Patents-Review.com
πŸ”— Permalink
Patent application title:

Dielectric ceramic composition and capacitor using the same

Publication number:

-

Publication date:
Application number:

10/255,614

Filed date:

2002-09-27

βœ… Patent granted

Patent number:

US 6,960,547 B2

Grant date:

2005-11-01

PCT filing:

-

PCT publication:

-

Examiner:

Mark Kopec

Adjusted expiration:

2023-08-27

Abstract:

A dielectric ceramic composition having a high maximum relative dielectric constant, a superior temperature characteristic of capacitance and a high AC breakdown voltage, and a capacitor using the same are provided. The dielectric ceramic composition includes a polycrystalline solid solution which contains barium titanate as a primary component and which is represented by the formula (Ba1βˆ’xCax)a(Ti1βˆ’yZry)bO3 in which 0<x≦0.25 and 0<y≦0.25 are satisfied. The dielectric ceramic composition also includes, with respect to 100 parts by weight of the primary component, a Y component in the form of Y2O3 in an amount in the range of more than zero to about 5 parts by weight; a Mg component in the form of MgO in an amount in the range of more than zero to about 2 parts by weight, and an Al component in the form of Al2O3 in an amount in the range of more than zero to about 2.5 parts by weight.

Inventors:

Assignee:

Interested in similar patents?

Get notified when new applications in this technology area are published.

Create Free Alert

Classification:

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to dielectric ceramic compositions having a high relative dielectric constant, a flat temperature characteristic of capacitance and a high AC breakdown voltage, and to capacitors using the same.

2. Description of the Related Art

As ceramic materials which have a high dielectric constant and have been widely used for single plate capacitors, multilayer ceramic capacitors, high-frequency ceramic capacitors, high-voltage ceramic capacitors and the like, a material primarily composed of a BaOβ€”CaOβ€”TiO2β€”ZrO2-based dielectric ceramic composition has been generally used in practice.

However, the conventional BaOβ€”CaOβ€”TiO2β€”ZrO2-based dielectric ceramic composition has problems in that a temperature characteristic of capacitance is degraded with an increase in relative dielectric constant and in addition, the AC breakdown voltage is also decreased.

As a dielectric ceramic composition which solves these problems, a material has been disclosed in Japanese Unexamined Patent Application Publication No. 7-267732; however, the only disclosed AC breakdown voltage is a maximum of 4.5 kV/mm.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a dielectric ceramic composition having a high maximum relative dielectric constant, a superior temperature characteristic of capacitance and a high AC breakdown voltage, and to provide a capacitor using the same.

A dielectric ceramic composition of the present invention comprises a polycrystalline solid solution which contains barium titanate as a primary component and which is represented by the formula (Ba1βˆ’xCax)a(Ti1βˆ’yZry)bO3 in which 0<x<0.25 and 0≦y≦0.25 are satisfied. In addition, with respect to 100 parts by weight of the primary component, the dielectric ceramic composition described above further comprises a Y component in the form of Y2O3 in an amount in the range of more than zero to about 5 parts by weight; a Mg component in the form of MgO in an amount in the range of more than zero to about 2 parts by weight, and an Al component in the form of Al2O3 in an amount in the range of more than zero to about 2.5 parts by weight.

In the polycrystalline solid solution containing barium titanate as the primary component represented by the formula (Ba1βˆ’xCax)a(Ti1βˆ’yZry)bO3, 0.965 a/b 1.03 is preferably satisfied.

The dielectric ceramic composition described above may further comprise a Mn component in the form of MnO as an accessory component in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

The dielectric ceramic composition described above may further comprise a Si component in the form of SiO2 as an accessory component in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

In addition, the dielectric ceramic composition described above may further comprise a Nb component in the form of Nb2O5 as an accessory component in an amount of about 1 part by weight or less with respect to 100 parts by weight of the primary component.

Furthermore, a capacitor according to the present invention comprises a dielectric ceramic sheet formed of the dielectric ceramic composition described above and electrodes provided on two surfaces of the dielectric ceramic sheet.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an embodiment of the present invention will be described with reference to an example.

