PREPARATION METHOD FOR LOW-TEMPERATURE-SINTERABLE Pb-BASED PEROVSKITE DIELECTRIC POWDERS
TECHNICAL FIELD The present invention relates to low-temperature-sinterable Pb-based perovskite dielectric powders, and more particularly to preparation methods for (1-x)[Pb(Mg1/3Nb2/3)O3] - x(PbTiO3)[(1-x) PMN-xPT) (wherein, x = 0 - 0.1 ).
BACKGROUND ART Preparation methods for PMN or PMN-PT used for multi-layered ceramic capacitors (MLCC) or relaxors, which have been generally applied so far, are a mixed-oxide method of PbO, MgO and Nb2O5 and a sol-gel method which uses organometalic compounds.
Since the conventional mixed-oxide method is always accompanied by the unwanted cubic pyrochlore phase because the reaction of PbO with Nb2O5 occurs prior to the reaction of MgO, a modified method which is commercially in use includes the steps of preparation of a precursor with the columbite structure by reacting MgO with Nb2O5 and reacting the precursor with PbO. More specifically, in order to inhibit the reaction between PbO and Nb2O5 which provides the undesirable pyrochlore phase in the method which undergoes via the columbite precursor, first, MgNb2O6 which is the columbite precursor is obtained by reacting MgO with Nb2O5 at a temperature of 1100°-1200°C, and then PMN with >95% of the perovskite phase is prepared by reacting MgNb2O6 with PbO at a temperature of 800°-900°C. The perovskite single phase PMN-PT powder can be prepared by mixing the above PMN powder with PbTiO3 which has been obtained by mixing PbO and TiO2 in the molar ratio of 1 :1 and heat- treating the mixture at a temperature of 800°C.
Since the perovskite phase PMN and PMN-PT powders are usually required to be sintered at temperatures of 1100°-1200°C to have >95% relative density, many studies have been focused on reducing the sintering temperature below 1100°C to be used for MLCC, so that low-cost Pd-Ag can be applied for the metal internal electrodes.
U.S. Patent No. 5,004,715 discloses that when adding CuO to PMN or
PMN-PT powder, the sintering temperature can be reduced to 950°-975°C, so that low-cost Cu internal electrodes can be used, besides the bending strength thereof can be improved >1000 Kg/cm2. It is shown that the compound according to the reference, which has a dielectric constant of 11000-13000 at 20°C, a specific resistivity of ~1012 Ω-cm, a 1.5-3% loss of dielectric constant and >97% of relative density, can be prepared by which appropriate amounts of PbO, MgO, Nb2O5, TiO2 and 3-10 mol% of CuO are placed in a polypropylene bottle, mixed with CaO-stabilized ZrO balls, calcined at 800°C for 2 hours and then sintered at 950°-975°C. Further, U.S. Patent No. 5,680,291 discloses that a preparation method for low-temperature-sinterable PMN-PT is provided by adding PbO, CuO and CaO to PMN or PMN-PT using the columbite method. According to the reference, first, PMN is prepared from a mixture of the MgNb2O6 columbite precursor, obtained by ball-milling MgO and Nb2O5 and heat-treating the mixture at 1100°-1200°C, and reacting the columbite precursor with PbO at 900°C, and then with PbTiO3, prepared by mixing PbO and TiO2 in the molar ratio of 1 :1 and calcining at a temperature of 800°C, and PbO, CaO and CuO are added thereto, and calcination at a temperature of 750°-850°C follows whereby, thus the low-temperature-sinterable PMN-PT powder is prepared. The above PMN- PT powder that is sintered at 845°-950° has a dielectric constant of 13000-
16000 at 20°C, a specific resistivity of ~1011 Ω cm and a 1.2-1.8% loss of dielectric constant. However, the reference does not disclose the sintered density and bending strength.
The above-mentioned references suggest the possibility of using Cu electrodes for the fabrication of a MLCC. However, the first reference with the simple one-step calcination process which is applied to the mixed-oxide method requires relatively high sintering temperatures of 950°-975°C, and the second reference has the cost problem due to the four calcination-milling processes for the powder preparation, though having low sintering temperatures of 845°- 950°C.
DISCLOSURE OF THE INVENTION
Accordingly, an object of the present invention is to provide a method for
preparing PMN and PMN-PT powders with a pure perovskite phase via one- step calcination process to prevent a pyrochlore phase being formed due to the reaction between Nb2O5 with PbO prior to the reaction of MgO.
