US20130057375A1 - Ferrite ceramic composition, ceramic electronic component, and process for producing ceramic electronic component - Google Patents

Ferrite ceramic composition, ceramic electronic component, and process for producing ceramic electronic component Download PDF

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Publication number
US20130057375A1
US20130057375A1 US13/601,917 US201213601917A US2013057375A1 US 20130057375 A1 US20130057375 A1 US 20130057375A1 US 201213601917 A US201213601917 A US 201213601917A US 2013057375 A1 US2013057375 A1 US 2013057375A1
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Prior art keywords
metal wire
electronic component
ferrite
mol
content
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US13/601,917
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Inventor
Tomoyuki ANKYU
Atsushi Yamamoto
Yuko Nomiya
Wataru KANAMI
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Murata Manufacturing Co Ltd
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Murata Manufacturing Co Ltd
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Assigned to MURATA MANUFACTURING CO., LTD. reassignment MURATA MANUFACTURING CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KANAMI, WATARU, ANKYU, TOMOYUKI, NOMIYA, YUKO, YAMAMOTO, ATSUSHI
Publication of US20130057375A1 publication Critical patent/US20130057375A1/en
Priority to US14/550,546 priority Critical patent/US9230722B2/en
Abandoned legal-status Critical Current

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    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Definitions

  • the technical field relates to a ferrite ceramic composition, a ceramic electronic component, and a process for producing a ceramic electronic component, and more specifically relates to a ferrite ceramic composition which can be fired simultaneously with an electrically conductive material containing Cu as the main component, a ceramic electronic component (e.g., a chip-type inductor) which is produced using the ferrite ceramic composition, and a process for producing the ceramic electronic component.
  • a ferrite ceramic composition which can be fired simultaneously with an electrically conductive material containing Cu as the main component, a ceramic electronic component (e.g., a chip-type inductor) which is produced using the ferrite ceramic composition, and a process for producing the ceramic electronic component.
  • chip-type inductors have been used widely as filters for high frequency applications that can remove noises generated in electronic devices such as mobile phones and notebook-size personal computers.
  • JP 7-22266 A proposes a process for producing an inductor element, which comprises: repeating a step, which comprises printing a ferrite paste containing an organic binder on a substrate and drying the printed ferrite paste, multiple times, thereby forming a first ferrite green sheet layer; placing a metal conductive body on the first ferrite green sheet layer; repeating a step, which comprises printing the ferrite paste on the first ferrite green sheet layer and the metal conductive body and drying the printed ferrite paste, multiple times, thereby forming a second ferrite green sheet layer on the first ferrite green sheet layer and the metal conductive body; compressing the first ferrite green sheet layer, the metal conductive body and the second ferrite green sheet layer together; and firing the compressed product.
  • JP 7-22266 A (claim 1, claim 2, paragraph Nos. [0007], [0017], etc.), it is described that one metal selected from Ag, Pd, Pt, Ni and Cu or an alloy of at least two metals selected from the above-mentioned metals is used as the metal conductive body.
  • JP 7-22266 A (claim 1, claim 2, paragraph Nos. [0007], [0017], etc.), it is contemplated to produce a high-quality chip-type inductor within a short time and without causing any structural defect and so on by employing the above-mentioned process.
  • JP 2001-52946 A proposes a process for producing a chip-type inductor, which comprises the steps of: inserting a conductive wire comprising a metal wire into a molding mold, holding both ends of the conductive wire by a support section formed inside of the molding mold to position the conductive wire at the center of the molding mold; injecting a magnetic ceramic slurry into the molding mold; molding the ceramic slurry that has been injected into the molding mold by a wet-mode pressing technique to form a molding having the conductive wire embedded therein; firing the molding to produce a magnetic core; and forming external electrodes, which are respectively connected to both ends of the conductive wire, at both end surfaces of the fired magnetic core.
  • JP 2001-52946 A (claim 1, paragraph Nos. [0014], [0026], etc.), it is described that Ag, Cu or an alloy of either one of these metals is used as the conductive wire.
  • JP 2001-52946 A (claim 1, paragraph Nos. [0014], [0026], etc.), it is contemplated to produce a high-density and high-quality chip-type inductor by producing the molding having the conductive wire embedded therein by a wet-mode pressing technique.
  • the present disclosure provides a ferrite ceramic composition, a ceramic electronic component including the ceramic composition, and a process of producing a ceramic electronic component including the ferrite ceramic composition of which the insulation performance can be secured even when fired simultaneously with a metal wire material containing Cu as the main component and which can exhibit good electric properties.
