JP5655039B2 - 誘電体セラミックス、積層セラミックコンデンサ及びそれらの製造方法 - Google Patents
誘電体セラミックス、積層セラミックコンデンサ及びそれらの製造方法 Download PDFInfo
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- JP5655039B2 JP5655039B2 JP2012170364A JP2012170364A JP5655039B2 JP 5655039 B2 JP5655039 B2 JP 5655039B2 JP 2012170364 A JP2012170364 A JP 2012170364A JP 2012170364 A JP2012170364 A JP 2012170364A JP 5655039 B2 JP5655039 B2 JP 5655039B2
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- 239000003985 ceramic capacitor Substances 0.000 title claims description 36
- 239000000919 ceramic Substances 0.000 title claims description 33
- 238000000034 method Methods 0.000 title description 11
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 46
- 229910052760 oxygen Inorganic materials 0.000 claims description 46
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- 239000002245 particle Substances 0.000 claims description 30
- 238000004519 manufacturing process Methods 0.000 claims description 15
- 239000012298 atmosphere Substances 0.000 claims description 12
- 239000003990 capacitor Substances 0.000 claims description 12
- 229910052689 Holmium Inorganic materials 0.000 claims description 11
- 229910052749 magnesium Inorganic materials 0.000 claims description 11
- 229910052692 Dysprosium Inorganic materials 0.000 claims description 10
- 229910052691 Erbium Inorganic materials 0.000 claims description 10
- 229910052765 Lutetium Inorganic materials 0.000 claims description 10
- 229910052769 Ytterbium Inorganic materials 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- 229910052804 chromium Inorganic materials 0.000 claims description 10
- 229910052802 copper Inorganic materials 0.000 claims description 10
- 238000010304 firing Methods 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 10
- 229910052748 manganese Inorganic materials 0.000 claims description 10
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- JCLFHZLOKITRCE-UHFFFAOYSA-N 4-pentoxyphenol Chemical compound CCCCCOC1=CC=C(O)C=C1 JCLFHZLOKITRCE-UHFFFAOYSA-N 0.000 claims 1
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- 239000000370 acceptor Substances 0.000 description 39
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Description
(1)誘電体原料粉末の調製
まず、積層セラミックコンデンサ1の誘電体層12となる誘電体セラミックスの主成分原料として、BaTiO3粉末(BT原料粉末)を使用した。BT原料粉末の平均粒径(BTサイズ)は100nm(=0.1μm)である。BTサイズは、走査型電子顕微鏡(SEM)で粉末を観察し、サンプル数500としてそのメジアン径をとることで求めた。
調製した誘電体原料粉末をポリビニルアセタール樹脂及び有機溶剤で湿式混合し、ドクターブレード法により1.0μm厚のセラミックグリーンシートを塗工して乾燥させた。カバー層15となるセラミックカバーシートについては、その厚みを10μmとした。また、誘電体層12となるグリーンシート上にNi導電ペーストを所定パターンでスクリーン印刷することにより内部電極層13を配置した。内部電極層13の厚さは0.5〜0.6μm程度である。
MLCC成型体の試料をN2雰囲気中で脱バインダし、その後、N2、H2、H2Oの還元性混合ガス(酸素分圧が1.0×10−9hPa)において1180〜1230℃の条件で1時間焼成した。焼成工程における昇降温度速度は3000℃/hである。この間、誘電体をその平均粒径において1.2倍以上粒成長させることが好ましい。すなわち、焼成後の平均グレイン径≧1.2×原料粉末平均粒径であることが好ましい。表1の条件1〜6では、アクセプタ組成比が低濃度であるために焼結が促進され、誘電体の平均結晶粒径が約4.4〜4.6倍に粒成長していることが判る。
