Patent Grant
6861622
1. Field of the Invention
The present invention relates to negative temperature coefficient thermistors (hereinafter referred to as NTC thermistors), and particularly relates to a multilayer NTC thermistor including internal electrodes and a method for manufacturing such a thermistor.
2. Description of the Related Art
Demands have been made for NTC thermistors, intended for temperature sensors and temperature compensators, having low resistance. To achieve that, the following technique, for example, is disclosed in Japanese Unexamined Patent Application Publication No. 4-328801: Cu is added to an NTC thermistor element comprising a sintered body of a spinel metal oxide containing Mn, Co, Ni, and so on, thereby reducing the resistivity.
The following technique is disclosed in Japanese Patent No. 3218906: an external electrode material containing Cu is applied to end faces of an NTC thermistor element and a Cu component contained in electrodes is localized at the interface between each electrode and the element to reduce the resistivity.
These conventional techniques are intended for lead-type NTC thermistors. When the techniques are used for chip-type NTC thermistors, problems arise.
In Japanese Unexamined Patent Application Publication No. 4-328801, as shown in
In Japanese Patent No. 3218906, as shown in
In order to solve the above problems of the conventional techniques, the following chip-type thermistor has been proposed, as shown in FIG. 3: a third NTC thermistor 21 including a third NTC thermistor element 21, third internal electrodes 24 disposed in the third NTC thermistor element 22, and third external electrodes 23 disposed at both ends of the third NTC thermistor element 22 and electrically connected to the third internal electrodes 24. However, even if a material for forming the third external electrodes 23 contains Cu, the quantity of diffused Cu is insufficient to control the resistance although Cu is diffused in the third NTC thermistor element 22 from the third internal electrodes 24. Thus, the resistance of the third NTC thermistor 21 cannot be sufficiently decreased.
It is an object of the present invention to provide an NTC thermistor including internal electrodes and having lower resistance and a method for manufacturing such a thermistor, wherein the thermistor can be subjected electrolytic plating without forming a metal coating on a thermistor element.
In a first aspect of the present invention, an NTC thermistor includes a thermistor element containing a transition metal oxide as a main component; internal electrodes disposed in the thermistor element; and external electrodes, electrically connected to the internal electrodes, each lying on corresponding ends of the thermistor element, wherein the internal electrodes contain a metal component other than Cu as a main component and at least one of Cu and Cu compounds as a sub-component.
In the NTC thermistor, the external electrodes contain a metal component other than Cu as a main component and at least one of Cu and Cu compounds as a sub-component.
The transition metal oxide contained in the thermistor element is preferably at least one selected from the group consisting of Mn, Ni, Co and Fe. The content of the transition metal oxide is preferably about 80 to 100%.
The material for forming the internal electrodes preferably contains at least one selected from the group consisting of Ag, Pd and Pt as a main component. The content of the main component is preferably about 84 to 96%. The content of Cu is preferably about 4 to 16%.
The material for forming the external electrodes preferably contains at least one selected from the group consisting of Ag, Pd and Pt as a main component. The content of the main component is preferably about 84 to 96%. The content of Cu is preferably about 4 to 16%.
In a second aspect of the present invention, a method for manufacturing an NTC thermistor includes a first step of preparing green ceramic sheets containing a transition metal oxide as a main component, for forming a thermistor element; a second step of applying a conductive paste containing a metal component other than Cu as a main component and at least one of Cu and Cu compounds, for forming internal electrodes on some of the green ceramic sheets to form layers for forming the internal electrodes; a third step of stacking the green ceramic sheets prepared in the first step and the paste-applied green ceramic sheets prepared in the second step in an arbitrary manner to form a green compact having opposed planes; a fourth step of firing the green compact to obtain a fired compact; and a fifth step of forming external electrodes on both ends of the fired compact by a firing process, wherein the fourth step includes a firing sub-step of firing the green compact at a maximum temperature of about 1,000 to 1,350° C. in an atmosphere containing about 20 to 80% of oxygen and a cooling sub-step of cooling the fired compact at a cooling rate of about 100 to 300° C./h after the firing sub-step.
In the above method, the external electrodes formed in the fifth step contain a metal component other than Cu as a main component and at least one of Cu and Cu compounds.
In the above method, the cooling sub-step of the fourth step includes an operation of cooling the fired compact to about 800 to 1,100° C. and an operation of holding the resulting compact at about 800 to 1,100° C. for about 60 to 600 minutes and then further cooling the resulting compact.