To achieve the above object, an embodiment according to the present invention provides a preparation method for perovskite PMN dielectric powder, which includes ball-milling PbO and Nb2O5 in alcohol to form a slurry, adding an aqueous solution in which Mg2+ is dissolved to the above slurry, obtaining a PMN(Pb(Mg1/3Nb2/3)O3) precursor by removing the solvent from the slurry, and performing calcination of the PMN precursor powder at a temperature of 800°- 950°C and sintering the resultant powder.
Another embodiment according to the present invention provides a preparation method for perovskite PMN-PT dielectric powder, which includes compounding PbO and Nb2O5, adding an aqueous solution in which Mg2+ is dissolved to an alcoholic slurry of PbO and Nb2O5, obtaining a PMN (Pb(Mg1/3Nb2/3)O3) precursor by removing the solvent from the solution, obtaining a PMN-PT (0.9Pb(Mg1/3Nb2/3)O3-0.1 PbTiO3)precursor by mixing and drying the PMN precursor and PbTiO3, and performing calcination of the PMN- PT precursor powder at a temperature of 750°-950°C and sintering the resultant powder. Wherein, it is desirable that the PbTiO3 is in the form of a single-phase tetragonal powder prepared by precipitating an aqueous TiCI4 solution with ammonia over a slurry of PbO, wherein the precipitate is filtered, washed and dried, which is followed by calcination at 500°-600°C.
In addition, another embodiment according to the present invention provides a preparation method for a perovskite PMN-PT dielectric powder, which includes ball-milling of PbO, Nb2O5 and TiO2 powder in alcohol to form a slurry, adding an aqueous solution in which Mg2+ is dissolved to the alcoholic slurry, obtaining a PMN-PT precursor by removing the solvent from the slurry, and performing calcination of the PMN-PT precursor powder at temperatures of 800°-950°C and sintering the resultant powder.
Additionally, in the above method, a solution in which Cu2+(2-5 mol%) is dissolved can be added before or after calcining the PMN-PT precursor.
MODES FOR CARRYING OUT THE PREFERRED EMBODIMENTS
According to the present invention, a PMN precursor was prepared by adding Mg(NO3)2 which is soluble in water or alcohol, instead of MgO which has been used for conventional mixed-oxide methods, to an alcoholic slurry of PbO and Nb2O5 and removing the solvent. The PMN precursor was calcined at
950°C for 2 hours to have the pure perovskite phase. The PMN powder that was sintered at 900°-1100°C had a dielectric constant of 13700-14400 at 20°C, a specific resistivity of ~1010 Ω-cm, 0.05-0.4% loss of dielectric constant and >95% relative density. The above PMN precursor is mixed with crystalline PT, which was prepared via precipitation of titanium hydroxide from an aqueous TiCI4 solution over PbO powder, the precipitate being filtered, washed and dried, which was followed by calcination at 600°C, and the resultant mixture was calcined at temperatures of 750°-950°C to thereby prepare a PMN-PT powder with a pure perovskite phase. The PMN-PT powder that was sintered at 850°-1200°C had a dielectric constant of 13000-25000, a specific resistivity of ~1010 Ω-cm, a 1.5- 7% loss of dielectric constant and 92-98% of relative density.
Additionally, a PMN-PT precursor was prepared by compounding PbO, Nb2O5 and TiO2 with ball milling, adding Mg(NO3)2 thereto and drying the resultant. The precursor was calcined once at 850°-950°C, whereby a PMN-PT powder with a single perovskite phase was prepared. The PMN-PT powder that was sintered at 850°-1000°C had a dielectric constant of 14400-19000, a specific resistivity of ~1011 Ω-cm, a 1-4% loss of dielectric constant and 94-98% of relative density. Further, 2-3 mol% of Cu(NO3)2, which had been dissolved in water or alcohol solution, instead of CuO, was added to the PMN-PT powders before or after calcination, whereby the sintering temperature could be reduced to 825°C. Such sintered powders had a dielectric constant of -15000, a specific resistivity of ~1011 Ω-cm, and >98% relative density. Here, it is to be noted that the heating rate of the calcination or sintering process was 5°C/min., and the calcination or sintering proceeded for 10min-2hrs only within a closed alumina crucible so as to restrain the volatilization of PbO, without applying embedding powder, and then the furnace was cooled down. In
addition, the dielectric constant and dielectric loss were measured at 20°C, 1 kHz and O.δVrms, and the electrical resistivity was measured after 1 min. since 25V DC has been applied.
