1. Field of the Invention
The present invention relates to ceramic material technology and more particularly, to a dielectric ceramic material, which uses binary oxides as initial powder materials and prepared in accordance with the corresponding proportion of the respective metal element.
2. Description of the Related Art
With the rapid development of technology, the direction of development of capacitor goes toward miniaturization, high capacity, high stability and high reliability. Nowadays, chip-based multilayer ceramic capacitor (MLCC) has been intensively used to substitute conventional capacitors, not only to reduce the size and increase the capacitor capacitance, but also reduce the production costs. So, multilayer ceramic capacitor is one of the currently mostly used electronic components in computers, mobile phones, automotive electronic devices.
According to different application ranges and electrical characteristics, US Electronic Industries Association (EIA) summarized capacitors as Class I temperature compensating type capacitors and Class II high dielectric constant capacitors whose capacitance is higher than that of Class I. The following Table I illustrates a capacitor specification constructed subject US Electronic Industries Association (EIA) Class II. For the advantage of high dielectric temperature stability, X8S (−55° C.˜150° C., ΔC/C≦22%) multilayer ceramic capacitor has been widely used in miniature electronic components and vehicles under a high temperature variation environment. Automobile electronic devices, such as engine control unit (ECU), anti-lock braking system ABS and proprietary digital electronic fuel injection system (PGMFI), need to operate in a fairly harsh environmental condition. Therefore, for safety reasons, when a multilayer ceramic capacitor to be applied to this fairly harsh environmental condition, it needs to have a more stable and higher temperature range (greater than 150° C.) of dielectric characteristic. Capacitor with ultra-high temperature stability will be essential elements for electronic systems for high temperature operation.
Further, Barium Titanate (BaTiO3) has excellent dielectric characteristic, and is often used as a dielectric ceramic material for capacitor. However, in order to fit different application requirements, modifying agents may be selectively added to alter the electrical characteristics of barium titanate (BaTiO3). U.S. Pat. No. 7,751,178 discloses a ceramic dielectric of which the static capacitance-temperature characteristics can satisfy EIA-X8R specifications. This dielectric ceramic includes a perovskite type compound represented by the composition formula (Ba1-x-yCaxSny)m(Ti1-zZrz)O3 (where x, y, z, and m satisfy 0.9990≦m≦1.015, 0≦x≦0.20, 0.02≦y≦0.20, 0≦z≦0.05 respectively) as a primary component; and RE as an accessory component (where RE is at least one selected from the group consisting of Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu), wherein 0.5 to 20 molar parts of RE is contained with respect to 100 molar parts of the primary component.
Taiwan Patent 1397090 discloses a dielectric ceramic composition of which the static capacitance-temperature characteristics can satisfy EIA-X8R specifications. This dielectric ceramic composition includes a BaTiO3 based primary component; and a glassy ingredient as an accessory component. The BaTiO3 based primary component includes the metal oxides of AO, MnO, B2O5 and Re2O3. Element A is selected from the group of Mg, Ca, Sr and Ba. Element B is selected from the group of V, Nb and Ta. Element Re is selected from the group of Y, Tb, Dy, Ho, Er, Tm and Yb. The glassy ingredient is composed of the oxide of SiO2—TiO2—XO wherein X is selected from the group of BaCa, SrMg, Zn and Mn.
Further, Taiwan Patent 201340146, issued to the present inventor, discloses a composite dielectric ceramic material that satisfies EIA-X8R and X9R specifications. This composite dielectric ceramic material includes (1-x)BaTiO3-xLiTaO3, (1-x)BaTiO3-xNaNbO3 and (1-x)BaTiO3-xBaCeO3 (in these three material groups, x: 0.01˜0.50). This invention also discloses a kind of high temperature stable dielectric ceramic material design principle that is based on the viewpoint of composite material to prepare a composite phase by mixing a dielectric material of high Curie temperature with a dielectric material of low Curie temperature. These two dielectric materials compensate for each other, wherein the dielectric material of low Curie temperature is based on the primary component of BaTiO3 of Curie temperature about 130° C.; the dielectric material of high Curie temperature is preferably over 200° C.