In the present invention, Cu can be diffused in the entire thermistor element, except for the vicinity of the surface thereof, from the internal electrodes since the internal electrodes contain at least one of Cu and Cu compounds. Thereby, the resistance of the NTC thermistor can be decreased.
Since Cu is not diffused in the vicinity of the surface of the thermistor element, the resistance of the surface vicinity is not decreased, thereby preventing a metal coating from being formed on the thermistor element.
The quantity of diffused Cu can be precisely adjusted by controlling the heating and cooling mode and the oxygen content in a furnace during firing. Thus, for the NTC thermistor element having a certain composition, the resistance and the B constant can be adjusted in a wide range.
First Embodiment
A first embodiment of the present invention will now be described.
The fourth NTC thermistor 31 includes a fourth NTC thermistor element 32, fourth internal electrodes 33 disposed in the fourth NTC thermistor element 32, and fourth external electrodes 34 each disposed at the corresponding end faces of the fourth NTC thermistor element 32 and electrically connected to the corresponding fourth internal electrodes 33.
The material for forming the fourth internal electrodes 33 contains Cu, which is diffused in the vicinities of the fourth internal electrodes 33. Thus, the inner part has a resistivity smaller than that of the surface in the fourth NTC thermistor element 32.
Example 1 will now be described with reference to
The fourth NTC thermistor 31 of Example 1 was prepared according to the following procedure: an organic binder, a dispersant, an anti-foaming agent, and water were added to a thermistor material containing 80% by weight of Mn3O4 and 20% by weight of NiO, thereby preparing a plurality of green ceramic sheets having a thickness of 40 μm.
A conductive paste containing an electrode material for forming fourth internal electrodes 33 was provided on some of the green ceramic sheets by a printing process and the resulting green ceramic sheets, which are referred to as first green ceramic sheets and the other green ceramic sheets having no conductive paste thereon are referred to as second green ceramic sheets, were then dried. The conductive paste is preferably prepared according to the following procedure: metal powder containing 63% by weight of Ag, 27% by weight of Pd and 10% by weight of Cu is prepared and then mixed with an organic solvent.
The first green ceramic sheets each having the conductive paste for forming fourth internal electrodes 33 and the second green ceramic sheets were stacked and pressed. The pressed green ceramic sheets were then cut into pieces having a chip size, thereby obtaining green compacts for forming fourth NTC thermistor element 32.
Each green compact was fired at a maximum temperature of 1,200° C. in a furnace, thereby obtaining the NTC thermistor element 32 (sintered compact). In this procedure, the oxygen content in the furnace was 20% and the sintered compact was cooled from the maximum temperature to room temperature at a cooling rate of 200° C./h.
A paste for forming fourth external electrodes 34 was applied onto both ends of the sintered compact and then fired, thereby forming the fourth external electrodes 34. This paste contained 90% by weight of Ag and 10% by weight of Pd. In this procedure, the firing temperature was 850° C. and the oxygen content in the furnace was 20%. The resulting sintered compact was then subjected to electrolytic plating, whereby a metal coating consisting of an Ni layer and an Sn layer disposed thereon was formed on each fourth external electrode 34. Thereby, the fourth NTC thermistor 31 was obtained.
For the fourth NTC thermistor 31, the following characteristics are shown in Table 1: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance.
Second Embodiment
A second embodiment of the present invention will now be described with reference to FIG. 4. The fourth NTC thermistor 31 of a second embodiment has the same configuration as that of the first embodiment. In this embodiment, the same components as those used in the first embodiment have the same reference numerals as those in the first embodiment.
In the fourth NTC thermistor 31 of the second embodiment, a material for forming fourth internal electrodes 33 and a material for forming fourth external electrodes 34 both contain Cu, which is diffused in regions of a fourth NTC thermistor element 32 adjacent to the fourth internal electrodes 33. Thus, in the fourth NTC thermistor element 32, the inner part has a resistivity smaller than that of the surface region.
Cu contained in the material for forming the fourth external electrodes 34 is diffused in regions of the fourth NTC thermistor element 32 adjacent to the fourth internal electrodes 33 from the fourth internal electrodes 33 when the external electrode material is fired.
Example 2 will now be described with reference to FIG. 4. The fourth NTC thermistor 31 of Example 2 has the same configuration as that of the first embodiment. In this example, the same components as those used in the first embodiment have the same reference numerals as those in the first embodiment.
