[0001] 1. Field of the Invention
[0002] The present invention relates to a dielectric ceramic composition which can be sintered simultaneously with Au, Ag, Cu or the like as a low resistant conductor and which is suitable for laminated ceramic parts because of its low dielectric loss (high Q-value); and laminated ceramic parts using the dielectric ceramic composition, such as a laminated ceramic capacitor and an LC filter. In particular, the present invention relates to a dielectric ceramic composition comprising a main component containing Zn
[0003] 2. Description of the Related Art
[0004] In recent years, to keep up with the tendency toward integrated microwave circuits, demands for a compact dielectric resonator having a small dielectric loss (tan δ) and exhibiting stable dielectric properties are increasing. The dielectric ceramic composition used for such a dielectric resonator is demanded to have a relatively large dielectric constant ε
[0005] For this type of dielectric ceramic composition. BaO—MgO—WO
[0006] In recent years, laminated ceramic parts formed by laminating a dielectric ceramic composition, such as a laminated ceramic capacitor or an LC filter, have been developed and the lamination by the simultaneous sintering of a dielectric ceramic composition and an internal electrode is being performed. However, the above-described conventional dielectric ceramic compositions have a difficulty in performing the simultaneous sintering with the internal electrode because of their high sintering temperature of 1300 to 1400° C. and therefore, for forming a lamination structure, material of the internal electrode is limited to a high-temperature resistant material such as palladium (Pd) or platinum (Pt). For this reason, there has been demanded a dielectric ceramic composition capable of performing the simultaneous sintering with the internal electrode at a low temperature of 1000° C. or less, using as the internal electrode material silver (Ag), Ag-Pd, Cu and the like, which are a low resistant conductor and inexpensive.
[0007] The object of the present invention is to provide a dielectric ceramic composition which can be sintered at such a temperature of about 800 to 1000° C. as to permit incorporation of and multilayer formation with a law resistant conductor such as Cu or Ag by the simultaneous sintering with the low resistant conductor and which has a low dielectric loss tan δ (high Q-value), a small absolute value in temperature coefficient τ
[0008] As a result of extensive investigations to solve the above-described problems in the conventional dielectric ceramic materials, the present inventors have found that the following composition satisfies the requirement for solving the problems.
[0009] According to the present invention, there is provided a dielectric ceramic composition characterized by containing a glass component in an amount of 5 to 150 parts by weight based on 100 parts by weight of the main component represented by the formula: xZn
[0010] The glass component is preferably a PbO-base glass, a ZnO-base glass, a SiO
[0011] Furthermore, the dielectric ceramic composition may contain CuO in an amount of 40 parts by weight or less based on 100 parts by weight of the main component.
[0012] Also, the dielectric ceramic composition may contain MO in an amount of 30 parts by weight or less based on 100 parts by weight of the main component.
[0013] According to the present invention, there is also provided a method of producing a dielectric ceramic composition characterized in that a calcined powder comprising Zn
[0014] According to the present invention, there is also provided laminated ceramic parts characterized by comprising a plurality of dielectric layers, an internal electrode formed between the dielectric layers and an external electrode electrically connected to the internal electrode, wherein the dielectric layer is constituted of dielectric ceramics obtained by sintering the dielectric ceramic composition, and the internal electrode is made of elemental Cu or elemental Ag, or an alloy material mainly comprising Cu or Ag.
[0015] By preparing a specific composition comprising a main component or matrix material component containing Zn
[0016]
[0017]
[0018]
[0019]
[0020] A dielectric ceramic composition of the present invention will be described in detail below.
[0021] The dielectric ceramic composition of the present invention is characterized by containing a glass component in an amount of 5 to 150 parts by weight based on 100 parts by weight of the main component represented by the formula: xZn
[0022] The composition wherein x satisfies 0<x<1 achieves the absolute value of temperature coefficient τ
[0023] If y is more than 0.5, the composition is not preferable because τ
[0024] The Zn
[0025] The dielectric ceramic composition of the present invention is characterized by containing a glass component in a predetermined amount. The glass used herein as the glass component means an amorphous solid substance obtained by fusion. A crystallized glass partially containing a crystallized substance in a glass is also included in the glass. The solid substance includes an inorganic substance comprising an oxide and examples of the glass for use in the present invention include a PbO-base glass, a ZnO-base glass, a SiO
[0026] As the glass for use in the present invention, in addition to the PbO-base glass, the ZnO-base glass and the SiO
[0027] According to the present invention, a glass component is incorporated in an amount of 5 to 150 parts by weight based on 100 parts by weight of the main component represented by the formula: xZn
[0028] In the present invention, before the sintering, Zn
[0029] In the present invention, further, CuO is incorporated into the dielectric ceramic composition as a side component to produce a dielectric ceramic composition containing a glass component in an amount of 5 to 150 parts by weight and CuO in an amount of 40 parts by weight or less, based on 100 parts by weight of the main component represented by the formula: xZn
[0030] In the present invention, also, MnO is similarly incorporated into the dielectric ceramic composition as a side component to produce a dielectric ceramic composition containing a glass component in an amount of 5 to 150 parts by weight and MnO in an amount of 30 parts by weight, based on 100 parts by weight of the main component represented by the formula: xZn
[0031] The CuO or the MnO, which is added as the side component, may be added individually or both of the components may be added in combination.
