Borosilicate Glass Ceramic Substrate Composition for Insulation Reliability
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Solution Overview
Problem
Ceramic substrates with existing low-temperature sintered compositions exhibit insufficient insulation reliability due to thinning of ceramic layers during the firing process, which affects the reliability of ceramic circuit components.
Innovation Solution
A composition for ceramic substrates comprising a higher borosilicate glass powder content and fine ceramic powder particles, along with a crystallinity modifier to control crystallization, ensuring dense sintering and enhanced insulation reliability by managing the softening and viscous flow of glass during firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the ceramic layer thickness is reduced to achieve thinner ceramic substrates, then the substrate size and weight are reduced, but the insulation reliability between ceramic layers deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the glass phase, specifically increasing B2O3 content to 5-17.5% and adjusting SiO2 to 28-44%, Al2O3 to 0-20%, and MO to 36-50%. These parameter changes modify the glass properties to achieve sufficient insulation reliability even in thinner ceramic layers.
Solution Approach 2:
The patent uses a composite material system consisting of glass phase (with specific borosilicate composition) and ceramic powder particles. This composite structure provides both mechanical strength and insulation properties, allowing thin substrates to maintain reliability through the synergistic effects of the glass-ceramic composite.
2Temperature
If the glass powder content is increased to improve densification and insulation, then the sintering temperature can be reduced, but the mechanical strength may deteriorate
Solution Approach 1:
The patent optimizes the glass composition parameters (B2O3: 5-17.5%, SiO2: 28-44%, Al2O3: 0-20%, MO: 36-50%) to achieve a balance where low sintering temperature (1000°C or less) is attained while maintaining adequate mechanical strength. The specific ratio of glass modifiers to network formers controls both softening behavior and strength.
Solution Approach 2:
The patent incorporates ceramic powder particles (0.4-1.5 μm) dispersed in the glass matrix, creating local reinforcement zones. This local quality enhancement maintains mechanical strength even when overall glass content is high, allowing low-temperature sintering without strength deterioration.
3Temperature
If fine ceramic powder particles are used to achieve dense sintering, then the sintering temperature can be reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a controlled particle size range of 0.4-1.5 μm for ceramic powder, optimizing the balance between sinterability and manufacturability. This parameter control enables dense sintering at low temperatures while maintaining reasonable manufacturing precision requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed composition achieves improved insulation reliability and mechanical strength in ceramic substrates, limiting layer thinning and maintaining high interlayer insulation, as demonstrated by increased Log IR values and transverse strength in multilayer ceramic circuit components.
Implementation Method 1
ensuring sufficient softening and viscous flow of glass during firing
Implementation Method 2
ensuring sufficient softening and viscous flow of glass during firing
Implementation Method 3
a crystallinity modifier to control the timing and degree of the crystallization of the borosilicate glass
Implementation Method 4
The ceramic powder has an average particle diameter D50 of 0.4 to 1.5 μm... These features contribute to densification of ceramic substrates made using the composition for ceramic substrates
Data Source
AI summary
A composition for ceramic substrates that includes a mixture of borosilicate glass powder and ceramic powder. The borosilicate glass powder contains 4% to 8% by weight B2O3, 38% to 44% by weight SiO2, 3% to 10% by weight Al2O3, and 40% to 48% by weight MO, where MO is at least one selected from CaO, MgO, and BaO. The mixing proportions of the borosilicate glass powder and the ceramic powder are 50% to 56% by weight the borosilicate glass powder and 50% to 44% by weight the ceramic powder. The ceramic powder has an average particle diameter D50 of 0.4 to 1.5 μm.