件下进行的。评价标准以-40％以上为良好。
如表1所示，当扩散区域之差超过60％时，虽然介电常数足够，但是温度特性不满足X8R，而且TC偏压恶化。扩散区域之差不足6％时，介电常数足够、温度特性满足X8R，但是ε为1300以下，薄层多层化变难。
与此相反，当扩散区域之差在本发明的范围内(6％～60％)时，可以确证介电常数变大、温度特性满足X8R，而且TC偏压特性优良。
顺便提及，对于表1中的“剥露”是不进行第一预烧结、在对钛酸钡原料进行第二预烧结时将全部副成分原料添加进去而形成的。可以确认温度特性和TC偏压恶化。
表1
  试样编号   第一预烧结(制作较薄的壳)   第二预烧结(使得壳厚度不均匀)   电介体粒子                  电容器试样
  预烧结温度(℃)   预烧结时间(h)   **副成分量比例(％)   预烧结温度(℃)   预烧结时间(h)   **副成分量比例(％)   *扩散区域之差(％)   壳厚度   150℃下容量变化率(％)   X8R   TC偏压(％)   介电常数
  1   700   0.2   30   400   1   70   90   不均匀   -17.6   ×   -42.1   1404
  2   700   3   30   450   3   70   60   不均匀   -14.2   ◎   -37.5   1402
  3   700   3   30   470   3   70   40   不均匀   -7.5   ◎   -35.4   1400
  4   700   3   30   500   3   70   20   不均匀   -6.4   ◎   -35.2   1391
  5   700   3   30   520   3   70   10   不均匀   -10.2   ◎   -32.1   1380
  6   700   3   30   550   3   70   6   不均匀   -11.5   ◎   -31.2   1371
  7   700   3   30   600   3   70   2   不均匀   -12.5   ◎   -31.0   1160
  8   700   3   50   900   3   50   0   均匀   -14.3   ◎   -30.0   1100
  9   -   -   -   1000   1   100   剥露   -   -26.5   ×   -65.0   1410
*扩散区域之差是指电介体粒子2a的壳24a的最大厚度t1和最小厚度t2之差(t1-t2)相对于表示平均粒径值的电介体粒子2a半径R(平均粒径的一半)的比例。
**副成分量的比例是指以各副成分原料最终添加量为100％时相对于该100％所占的比例。
实施例2
除了将第一预烧结时添加的副成分原料量(添加量)改为各副成分原料最终添加量的10％、20％、40％以外，与实施例1的试样4同样操作，进行与实施例1相同的评价。结果见表2。
表2
  试样编号   第一预烧结(制作较薄的壳)   第二预烧结(使得壳厚度不均匀)   电介体粒子                  电容器试样
  预烧结温度(℃)   预烧结时间(h) **副成分量比例(％)   预烧结温度(℃)   预烧结时间(h)   **副成分量比例(％)   *扩散区域之差％)   壳厚度  150℃下容量变化率(％)   X8R   TC偏压(％)   介电常数
  10   700   3 10   500   3   90   25   不均匀  -7.2   ◎   -35.2   1391
  11   700   3 20   500   3   80   15   不均匀  -8.1   ◎   -33.6   1370
  4   700   3 30   500   3   70   20   不均匀  -6.4   ◎   -35.2   1391
  12   700   3 40   500   3   60   8   不均匀  -12.3   ◎   -32.1   1320
*扩散区域之差是指电介体粒子2a的壳24a的最大厚度t1和最小厚度t2之差(t1-t2)相对于表示平均粒径值的电介体粒子2a半径R(平均粒径的一半)的比例。
**副成分量的比例是指以各副成分原料最终添加量为100％时在100％中所占的比例。
如表2所示，可以确认任一试料的扩散区域之差均在本发明的范围内(6～60％)，得到了同样的结果。
实施例3
除了将第一预烧结时的保持温度改为400℃、600℃、800℃以外，与实施例1的试样4相同操作，进行与实施例1相同的评价。结果见表3。
表3
试样编号 第一预烧结(制作较薄的壳) 第二预烧结(使得壳厚度不均匀)   电介体粒子                  电容器试样
预烧结温度(℃) 预烧结时间(h) **副成分量比例(％) 预烧结温度(℃) 预烧结时间(h) **副成分量比例(％) *扩散区域之差(％) 壳厚度 150℃下容量变化率(％)     X8R  TC偏压(％) 介电常数
  13   400     3     30   500     3     70     37 不均匀     -7.8     ◎   -25.9   1399
  14   600     3     30   500     3     70     25 不均匀     -7.0     ◎   -35.0   1350
  4   700     3     30   500     3     70     20 不均匀     -6.4     ◎   -35.2   1391
  15   800     3     30   500     3     70     10 不均匀     -9.9     ◎   -32.0   1340
*扩散区域之差是指电介体粒子2a的壳24a的最大厚度t1和最小厚度t2之差(t1-t2)相对于表示平均粒径值的电介体粒子2a半径R(平均粒径的一半)的比例。
**副成分量的比例是指以各副成分原料最终添加量为100％时在100％中所占的比例。
如表3所示，可以确证任一试料的扩散区域之差均在本发明的范围内(6～60％)，得到了同样的结果。
实施例4
除了将烧结时间改为0.5小时、1小时、3.5小时、4小时、5小时以外，与实施例1的试样4相同操作，进行与实施例1相同的评价。结果见表4。
表4
试样编号 第一预烧结(制作较薄的壳) 第二预烧结(使得壳厚度不均匀)   烧结时间(h)        电介体粒子                    电容器试样
预烧结温度(℃)   预烧结时间(h) **副成分量比例(％) 预烧结温度(℃)   预烧结时间(h) **副成分量比例(％) *扩散区域之差(％)   壳厚度 150℃下容量变化率(％)    X8R   TC偏压(％) 介电常数
  16   700     3     30   500     3     70     0.5     4.5     不均匀     -10.4     ◎   -37.7   1430
  17   700     3     30   500     3     70     1     3.5     不均匀     -7.8     ◎   -36.0   1400
  4   700     3     30   500     3     70     2     20     不均匀     -6.4     ◎   -35.2   1391
  18   700     3     30   500     3     70     3.5     15     不均匀     -8.9     ◎   -33.6   1370
  19   700     3     30   500     3     70     4     7.5     不均匀     -11.0     ◎   -32.4   1300
  20   700     3     30   500     3     70     5     3     不均匀     -14.6     ◎   -30.4   1145
*扩散区域之差是指电介体粒子2a的壳24a的最大厚度t1和最小厚度t2之差(t1-t2)相对于表示平均粒径值的电介体粒子2a半径R(平均粒径的一半)的比例。
**副成分量的比例是指以各副成分原料最终添加量为100％时在100％中所占的比例。
如表4所示，可以确证随着烧结时间的延长，扩散区域之差有增加的趋势。而且，如果烧结时间超过4个小时，则扩散区域之差为6％以下，介电常数降低；只要在4个小时以下，扩散区域之差就均在本发明的范围内(6～60％)。