[0032] The production method of the dielectric ceramic composition of the present invention is described below.
[0033] The dielectric ceramic composition can be produced by preparing a calcined powder comprising Zn
[0034] More detailed description will be provided hereinafter.
[0035] Titanium oxide (TiO
[0036] ZnTiO
[0037] That is, titanium oxide (TiO
[0038] In case that the above predetermined molar ratio of TiO
[0039] Instead of obtaining the ZnTiO
[0040] The dielectric ceramic composition of the present invention is evaluated in a pellet form on the dielectric properties. Specifically, in the above-described starting material powder, an organic binder such as polyvinyl alcohol is mixed. The mixture is rendered uniform, dried and pulverized, followed by molding under pressure (pressure: on the order of from 100 to 1000 kg/cm
[0041] If desired, the dielectric ceramic composition is processed to a proper shape and size, formed to a sheet by the doctor blade method and laminated by using the sheet and electrodes, whereby the composition may be used as materials for various laminated ceramic parts. Examples of the laminated ceramic parts include a laminated ceramic capacitor, an LC filter, a dielectric resonator and a dielectric substrate.
[0042] The laminated ceramic parts of the present invention comprises a plurality of dielectric layers, an internal electrode formed between the dielectric layers and an external electrode electrically connected to the internal electrode, wherein the dielectric layer is constituted of dielectric ceramics obtained by sintering the dielectric ceramic composition and the internal electrode is made of elemental Cu or elemental Ag, or an alloy material mainly comprising Cu or Ag. The laminated ceramic parts of the present invention can be obtained by laminating the dielectric layers each containing the dielectric ceramic composition and a layer of elemental Cu, elemental Ag or an alloy material mainly comprising Cu or Ag, and simultaneously sintering then.
[0043] Examples of one embodiment of the laminated ceramic parts include a tri-plate type resonator shown in
[0044]
[0045] 0.33 mol of titanium oxide (TiO
[0046] The thus-obtained dielectric ceramic composition was processed to a size of 7 mm in diameter and 3 mm in thickness and then, determined on the unloaded Q-value (Q) at the resonant frequency of 7 to 11 GHz, the dielectric constant ε
TABLE 1 Matrix Matrix Material Composition Material Glass CuO MnO Average (molar ratio) Amount Amount Amount Amount Particle Zn ZnTiO TiO Glass Composition (% by weight) (parts (parts (parts (parts Size x 1 − x y SiO Al ZnO PbO BaO B by wt) by wt) by wt) by wt) (μm) Example 1 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 0 1.0 2 0.22 0.78 0.01 6 12 52 — — 30 100 40 0 0 1.0 3 0.22 0.78 0.01 6 12 52 — — 30 100 80 0 0 1.0 4 0.22 0.78 0.01 6 12 52 — — 30 100 120 0 0 1.0 5 0.86 0.14 0.20 10 10 40 — — 40 100 12 0 0 1.0 6 0.56 0.44 0.01 10 10 40 — — 40 100 12 0 0 1.0 7 0.33 0.67 0.10 10 10 40 — — 40 100 12 0 0 1.0 8 0.13 0.87 0.30 10 10 40 — — 40 100 12 0 0 1.0 9 0.33 0.67 0.50 10 10 40 — — 40 100 12 0 0 1.0 10 0.04 0.96 0.01 10 10 40 — — 40 100 12 0 0 1.0 11 0.98 0.02 