Patent Application
20250162947
The present disclosure relates to a ceramic substrate, a method for obtaining the same and its use.
Ceramic compositions or substrates are widely used as substrates for mounting electronic components via a metal layer. In this case a ceramic composition acts as an isolating layer on which a metal layer is disposed. An electronic component may then be provided on the metal layer.
Ceramic compositions or substrates used for mounting electronic components are required to have excellent discharge properties, in particular a high coefficient of thermal conductivity. At the same time the ceramic substrate shall have a good mechanical strength as a mounting substrate. This is in particular necessary, when reducing the thickness of the ceramic substrate due to the ongoing miniaturization of electronic components. Therefore, a ceramic substrate is required that has both a high coefficient of thermal conductivity and a high mechanical strength.
A known type of ceramic substrate used in such a set-up is an alumina substrate containing zirconium oxide (zirconia toughened alumina substrate-ZTA substrate).
Such a ceramic substrate is for example described in EP 2 911 994 B1 refers to a metal ceramic substrate comprising Al2O3, ZrO2 and Y2O3, wherein the average grain size of the used Al2O3 is between 2 and 8 μm. However, the document does not define if the Al2O3 grain size refers to the grain size of the starting material or the sintered material. There is also no method for determining the grain size provided.
EP 3786134A1 describes a substrate comprising 70-95 wt % alumina particles in a size between 1.2 μm to 1.9 μm and 5-30 wt % zirconia and hafnia. The size of the zirconia particles is between 0.4 μm and 0.7 μm.
US 2021/0261473A1 also concerns ceramic substrates with different Al2O3 and ZrO2 particle sizes. The size of Al2O3 particles is between 1.7 and 1.9 μm and of ZrO2 particles is between 0.7 and 0.9 μm.
In EP 3 315 476 B1 ceramic substrate are described that comprise aluminum oxide crystals with an average crystal size between 0.9 and 1.6 μm and zirconium oxide crystals with an average crystal size between 0.28 and 0.6 μm.
The authors describe that when the average crystal size of zirconium oxide exceeds 0.5 μm the mechanical strength is hampered. When the crystal size of aluminum oxide is less than 1.0 μm a high coefficient of thermal conductivity is not achieved. At the same time if the crystal size of aluminum oxide exceeds 1.5 μm a high mechanical strength is not achieved.
Thus, in order to achieve both a good thermal conductivity and a mechanical strength a fine tuning of the crystal size of aluminum oxide and zirconium oxide seems to be required.
Thus, the object of the present disclosure was to provide a ceramic substrate combining a good thermal conductivity and mechanical strength.
This object was solved by the ceramic substrate with features as described herein.
Accordingly, a ceramic substrate is provided that comprises:
The ceramic substrate of the disclosure is characterized by a good thermal stability and a good mechanical strength as illustrated by the data provided below. In particular, the good mechanical strength was not expected due to the grain size of ZrO2 determined in the ceramic substrate. In contrast to the prior art as described above a ZrO2 grain size of more than 0.6 μm did not hamper the mechanical strength, on the contrary it was even possible to increase the mechanical strength to a certain extent.
The present ceramic substrate has a dense crystal arrangement and consists of two phases of ZrO2 and Al2O3 grains. The ZrO2 grains are tetragonal or monocline.
In some embodiments, the present ceramic substrate has the following composition:
Yttrium oxide is contained in commercially available zirconium oxide as stabilizer; i.e., commercially available yttria stabilized zirconia is used as starting material in the preparation method as described in more detail below. Besides yttrium oxide, commercially available Zirconium oxide also contains hafnium oxide HfO2. HfO2 may be present within a range of not less than 1 part by mass and not greater than 3 parts by mass per 100 parts of zirconium oxide.