Example 1
PbO(0.30mol:99.9% purity, Aldrich Chemical Co., USA) and Nb2O5(0.10mol: 99.9% purity, Aldrich Chemical Co., USA) were placed with isopropanol in a polypropylene bottle and ball milled with zirconia balls of 5mm diameter for 24 hrs, and an aqueous solution of Mg(NO3)26H2O (0.105mol: 98% purity, Aldrich Chemical Co., USA)was added thereto and then the mixture was additionally ball milled for 2 hrs and dried. The preformed powder was heat- treated at 900°C for 2 hrs to thereby obtain the PMN powder having the 100% pure perovskite phase, studied by using X-ray diffractometry (XRD). The powder which had been calcined was added to 0.5 wt% of PVA 217 (Kurari Co., Japan) and ball milled with ZrO2 balls in distilled water in a polypropylene bottle for 24 hrs and then dried. The dried powder was sieved through a 100 mesh sieve and pressed into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at a temperature of 850°-1200°C for 2 hrs. The results of the sintered pallets are shown in Table 1. Here, it is noted that the grain size of the powder sintered at 950°C was 2-4 μm.
Table 1
Effect of Sintering Temperature on Density and Dielectric Properties of PMN
PbTiO3 with a tetragonal phase was prepared by precipitating titanium hydroxide from an aqueous TiCI4 solution with ammonia at pH 9.5 over PbO powder in distilled water, the precipitate being filtered, washed and dried, which was followed by calcination at 600°C for 1 hr. The PbTiO3 powder(0.03mol) and the PMN precursor powder(0.27mol) which had been prepared in Example 1 were placed with isopropanol in a polypropylene bottle and ball milled with ZrO2 balls for 24 hrs and dried. When the mol% of MgO was varied at 98, 100, 105 and 110%, the volume of the perovskite phase of the resultant PMN-PT powder which had been formed after 2hr-calcination at 950°C showed 95.6, 98.7, 100 and 100%, respectively. Thus, 105 mol% of MgO was selected. When heat- treating the PMN-PT precursor powder prepared with such composition at 730°C for 2 hrs, the perovskite phase of 17.2% was developed, but when the preformed powder was calcined at 750°C and 950°C, respectively, for 2 hrs, the powder had the pure perovskite phase. Both calcined powders were bail milled with 0.5 wt% of PVA 217 and ZrO2 balls in distilled water in a polypropylene bottle for 24 hrs and dried. The dried powder was sieved through a 100 mesh sieve and pressed into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at temperatures of 850°- 1200°C for 2 hrs. The results of the sintered pallets are shown in Table 2.
Table 2
Effect of Calcination Temperature on Density and Dielectric Properties of
0.9PMN-0.1 PT Powder
Example 3
PbO(1.0mol:99.9% purity, Aldrich Chemical Co., USA), Nb2O5(0.3mol: 99.9% purity, Aldrich Chemical Co., USA) and TiO2 (0.1mol: anatase 99.9% purity, Aldrich Chemical Co., USA) were placed with isopropanol in a polypropylene bottle and ball milled with zirconia balls having a diameter of
5mm for 24 hrs, and an aqueous solution of Mg(NO3)26H2O (0.315mol: 98% purity, Aldrich Chemical Co., USA) was added thereto and then the mixture was additionally ball milled for 2 hrs and dried. The resultant powder was preformed and heat-treated at 950°C for 2 hrs to thereby obtain the PMN-PT powder having the 100% pure perovskite phase, studied by using XRD. The powder which had been calcined was treated in accordance with the method performed in Example 2 and sintered at 850°-950°C for 2 hrs. The properties of the sintered pellets are shown in Table 3.