EXAMPLE

As starting materials, barium carbonate (BaCO3), calcium. carbonate (CaCO3), titanium oxide (TiO2), zirconium oxide (ZrO2), yttrium oxide (Y2O3), magnesium oxide (MgO), aluminum oxide (Al2O3), manganese oxide (MnO), silicon oxide (SiO2) and niobium oxide (Nb2O5) were prepared, and after these starting materials were weighed and wet-mixed by a ball mill so as to obtain final compositions shown in Tables 1 and 2, drying thereof was performed by evaporation.

TABLE 1
Primary Component
Sample Ba Ca Ti Zr Accessory Component PBW*
# a/b (1-x) (x) (1-y) (y) Y2O3 MgO Al2O3 MnO SiO2) Nb2O5
1 1.003 0.950 0.050 0.860 0.140 1.0 0.2 0.2 0 0 0
2 1.003 0.930 0.070 0.920 0.080 1.0 0.2 0.2 0 0 0
3 1.003 0.880 0.120 0.880 0.120 1.0 0.2 0.2 0 0 0
4 1.003 0.860 0.140 0.820 0.180 1.0 0.2 0.2 0 0 0
5 1.003 0.830 0.170 0.960 0.040 1.0 0.2 0.2 0 0 0
6 1.003 0.890 0.110 0.750 0.250 1.0 0.2 0.2 0 0 0
7 1.003 0.750 0.250 0.880 0.120 1.0 0.2 0.2 0 0 0
*8 1.003 0.960 0.040 0.700 0.300 1.0 0.2 0.2 0 0 0
*9 1.003 0.860 0.140 0.700 0.300 1.0 0.2 0.2 0 0 0
*10 1.003 0.700 0.300 0.840 0.160 1.0 0.2 0.2 0 0 0
*11 1.003 0.700 0.300 0.930 0.070 1.0 0.2 0.2 0 0 0
*12 1.001 0.930 0.070 0.920 0.080 0 0.4 0.3 0 0 0
13 1.001 0.930 0.070 0.920 0.080 0.1 0.4 0.3 0 0 0
14 1.001 0.930 0.070 0.920 0.080 2.0 0.4 0.3 0 0 0
15 1.001 0.930 0.070 0.920 0.080 5.0 0.4 0.3 0 0 0
*16 1.001 0.930 0.070 0.920 0.080 6.0 0.4 0.3 0 0 0
*17 0.999 0.950 0.050 0.860 0.140 0.4 0 0.3 0 0 0
18 0.999 0.950 0.050 0.860 0.140 0.4 0.1 0.3 0 0 0
19 0.999 0.950 0.050 0.860 0.140 0.4 2.0 0.3 0 0 0
*20 0.999 0.950 0.050 0.860 0.140 0.4 3.0 0.3 0 0 0
*21 1.007 0.870 0.130 0.800 0.200 1.2 0.3 0 0 0 0
22 1.007 0.870 0.130 0.800 0.200 1.2 0.3 0.1 0 0 0
23 1.007 0.870 0.130 0.800 0.200 1.2 0.3 0.5 0 0 0
24 1.007 0.870 0.130 0.800 0.200 1.2 0.3 2.5 0 0 0
*25 1.007 0.870 0.130 0.800 0.200 1.2 0.3 5.0 0 0 0
*26 1.002 0.950 0.050 0.860 0.140 0 0 0 0 0 0
*27 1.002 0.950 0.050 0.860 0.140 0.8 0 0 0 0 0
*28 1.002 0.950 0.050 0.860 0.140 0 0.3 0 0 0 0
*29 1.002 0.950 0.050 0.860 0.140 0 0 0.2 0 0 0
30 1.002 0.950 0.050 0.860 0.140 0.8 0.3 0.2 0 0 0
31 0.960 0.910 0.090 0.870 0.130 0.8 0.2 0.1 0 0 0