The fourth NTC thermistor 31 of Example 2 including fourth NTC thermistor element 32 (sintered compact) was prepared according to the same procedure as that for preparing the fourth NTC thermistor 31 of Example 1, except for the following procedure: an external electrode material containing 80% by weight of Ag, 10% by weight of Pd and 10% by weight of Cu was applied to both ends of fourth NTC thermistor element 32.
For the fourth NTC thermistor 31 of the Example 2, the following characteristics are shown in Table 1: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance.
In Comparative Example 1, a second NTC thermistor 11 including no internal electrodes was prepared, wherein this thermistor is a conventional one shown in FIG. 2. The Cu content in the paste for forming second external electrodes 13 was 10% by weight. For the second NTC thermistor 11, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance were measured in the same manner as those of Examples 1 and 2. The obtained measurements are shown in Table 1.
In Comparative Example 2, a third NTC thermistor 21 including third external electrodes 34 containing Cu was prepared, wherein this thermistor is a conventional one shown in FIG. 3. The Cu content in a paste for forming the external electrodes was 10% by weight. For the third NTC thermistor 21, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance were measured in the same manner as those of Examples 1 and 2. The obtained measurements are shown in Table 1.
As shown in Table 1, the second NTC thermistor 11 including no internal electrodes (Comparative Example 1), has a resistance which is not sufficiently decreased even if the external electrode-forming material contains Cu. This is because the diffusion of Cu is limited within regions A adjacent to the second external electrodes 13 while the external electrodes 13 are formed by a firing process.
The resistance is not sufficiently decreased even if the external electrode-forming material only contains Cu in the third NTC thermistor 21 including the third internal electrodes 24 (Comparative Example 2). This is because the quantity of diffused Cu is insufficient although Cu is diffused in the inner part of the third NTC thermistor element 22 from the third external electrodes 23 via the third internal electrodes 24 while the external electrodes 23 are formed by a firing process.
In contrast, the resistance can be sufficiently decreased in Example 1 using the fourth NTC thermistor 31 including the fourth internal electrodes 33 containing Cu. This is because Cu can be diffused in the entire fourth NTC thermistor element 32, except for the surface region thereof, from the fourth internal electrodes 33 during firing, thereby sufficiently increasing the quantity of diffused Cu.
Since Cu-diffused layers are formed in the vicinities of the fourth internal electrodes 33, the fourth internal electrodes 33 are chemically joined to the fourth NTC thermistor element 32, thereby enhancing the bonding strength between the metal material and the ceramic material. Since a plurality of the fourth internal electrodes 33 are disposed in the fourth NTC thermistor element 32, the gradient of the Cu content in the fourth NTC thermistor element 32 is decreased, thereby reducing the resistance, the difference in B constant, and time-lapse changes in resistance.
In Example 2, the internal electrode-forming material and the external electrode-forming material used for preparing the fourth NTC thermistor 31, both contain Cu. Therefore, Cu can be diffused in the entire fourth NTC thermistor element 32, except for the surface region thereof, from the fourth internal electrodes 33 not only during the firing of the fourth NTC thermistor element 32 but also during the formation of the fourth external electrodes 34 by a firing process. Thus, the resistance can be further lowered as compared with Example 1.
The thickness of a metal coating on a thermistor element is shown in Table 2 for Example 1 and Comparative Example 1. This measurement was performed according to the following procedure: external electrodes were formed on an NTC thermistor element by a firing process, and the resulting NTC thermistor element was then subjected to electrolytic plating, whereby metal coatings consisting of an Ni layer and an Sn layer disposed thereon were each formed on the corresponding external electrodes, wherein the Cu content in a material for forming the internal electrodes and a material for forming the external electrodes was varied such that the thickness of the metal coating formed on the thermistor element was varied.
As shown in Table 2, the second NTC thermistor 11 including no internal electrodes, Comparative Example 1, has metal coating formed on the second NTC thermistor element 12 even if the external electrode-forming material contains Cu. This is because Cu-diffused layers are formed in regions A of the second NTC thermistor element 12 adjacent to the second external electrodes 13 and therefore these regions have a resistivity smaller than that of other regions, whereby such a metal coating is formed on the second NTC thermistor element 12. For this phenomenon, it is presumed that regions a of the surface of the second NTC thermistor element 12 function as cores from which coatings grow to form the metal coating.