Yttrium oxide may be present in zirconium oxide in an amount of up to 6 wt %, preferably about 5-5.5 wt %. Preferably 2.5-3.5 mol %, more preferably 3 mol % of Y2O3 act as a stabilizer for ZrO2 (Based on the amount of the ZrO2). Commercially Zirconium oxide also contains further components such as up to 0.55 wt % aluminum oxide Al2O3.
As mentioned above the ceramic substrate also contains sintering agents, in particular silicon dioxide (SiO2). A preferred sintering agent is SiO2. SiO2 may be contained in the ceramic substrate in an amount up to 0.5 wt %, preferably up to 0.35 wt %.
In some embodiments, the present ceramic substrate comprises
In some embodiments, the present ceramic substrate comprises
In some embodiments, the present ceramic substrate comprises
In some embodiments, the ceramic substrate has a bending strength (measured according to ASTM C1499-15) of more than 620 MPa, preferably of more than 650 MPa, more preferably of more than 670 MPa, even more preferably of more than 680 MPa, such as 690 MPa. The bending strength may be in a range between 620-800 MPa, preferably in a range between 630-760 MPa, even more preferably in a range between 650-730 MPa.
In some embodiments, the ceramic substrate has a thermal conductivity (measured at 20° C. according to ISO 18755:2005) of more than 20 W/m*K, preferably of more than 22 W/m*K, even more preferably of more than 24 W/m*K. The thermal conductivity may be in a range between 20-40 W/m*K, preferably between 22-35 W/m*K, more preferably between 23-30 W/m*K, even more preferably between 24-27 W/m*K.
In some embodiments, the ceramic substrate has a modulus of elasticity or E-module (Young's Modulus) as determined in a Grindosonic (method described in the experimental section) of more than 310 GPa, preferably of more than 350 GPa, even more preferably of more than 360 GPa. The E-module may be in a range between 310-400 GPa, preferably in a range between 330-390 GPa, more preferably in a range between 350-380 GPa.
In some embodiments, if the ceramic substrate has a fracture toughness KIc Niihara (measured according to the IF-method as described in the experimental section) of 3-5 MPa m1/2, preferably of 3.5-4.5 MPa m1/2, more preferably of 3.8-4.2 MPa m1/2. The Vickers Hardness of the ceramic substrate is between 1500-2000 HV, preferably between 1600-1900 HV, more preferably between 1700-1850 HV, even more preferably between 1750-1830 HV.
In some embodiments, if the ceramic substrate has a surface roughness Ra (measured according to DIN EN ISO 4288) of less than 0.5 μm, preferably of less than 0.4 μm, more preferably of less than 0.2 μm, such as 0.19 μm.
The bulk density (measured according to DIN 993-1/ISO 18754) of the ceramic substrate is more than 3.5 g/cm3, preferably of more than 3.95 g/cm3, even more preferably of more than 4 g/cm3, such as 4.0-4.1 g/cm3.
In some embodiments, the ceramic substrate has an electric breakdown strength (measured at 20° C. following DIN EN 60243 ff) of more than 20 kV/mm, preferably of more than 25 kV/mm. more preferably of more than 30 kV/mm. The electric breakdown strength may be in a range between 20-40 kV/mm, preferably in a range between 25-35 kV/mm, more preferably between 28-33 kV/mm.
Specific heat capacity (measured using DSC device as described in the experimental section) of the ceramic substrate is of more than 620 J/gK, preferably of more than 650 J/gK, more preferably more than 670 J/gK. The specific heat capacity may be in a range between 620-750 J/gK, preferably in a range between 650-720 J/gK, more preferably between 670-710 J/gK.
Coefficient of thermal expansion CTE (determined using a dilatometer as described in the experimental section) of the ceramic substrate is at 20-300° C. of more than 7 10−6/K, at 300-600° C. of more than 810−6/K, at 600-900° C. of more than 8.6 10−6/K.