  • a ferrite ceramic composition comprises at least Fe, Mn, Ni and Zn, where in ferrite ceramic composition, a molar content of Cu is 0 to 5 mol % in terms of CuO content, and is characterized in that, when a molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and a molar content (y (mol %)) of Mn in terms of Mn 2 O 3 content are expressed by a coordinate point (x,y), the coordinate point (x,y) is located in an area bounded by coordinate points A (25,1), B (47,1), C (47,7.5), D (45,7.5), E (45,10), F (35,10), G (35,7.5) and H (25,7.5).
  • a molar content of Zn may be 33 mol % or less in terms of ZnO content.
  • a molar content of Zn may be 6 mol % or more in terms of ZnO content.
  • a ceramic electronic component in another aspect of the disclosure, includes a magnetic body part and a metal wire material embedded in the magnetic body part, and is characterized in that the metal wire material comprises an electrically conductive material containing Cu as the main component and the magnetic body part comprises any one of the above-mentioned ferrite ceramic compositions.
  • the metal wire material may have a linear shape.
  • the metal wire material may have a spiral shape.
  • the magnetic body part may be fired in an atmosphere having an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O.
  • a process for producing a ceramic electronic component includes a calcination step of weighing an Fe compound, an Mn compound, a Cu compound, a Zn compound and an Ni compound precisely in such a manner that a molar content of Cu becomes 0 to 5 mol % in terms of CuO content and, when a molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and a molar content (y (mol %)) of Mn in terms of Mn 2 O 2 content are expressed by a coordinate point (x,y), the coordinate point (x,y) can be located in an area bounded by coordinate points A (25,1), B (47,1), C (47,7.5), D (45,7.5), E (45,10), F (35,10), G (35,7.5) and H (25,7.5), mixing the weighed compounds together, and calcining the resultant mixture, thereby producing a calcined powder.
  • the process includes a ceramic thin layer body production step of producing ceramic thin layer bodies from the calcined powder, a laminate formation step of laminating the multiple ceramic thin layer bodies on each other in such a manner that a metal wire material containing Cu as the main component and having a linear shape is intercalated between at least a pair of the ceramic thin layer bodies, thereby forming a laminate, and a firing step of firing the laminate in a firing atmosphere having an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O.
  • a process for producing a ceramic electronic component includes a calcination step of weighing an Fe compound, an Mn compound, a Cu compound, a Zn compound and an Ni compound precisely in such a manner that a molar content of Cu becomes 0 to 5 mol % in terms of CuO content and, when a molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and a molar content (y (mol %)) of Mn in terms of Mn 2 O 3 content are expressed by a coordinate point (x,y), the coordinate point (x,y) can be located in an area bounded by coordinate points A (25,1), B (47,1), C (47,7.5), D (45,7.5), E (45,10), F (35,10), G (35,7.5) and H (25,7.5), mixing the weighed compounds together, and calcining the resultant mixture, thereby producing a calcined powder.
  • the process further includes ferrite paste production step of producing a ferrite paste from the calcined powder, a molding production step of placing a metal wire material containing Cu as the main component in a mold, then injecting the ferrite paste into the mold and carrying out a molding treatment to produce a molding, and a firing step of firing the molding in a firing atmosphere having an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O.
  • FIG. 1 is a view illustrating the content ranges of Fe 2 O 3 and Mn 2 O 3 for the ferrite ceramic composition according to an exemplary embodiment.
  • FIG. 2 is a perspective view illustrating an embodiment (a first embodiment) of a chip-type inductor as the ceramic electronic component according an exemplary embodiment.
  • FIG. 3 is a cross sectional view of FIG. 2 taken along line A-A.
  • FIG. 4 is an exploded perspective view illustrating the main part of the first exemplary embodiment.
  • FIG. 5 is a perspective view illustrating a second exemplary embodiment of a chip-type inductor as a ceramic electronic component.
  • FIG. 6 is a vertical sectional view of FIG. 5 .
  • FIG. 7 is a cross sectional view illustrating the main part of the production process of the second exemplary embodiment.
  • FIG. 8 is a cross sectional view of a sample for use in the specific resistance measurement, which is produced in Example 1.
  • FIG. 9 is a view illustrating the impedance property of a sample produced in Example 2, together with the impedance property of a sample of a comparative example which is out of the scope of the present disclosure.
  • JP 7-22266 A (claim 1, claim 2, paragraph Nos. [0007], [0017], etc.), Ag, Pd, Pt, Ni, Cu, or an alloy of any one of these elements is used.
  • a noble metal material such as Ag, Pd, and Pt is used, such a problem occurs that the material cost is increased and productivity is deteriorated.