Claims (6)

1.一种电介体陶瓷组合物，该电介体陶瓷组合物含有多个具有壳的电介体粒子，所述壳是在基本上由主成分构成的芯周围使副成分扩散至主成分而形成的，其特征在于，
在以表示平均粒径值的电介体粒子为对象时，上述壳的最大厚度t1和最小厚度t2之差(t1-t2)被控制为上述电介体粒子半径R的6～60％。
2.如权利要求1所述的电介体陶瓷组合物，其中，上述主成分含有钛酸钡，上述副成分含有Mg的氧化物、稀土类元素的氧化物以及Mg除外的碱土类金属元素的氧化物。
3.如权利要求1所述的电介体陶瓷组合物，其中，上述主成分含有钛酸钡，上述副成分含有：
从MgO、CaO、BaO及SrO中选择的至少一种作为第1副成分；
氧化硅作为第2副成分；
从V2O5、MoO3及WO3中选择的至少一种作为第3副成分；
R1的氧化物作为第4副成分，其中，R1为从Sc、Er、Tm、Yb及Lu中选择的至少一种；
CaZrO3或者是CaO+ZrO2作为第5副成分2；
R2的氧化物作为第6副成分，其中，R2为Y、Dy、Ho、Tb、Gd及Eu中选择的至少一种)；
MnO作为第7副成分；
相对于100摩尔的上述主成分，各副成分的比例为：
第1副成分：0.1～3摩尔；
第2副成分：2～10摩尔；
第3副成分：0.01～0.5摩尔；
第4副成分：0.5～7摩尔，其中，第4副成分的摩尔数为R1单独时的比例；
第5副成分：0＜第5副成分≤5摩尔；
第6副成分：9摩尔以下，其中，第6副成分的摩尔数为R2单独时的比例；
第7副成分：0.5摩尔以下。
4.如权利要求1所述的电介体陶瓷组合物，其中，上述主成分含有钛酸钡，上述副成分含有：
AE的氧化物作为第1副成分，其中，AE为从Mg、Ca、Ba及Sr中选择的至少一种；
R的氧化物作为第2副成分，其中，R为从Y、Dy、Tm、Ho及Er中选择的至少一种；
MxSiO3作为第3副成分，其中，M为从Ba、Ca、Sr、Li及B中选择的至少一种，当M＝Ba时x＝1；当M＝Ca时，x＝1；当M＝Sr时，x＝1；当M＝Li时，x＝2；当M＝B时，x＝2/3；
MnO作为第4副成分；
从V2O5、MoO3及WO3中选择的至少一种作为第5副成分；
CaZrO3或者是CaO+ZrO2作为第6副成分；
相对于100摩尔的上述主成分，各副成分的比例为：
第1副成分：0～0.1摩尔，但不包括0和0.1摩尔；
第2副成分：1～7摩尔，但不包括1摩尔和7摩尔；
第3副成分：2～10摩尔；
第4副成分：0～0.5摩尔，但不包括0；
第5副成分：0.01～0.5摩尔；
第6副成分：0～5摩尔，但不包括0和5摩尔。
5.一种电子部件，该电子部件具有由电介体陶瓷组合物构成的电介体层，其特征为，上述电介体陶瓷组合物由权利要求1～4任一项所述的电介体陶瓷组合物构成。
6.一种多层陶瓷电容器，该多层陶瓷电容器具有由电介体陶瓷组合物构成的电介体层和内部电极层交替层压而成的电容器元件主体，其特征在于，上述电介体陶瓷组合物由权利要求1～4任一项所述的电介体陶瓷组合物构成。
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JP2004111951A (ja) 2002-08-29 2004-04-08 Matsushita Electric Ind Co Ltd 積層セラミックコンデンサ及びその製造方法

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CN1776844B (zh) 2010-06-23
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EP1648004B1 (en) 2009-02-18
ATE423387T1 (de) 2009-03-15
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