However, the aforesaid various dielectric ceramic materials commonly use BaTiO3 or Pervovskite compound as the primary component and at least one modifying agent, glassy ingredient or metal oxides (such as LiTaO3, Li2CO3 and Ta2O5) as an accessory component to alter the electric characteristics of BaTiO3, and to stabilize the rate of change of the temperature of the dielectric constant. However, these dielectric ceramic material systems need to use a ternary oxide (such as BaTiO3, LiTaO3 or Li2CO3) as the initial powder material and prepared in accordance with a predetermined ratio. The material is difficult to get and more expensive. Further, the manufacturing process of the dielectric ceramic material system is complicated or cumbersome, and other unnecessary compounds (such as Li3TaO4) can be produced during the manufacturing process, resulting in that the overall costs of the materials needed for the production cannot be effectively reduced. So, adding a predetermined ratio of compounds to barium titanate to prepare a dielectric ceramic material having ultra stable dielectric characteristics that comply with actual application is the major subject to be engaged in this industry.
The present invention has been accomplished under the circumstances in view. It is one object of the present invention to provide a dielectric ceramic material, which includes the composite dielectric ceramic powders of BaTiO3 and Ba2LiTa5O15, or, BaTiO3 and Ba2LiNb5O15, wherein BaTiO3 and Ba2LiTa5O15, or, BaTiO3 and Ba2LiNb5O15 use the oxides of BaO, TiO2, Li2O and Ta2O5, or the oxides of BaO, TiO2, Li2O and Nb2O5 as the initial powder materials prepared subject to a predetermined percentage. This dielectric ceramic material simply uses simple binary oxides as initial powder materials that are easy to obtain and inexpensive, and that eliminate the complicated manufacturing process of synthesizing BaTiO3, Ba2LiTa5O15 and Ba2LiNb5O15, making the whole process more simple and the manufacturing cost more cheaper and preventing the formation of other compounds.
It is another object of the present invention to provide a dielectric ceramic material, which is based on the composite dielectric ceramic powders (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNb5O15) that is respectively prepared by the initial oxide powders of BaO, TiO2, Li2O and Ta2O5, or, BaO, TiO2 Li2O and Nb2O5 subject to a respective predetermined percentage, wherein BaTiO3 in (1-x)(BaTiO3)-x(Ba2LiTa5O15) has a mole percentage from 50% to 98% and Ba2LiTa5O15 in (1-x)(BaTiO3)-x(Ba2LiTa5O15) has a mole percentage from 2% to 50%; BaTiO3 in (1-x)(BaTiO3)-x(Ba2LiNb5O15) has a mole percentage from 60% to 95% and Ba2LiNb5O15 in (1-x)(BaTiO3)-x(Ba2LiTa5O15) has a mole percentage from 5% to 40%.
Other advantages and features of the present invention will be fully understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference signs denote like components of structure.
Referring to
Referring to
Further, when using the composite dielectric ceramic material to make multilayer ceramic capacitor (MLCC) examples, use initial powder materials of at least two group materials including BaO, TiO2, Li2O and Ta2O5, or, BaO, TiO2, Li2O and Nb2O5 to prepare composite dielectric ceramic powders (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNb5O15) according to the formula tables of Table 2 and Table 3 and the preparation flow charts of
Thereafter, stack up printed thin ceramic green sheets, and then use hydrostatic pressure to compress the stacked, printed thin ceramic green sheets, and then cut the stacked, printed thin ceramic green sheets into designed multilayer ceramic green chip, and then heat the multilayer ceramic green chip under the pure N2 atmosphere at 330° C. (at the heating rate of 2° C./min) for 12 hours to burn out organic matters, and then sinter the multilayer ceramic green chip under a reducing atmosphere composed of 98% N2-2% H2 and 35° C. saturated water vapor at 1100° C.˜1400° C. (at the heating rate of 3° C./min) for 2 hours and then reduce the heating the temperature to 900° C.˜1050° C. (at the cooling rate of 4° C./min), and then apply an reoxidation heat treatment to the sintered bulk under 60 ppm˜150 ppm or air atmosphere environment, and then reduce the temperature to room temperature to obtain multilayer ceramic sintered bulk. Thereafter, dip Ag or Cu external electrode paste on exposed ends of the internal electrodes, and then raise the temperature to 800° C.˜900° C. (at the heating rate of 15° C./min) under the pure N2 atmosphere, and then cool down the stove to room temperature, and the desired multilayer ceramic capacitor (MLCC) examples are prepared.