  • Ni—Zn-based ferrite is fired in an air atmosphere.
  • a poor metal material such as Ni and Cu is used as a metal wire material
  • the metal wire material might be oxidized during the firing in an air atmosphere.
  • JP 7-22266 A (claim 1, claim 2, paragraph Nos. [0007], [0017], etc.)
  • the poor metal material such as Cu and Ni and the ferrite material
  • the firing is performed in such a reductive atmosphere that the poor metal material is not oxidized
  • Fe 2 O 3 is reduced into Fe 2 O 4 and consequently the specific resistance ⁇ is decreased, which might result in the deterioration in electric properties including an impedance property, because there is not any area in which the poor metal material and Fe 2 O 3 can coexist.
  • the present inventors have made intensive studies on ferrite materials having a spinel-type crystal structure represented by general formula X 2 O 3 .MeO (wherein X represents Fe or Mn; and Me represents Zn, Cu or Ni).
  • X represents Fe or Mn
  • Me represents Zn, Cu or Ni
  • One exemplary embodiment of the ferrite ceramic composition has a spinel-type crystal structure represented by general formula X 2 O 3 .MeO, and contains at least Fe 2 O 3 and Mn 2 O 3 which are trivalent element compounds and ZnO and NiO which are bivalent element compounds, and optionally contains CuO which is a bivalent element compound.
  • the ferrite ceramic composition contains CuO at a molar content of 0 to 5 mol %, also contains Fe 2 O 3 and Mn 2 O 3 at such molar contents that, when the molar content of Fe 2 O 3 is expressed by x (mol %), the molar content of Mn 2 O 3 is expressed by y (mol %) and the molar content of Fe 2 O 3 and the molar content of Mn 2 O 3 are expressed by a coordinate point (x,y), the coordinate point (x,y) is located within a shaded area (X) defined by points A to H, as shown in FIG. 1 , wherein the remainder is made up by ZnO and NiO.
  • the coordinate points (x,y) for the coordinate points A to H correspond to the following molar contents: A (25,1), B (47,1), C (47,7.5), D (45,7.5), E (45,10), F (35,10), G (35,7.5), and H (25,7.5).
  • the ferrite magnetic composition when CuO, which has a melting point of as low as 1,026° C., is added to the ferrite ceramic composition, the ferrite magnetic composition can be fired at a lower temperature and the sintering properties can be improved.
  • the amount of CuO to be added is controlled in such a manner that the molar content of CuO becomes 5 mol % or less, i.e., 0 to 5 mol %.
  • the content of Fe 2 O 3 in the composition is smaller than the content defined in the stoichiometric composition, and Mn 2 O 2 is contained by substituting a portion of Fe by Mn, whereby the decrease in a specific resistance ⁇ can be avoided and insulation performance can be improved.
  • the ratio of X 2 O 3 (wherein X: Fe, Mn) to MeO (wherein Me: Ni, Zn, Cu) is 50:50 according to the stoichiometric composition, and X 2 O 3 and MeO are added at contents substantially defined in the stoichiometric composition.
  • a reductive atmosphere for Mn 2 O 3 can be achieved at a higher oxygen partial pressure than that for Fe 2 O 3 . Therefore, at an oxygen partial pressure that is equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O, the atmosphere for Mn 2 O 3 becomes strongly reductive compared that for Fe 2 O 3 . Therefore, the firing can be accomplished while reducing Mn 2 O 3 preferentially. That is, since Mn 2 O 3 is reduced preferentially than Fe 2 O 3 , the firing treatment can be accomplished before Fe 2 O 3 is reduced into Fe 3 O 4 .
  • the molar content of Mn 2 O 3 is less than 1 mol %, the molar content of Mn 2 O 3 is reduced excessively, and therefore Fe 2 O 3 can be reduced into Fe 3 O 4 more readily. As a result, the specific resistance ⁇ is decreased and satisfactory insulation performance cannot be secured.
  • the molar content of Fe 2 O 3 is 25 mol % or more but is less than 35 mol %, and in the case where the molar content of Fe 2 O 3 is 45 mol % or more but less than 47 mol %, if the molar content of Mn 2 O 3 exceeds 7.5 mol %, the decrease in a specific resistance ⁇ is caused and desired insulation performance cannot be secured.
  • the molar contents of Fe 2 O 3 and Mn 2 O 3 are controlled so as to fall within the area bounded by the coordinate points A to H shown in FIG. 1 .
  • the molar contents of ZnO and NiO are not particularly limited and can be set properly in accordance with the molar contents of Fe 2 O 3 , Mn 2 O 3 and CuO.
