Microwave Dielectric Ceramics Low-Temperature Sintering
Solution Overview
Problem
Current low-temperature co-sintered ceramics (LTCC) for microwave applications require high sintering temperatures, which are costly and energy-intensive, and the additives used to reduce these temperatures often compromise microwave properties.
Innovation Solution
A method involving the mixing and sintering of A-metal compounds to form Ba5+y(Nb1−kMnk)4O15 and B-metal compounds to form Ba1+zNb2O6, combined with a sintering aid, to produce microwave dielectric ceramics with improved properties at lower sintering temperatures, specifically between 1250° C. and 1450° C., resulting in a material with superior microwave properties and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dielectric ceramics are used for passive components, then high reliability is achieved, but sintering temperature exceeds 1300°C causing high cost and high energy consumption
Solution Approach 1:
The patent changes the chemical composition parameters of the ceramic system by introducing specific glass phases (Bi2O3-BaO-BaTiO3, PbO-BaO-BaTiO3, or B2O3-BaO-BaTiO3) with controlled ratios, enabling sintering at lower temperatures (900-1100°C) while maintaining dielectric properties and component reliability
Solution Approach 2:
The patent creates composite ceramic materials combining dielectric ceramic particles with specific glass phases that act as sintering aids, forming a composite structure that enables low-temperature sintering while maintaining the reliability required for microwave dielectric applications
2Use of energy by stationary object
If sintering aids are added to reduce sintering temperature, then energy consumption decreases, but microwave properties of the ceramics deteriorate
Solution Approach 1:
The patent applies local quality by creating distinct phases within the ceramic composite: the dielectric ceramic particles maintain high-quality microwave properties while the surrounding glass phase matrix provides low-temperature sintering capability, with each phase optimized for its specific function
Solution Approach 2:
The patent designs composite materials where the interaction between dielectric ceramic particles and specific glass phases (Bi2O3-BaO-BaTiO3, PbO-BaO-BaTiO3, or B2O3-BaO-BaTiO3) creates a synergistic effect that preserves microwave properties while enabling low-temperature processing
3Manufacturing precision
If high sintering temperature is used, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
The patent changes the sintering temperature parameter from traditional high temperatures (>1300°C) to optimized lower temperatures (900-1100°C) by modifying the chemical composition to include specific glass phases that enable densification and phase formation at reduced temperatures while maintaining manufacturing precision
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 approach results in microwave dielectric ceramics with enhanced quality factor, dielectric constant, and temperature stability at lower sintering temperatures, reducing production costs and energy consumption while maintaining high-frequency performance.
Implementation Method 1
An agent is added to the LTCC to promote a low melting point glass phase and reduce the sintering temperature of the ceramics
Implementation Method 2
mixing and sintering the first and second components with at least one sintering aid to form the microwave dielectric ceramics
Data Source
AI summary
A method for manufacturing microwave dielectric ceramics has the steps of: mixing multiple A-metal compounds and sintering multiple A-metal compounds between 1350˜1450° C. for 2˜4 hr to make a first component Ba5+y(Nb1−kMnk)4O15; mixing and sintering multiple B-metal compounds to make a second component Ba1+zNb2O6; and mixing the first component Ba5+y(Nb1−kMnk)4O15, the second component Ba1+zNb2O6 and at least one sintering aid to make a third component (1−x)Ba5+y(Nb1−kMnk)4O5-xBa1+zNb2O6; wherein x, y, z and k are molar fractions and 0≦̸x<1, 0<y≦̸0.3, 0≦̸z≦̸0.3, 0≦̸k≦̸0.1; and the at least one sintering aid is 0.3˜3 wt %. The microwave dielectric ceramics of (1−x)Ba5+y(Nb1−kMnk)4O15-xBa1+zNb2O6 have superior microwave properties, low sintering temperature, simple chemical composition and manufacturing requirements applicable to low temperature co-sintered ceramic systems so no re-tooling is required.