低濃度のアクセプタ元素を含むMLCCの焼結体10をこのように還元焼成することにより、誘電体層12には、一次的に多量の酸素欠陥が包含されることになる。そこで、酸素欠陥濃度を低減させるために、MLCC焼結体を酸化性雰囲気中(例えば酸素分圧が1.0×10−2hPa)、約900℃で再酸化処理を行った。
(1)酸素欠陥濃度の測定
焼成後、再酸化処理を行った積層セラミックコンデンサ1を150℃の恒温槽内に1時間静置し、更に室温25℃で24時間静置させた。アニールにより試料の条件を揃えた後、TEM−EELS法により誘電体層12の酸素欠陥濃度(主成分BT中の酸素に対する酸素欠陥濃度)を測定した。
積層セラミックコンデンサ1の試料の一部を研磨することにより断面を抽出し、走査型電子顕微鏡(SEM)で断面を撮影した写真に基づいて誘電体焼結粒子のグレイン径を測定した。本明細書では「グレイン径」を、内部電極層に平行する方向(つまり電界方向に対し直交する方向)における焼成後の結晶粒子の最大長さの平均と定義する。なお、グレイン径を測定する誘電体焼結粒子のサンプリングに関しては、サンプル数を500個以上とし、一か所の観察部位(例えばSEMで2000倍に拡大したときの写真1枚)で500個以上ある場合はその中の誘電体粒子全部についてサンプリングし、500個に満たない場合は複数個所で観察(撮影)を行って500個以上になるようにした。
積層セラミックコンデンサ1に対しインピーダンスアナライザを用いて静電容量Cmを測定した。測定のための電圧印加条件を、1kHz、1.0Vrmsとした。測定された静電容量Cmから下記の式(1)を用いて比誘電率εを求めた。
ここで、ε0は真空の誘電率であり、n、S、tは、それぞれ、誘電体層の積層数、内部電極層の面積、誘電体層の一層の厚さである。
各条件で作製した試料の積層セラミックコンデンサ1の評価結果を説明する。なお、表1のアクセプタ添加量(Ho添加量、Mg添加量)は、積層セラミックコンデンサ1を粉砕して、ICP分析(Inductively Coupled Plasma:誘導結合プラズマ分析)で分析し、各成分についての定量データを検出し、BaTiO3の定量データに対する各成分の定量データを、BaTiO3を100molに対するmol数に換算したものである。
図3には、誘電体セラミックスからなる誘電体層12に関し、表1の結果に基づいてアクセプタの添加量と比誘電率との関係が示される。また、図4には、同じく表1の結果に基づいて酸素欠陥濃度と比誘電率との関係が示される。
10 焼結体
12 誘電体層(誘電体セラミックス)
13 内部電極層
15 カバー層
20 外部電極
Claims (8)
- 誘電体を構成する焼結粒子の平均粒径が0.2〜1.0μmであり、
前記誘電体がABO 3 (AはBaを含む元素であり、BはTiを含む元素である)を主成分とし、ABO 3 100molに対してamolのアクセプタ元素を含有しており、前記アクセプタ元素のmol数を示すaが0<a≦0.5であり、
前記誘電体を構成する焼結粒子の酸素欠陥濃度が0.2〜0.5%である誘電体セラミックス。 - 前記アクセプタ元素がSc、Cr、Mn、Fe、Co、Ni、Cu、Zn、Mg、Al、Dy、Ho、Er、Yb及びLuからなる群より選ばれる少なくとも1種又は2種以上の元素である、請求項1に記載の誘電体セラミックス。
- 誘電体層と電極層とが交互に積層されてなる積層セラミックコンデンサであって、
前記誘電体層を構成する焼結粒子の平均粒径が0.2〜1.0μmであり、
前記誘電体層がABO 3 (AはBaを含む元素であり、BはTiを含む元素である)を主成分とし、ABO 3 100molに対してamolのアクセプタ元素を含有しており、前記アクセプタ元素のmol数を示すaが0<a≦0.5であり、
前記誘電体層を構成する焼結粒子の酸素欠陥濃度が0.2〜0.5%である積層セラミックコンデンサ。 - 前記アクセプタ元素がSc、Cr、Mn、Fe、Co、Ni、Cu、Zn、Mg、Al、Dy、Ho、Er、Yb及びLuからなる群より選ばれる少なくとも1種又は2種以上の元素である、請求項3に記載の積層セラミックコンデンサ。
- ABO3(AはBaを含む元素であり、BはTiを含む元素である)を主成分とし、ABO3 100molに対してamolのアクセプタ元素を含有しており、前記アクセプタ元素のmol数を示すaが0<a≦0.5である誘電体を還元性雰囲気中で焼成するステップと、
焼成された前記誘電体を酸化性雰囲気中で酸化処理を行うことにより、前記誘電体を構成する焼結粒子の酸素欠陥濃度を低減するステップとを含み、
前記誘電体を構成する焼結粒子の平均粒径が0.2〜1.0μmであり、その酸素欠陥濃度が0.2〜0.5%である、誘電体セラミックスの製造方法。 - 前記アクセプタ元素がSc、Cr、Mn、Fe、Co、Ni、Cu、Zn、Mg、Al、Dy、Ho、Er、Yb及びLuからなる群より選ばれる少なくとも1種又は2種以上の元素である、請求項5に記載の誘電体セラミックスの製造方法。
- ABO3(AはBaを含む元素であり、BはTiを含む元素である)を主成分とし、ABO3 100molに対するmol数が0.5mol以下のアクセプタ元素を含有するように誘電体グリーンシートを調製するステップと、
前記誘電体グリーンシート上に内部電極層となる導電ペーストを印刷するステップと、
前記導電ペーストを印刷した前記誘電体グリーンシートを積層してコンデンサ積層体を形成するステップと、
前記コンデンサ積層体を還元性雰囲気中で焼成するステップと、
焼成された前記コンデンサ積層体を酸化性雰囲気中で酸化処理を行うことにより、前記コンデンサ積層体のうち誘電体層を構成する焼結粒子の酸素欠陥濃度を低減するステップとを含み、
前記誘電体層を構成する焼結粒子の平均粒径が0.2〜1.0μmであり、その酸素欠陥濃度が0.2〜0.5%である、積層セラミックコンデンサの製造方法。 - 前記アクセプタ元素がSc、Cr、Mn、Fe、Co、Ni、Cu、Zn、Mg、Al、Dy、Ho、Er、Yb及びLuからなる群より選ばれる少なくとも1種又は2種以上の元素である、請求項7に記載の積層セラミックコンデンサの製造方法。
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