In contrast, the internal electrode-forming material in Example 1, used for preparing the fourth NTC thermistor 31 including the internal electrodes, contains Cu. Therefore, Cu is diffused in the entire fourth NTC thermistor element 32, except for the surface thereof and the vicinity, from the fourth internal electrodes 33, whereby the resistivity of the inner part of the NTC thermistor element 32 is lowered.
Thus, the resistivity of the surface is larger than that of the inner part in the fourth NTC thermistor element 32, whereby the metal coating can be prevented from being formed on the fourth NTC thermistor element 32.
Samples were prepared according to the same procedure as that for preparing the fourth NTC thermistor 31 of Example 1 except for the following conditions.
For the samples prepared under the conditions shown in Table 3, the following characteristics were measured: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance. Obtained measurements are shown in Table 4.
Samples were prepared according to the same procedure as that for preparing the fourth NTC thermistor 31 of Example 2 except for the following conditions.
Particular conditions are shown in Table 5.
13A*1
For the samples prepared under the conditions shown in Table 5, the following characteristics were measured: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance. In the above manufacturing procedure, an internal electrode-forming paste and external electrode-forming paste both containing 16% by weight of Cu were used. Obtained measurements are shown in Table 6.
Samples were prepared according to the same procedure as that for manufacturing the fourth NTC thermistor 31 of Example 1 except for the following procedure.
Green compacts for preparing the fourth NTC thermistor element 32 were fired at a maximum temperature of 1,200° C. in an atmosphere containing 20% of oxygen in a furnace. The resulting compacts were cooled from the maximum temperature to the temperature shown in Table 7 at a cooling rate of 200° C./h and then held at the temperature for a time shown in Table 7. After the predetermined time passed, the resulting compacts were cooled to room temperature at a cooling rate of 200° C./h, thereby obtaining fired compacts for forming the fourth NTC thermistor element 32.
For the obtained samples, the following characteristics were measured: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance. Obtained measurements are shown in Table 8.
Samples were prepared according to the same procedure as that for manufacturing the fourth NTC thermistor 31 of Example 2 except for the following procedure.
Green compacts for preparing the fourth NTC thermistor element 32 were fired at a maximum temperature of 1,200° C. in an atmosphere containing 20% of oxygen in a furnace. The resulting compacts were cooled from the maximum temperature to the temperature shown in Table 9 at a cooling rate of 200° C./h and then held at the temperature for a time shown in Table 9. After a predetermined time passed, the resulting compacts were cooled to room temperature at a cooling rate of 200° C./h, thereby obtaining fired compacts.
For the obtained samples, the following characteristics were measured: the Cu content in the internal electrodes, the resistance, the difference in resistance, the B constant, the difference in B constant, and the change in resistance. In the above manufacturing procedure, an internal electrode-forming paste and external electrode-forming paste both containing 16% by weight of Cu were used. Obtained measurements are shown in Table 10.
In a method for manufacturing an NTC thermistor according to any one of Examples 3 to 6, the quantity of diffused Cu can be precisely adjusted by controlling the heating and cooling mode, the oxygen content in a furnace, and the cooling conditions while a green compact is fired, thereby adjusting the resistance and the B constant over a wide range, as shown in Tables 3 to 10. Furthermore, the difference in resistance, the difference in B constant, and the time-lapse change in resistance can be reduced, thereby enhancing the reliability.
Samples 1 to 10, which are NTC thermistors including external electrodes containing no Cu, have a small resistance, difference in resistance, difference in B constant, and time-lapse change in resistance after high-temperature treatment, as shown in Table 4. Such samples can be prepared using sintered compacts obtained by firing green compacts at a maximum temperature of 1,000 to 1,350° C. in an atmosphere containing 20 to 80% of oxygen, as shown in Table 3.
Samples 1A to 10A, which are NTC thermistors including external electrodes containing Cu, have the same advantages as those of Samples 1 to 10, as shown in Tables 5 and 6.
Samples 11 to 15, which are NTC thermistors including external electrodes containing no Cu, have a small resistance, difference in resistance, difference in B constant, and time-lapse change in resistance after high-temperature treatment, as shown in Table 4. Such samples can be prepared using sintered compacts obtained by firing green compacts under the same conditions as the above and then cooing the resulting compacts at a cooling rate of 100 to 300° C./h, as shown in Table 3.
Samples 11A to 15A, which are NTC thermistors including external electrodes containing Cu, have the same advantages as those of Samples 11 to 15, as shown in Tables 5 and 6.