0.01 67 3 — — — 30 100 9 0 0 1.0 12 0.98 0.02 0.01 69 1 — — — 30 100 9 0 0 1.0 13 0.98 0.02 0.01 26 2 12 30 — 30 100 9 0 0 1.0 14 0.02 0.98 0.01 39 3 18 10 — 30 100 9 0 0 1.0 15 0.02 0.98 0.01 8 2 46 — 14 30 100 9 0 0 1.0 16 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 0 0.5 17 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 0 0.1 18 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 2.5 1.0 19 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 10 1.0 20 0.22 0.78 0.01 6 12 52 — — 30 100 10 0 30 1.0 21 0.22 0.78 0.01 6 12 52 — — 30 100 10 5 0 1.0 22 0.22 0.78 0.01 6 12 52 — — 30 100 10 15 0 1.0 23 0.22 0.78 0.01 6 12 52 — — 30 100 10 40 0 1.0 24 0.22 0.78 0.01 6 12 52 — — 30 100 10 2.5 2.5 1.0 25 0.22 0.78 0.01 6 12 52 — — 30 100 10 15 10 1.0 Com. Example 1 0.22 0.78 0.03 6 12 52 — — 30 100 0 0 0 1.0 2 0.22 0.78 0.03 6 12 52 — — 30 100 1 0 0 1.0 3 0.22 0.78 0.03 6 12 52 — — 30 100 3 0 0 1.0 4 0.22 0.78 0.03 6 12 52 — — 30 100 160 0 0 1.0 5 0.97 0.03 0.60 6 12 52 — — 30 100 10 0 0 1.0
[0047]
TABLE 2 Sintering τf Temp. εr Q × f (ppm/° C.) (° C.) Example 1 20 10000 0 900 2 15 9000 −20 840 3 12 8000 −30 840 4 10 6000 −30 840 5 19 9000 −10 900 6 24 10000 56 900 7 17 15000 −15 900 8 20 12000 0 900 9 22 12000 60 900 10 24 10000 46 900 11 15 14700 4 900 12 15 16500 12 900 13 13 2000 −60 840 14 16 15000 14 900 15 18 8000 −60 900 16 21 11000 0 850 17 21 11500 0 800 18 20 9000 6 880 19 22 6000 15 850 20 16 3000 −40 830 21 20 9000 0 880 22 18 9000 −30 850 23 16 7000 −40 830 24 20 9000 −30 850 25 22 6000 −5 850 Com. Example 1 composition is not sintered at 1000° C. or less 2 composition is not sintered at 1000° C. or less 3 composition is not sintered at 1000° C. or less 4 glass is eluted 5 30 10000 80 900
[0048] Also, to 100 g of a mixture of the matrix material and the glass, 9 g of polyvinyl butyral as a binder, 6 g of dibutylphthalate as a plasticizer, and 60 g of toluene and 30 g of isopropyl alcohol both as a solvent were added to produce a green sheet having a thickness of 100 μm by the doctor blade method. Then, 22 layers of the green sheets were laminated by the thermo compression bonding of applying a pressure of 200 kg/cm
[0049] The obtained tri-plate type resonator was evaluated on the unloaded Q-value at a resonant frequency of 2 GHz. As a result, the percentage of contraction or shrinkage was 19% at the sintering temperature of 900° C., the dielectric constant ε
[0050] In the same manner as in Example 1, Zn
[0051] In the same manner as in Example 1, Zn
[0052] In the same manner as in Example 1, Zn
[0053] In the same manner as in Example 1, Zn
[0054] In the same manner as in Example 1, Zn
[0055] In the same manner as in Example 1, Zn
[0056] In the same manner as in Example 1, Zn
[0057] 0.45 mol of titanium oxide (TiO
[0058] The thus-obtained dielectric ceramic composition was processed to a size of 7 mm in diameter and 3 mm in thickness and then, determined on the unloaded Q-value (Qxf) at the resonant frequency of 7 to 11 GHz, the dielectric constant ε