32 0.965 0.910 0.090 0.870 0.130 0.8 0.2 0.1 0 0 0
33 0.985 0.910 0.090 0.870 0.130 0.8 0.2 0.1 0 0 0
34 1.000 0.910 0.090 0.870 0.130 1.2 0.3 0.5 0 0 0
35 1.030 0.910 0.090 0.870 0.130 0.8 0.2 0.1 0 0 0
36 1.035 0.910 0.090 0.870 0.130 0.8 0.2 0.1 0 0 0
Initial Characteristics
Rate of Rate of
Change in Change in AC
Firing Capacitance Capacitance Insulation Breakdown
Sample Temperature (βˆ’50Β° C.)** (+50Β° C.)*** Resistance Voltage
# (Β° C.) Ξ΅max (%) (%) (MΞ©) (kV/mm)
1 1400 12500 βˆ’57 βˆ’56 8.6 Γ— 1011 5.1
2 1400 11600 βˆ’55 βˆ’54 7.1 Γ— 1011 5.2
3 1400 10600 βˆ’54 βˆ’53 6.4 Γ— 1011 5.3
4 1400 6200 βˆ’44 βˆ’45 7.8 Γ— 1011 5.1
5 1400 6700 βˆ’48 βˆ’47 4.1 Γ— 1011 5.2
6 1400 8600 βˆ’49 βˆ’50 5.5 Γ— 1011 5.4
7 1400 6400 βˆ’43 βˆ’48 3.9 Γ— 1011 5.1
*8 1400 Insufficient Sintering
*9 1400 Insufficient Sintering
*10 1400 Insufficient Sintering
*11 1400 Insufficient Sintering
*12 1400 13900 βˆ’62 βˆ’67 2.0 Γ— 1011 5.0
13 1400 12100 βˆ’57 βˆ’58 3.4 Γ— 1011 5.1
14 1400 9600 βˆ’54 βˆ’53 5.2 Γ— 1011 5.2
15 1400 6300 βˆ’48 βˆ’45 7.9 Γ— 1010 5.1
*16 1400 5800 βˆ’42 βˆ’44 8.1 Γ— 109  5.1
*17 1390 12800 βˆ’61 βˆ’63 5.7 Γ— 1011 5.0
18 1390 10500 βˆ’55 βˆ’56 6.1 Γ— 1011 5.0
19 1400 8100 βˆ’51 βˆ’50 3.4 Γ— 1011 5.1
*20 1400 5900 βˆ’43 βˆ’44 5.5Γ— 1011 5.1
*21 1390 8400 βˆ’51 βˆ’51 1.4 Γ— 1011 4.6
22 1390 8200 βˆ’47 βˆ’49 3.1 Γ— 1011 5.1
23 1390 8100 βˆ’48 βˆ’50 5.9 Γ— 1011 5.4
24 1390 8200 βˆ’49 βˆ’51 6.3 Γ— 1010 5.5
*25 1390 7800 βˆ’49 βˆ’48 5.4 Γ— 108  5.2
*26 1400 15100 βˆ’76 βˆ’79 2.1 Γ— 1011 45
*27 1400 14300 βˆ’68 βˆ’65 2.7 Γ— 1011 4.6
*28 1400 13600 βˆ’65 βˆ’64 3.6 Γ— 1011 47
*29 1400 15300 βˆ’77 βˆ’76 3.8 Γ— 1011 51
30 1400 12900 βˆ’59 βˆ’57 4.9 Γ— 1011 5.1
31 1390 12300 βˆ’62 βˆ’63 2.2 Γ— 109  5.0
32 1390 12200 βˆ’59 βˆ’59 2.2 Γ— 1011 5.1
33 1390 12100 βˆ’58 βˆ’57 3.4 Γ— 1011 5.0
34 1390 11900 βˆ’56 βˆ’57 4.7 Γ— 1011 5.2
35 1390 7000 βˆ’51 βˆ’49 6.8 Γ— 1011 5.1
36 1390 5700 βˆ’46 βˆ’45 7.1 Γ— 109  5.0
*PBW means parts by weight
**Rate of Change in capacitance between the temperature exhibiting a maximum capacitance and 50Β° therefrom
***Rate of Change in capacitance between thetemperature exhibiting a maximum capacitance and +50Β° therefrom