  • ZnO and NiO are added in such a manner that the molar content of ZnO becomes 6 to 33 mol % and the remainder is made up by NiO.
  • the content of ZnO is preferably 33 mol % or less.
  • ZnO has an effect of improving a magnetic permeability ( ⁇ ). For achieving the effect, it is needed to add ZnO at a molar content of 6 mol %.
  • the molar content of ZnO is preferably 6 to 33 mol %.
  • the ferrite ceramic composition has a molar content of Cu of 0 to 5 mol % in terms of CuO content, and also has such molar contents of Fe and Mn that, when the molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and the molar content (y (mol %)) of Mn in terms of Mn 2 O 3 content are expressed by a coordinate point (x,y), the coordinate point (x,y) is located within an area bounded by the coordinate points A to H. Therefore, when the ferrite ceramic composition is fired simultaneously with a Cu-based material, the specific resistance ⁇ is not decreased and desired insulation performance can be secured.
  • the ferrite ceramic composition since the molar content of Zn is 6 to 33 mol % in terms of ZnO content, good magnetic permeability can be achieved and a satisfactory Curie point can be secured.
  • the composition enables the production of a ceramic electronic component which can be operated under conditions including a high operation temperature.
  • FIG. 2 is a perspective view illustrating one exemplary embodiment (a first embodiment) of a laminated inductor as the ceramic electronic component according to the present disclosure
  • FIG. 3 is a cross sectional view of FIG. 2 taken along line A-A.
  • a component body ( 1 ) comprises a magnetic body part ( 2 ) and a metal wire material ( 3 ) embedded in the magnetic body part ( 2 ). At both ends of the component body ( 1 ), external electrodes ( 4 a , 4 b ) are formed.
  • the metal wire material ( 3 ) is formed in a linear shape and is embedded in substantially the longitudinal direction center of the magnetic body part ( 2 ), and both ends of the metal wire material ( 3 ) are electrically connected to the external electrodes ( 4 a , 4 b ), respectively.
  • the metal wire material ( 3 ) comprises an electrically conductive material containing Cu as the main component
  • the magnetic body part ( 2 ) comprises the above-mentioned ferrite ceramic composition according to the present disclosure.
  • the specific resistance ⁇ can be improved to 10 7 ⁇ cm or more, and a laminated inductor that has a high impedance value in a specific frequency range and is suitable for the absorption of noises can be produced.
  • FIG. 4 is an exploded perspective view of the component body ( 1 ), and an exemplary process for producing the laminated inductor is now described in detail with reference thereto.
  • Fe 2 O 3 , ZnO, NiO, and optionally CuO are provided as the ceramic raw materials.
  • the ceramic raw materials are weighed precisely so as to have a CuO content of 0 to 5 mol % and such Fe 2 O 3 and Mn 2 O 3 contents that the contents of Fe 2 O 3 and Mn 2 O 3 fulfill the specified area bounded by the coordinate points A to H of FIG. 1 .
  • the precisely weighed materials are introduced into a pot mill together with pure water and cobbled stones such as PSZ (partially stabilized zirconia) balls, the mixture is fully mixed and milled in a wet mode, and the milled product is evaporated to dryness and then calcined at a temperature of 700 to 800° C. for a predetermined time.
  • pure water and cobbled stones such as PSZ (partially stabilized zirconia) balls
  • the calcined powder is introduced into the pot mill again together with an organic binder such as polyvinyl butyral, an organic solvent such as ethanol, and toluene and PSZ balls, and the resultant mixture is fully mixed and milled, thereby producing a ceramic slurry.
  • an organic binder such as polyvinyl butyral
  • an organic solvent such as ethanol, and toluene and PSZ balls
  • the ceramic slurry is molded into a sheet-like form employing a doctor blade method or the like, thereby producing a magnetic ceramic green sheet (a ceramic thin layer body; simply referred to as “a magnetic material sheet”, hereinafter) (5) having a predetermined thickness.
  • a magnetic ceramic green sheet a ceramic thin layer body; simply referred to as “a magnetic material sheet”, hereinafter
  • first magnetic material layer ( 6 a ) multiple pieces of the multiple magnetic material sheets ( 5 ) are laminated on each other to form a first magnetic material layer ( 6 a ), and a metal wire material ( 3 ) having a diameter of about 50 to 100 ⁇ m is arranged on the upper surface of the first magnetic material layer ( 6 a ) in parallel with the side surfaces of the first magnetic material layer ( 6 a ) at substantially the center parts of the both end surfaces.