Referring to
Referring to the following Table 4 and
we can know that a composite dielectric ceramic capacitor based on the dielectric ceramic material of (1-x)(BaTiO3)-x(Ba2LiTa5O15) according to the present invention has excellent dielectric characteristic stability with dielectric-loss factor (DF) within 1.5% when x value=0.03˜0.50 (examples 1˜10), it can effectively stabilize the dielectric characteristics; when x value is increased from 0.10 to 0.20, the most optimal dielectric characteristic stability can be obtained to satisfy EIA X9R specifications.
Referring to the following Table 5 with reference to
The above-described (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNb5O15) capacitors and their initial oxide powder materials are not intended for use to limit the scope and spirit of the present invention. The most optimal form of the present invention is to use initial powder materials of at least two group materials including BaO, TiO2, Li2O and Ta2O5, or, BaO, TiO2, Li2O and Nb2O5 to prepare composite dielectric ceramic powders (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNb5O15).
In accordance with the popular ceramic material common sense can infer that sintering BaO, TiO2, Li2O, Ta2O5 and Nb2O5 can produce various compounds, such as the oxides of BaTiO3, BaTa2O6, BaNb2O6, Ba(Ti0.5Nb0.5)O3, Li2TiO3, Li4TiO4, LiTaO3 and LiNbO3. These oxides can be used as initial powder materials for making (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNb5O15) capacitors subject to a predetermined percentage. In actual application, carbonates of BaCO3, BaCl2, Li2CO3 and LiOH, chlorides and hydroxides can be converted into oxides under a high temperature. Therefore, these oxides can be prepared in accordance with the corresponding proportion of the respective metal element as initial powder materials for the (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x(Ba2LiNB5O15) capacitors
Therefore, the invention provides dielectric ceramic materials of (1-x)(BaTiO3)-x(Ba2LiTa5O15) and (1-x)(BaTiO3)-x (Ba2LiTa5O15) that comprise BaO, TiO2, Li2O and Ta2O5, or Bao, TiO2, Li2O and Nb2O5 as the initial oxide powders, and is prepared in accordance with the corresponding proportion of the respective metal element. These dielectric ceramic materials simply use simple binary oxides as initial powder materials that are easy to obtain and inexpensive, and that eliminate the complicated manufacturing process of using other oxides of BaTiO3 and LiTaO3 or BaTiO3, Li2CO3 and Ta2O5 as the initial powder materials to synthesize BaTiO3, Ba2LiTa5O15 and Ba2LiNb5O15, making the whole process more simple and the manufacturing cost more cheaper and preventing the formation of other compounds (Such as Li3TaO4). These dielectric ceramic materials are very practical for industrial application and have great commercial value, making the products more competitive.
Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
Number | Date | Country | Kind |
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101109970 | Mar 2012 | TW | national |
103119920 | Jun 2014 | TW | national |
This application is a Continuation-In-Part of co-pending application Ser. No. 13/569,616, filed on Aug. 8, 2012, for which priority is claimed under 35 U.S.C. §120, and this application claims priority of Application No. 101109970 filed in Taiwan, R.O.C. on Mar. 22, 2012 and Application No. 103119920 filed in Taiwan, R.O.C. on Jun. 9, 2014, for which priority is claimed under 35 U.S.C. §119, the entire contents of all of which are hereby incorporated by reference.
Number | Date | Country | |
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Parent | 13569616 | Aug 2012 | US |
Child | 14577905 | US |