TABLE 2
Primary Component
Sample Ba Ca Ti Zr Accessory Component PBW*
# a/b (1-x) (x) (1-y) (y) Y2O3 MgO Al2O3 MnO SiO2) Nb2O5
37 1.000 0.880 0.120 0.880 0.120 1.1 0.3 0.2 0 0 0
38 1.000 0.880 0.120 0.880 0.120 1.1 0.3 0.2 0.1 0 0
39 1.000 0.880 0.120 0.880 0.120 1.1 0.3 0.2 0.5 0 0
40 1.000 0.880 0.120 0.880 0.120 1.1 0.3 0.2 2.0 0 0
41 1.000 0.880 0.120 0.880 0.120 1.1 0.3 0.2 3.0 0 0
42 1.007 0.870 0.130 0.800 0.200 2.0 0.2 0.1 0 0 0
43 1.007 0.870 0.130 0.800 0.200 2.0 0.2 0.1 0 0.2 0
44 1.007 0.870 0.130 0.800 0.200 2.0 0.2 0.1 0 0.5 0
45 1.007 0.870 0.130 0.800 0.200 2.0 0.2 0.1 0 2.0 0
46 1.007 0.870 0.130 0.800 0.200 2.0 0.2 0.1 0 3.0 0
47 1.006 0.950 0.050 0.860 0.140 1.5 0.3 0.2 0 0 0
48 1.006 0.950 0.050 0.860 0.140 1.5 0.3 0.2 0 0 0.2
49 1.006 0.950 0.050 0.860 0.140 1.5 0.3 0.2 0 0 0.5
50 1.006 0.950 0.050 0.860 0.140 1.5 0.3 0.2 0 0 1.0
51 1.006 0.950 0.050 0.860 0.140 1.5 0.3 0.2 0 0 2.0
52 1.004 0.950 0.050 0.850 0.150 0.8 0.3 0.2 0 0.4 0.2
53 1.004 0.950 0.050 0.850 0.150 0.8 0.3 0.2 0.15 0 0.2
54 1.004 0.950 0.050 0.850 0.150 0.8 0.3 0.2 0.15 0.4 0
55 1.004 0.950 0.050 0.850 0.150 0.8 0.3 0.2 0.15 0.4 0.2
Initial Characteristics
Rate of Rate of
Change in Change in AC
Firing Capacitance Capacitance Insulation Breakdown
Sample Temperature (βˆ’50Β° C.)** (+50Β° C.)*** Resistance Voltage
# (Β° C.) Ξ΅max (%) (%) (MΞ©) (kV/mm)
37 1390 10400 βˆ’55 βˆ’57 6.4 Γ— 1011 5.2
38 1380 9900 βˆ’53 βˆ’53 4.6 Γ— 1011 5.1
39 1370 8200 βˆ’47 βˆ’48 1.3 Γ— 1011 5.2
40 1360 6500 βˆ’43 βˆ’42 5.4 Γ— 1010 5.0
41 1360 5300 βˆ’40 βˆ’41 7.2 Γ— 109  5.0
42 1390 8300 βˆ’51 βˆ’52 5.1 Γ— 1011 5.1
43 1380 8100 βˆ’49 βˆ’50 4.4 Γ— 1011 5.1
44 1370 8300 βˆ’51 βˆ’49 6.7 Γ— 1011 5.4
45 1360 8200 βˆ’50 βˆ’48 1.4 Γ— 1011 5.2
46 1360 8000 βˆ’49 βˆ’47 9.1 Γ— 109  5.0
47 1380 11200 βˆ’56 βˆ’54 2.7 Γ— 1011 5.2
48 1380 11000 βˆ’55 βˆ’53 3.4 Γ— 1011 5.1
49 1380 10500 βˆ’54 βˆ’57 7.6 Γ— 1011 5.3
50 1380 10800 βˆ’53 βˆ’56 8.4 Γ— 1011 5.2
51 1380 10300 βˆ’50 βˆ’54 6.4 Γ— 109  5.0
52 1380 11700 βˆ’54 βˆ’52 5.7 Γ— 1011 5.0
53 1380 11000 βˆ’53 βˆ’53 5.9 Γ— 1011 5.7
54 1370 10200 βˆ’49 βˆ’48 4.8 Γ— 1011 5.4
55 1370 10000 βˆ’50 βˆ’49 5.6 Γ— 1011 5.3
*PBW means parts by weight
**Rate of Change in capacitance between thetemperature exhibiting a maximum capacitance and βˆ’50Β° therefrom
***Rate of Change in capacitance between the temperature exhibiting a maximum capacitance and +50Β° therefrom