  • first magnetic material layer ( 6 a ) and the metal wire material ( 3 ) multiple pieces of the multiple magnetic material sheets ( 5 ) are laminated, thereby forming a second magnetic material layer ( 6 b ).
  • the resultant laminate is pressurized and compressed, and is then cut into a predetermined size, thereby producing a laminated molding.
  • the laminated molding is fully defatted by heating in an atmosphere that does not cause the oxidation of Cu.
  • the defatted laminated molding is fed into a firing furnace of which the atmosphere has been controlled with an N 2 —H 2 —H 2 O mixed gas so as to have an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O, and is then fired at 900 to 1,050° C. for a predetermined time, thereby producing a component body ( 1 ) in which the metal wire material ( 3 ) is embedded in the magnetic body part ( 2 ).
  • an electrically conductive paste for external electrodes which contains Cu or the like as the main component is applied to both ends of the component body ( 1 ).
  • the electrically conductive paste is dried and then baked at 900° to form external electrodes ( 4 a , 4 b ). In this manner, the above-mentioned laminated inductor can be produced.
  • the first embodiment comprises: a calcination step of weighing an Fe compound, an Mn compound, a Cu compound, a Zn compound and an Ni compound precisely in such a manner that the molar content of Cu becomes 0 to 5 mol % in terms of CuO content and, when the molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and the molar content (y (mol %)) of Mn in terms of Mn 2 O 3 content are expressed by a coordinate point (x,y), the coordinate point (x,y) can be located in the specified area bounded by coordinate points A to H (see FIG.
  • FIG. 5 is a perspective view illustrating an inductor which is a second exemplary embodiment of a ceramic electronic component according to the present disclosure
  • FIG. 6 is a cross sectional view of FIG. 5 .
  • the inductor is substantially the same as the first exemplary embodiment, and the component body ( 11 ) comprises a magnetic body part ( 12 ) and a metal wire material ( 13 ) embedded in the magnetic body part ( 12 ). At both ends of the component body ( 11 ), external electrodes ( 14 a , 14 b ) are formed.
  • the metal wire material ( 13 ) is formed in a spiral shape and is embedded in substantially the longitudinal direction center of the magnetic body part ( 12 ), and both ends of the metal wire material ( 13 ) are electrically connected to the external electrodes ( 14 a , 14 b ), respectively.
  • the metal wire material ( 13 ) since the metal wire material ( 13 ) has a spiral shape, it becomes possible to produce an inductor having a higher inductance value compared with that of the first embodiment in which a metal wire material having a linear shape is used.
  • the metal wire material ( 13 ) is also composed of an electrically conductive material containing Cu as the main component and the magnetic body part ( 12 ) is also composed of the above-mentioned ferrite ceramic composition according to the present disclosure.
  • a calcined power is produced by the same methods and procedures as those employed in the first embodiment.
  • the calcined powder is mixed with an organic vehicle comprising a resin such as an ethyl cellulose resin and an organic solvent such as terpineol, and the mixture is kneaded using a triple ball mill, thereby producing a ferrite paste.
  • an organic vehicle comprising a resin such as an ethyl cellulose resin and an organic solvent such as terpineol
  • FIG. 7 is a cross sectional view of a molding apparatus. That is, the molding apparatus ( 15 ) comprises an upper mold ( 18 ) having a first cavity ( 16 ) and a paste injection port ( 17 ) and a lower mold ( 20 ) having a second cavity ( 19 ).
  • a metal wire material ( 13 ) containing Cu as the main component and shaped into a spiral form is latched in a support groove (not shown) in the lower mold ( 20 ) to tightly adhere the metal wire material ( 13 ) between the upper mold ( 20 ) and the lower mold ( 20 ), the ferrite paste is injected through the paste injection port ( 17 ), the molding apparatus ( 15 ) is heated while applying a pressure to evaporate and remove the organic solvent, thereby producing a molding.
  • the molding is removed from the molding apparatus ( 15 ).
  • the molding is fully defatted by heating under an atmosphere that does not cause the oxidation of Cu, is then fed into a firing furnace of which the atmosphere has been adjusted with an N 2 —H 2 —H 2 O mixed gas so as to have an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O, and is then fired at 900 to 1,050° C. for a predetermined time.
  • a component body ( 11 ) in which the metal wire material ( 13 ) is embedded in the magnetic body part ( 12 ) can be produced.
  • an electrically conductive paste for external electrodes which contains Cu or the like as the main component is applied to both ends of the component body ( 11 ), is dried, and is then baked at 900° C., thereby forming external electrodes ( 14 a , 14 b ). In this manner, the above-mentioned inductor can be produced.
