Glass-Ceramic Laminate Composition for Low-Loss Strong Substrates
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Solution Overview
Problem
Multilayer ceramic substrates face challenges in achieving low permittivity, low dielectric loss, high mechanical strength, and high coefficient of thermal expansion, which are essential for high-frequency electrical signal handling and reliable electronic component mounting.
Innovation Solution
A glass ceramic material composed of SiO2, B2O3, Al2O3, and an alkali metal oxide, combined with a filler containing quartz, Al2O3, and ZrO2, is developed, allowing for sintering at low temperatures and optimizing the substrate's properties through precise composition and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional dielectric materials are used to achieve low permittivity and low dielectric loss, then electrical signal handling at higher frequencies is improved, but mechanical strength decreases
Solution Approach 1:
The patent employs a composite glass-ceramic material system combining multiple oxides (SiO2, B2O3, Al2O3, M2O) with specific fillers (quartz, Al2O3, ZrO2) to achieve both low dielectric loss and high mechanical strength. The glass matrix provides low permittivity and dielectric loss, while the crystalline filler phases, particularly ZrO2, contribute to enhanced mechanical strength through their inherent properties and reinforcement effect.
Solution Approach 2:
The patent systematically adjusts the chemical composition parameters within specific ranges: glass content (57.4-67.4 wt%), quartz (29-39 wt%), Al2O3 (1.8-5 wt%), and ZrO2 (0.3-1.8 wt%). These parameter changes enable optimization of both dielectric properties and mechanical strength, resolving the contradiction by finding the optimal composition window where both requirements are satisfied.
2Strength
If conventional ceramic materials are used to achieve high mechanical strength, then structural integrity is improved, but coefficient of thermal expansion decreases
Solution Approach 1:
The glass-ceramic composite structure allows simultaneous achievement of high mechanical strength and high coefficient of thermal expansion. The glass matrix provides thermal expansion characteristics, while the crystalline filler phases provide mechanical strength. This composite approach enables both requirements to be met concurrently.
Solution Approach 2:
By controlling the composition within specified ranges, particularly the balance between glass content and filler content, the patent achieves both high mechanical strength and high coefficient of thermal expansion. The specific ranges ensure adequate glass matrix for thermal expansion while maintaining sufficient filler for mechanical strength.
3Productivity
If low temperature sintering is employed to reduce manufacturing cost and energy consumption, then production efficiency is improved, but mechanical strength and density decrease
Solution Approach 1:
The patent enables low-temperature sintering (1000-1200°C) by optimizing the chemical composition, particularly the glass content (57.4-67.4 wt%) and filler content ratios. This composition optimization lowers the sintering temperature while maintaining adequate mechanical strength, resolving the contradiction between production efficiency and product quality.
Solution Approach 2:
The glass-ceramic composite system facilitates low-temperature sintering because the glass matrix acts as a flux that promotes densification at lower temperatures. The filler particles provide structural framework that maintains mechanical strength even at reduced sintering temperatures, enabling both low energy consumption and adequate strength.
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 a low permittivity, low dielectric loss, high mechanical strength, and high coefficient of thermal expansion, enhancing the reliability and performance of multilayer ceramic substrates for electronic components.
Implementation Method 1
a sintered article of the glass ceramic material
Data Source
AI summary
The glass ceramic material of the present disclosure contains a glass that contains SiO2, B2O3, Al2O3, and M2O, where M is an alkali metal, and a filler that contains quartz, Al2O3, and ZrO2. The glass ceramic material contains the glass in an amount of 57.4% by weight or more and 67.4% by weight or less, the quartz in the filler in an amount of 29% by weight or more and 39% by weight or less, the Al2O3 in the filler in an amount of 1.8% by weight or more and 5% by weight or less, and the ZrO2 in the filler in an amount of 0.3% by weight or more and 1.8% by weight or less.