Subsequently, the powdered mixtures thus obtained were calcined at 1,150Β° C. for 2 hours, thereby forming predetermined powdered compounds.

Five parts by weight of a vinyl acetate-based material functioning as a binder was added to 100 parts by weight of each powdered compound and was then wet-mixed by a ball mill.

Next, these mixtures were dried by evaporation and were granulated to produce powders, and these powdered starting materials were molded into disks 15 mm in diameter and 1.0 mm thick at a pressure of 2.5 ton/cm3.

These disks thus molded were fired in the air in an electric furnace at temperatures shown in Tables 1 and 2, thereby forming ceramic bodies. After an Ag paste was applied to two surfaces of each ceramic body, firing was performed at 800Β° C. in the air to form electrodes, and lead wires were then soldered thereto, thereby forming ceramic capacitor samples for evaluation.

Next, a voltage of 250 V was applied to each sample thus formed for 2 minutes for measuring insulation resistance.

In addition, under conditions of 1 kHz and 1 Vrms, the temperature characteristic of capacitance was measured, and rates of change (%) in capacitance between a temperature exhibiting a maximum capacitance, which was used a standard, and +50Β° C. and βˆ’50Β° C. therefrom were calculated. The reason this type of calculation was used is as follows. When temperature characteristics of capacitance at βˆ’25 and 85Β° C. areused, there may be a material which does not have a transition point in the vicinity of room temperature in some cases. Accordingly, when the rate of change in temperature characteristic of capacitance is calculated from the difference between temperature characteristic of capacitance at the transition point, which is used as the standard, and that at +50Β° C. or that at βˆ’50Β° C. therefrom, the characteristics of individual samples are easily compared to each other.

In addition, the maximum relative dielectric constant (β„«max) was calculated in accordance with equation 1 shown below:
β„«max=(CmaxΓ—T)/{β„«0Γ—(D/2)2Γ—Ο€}  Equation 1

    • where Cmax=maximum value of capacitance (F),
    • T=thickness of ceramic (m),
    • β„«0=dielectric constant in vacuum (F/m)=8.854Γ—10βˆ’12,
    • D=diameter of ceramic (m), and
    • Ο€=circular constant.

In addition, the breakdown voltage was obtained as an AC breakdown voltage per 1 mm thick by calculation.

The results are shown in Tables 1 and 2. In these Tables, samples marked with asterisks were out of the scope of the present invention.

Next, the reasons the ranges of the dielectric ceramic composition of the present invention are limited will be described.

When the molar amount of Ca (x) exceeds 0.25, the sintering properties are degraded so that sintering cannot be sufficiently performed even at a temperature of 1,400Β° C., as can be seen from the results of samples 10 and 11. A higher temperature is necessary in order to sinter the samples mentioned above, and that is not preferable since production cost is increased. Accordingly, x of the Ca is preferably in the range of more than zero to 0.25.

When the molar amount of Zr (y) exceeds 0.25, the sintering properties are degraded so that sintering cannot be sufficiently performed even at a temperature of 1,400Β° C., as can be seen from the results of samples 8 and 9. A higher temperature is necessary in order to sinter the samples mentioned above, which is not preferable since production cost is increased. Accordingly, y of the Zr is preferably in the range of more than zero to 0.25.

Addition of a Y component has an effect of decreasing the variation in temperature dependence of capacitance; however, as can be seen from the result of sample 12, when the Y2O3 amount is zero parts by weight, the rates of change in temperature dependence of capacitance between the transition point and +50Β° C. and βˆ’50Β° C. therefrom, which are obtained using a temperature characteristic of capacitance at the transition point as the standard, are decreased to below βˆ’60%, which is not preferable. In addition, as can be seen from the result of sample 16, when the Y2O3 amount is more than about 5 parts by weight, the β„«max is considerably decreased to less than 6,000, and that is not preferable. Accordingly, the Y2O3 amount is preferably in the range of more than zero to about 5 parts by weight with respect to 100 parts by weight of the primary component.

Addition of a Mg component has an effect of decreasing the variation in temperature dependence of capacitance; however, as can be seen from the result of sample 17, when the MgO amount is zero parts by weight, the rates of change in temperature dependence of capacitance between the transition point and +50Β° C. and βˆ’50Β° C. therefrom, which are obtained using a temperature characteristic of capacitance at the transition point, are decreased to below βˆ’60%, and that is not preferable. In addition, as can be seen from the result of sample 20, when the MgO amount is more than about 2 parts by weight, the β„«max is considerably decreased to less than 6,000, which is not preferable. Accordingly, the MgO amount is preferably in the range of more than zero to about 2 parts by weight with respect to 100 parts by weight of the primary component.