  • the second exemplary embodiment substantially like the first embodiment, even when the ferrite material is fired under a firing atmosphere having an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O together with the spiral-shaped metal wire material ( 13 ) containing Cu as the main component, the oxidation of Cu or the reduction of Fe does not occur. Therefore, it becomes possible to produce an inductor having good insulation performance and good electric properties.
  • the present disclosure is not limited to the above-mentioned embodiments.
  • the ceramic green sheet ( 5 ) is produced from a calcined powder
  • any other ceramic thin layer body may also be used.
  • a magnetic coating film may be formed on a PET film by a printing treatment.
  • the shape of the metal wire material ( 13 ) is not particularly limited and a prismatic shape, a flattened shape or the like, of course, may also be employed.
  • the ferrite ceramic composition according to the present disclosure can be used for various types of inductors, can also be used widely for use applications in which the ferrite ceramic composition is fired simultaneously with an electrically conductive material containing Cu as the main component, and can also be used for other ceramic electronic components.
  • Fe 2 O 3 , Mn 2 O 3 , ZnO, CuO and NiO were provided as ceramic raw materials, and the ceramic raw materials were weighed precisely so that the molar contents of the ceramic raw materials became those shown in Tables 1 to 3. That is, the ceramic raw materials were weighed precisely in such a manner that the contents of ZnO and CuO were fixed to 30 mol % and 1 mol %, respectively, the molar content of each of Fe 2 O 3 and Mn 2 O 3 was varied and the remainder was made up by NiO.
  • the precisely weighed materials were placed in a pot mill made of vinyl chloride together with pure water and PSZ balls, the mixture was fully mixed and milled in a wet mode, the resultant mixture was evaporated to dryness, and the dried product was calcined at 750° C., thereby producing a calcined powder.
  • the calcined powder was placed again in the pot mill made of vinyl chloride together with a polyvinyl butyral binder (an organic binder), ethanol (an organic solvent) and PSZ balls, and the mixture was fully mixed and milled, thereby producing a ceramic slurry.
  • a polyvinyl butyral binder an organic binder
  • ethanol an organic solvent
  • the ceramic slurry was shaped into a sheet-like form having a thickness of 25 ⁇ m employing a doctor blade method, and the sheet-like material was then punched out into a size of 50 mm in length and 50 mm in width. In this manner, a magnetic material sheet was produced.
  • the oxygen partial pressure of 6.7 ⁇ 10 ⁇ 2 Pa is the equilibrium oxygen partial pressure for Cu—Cu 2 O at 1,000° C.
  • the ceramic molding was fired for 2 hours under the equilibrium oxygen partial pressure for Cu—Cu 2 O. In this manner, ring-shaped samples Nos. 1 to 104 were produced.
  • a soft copper wire was wound around each of the ring-shaped samples Nos. 1 to 104 20 turns, the inductance of the resultant product was measured at a measurement frequency of 1 MHz using an impedance analyzer (Agilent Technologies, E4991A), and a magnetic permeability (i) was determined from the measurement value.
  • an impedance analyzer Align Technologies, E4991A
  • an organic vehicle comprising terpineol (an organic solvent) and an ethyl cellulose resin (a binder resin) was mixed with a Cu powder, and the mixture was kneaded with a triple roll mill. In this manner, a Cu paste was produced.
  • the Cu paste was screen-printed on the surface of the magnetic material sheet, thereby producing an electrically conductive film having a predetermined pattern on the magnetic material sheet.
  • a predetermined number of the magnetic material sheets each having the electrically conductive film formed thereon were laminated in a predetermined order.
  • the resultant laminate was intercalated between the magnetic material sheets on each of which the electrically conductive film was not formed, and the resultant laminate was compressed and then cut into a predetermined size. In this manner, a laminated molding was produced.
  • the laminated molding was defatted sufficiently, an N 2 —H 2 —H 2 O mixed gas was fed to a firing furnace to adjust the oxygen partial pressure in the firing furnace to 6.7 ⁇ 10 ⁇ 2 Pa (the equilibrium oxygen partial pressure for Cu—Cu 2 O at 1,000° C.).
  • the laminated molding was introduced into the firing furnace, and was then fired at 1,000° C. for 2 hours. In this manner, a sintered ceramic body having an internal electrode embedded therein was produced.
  • the sintered ceramic body was introduced into a pot together with water, and the sintered ceramic body was subjected to a barrel treatment using a centrifugal barrel machine. In this manner, a ceramic body was produced.
  • Each of the specific resistance measurement samples had an outer size of 3.0 mm in length, 3.0 mm in width and 1.0 mm in thickness.