Table 3
Effect of Single-step Calcination(950°C, 2hrs) on Density and Dielectric
Properties of 0.9PMN-0.1 PT Dielectrics
Example 4
PbO(1.0mol:99.9% purity, Aldrich Chemical Co., USA), Nb2O5(0.3mol: 99.5% purity, Aldrich Chemical Co., USA), TiO2 (0.1 mol: anatase 99.9% purity,
Aldrich Chemical Co., USA) and Mg(NO3)26H2O (0.315mol: 98% purity, Aldrich Chemical Co., USA) were placed with isopropanol in a polypropylene bottle and ball milled with zirconia balls having a diameter of 5mm for 24 hrs and distilled water (2.5 mol) was added thereto, and then the mixture was additionally ball milled for 2 hrs and dried. The resultant powder was preformed and heat- treated at 850°C for 2 hrs to thereby obtain the PMN-PT powder having the
100% pure perovskite phase, studied by using XRD. The powder which had been calcined was treated in accordance with the method performed in Example 2 and sintered at 850°-950°C for 2 hrs. Single phase perovskite powders of 0.95PMN-0.05PT composition were prepared by the same procedure as the above. The properties of the sintered pellets are shown in Table 4.
Table 4
Effect of Single-step Calcination(950°C, 2hrs) on Density and Dielectric
Properties of different composition of (l-x)PMN-xPT
0.9PMN - 0.1 PT
A PMN-PT precursor powder was preformed according to the same method as in Example 3 and calcined at 950°C for 2 hrs, for thus having the 100% pure perovskite phase. The resultant powder was added to an aqueous solution of Cu(NO3)23H2 O (3.0 mol%: 99% purity, Junsei Chemical Co., Japan), and then the mixture was ball milled with zirconia balls and isopropanol for 4 hrs and dried. The dried powder was sieved through a 100 mesh sieve and pressed into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at temperatures of 825°-900°C for 2 hrs. The properties of the sintered powder are shown in Table 5.
Table 5
Effect of CuO(3 mol%) Addition on Density and Dielectric Properties of Calcined
(1-x)PMN - xPT powder
(0.9 PMN - 0.1 PT)
A PMN-PT precursor powder preformed according to the same method as in Example 3 was calcined at 850°C for 2 hrs, for thus having 98% of the perovskite phase. The resultant powder was added to an aqueous solution of Cu(NO3)23H2O (2.0 mol%), and then the mixture was ball milled with PbO of 2.0 mol%, zirconia balls and isopropanol for 4 hrs and dried. The dried powder which had been preformed was sieved through a 100 mesh sieve and pressed into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at temperatures of 850°-950°C for 2 hrs. Different compositions of (l-x)PMN-xPT were also prepared in the same way as the above. The properties of the sintered pellets are shown in Table 6.
Table 6
Effect of Sintering Temperature on Density and Dielectric Properties of Calcined
0.9PMN-0.1 PT Powder with additive CuO(2 mol%)
Example 7
A PMN-PT precursor powder preformed according to the same method as in Example 3 was calcined at 850°C for 2 hrs, for thus having 100% of the perovskite phase. The resultant powder was added to an aqueous solution of Cu(NO3)23H2O (3.0 mol%: 99% purity, Junsei Chemical Co., Japan), and then the mixture was ball milled with PVA, zirconia balls and isopropanol for 4 hrs and dried. The dried powder was sieved through a 100 mesh sieve and pressed
into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at a temperature of 825°-900°C for 2 hrs. The properties of the sintered powder are shown in Table 7.
Table 7
Effect of Sintering Temperature on Density and Dielectric Properties of One
Step-Calcined 0.9PMN-0.1 PT Powder With Additive CuO(3 mol%)
Example 8
A PMN-PT precursor powder preformed according to the same method as in Example 2 was calcined at 850°C for 2 hrs, for thus having 100% of the perovskite phase. The resultant powder was added to an aqueous solution of Cu(NO3)23H2O (3.0 mol%: 99% purity, Junsei Chemical Co., Japan), and then the mixture was ball milled with 0.5 wt% of PVA, zirconia balls in isopropanol for 4 hrs and dried. The dried powder was sieved through a 100 mesh sieve and pressed into pellets under a pressure of 800kg/cm2 using a mold having a diameter of 10 mm. The pellets were sintered at temperatures of 825°-900°C for 2 hrs. The properties of the sintered pellets are shown in Table 8.
Table 8
Effect of Sintering Temperature on Density and Dielectric Properties of Two
Step-Calcined 0.9PMN-0.1PT Powder With Additive CuO(3 mol%)
It will be apparent to those skilled in the art that various modifications and variations can be made in the preparation method for the low-temperature- sinterable Pb-based perovskite dielectric powder of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.