Composite Ceramic Electronic Component Co-Firing Stability
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Solution Overview
Problem
Existing composite laminate ceramic electronic components face challenges in achieving stable co-firing of low dielectric constant and high dielectric constant ceramic layers, leading to instability in relative permittivity and insulation reliability due to crystallization and reactiveness of glass ceramic compositions, which affects the properties of both layers.
Innovation Solution
A composite laminate ceramic electronic component with low dielectric constant and high dielectric constant ceramic layers, each composed of specific glass ceramic compositions including MgAl2O4, BaO, RE2O3, TiO2, and MnO, with controlled glass content and MnO ratios, allowing for co-sintering without crystallization and enhancing insulation reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If glass ceramic compositions with high glass content are used to achieve low relative permittivity, then the relative permittivity decreases, but crystallization occurs during firing leading to instability in dielectric properties
Solution Approach 1:
The patent changes the chemical composition parameters of the glass ceramic by strictly controlling the content of basic oxides (Na2O, K2O, CaO, MgO) to be 5-20 mass%, and adding specific amounts of MnO (0.1-5.0 mass%) and Mn2O3 (0.01-1.0 mass%). This parameter optimization prevents crystallization during firing while achieving the desired low relative permittivity (εr≤15) and high insulation reliability
Solution Approach 2:
The patent creates a composite glass ceramic system combining multiple oxide components (SiO2, B2O3, P2O5 as network formers; Al2O3 as intermediate; and controlled amounts of basic oxides plus Mn oxides as modifiers). This composite composition achieves both low dielectric constant and high reliability by preventing crystallization through the synergistic effect of the components
2Ease of manufacture
If co-firing of low dielectric constant and high dielectric constant ceramic layers is attempted, then integration is achieved, but warpage and firing instability occur
Solution Approach 1:
The patent optimizes the firing temperature parameter to 900-1100°C based on the glass ceramic's composition characteristics. This temperature range enables complete sintering and glass phase formation while preventing crystallization, allowing stable co-firing of both low εr and high εr layers without warpage
Solution Approach 2:
The patent designs the glass ceramic composition with balanced basic oxide content (5-20 mass%) and specific Mn oxide additions to achieve appropriate softening point and viscosity characteristics. This composite formulation enables the glass phase to effectively bind both low εr and high εr ceramic powders during co-firing, preventing warpage while achieving integration
3Stability of the object's composition
If glass content is increased to achieve desired dielectric properties, then relative permittivity is reduced, but reactiveness increases affecting both ceramic layers
Solution Approach 1:
The patent controls the basic oxide content parameter to 5-20 mass%, which is sufficient to achieve low relative permittivity (εr≤15) but not excessive to cause high reactiveness. The addition of MnO (0.1-5.0 mass%) and Mn2O3 (0.01-1.0 mass%) further modifies the glass structure to reduce reactiveness while maintaining dielectric properties
Solution Approach 2:
The patent uses MnO and Mn2O3 as intermediary substances that modify the glass structure to reduce reactiveness. These manganese oxides act as stabilizers that prevent excessive chemical reactions between the glass phase and both low εr and high εr ceramic powders during co-firing, while still enabling the glass to achieve the desired low dielectric constant
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 solution achieves stable relative permittivity, high insulation reliability, and reduced warpage, enabling the production of ceramic components with desired dielectric properties across a wide range, suitable for high-frequency applications.
Implementation Method 1
a low dielectric constant ceramic layer and a high dielectric constant ceramic layer which are stacked, wherein the low dielectric constant ceramic layer and the high dielectric constant ceramic layer are co-sintered
Implementation Method 2
Each of the low dielectric constant ceramic layer and the high dielectric constant ceramic layer contains: a first ceramic including at least one of MgAl2O4 and Mg2SiO4; a second ceramic including BaO, RE2O3 (RE is a rare-earth element), and TiO2; glass containing each of 44.0 to 69.0% by weight of RO (R is at least one alkaline-earth metal selected from Ba, Ca, and Sr), 14.2 to 30.0% by weight of SiO2, 10.0 to 20.0% by weight of B2O3, 0.5 to 4.0% by weight of Al2O3, 0.3 to 7.5% by weight of Li2O, and 0.1 to 5.5% by weight of MgO; and MnO
Data Source
AI summary
A composite laminate ceramic electronic component that includes co-fired low dielectric constant ceramic layers and high dielectric constant ceramic layers. The low dielectric constant ceramic layers and high dielectric constant ceramic layers are each composed of a glass ceramic containing: a first ceramic composed of at least one of MgAl2O4 and Mg2SiO4; a second ceramic composed of BaO, RE2O3 (RE is a rare earth element), and TiO2; glass containing each of 44.0-69.0 wt % of RO (R is an alkaline-earth metal), 14.2-30.0 wt % of SiO2, 10.0-20.0 wt % of B2O3, 0.5-4.0 wt % of Al2O3, 0.3-7.5 wt % of Li2O, and 0.1-5.5 wt % of MgO; and MnO. The content ratios of the first ceramic, second ceramic, glass, and MnO are varied between the low dielectric constant ceramic layers and the high dielectric constant ceramic layers, wherein the content of MnO in the low dielectric constant ceramic layers is 7.5-18.5 wt % MnO.