TABLE 3 Matrix Material Matrix Composition Material Glass CuO MnO Average (molar Ratio) Amount Amount Amount Amount Particle Zn ZnTiO Glass Composition (% by weight) (parts (parts (parts (parts Size x 1 − x SiO Al ZnO PbO BaO B by wt) by wt) by wt) by wt) (μm) Example 1′ 0.22 0.78 6 12 52 — — 30 100 10 0 0 1.0 2′ 0.22 0.78 6 12 52 — — 30 100 40 0 0 1.0 3′ 0.22 0.78 6 12 52 — — 30 100 80 0 0 1.0 4′ 0.22 0.78 6 12 52 — — 30 100 120 0 0 1.0 5′ 0.86 0.14 10 10 40 — — 40 100 12 0 0 1.0 6′ 0.56 0.44 10 10 40 — — 40 100 12 0 0 1.0 7′ 0.33 0.67 10 10 40 — — 40 100 12 0 0 1.0 8′ 0.13 0.87 10 10 40 — — 40 100 12 0 0 1.0 9′ 0.04 0.96 10 10 40 — — 40 100 12 0 0 1.0 10′ 0.98 0.02 67 3 — — — 30 100 9 0 0 1.0 11′ 0.98 0.02 69 1 — — — 30 100 9 0 0 1.0 12′ 0.98 0.02 26 2 12 30 — 30 100 9 0 0 1.0 13′ 0.02 0.98 39 3 18 10 — 30 100 9 0 0 1.0 14′ 0.02 0.98 8 2 46 — 14 30 100 9 0 0 1.0 15′ 0.22 0.78 6 12 52 — — 30 100 10 0 0 0.5 16′ 0.22 0.78 6 12 52 — — 30 100 10 0 0 0.1 17′ 0.22 0.78 6 12 52 — — 30 100 10 0 2.5 1.0 18′ 0.22 0.78 6 12 52 — — 30 100 10 0 10 1.0 19′ 0.22 0.78 6 12 52 — — 30 100 10 0 30 1.0 20′ 0.22 0.78 6 12 52 — — 30 100 10 5 0 1.0 21′ 0.22 0.78 6 12 52 — — 30 100 10 15 0 1.0 22′ 0.22 0.78 6 12 52 — — 30 100 10 40 0 1.0 23′ 0.22 0.78 6 12 52 — — 30 100 10 2.5 2.5 1.0 24′ 0.22 0.78 6 12 52 — — 30 100 10 15 10 1.0 Com. Example 1′ 0.22 0.78 6 12 52 — — 30 100 0 0 0 1.0 2′ 0.22 0.78 6 12 52 — — 30 100 1 0 0 1.0 3′ 0.22 0.78 6 12 52 — — 30 100 3 0 0 1.0 4′ 0.22 0.78 6 12 52 — — 30 100 160 0 0 1.0
[0059]
TABLE 4 Sintering τf Temp. εr Q × f (ppm/° C.) (° C.) Example 1′ 20 10000 0 900 2′ 15 7000 −20 840 3′ 12 6000 −30 840 4′ 10 14000 −30 840 5′ 16 15000 −60 900 6′ 17 12000 −58 900 7′ 19 11000 −20 900 8′ 19 10000 24 900 9′ 22 10000 45 900 10′ 24 15000 4 900 11′ 15 16000 12 900 12′ 15 1500 −53 840 13′ 19 3000 −60 900 14′ 18 13000 −58 900 15° 20 11000 0 850 16′ 21 11500 0 800 17′ 20 9000 5 880 18′ 22 6000 13 850 19′ 16 3000 −42 830 20′ 20 9000 −1 880 21′ 18 9000 −31 850 22′ 16 7000 −42 830 23′ 20 9000 −32 850 24′ 22 6000 −7 850 Com. Example 1′ composition is not sintered at 1000° C. or less 2′ composition is not sintered at 1000° C. or less 3′ composition is not sintered at 1000° C. or less 4′ glass is eluted
[0060] Also, to 100 g of a mixture of the matrix material and the glass, 9 g of polyvinyl butyral as a binder, 6 g of dibutylphthalate as a plasticizer, and 60 g of toluene and 30 g of isopropyl alcohol both as a solvent were added to produce a green sheet having a thickness of 100 μm by the doctor blade method. Then, 22 layers of the green sheets were laminated by the thermo compression bonding of applying a pressure of 200 kg/cm
[0061] The obtained tri-plate type resonator was evaluated on the unloaded Q-value at a resonant frequency of 2 GHz. As a result, the percentage of contraction or shrinkage was 19% at the sintering temperature of 900° C., the dielectric constant ε
[0062] In the same manner as in Example 1′, TiO
[0063] In the same manner as in Example 1′, TiO
[0064] In the same manner as in Example 1′, Zn
[0065] In the same manner as in Example 1′, Zn
[0066] In the same manner as in Example 1′, Zn
[0067] In the same manner as in Example 1′, Zn
[0068] According to the dielectric ceramic composition of the present invention, a dielectric ceramic composition can be provided such that the dielectric constant ε