  • FIG. 8 is a cross sectional view of each of the specific resistance measurement samples.
  • internal electrodes ( 52 a to 52 d ) were embedded in the magnetic material layer ( 53 ) in such a manner that the extraction sections were arranged in a staggered configuration, and external electrodes ( 54 a , 54 b ) were formed at both ends of the ceramic body ( 51 ).
  • a voltage of 50 V was applied to each of the external electrodes ( 54 a , 54 b ) for 30 seconds, and a current generated upon the application of the voltage was measured.
  • a resistivity was calculated from the measurement value, and a logarithm log ⁇ for a specific resistance (referred to as “a specific resistance log ⁇ ,” hereinafter) was calculated from the outer size of each of the samples.
  • the specific resistance log ⁇ was as small as less than 7 and desired insulation performance could not be achieved, since the composition was located in the outside of the shaded area (X) in FIG. 1 .
  • Ceramic raw materials were weighed precisely in such a manner that the molar content of Fe 2 O 3 was 44 mol % and the molar content of Mn 2 O 3 was 5 mol % (which fall within the ranges defined in the present disclosure), the molar content of ZnO was 30 mol %, the molar content of CuO was varied, and the remainder was made up by NiO, as shown in Table 4. Except for this matter, the same methods and procedures as in Example 1 were performed, thereby producing ring-shaped samples Nos. 201 to 209 and specific resistance measurement samples Nos. 201 to 209.
  • Example 2 The same methods and procedures as in Example 1 were performed, except that ceramic raw materials were weighed precisely in such a manner that the molar content of Fe 2 O 3 was 44 mol %, the molar content of Mn 2 O 3 was 5 mol % and the molar content of CuO was 1 mol % (which fall within the ranges defined in the present disclosure), the molar content of ZnO was varied, and the remainder was made up by NiO, as shown in Table 5. In this manner, ring-shaped samples Nos. 301 to 309 and specific resistance measurement samples Nos. 301 to 309 were produced.
  • the temperature dependency of saturation magnetization was determined by applying a magnetic field of 1 T (tesla) using a vibrating sample magnetometer (Toei Industry Co., Ltd.; model VSM-5-15).
  • a Curie point (Tc) was determined from the result of the temperature dependency of saturation magnetization.
  • the magnetic permeability ( ⁇ ) was decreased to 20 or less since the molar content of ZnO was less than 6 mol %, although the specific resistance log ⁇ and the Curie point (Tc) were satisfactory.
  • samples Nos. 1′ and 27′ Two types of laminated inductors (samples Nos. 1′ and 27′) were produced respectively using two types of magnetic material sheets, i.e., magnetic material sheets each having the same composition as that of sample No. 1 produced in Example 1 and magnetic material sheets each having the same composition as that of sample No. 27 produced in Example 1. (See FIGS. 2 to 4 ).
  • magnetic material sheets each having the same composition as that of sample No. 1 and magnetic material sheets each having the same composition as that of sample No. 27 were prepared. With respect to each type of the magnetic material sheets, the magnetic material sheets were laminated together to form a first magnetic material layer. On the upper surface of the first magnetic material layer, a Cu wire having a diameter of 100 ⁇ m was placed on substantially the center of the first magnetic material layer in parallel with the side surface of the first magnetic material layer. On the surface of the first magnetic material layer having the Cu wire placed thereon, multiple pieces of the magnetic material sheets were laminated to form a second magnetic material layer. Subsequently, the resultant product was heated to 60° C., and was then compressed by applying a pressure of 100 MPa for 60 seconds. The compressed product was cut into a predetermined size, thereby forming a laminated molding.
  • the laminated molding was fully defatted at a temperature of 600° C. in an atmosphere of which the oxygen partial pressure was adjusted to 1.0 ⁇ 10 ⁇ 15 Pa so as to avoid the oxidation of Cu.
  • the defatted laminated molding was introduced into a firing furnace in which the atmosphere had been adjusted to 6.7 ⁇ 10 ⁇ 2 Pa with an N 2 —H 2 —H 2 O mixed gas, and was then fired at 1,000° C. for 2 hours. In this manner, a sintered ceramic body in which the Cu wire was embedded in the magnetic body part was produced.
  • Each of samples Nos. 1′ and 27′ had an outer size of 1.6 mm in length, 0.8 mm in width and 0.8 mm in thickness.
  • FIG. 9 the measurement results are shown.
  • a solid line indicates the impedance property of sample No. 27′, which is a sample according to the present disclosure
  • a dashed line indicates the impedance property of sample No. 1′, which is a sample that is out of the scope of the present disclosure.