Samples 16 to 26, which are NTC thermistors including external electrodes containing no Cu, have a small resistance, difference in resistance, difference in B constant, and time-lapse change in resistance after high-temperature treatment, as shown in Table 8. Such samples can be prepared using sintered compacts obtained by firing green compacts, cooling the resulting compacts to 800 to 1,100° C., maintaining the resulting compacts at such a temperature for 60 to 600 minutes, and then further cooling the resulting compacts to room temperature, as shown in Table 7.
Samples 16A to 26A, which are NTC thermistors including external electrodes containing Cu, have the same advantages as those of Samples 16 to 26, as shown in Tables 7 and 8.
The mechanism of the above phenomena is believed to be as follows.
The firing of green compacts containing ceramics for forming NTC thermistors produces a spinel phase and a halite phase. The ratio of the halite phase to the spinel phase depends on the firing temperature and the firing atmosphere.
The firing atmosphere becomes reductive when the firing temperature exceeds the above temperature range or the oxygen content in a furnace falls short of the above content range, thereby increasing the ratio of the halite phase.
Since the halite phase has an affinity to Cu, a large quantity of Cu contained in the fourth internal electrodes 33 is diffused in the fourth NTC thermistor element 32 when the ratio of the halite phase is high.
Thus, reoxidation is prevented from proceeding when the ratio of the halite phase is excessively high, whereby the spinel phase is prevented from being sufficiently formed. As a result, Cu remains in the halite phase, thereby preventing the resistance from being decreased.
In contrast, the halite phase is prevented from being formed when the firing temperature falls short of the above temperature range or the oxygen content in a furnace exceeds the above content range. Thus, Cu cannot migrate out of the fourth internal electrodes 33, thereby preventing the resistance from being decreased.
The quantity of the halite phase converted into the spinel phase, that is, the quantity of the halite phase that is reoxidized, depends on the cooling rate, the cooling hold time, and the cooling temperature. Therefore, reoxidation is prevented when the cooling rate exceeds the above rate range or the cooling hold time falls short of the above time range and the cooling temperature falls short of the above temperature range. Thereby, the resistance is prevented from being decreased.
In contrast, the degree of the reoxidation becomes excessively high when the cooling rate falls short of the above rate range or the cooling hold time exceeds the above time range and the cooling temperature exceeds the above temperature range. As a result, Cu remaining in both the original spinel phase and the spinel phase converted from the halite phase migrates back to the fourth internal electrodes 33. Thus, the Cu-diffused layers are not formed in the vicinities of the fourth internal electrodes 33, thereby preventing the resistance to be decreased.
An NTC thermistor of the present invention includes internal electrodes containing at least one of Cu and Cu compounds. Thus, such a Cu component can be diffused in an entire NTC thermistor element, except for the vicinity of the element surface, from the internal electrodes during firing. Thereby, the resistance of the NTC thermistor can be decreased.
In the vicinity of the element surface, the Cu component is not diffused and therefore the resistance is not lowered. Thus, a metal coating can be prevented from being formed on the NTC thermistor element while the NTC thermistor is subjected to electrolytic plating in order to form metal coatings on the external electrodes.
Since Cu-diffused layers are each disposed in the corresponding vicinities of the internal electrodes, the internal electrodes are chemically joined to the NTC thermistor element, that is, the bonding strength between the metal material and a ceramic material is improved. The presence of the internal electrodes lowers the effect of the diffusion distance, thereby reducing the resistance, the difference in B constant, the time-lapse change in resistance.
According to the method for manufacturing an NTC thermistor of the present invention, the quantity of diffused Cu can be precisely adjusted by controlling the heating and cooling mode and the oxygen content in a furnace during firing, the cooling rate, the cooling hold time, and the cooling time.
For an NTC thermistor element having a certain composition, the resistance and the B constant can thus be adjusted in a wide range and the difference in resistance and the difference in B constant can be reduced, thereby improving the reliability.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2002-216770 | Jul 2002 | JP | national |
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| 4912450 | Yoneda et al. | Mar 1990 | A |
| 6400553 | Yoshii et al. | Jun 2002 | B2 |
| 6469612 | Nakayama et al. | Oct 2002 | B2 |
| 6525395 | Kawase et al. | Feb 2003 | B1 |
| Number | Date | Country |
|---|---|---|
| 04-328801 | Nov 1992 | JP |
| 05-021209 | Jan 1993 | JP |
| 05-021210 | Jan 1993 | JP |
| 08-236309 | Sep 1996 | JP |
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| 11-283804 | Oct 1999 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20040020918 A1 | Feb 2004 | US |