Addition of an Al component has an effect of increasing the AC breakdown voltage; however, as can be seen from the result of sample 21, when the Al2O3 amount is zero parts by weight, the AC breakdown voltage is decreased to less than 5.0 kV/mm, which is not preferable. In addition, as can be seen from the result of sample 25, when the Al2O3 amount is more than 2.5 parts by weight, the insulation resistance is decreased to less than 1.0Γ—1010, and that is not preferable. Accordingly, the Al2O3 amount is preferably in the range of more than zero to about 2.5 parts by weight with respect to 100 parts by weight of the primary component.

The addition components, Y2O3, MgO, and Al2O3, are necessary. When the conditions described above cannot be satisfied, as can be seen from the results of samples 26 to 29, it is not preferable since the rates of change in temperature dependence of capacitance between the transition point and +50Β° C. and βˆ’50Β° C. therefrom, which are obtained using a temperature characteristic of capacitance at the transition point, are decreased to below βˆ’60% or the AC breakdown voltage is decreased to less than 5.0 kV/mm.

The result of sample 31 shows that when a/b is less than 0.965, it is not preferable since the insulation resistance is decreased to less than 1.0Γ—1010. In addition, as can be seen from the result of sample 36, when a/b is more than 1.03, it is not preferable since the insulation resistance is decreased to less than 1.0Γ—1010. Accordingly, a/b is preferably in the range of 0.965 to 1.03.

Addition of a Mn component has the effects of decreasing the sintering temperature and improving the temperature characteristic of capacitance; however, as can be seen from the result of sample 41, when the Mn component in the form of MnO is added in an amount of more than about 2 parts by weight, it is not preferable since the insulation resistance is decreased to less than 1.0Γ—1010. Accordingly, the MnO amount is preferably about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

Addition of a Si component has an effect of decreasing the sintering temperature; however, as can be seen from the result of sample 46, when the Si component in the form of SiO2 is added in an amount of more than abut 2 parts by weight, it is not preferable since the insulation resistance is decreased to less than 1.0Γ—1010. Accordingly, the SiO2 amount with respect to 100 parts by weight of the primary component is preferably about 2 parts by weight or less.

Addition of a Nb component has an effect of increasing the insulation resistance; however, as can be seen from the result of sample 51, when the Nb component in the form of Nb2O5 is added in an amount of more than about 1 part by weight, it is not preferable since the insulation resistance is decreased to less than 1.0Γ—1010. Accordingly, the Nb2O5 amount is preferably about 1 part by weight or less with respect to 100 parts by weight of the primary component.

In this example, as the starting materials, barium carbonate (BaCO3), calcium carbonate (CaCO3), titanium oxide (TiO2), zirconium oxide (ZrO2), yttrium oxide (Y2O3), magnesium oxide (MgO), aluminum oxide (Al2O3), manganese oxide (MnO), silicon oxide (SiO2) and niobium oxide (Nb2O5) were mixed together in accordance with predetermined compositions and were then calcined. However, when yttrium oxide (Y2O3), magnesium oxide (MgO), aluminum oxide (Al2O3), manganese oxide (MnO), silicon oxide (SiO2) and niobium oxide (Nb2O5) are added to a mixture which is formed beforehand by mixing barium carbonate (BaCO3), calcium carbonate (CaCO3), titanium oxide (TiO2) and zirconium oxide (ZrO2) together followed by calcination, the same advantages as those in this example can be obtained.

In addition, the starting materials in this example were barium carbonate (BaCO3), calcium carbonate (CaCO3), titanium oxide (TiO2), zirconium oxide (ZrO2), yttrium oxide (Y2O3), magnesium oxide (MgO), aluminum oxide (Al2O3), manganese oxide (MnO), silicon oxide (SiO2) and niobium oxide (Nb2O5); however, the present invention is not limited to compositions formed of these starting material. For example, carbonates, oxalates, hydroxides, alkoxides and the like may also be used. In addition, when compounds such as BaTiO3, BaZrO3, CaTiO3 and CaZrO3 are used as the starting material, the same advantages as described above can be obtained.