  • frequencies (MHz) were plotted on the abscissa axis and values of impedance ( ⁇ ) were plotted on the ordinate axis.
  • Sample No. 1′ had a specific resistance log ⁇ of as low as 2.8, and therefore was out of the scope of the present disclosure. Therefore, the highest value of impedance was about 15 ⁇ , and a high level of impedance could not be achieved.
  • sample No. 27′ has a specific resistance log ⁇ of 7.6 which was sufficiently high, and was within the scope of the present disclosure. Therefore, high impedance could be achieved (i.e., the highest value of impedance was about 50 ⁇ ) and a bell-shaped high and desired impedance pattern could be obtained in a specific frequency region.
  • the ferrite material can exhibit good insulation performance even when the ferrite material having, embedded therein, an electrically conductive material containing Cu as the main component. Therefore, it becomes possible to provide a ceramic electronic component, such as an inductor, having good insulation performance and good electric properties by using the ferrite material.
  • the molar content of Cu is 0 to 5 mol % in terms of CuO content and, when the molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and the molar content (y (mol %)) of Mn in terms of Mn 2 O 3 content are expressed by a coordinate point (x,y), the coordinate point (x,y) is located in an area bounded by the above-mentioned coordinate points A to H.
  • the molar content of Zn is 33 mol % or less in terms of ZnO content, a sufficient Curie point can be secured and therefore it becomes possible to produce a ceramic electronic component which can be operated under conditions including a high operation temperature.
  • the molar content of Zn is 6 mol % or more in terms of ZnO content, good magnetic permeability can be secured.
  • An embodiment of a ceramic electronic component according to the present disclosure includes a magnetic body part and a metal wire material having a linear or spiral shape and embedded in the magnetic body part, where the metal wire material include an electrically conductive material containing Cu as the main component and the magnetic body part include any of the above-mentioned ferrite ceramic compositions (i.e., those within the scope of the disclosure). Therefore, even when the magnetic body part having the metal wire material embedded therein is fired, the occurrence of the oxidation of Cu or the reduction of Fe 2 O 3 can be avoided, and it becomes possible to produce a ceramic electronic component having a desired specific resistance ⁇ and good electric properties.
  • the magnetic body part having an electrically conductive material containing Cu as the main component embedded therein is fired in an atmosphere having an oxygen partial pressure equal to or lower than the equilibrium oxygen partial pressure for Cu—Cu 2 O, the magnetic body part can be sintered without undergoing the oxidation of Cu or the reduction of Fe 2 O 3 . Therefore, it becomes possible to produce a chip-type inductor having good electric properties as a ceramic electronic component.
  • An embodiment of present disclosure includes a process for producing a ceramic electronic component having a calcination step of weighing an Fe compound, an Mn compound, a Cu compound, a Zn compound and an Ni compound precisely in such a manner that a molar content of Cu becomes 0 to 5 mol % in terms of CuO content and, when a molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and a molar content (y (mol %)) of Mn in terms of Mn 2 O 2 content are expressed by a coordinate point (x,y), the coordinate point (x,y) can be located in a specific area bounded by coordinate points A to H, mixing the weighed compounds together, and calcining the resultant mixture, thereby producing a calcined powder; a ceramic thin layer body production step of producing ceramic thin layer bodies from the calcined powder; a laminate formation step of laminating the multiple ceramic thin layer bodies on each other in such a manner that a metal wire material containing Cu as the
  • An embodiment of present disclosure includes a process for producing a ceramic electronic component having a calcination step of weighing an Fe compound, an Mn compound, a Cu compound, a Zn compound and an Ni compound precisely in such a manner that a molar content of Cu becomes 0 to 5 mol % in terms of CuO content and, when a molar content (x (mol %)) of Fe in terms of Fe 2 O 3 content and a molar content (y (mol %)) of Mn in terms of Mn 2 O 2 content are expressed by a coordinate point (x,y), the coordinate point (x,y) can be located in a specific area bounded by coordinate points A to H, mixing the weighed compounds together, and calcining the resultant mixture, thereby producing a calcined powder; a ferrite paste production step of producing a ferrite paste from the calcined powder; a molding production step of placing a metal wire material containing Cu as the main component in a mold, then injecting the ferrite paste

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US20150077210A1 (en) 2015-03-19
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KR20130025835A (ko) 2013-03-12
US9230722B2 (en) 2016-01-05
CN102976727A (zh) 2013-03-20
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TWI486321B (zh) 2015-06-01
JP5761609B2 (ja) 2015-08-12

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