In some embodiments, the present ceramic may have the following properties:
In some embodiments, the present ceramic may have the following properties:
The ceramic substrate may be obtained in a method comprising the following steps:
In some embodiments of the present method, the first grade of Al2O3 may have a particle size d50 of 0.3-0.6 μm and d90 of less than 3.0, preferably less than 2.0 μm and the second grade of Al2O3 may have a particle size d50 of 1.0-1.5 μm and d90 of less than 4.0, preferably less than 3.6 μm.
In some embodiments of the present method, the first grade of ZrO2 may have a particle size d50 of 0.25-0.35 μm and d98 less than 2.0 μm and the second grade of ZrO2 may have a particle size d50 of 0.9-1.25 μm, and d80 1.5-2.2 μm.
In some embodiments of the present method, the following first mixture is provided as aluminum oxide starting material, the first mixture comprising
Thus, the two types of aluminum oxides having preferably different particle sizes and used as starting material are provided in a weight ratio of about 1:1, i.e. about 50 wt % of each type.
In some embodiments of the present method, the following second mixture is provided as zirconium oxide starting material, the second mixture comprising
Thus, preferably about 70 wt % of at least one first type of zirconium oxide having a particle size between d50 0.2-0.5 μm preferably d50 0.25-0.35 μm and about 30 wt % at least one second type of zirconium oxide having a particle size between d50 0.8-1.4 μm, preferably d50 0.9-1.25 μm are used as starting material.
In some embodiments of the present method sintering aids such as SiO2 and organic compounds such as binder (for example PVA or PVB) are added to the Al2O3/ZrO2 mixture.
The powdery mixture of Al2O3/ZrO2 (containing Y2O3)/sintering aids is subsequently added into a mill together with a solvent such as water or organic solvents, preferably containing a dispersing agent to obtain a dispersion.
In a next shaping step, a green sheet or film is obtained by a doctor blade method using this slurry. Alternatively, using a granulated body prepared by spray-drying the slurry using a spray dryer, a green sheet is obtained by a powder press molding method or a roller compaction method.
Next, a compact may be obtained by performing profile shape machining with a metal mold or a laser. The green sheet may be used directly as a compact and subjected to profile shape machining with a laser after being subject to firing. In addition, taking into consideration mass productivity, a multipiece compact is preferably used.
The sintering step is carried out in a furnace. The sintering temperature is preferably 1400-1700° C.
The ceramic substrate of the disclosure may be used in an electronic device. Such an electronic device may include the ceramic substrate as a support with a metal layer located on one or both surfaces of the ceramic substrate. An electronic component may be provided on the metal layer.
The electronic component provided on the metal layer of the ceramic substrate may be used, for example, in a semiconductor element such as an insulated gate bipolar transistor (IGBT) element, an intelligent power module (IPM) element, a metal oxide semiconductor field effect transistor (MOSFET) element, an LED element, a freewheeling diode (FWD) element, a giant transistor (GTR) element, or a Schottky barrier diode (SBD). In addition, the electronic component may be used in a heat-generating element for a sublimation type thermal printer head or a thermal inkjet printer head. Further, the electronic component may be used in a Peltier element.
The solution is now explained in more detail with reference to the examples.
The following Examples are included to demonstrate certain aspects and embodiments of the disclosure as described in the claims. It should be appreciated by those of skill in the art, however, that the following description is illustrative only and should not be taken in any way as a restriction of the disclosure.
The starting materials ZrO2, Al2O3 and SiO2 are subjected to an incoming raw material inspection. Two different grades are used for both the Al2O3 and the ZrO2 to achieve the grain size distributions shown in the final product.
The mass preparation (slurry) takes place in a mill. The mass preparation contains mixing of the raw materials, meaning the ceramic starting material and the organic compounds. The slurry is cast to form a ceramic green film. The green film is cut to specified dimensions. The ceramic films are sintered at 1400 bis 1700° C.
Grain size: planimetric method applied to the sintered ceramic substrate
The planimetric method applied for determining the average crystal grain size of alumina and zirconia is now described. First, the surface of the ceramic substrate 1 is subjected to mirror finishing and is heat-treated in a temperature range from 50 to 100° C. lower than the firing temperature. The heat-treated surface is then used as a measurement surface and is photographed at a multiplication factor of 5000 times using an SEM. Next, the photographed image data is analyzed using image analysis software (for example, Win ROOF available from the Mitani Corporation). As a result, the data for the respective crystal grain sizes of alumina and zirconia present in the image data can be obtained.
Although the ceramic substrate may contain crystals with a crystal grain size of less than 0.05 mm, only crystals with a crystal grain size of at least 0.05 mm are targeted in the analysis by the image analysis software. In addition, when image analysis software such as that described above is used, separate measurements are possible because there is a difference in color tone between alumina crystal grains and zirconia crystal grains.
The average value of an equivalent circle diameter of each crystal grain calculated from the area of each crystal grain of alumina is the average crystal grain size of alumina, and the average value of an equivalent circle diameter of each crystal grain calculated from the area of each crystal grain of zirconia is the average crystal grain size of zirconia.
The standard deviation of the crystal grain size of alumina can be determined by the same method as that used to determine the average crystal grain size described above from the data of the crystal grain size of alumina obtained using image analysis software.
Determination of the Fracture Toughness (KIc Value) of Ceramic Substrates According to the IF Method with Evaluation According to Niihara and Anstis
The KIc value was determined using the IF method as described in A. G. Evans, E. A. Charles, J. Am. Ceram. Soc. 1976, 56, 371-372. Und G. R. Anstis, P. Chantikul, et al., J. Am. Ceram. Soc. 1981, 64, 533-538.
In short: substrates were supplied. A sample was broken out of each substrate, embedded in Clarocit and ground and polished.
Subsequently, a large number of Vickers indentations were made in each substrate so that there were at least 5 (but usually up to 10) indentations of sufficient quality. Sufficient quality means that the cracks running away from the corners of the indentations were clearly identifiable (one clean, relatively straight crack each with a relatively clearly identifiable crack end and no branching) and no large breakouts were visible on the indentation. The creation of these clear cracks without large break-outs in the indentation first required the determination of the appropriate indentation load. If the indentation load is too low, no cracks will appear. If the indentation load is too high, either the substrate breaks or massive chipping occurs in the indentation, making it impossible to evaluate the indentation. With lower indentation loads, no or too short cracks occur.
The evaluation and thus the calculation of the KIc value was done according to the formula of Niihara as well as Anstis:
For the modulus of elasticity, literature values were used (360 GPa). The hardness values were determined and output directly when the hardness indentation was applied. The crack lengths and indentation diagonals were measured directly on the tester after each hardness indentation.
The hardness and KIc values of the measured samples are shown in table 1 below. The mean value with standard deviation is given in each case. As written above, the mean values were formed from at least 5 measured hardness impressions per material.
The specific heat capacity or heat capacity is a measurable physical quantity that corresponds to the ratio of the heat supplied to an object to the resulting temperature change.
The equation is as follows:
The specific heat is the amount of heat needed to raise the temperature of one gram of the material by 1 degree Celsius.
DSC measurements are done according to DIN 51007 and ISO 11357-1.
A DSC measuring cell consists of a furnace and an integrated sensor with corresponding footprints for sample and reference crucibles. The sensor surfaces are connected to thermocouples or are even part of the thermocouples themselves. This makes it possible to record both the temperature difference between the sample and reference sides (DSC signal) and the absolute temperature of the sample or reference side. Due to the heat capacity cp of the sample, the reference side (usually empty crucible) usually heats up faster than the sample side when heating up a DSC measuring cell, i.e. the reference temperature (TR) rises somewhat faster than the sample temperature (TP). Both curves behave parallel to each other during heating with a constant heating speed—until a sample reaction occurs. In the present case, the sample begins to melt at t1. During the melting process, the temperature in the sample does not change; however, the temperature of the reference side remains unaffected and continues to rise linearly. After the melting is finished, the sample temperature also increases again and shows a linear slope again from time t2 onwards.
The difference signal (ΔT) of the two temperature curves is used. In the middle area of the curve, a peak is formed by the difference formation, which represents the endothermic melting process. Depending on whether the reference temperature was subtracted from the sample temperature during the difference formation or vice versa, the resulting peak points upwards or downwards in the graph. The area of the peak is related to the heat content of the conversion (enthalpy in J/g).
The measurement setup consists of the Grindosonic with connected microphone or piezo sensor, a suitable clapper and a special specimen holder with supports matched to the respective specimen geometry. The device is also connected to the PC for recording the measured values. Elasticity of a material means that a material deforms under external load, but returns to its original state as soon as the load disappears. This strain is linearly proportional to the applied load (Hooke's Law). The quotient of strain and load results in a proportionality factor known as the Young's modulus of the material.
A measuring device from company Netzsch is used to measure the linear thermal expansion of a sample as a function of temperature. Thermal expansion is a measure of the change in volume of a body in response to changes in temperature. Measuring according to manufacturer's specification DIL 402 Expedis Select & Supreme—NETZSCH Analyzing & Testing (netzsch-thermal-analysis.com)
The following table summarizes parameter values measured by standard methods table 2
In the following tables 3-4 several examples according to the disclosure (inventive examples IE 1-2) and their properties are summarized.
In table 3 type and amount of starting material is provided for the inventive examples. The first grade of Al2O3 has a particle size d50 of 0.5 μm and d90 of 2.0 μm and the second grade of Al2O3 has a particle size d50 of 1.3 μm and d90 of 3.2 μm. The first grade of ZrO2 has a particle size d50 of 0.3-0.32 μm and d90 of 0.60 μm and the second grade of ZrO2 has a particle size d50 of 1.17 μm and d80 of 2.06 μm.
Further additives that are used are SiO2 as sintering agent,
Further additives may be added, wherein the sum of all ingredients always adds up to 100 wt %.
The ceramic substrate obtained contains Al2O3, ZrO2, Y2O3 and SiO2. Further components in the ceramic substrates can be: Na2O, MgO, K2O, CaO, TiO2, Cr2O3, Fe2O3, SrO, CeO.
Table 4 summarizes the mechanical, thermal and electrical properties of the inventive examples of Table 3.
As can be seen in Table 4, bending strength reaches a high value of over 650 MPa, even over 680 MPa while the thermal conductivity is 24-25 W/(m*K). Thus, the inventive examples combine both an excellent mechanical strength and a good thermal conductivity.
The effect of specific ZrO2 grain size and the amount of ZrO2 used in the inventive examples IE 1 and IE2 is furthermore illustrated in Table 5 with reference to comparative examples CE1 and CE2.
Comparative Examples CE 1 and CE2 were obtained according to conventional methods as described previously. In particular, the required amounts of Al2O3, ZrO2 and SiO2 powder were mixed, pulverizing, granulating and compact sintering.
As can be seen for CE2, when using ZrO2 of a smaller grain size of 0.49 μm a bending strength of the final ceramic of 640 MPa is achieved. However, when using ZrO2 with grain sizes of 0.65 (IE1) and 0.72 (IE2) even higher bending strengths of over 650 and 680 MPa were detected. Thus, a ZrO2 grain size of more than 0.6 μm did not hamper the mechanical strength, on the contrary it was even possible to increase the mechanical strength to a certain extent.
This effect was not to be expected and contrary to the prior art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22161680.8 | Mar 2022 | EP | regional |
This application is the United States national phase of International Patent Application No. PCT/EP2023/056172 filed Mar. 10, 2023, and claims priority to European Patent Application No. 22161680.8 filed Mar. 11, 2022, the disclosures of which are hereby incorporated by reference in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2023/056172 | 3/10/2023 | WO |