Furthermore, a ceramic capacitor provided with the electrodes at the two surfaces thereof was formed in this example; however, the present invention is not limited thereto. For example, when the present invention is applied to a multilayer capacitor formed of dielectric ceramic layers laminated to each other, internal electrodes provided between the dielectric ceramic layers and external electrodes electrically connected to the internal electrodes, the same advantages as described above can be obtained.

According to the present invention, a dielectric ceramic composition can be obtained which has a high maximum relative dielectric constant of 6,000 or more, a flat temperature characteristic of capacitance having rates of change in temperature dependence of capacitance of βˆ’60% or above between a transition point and +50Β° C. and βˆ’50Β° C. therefrom, obtained using a temperature characteristic of capacitance at the transition point used as the standard, and a high AC breakdown voltage of 5.0 kV/mm or more.

In addition, when a dielectric ceramic is formed using the dielectric ceramic composition of the present invention and electrodes are provided on two surfaces of the dielectric ceramic to form a capacitor, a ceramic capacitor having superior characteristics of the dielectric ceramic composition described above can be obtained.

Claims

1. A dielectric ceramic composition comprising:

a polycrystalline solid solution comprising barium titanate as a primary component and which is represented by the formula (Ba1βˆ’xCax)a(Ti1βˆ’yZry)bO3 in which 0<x≦0.25 and 0<y≦0.25 and 960≦a/b≦1.035, and with respect to 100 parts by weight of the primary component:

a Y component in the form of Y2O3 in an amount in the range of more than zero to about 5 parts by weight;

a Mg component in the form of MgO in an amount in the range of more than zero to about 2 parts by weight, and

an Al component in the form of Al2O3 in an amount in the range of more than zero to about 2.5 parts by weight.

2. A dielectric ceramic composition according to claim 1, further comprising a Mn component as an accessory component in the form of MnO in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

3. A dielectric ceramic composition according to claim 2, further comprising a Si component as an accessory component in the form of SiO2 in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

4. A dielectric ceramic composition according to claim 3, further comprising a Nb component as an accessory component in the form of Nb2O5 in an amount of about 1 parts by weight or less with respect to 100 parts by weight of the primary component.

5. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 4 and electrodes provided on two surfaces of the dielectric ceramic.

6. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 3 and electrodes provided on two surfaces of the dielectric ceramic.

7. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 2 and electrodes provided on two surfaces of the dielectric ceramic.

8. A dielectric ceramic composition according to claim 1, further comprising a Si component as an accessory component in the form of SiO2 in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

9. A dielectric ceramic composition according to claim 8, further comprising a Nb component as an accessory component in the form of Nb2O5 in an amount of about 1 parts by weight or less with respect to 100 parts by weight of the primary component.

10. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 8 and electrodes provided on two surfaces of the dielectric ceramic.

11. A dielectric ceramic composition according to claim 1, further comprising a Nb component as an accessory component in the form of Nb2O5 in an amount of about 1 parts by weight or less with respect to 100 parts by weight of the primary component.

12. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 11 and electrodes provided on two surfaces of the dielectric ceramic.

13. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 1 and electrodes provided on two surfaces of the dielectric ceramic.

14. A dielectric ceramic composition according to claim 1, wherein 0.960≦a/b≦1.03.

15. A dielectric ceramic composition according to claim 14, further comprising an Mn component as an accessory component in the form of MnO in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

16. A dielectric ceramic composition according to claim 15, further comprising a Si component as an accessory component in the form of SiO2 in an amount of about 2 parts by weight or less with respect to 100 parts by weight of the primary component.

17. A dielectric ceramic composition according to claim 16, further comprising an Nb component as an accessory component in the form of Nb2O5 in an amount of about 1 parts by weight or less with respect to 100 parts by weight of the primary component.

18. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 17 and electrodes provided on two surfaces of the dielectric ceramic.

19. A capacitor comprising a dielectric ceramic having a plurality of surfaces and a dielectric ceramic composition according to claim 14 and electrodes provided on two surfaces of the dielectric ceramic.

Resources

Sources:

Similar patent applications:

Recent applications in this class:

Recent applications for this Assignee: