WO2018168845A1 - Ceramic composite sheet and capacitor - Google Patents
Ceramic composite sheet and capacitor Download PDFInfo
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- WO2018168845A1 WO2018168845A1 PCT/JP2018/009710 JP2018009710W WO2018168845A1 WO 2018168845 A1 WO2018168845 A1 WO 2018168845A1 JP 2018009710 W JP2018009710 W JP 2018009710W WO 2018168845 A1 WO2018168845 A1 WO 2018168845A1
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- ceramic composite
- dielectric
- composite sheet
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- metal foil
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/002—Details
- H01G4/018—Dielectrics
- H01G4/06—Solid dielectrics
- H01G4/14—Organic dielectrics
- H01G4/18—Organic dielectrics of synthetic material, e.g. derivatives of cellulose
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/32—Wound capacitors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/33—Thin- or thick-film capacitors (thin- or thick-film circuits; capacitors without a potential-jump or surface barrier specially adapted for integrated circuits, details thereof, multistep manufacturing processes therefor)
Definitions
- the present invention relates to a ceramic composite sheet in which a dielectric layer containing an organic resin and a dielectric ceramic powder is laminated on a metal foil, and a capacitor including the same.
- the ceramic capacitor is formed by laminating a dielectric layer mainly composed of dielectric ceramic powder such as barium titanate particles and an internal electrode layer made of metal such as nickel. Ceramic capacitors have a high dielectric constant and high heat resistance. However, the ceramic capacitor has low toughness of the dielectric layer, and is easily broken by electrostriction deformation.
- the metallized film capacitor is formed by depositing a metal such as aluminum on the surface of a dielectric film made of an organic resin such as a polyamide-imide resin.
- the metallized film capacitor has a high potential gradient of the dielectric layer, and is soft and tough. However, the metallized film capacitor has a low capacity density and low heat resistance.
- a dielectric layer containing a dielectric ceramic powder and an organic resin is prepared by mixing a dispersion of a dielectric ceramic powder and a dispersion of an organic resin, applying the mixture to a metal foil such as an aluminum foil, and drying the solvent by heat treatment. Is formed on the metal foil, and the metal foil is further superposed on the dielectric layer and adhered by applying heat and pressure to produce the sheet-shaped ceramic composite capacitor.
- the sheet-shaped ceramic composite capacitor has a problem that the dielectric layer and the metal foil easily peel off.
- the reason is that a sufficient amount of organic resin does not exist on the surface of the dielectric layer, and the adhesive force is insufficient by the thermocompression bonding simply utilizing the thermoplasticity of the organic resin.
- a dielectric layer is formed on one metal foil, an organic resin slurry is applied to the other metal foil to form an organic resin film, and the dielectric layer and the organic resin film face each other with heat and heat.
- a method of applying pressure has been proposed (see, for example, Patent Document 1). By interposing the slurry-like organic resin film, the organic resin comes into close contact with the metal foil, the air layer disappears inside the organic resin, and the organic resins are thermocompression-bonded, so that the adhesion is increased.
- the capacitor has a high withstand voltage so as not to cause a short circuit even under severe conditions where an abnormal voltage exceeding the rated voltage is applied. Therefore, in order to increase the withstand voltage of the dielectric layer, it is desirable that the particles contained in the dielectric layer have a certain size or more.
- the organic resin film functions as a dielectric layer in the capacitor. The particles contained in the film are also regulated to a certain size or more as the dielectric layer.
- the surface of the organic resin film cannot be made highly smooth due to the presence of large particles in the organic resin film, and the adhesion between the organic resin film and the metal foil is reduced. End up. Therefore, a dielectric layer is formed on one metal foil, an organic resin slurry is applied to the other metal foil to form an organic resin film, and heat and pressure are applied to the dielectric layer and the organic resin film facing each other.
- the withstand voltage was improved, and the adhesion between the organic resin film and the metal foil could not be sufficiently increased, and the metal foil could not be reliably peeled off.
- the present invention provides a ceramic composite that can more reliably prevent peeling between ceramic composite sheets in which a dielectric layer is laminated on a metal foil while improving withstand voltage. It is providing a capacitor
- a ceramic composite sheet according to the present invention comprises a metal foil, a dielectric layer laminated on the metal foil and containing an organic resin and a dielectric ceramic powder, and the dielectric layer. And a conductive layer to be laminated.
- the conductive layer is not subject to restrictions such as an organic resin film that requires voltage resistance, and can be designed with emphasis on adhesion to the metal foil, and can prevent the metal foil from peeling more reliably.
- the conductive layer may include a conductive material having a tabular grain shape. Since the flat conductive material is in surface contact with the metal foil, the contact area with the metal foil is larger than that of the spherical particles, and the conductive layer containing the flat conductive material is in close contact with the metal foil.
- the conductive layer may further include a conductive material having a spherical particle shape.
- a conductive material having a spherical particle shape By interposing the conductive material having a spherical particle shape while maintaining the adhesion with the metal foil, the conductive material is interposed between the conductive materials having a flat particle shape, and the conductivity is increased.
- the content of the dielectric ceramic powder in the dielectric layer may be 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin. Below this lower limit, the dielectric layer containing a large amount of voids results in a reduction in withstand voltage. On the other hand, if this upper limit is exceeded, it becomes a dielectric layer containing many cracks and voids, and instead of lowering the withstand voltage, it is difficult to use it as a dielectric layer in the worst case.
- the organic resin may be a polyamide-imide resin
- the dielectric ceramic powder may be a barium titanate powder.
- the conductive layer may include graphite and carbon black.
- a capacitor including this ceramic composite sheet is also an aspect of the present invention, and the capacitor of the present invention includes the plurality of ceramic composite sheets.
- the adhesion of the ceramic composite sheet can be increased.
- the ceramic composite sheet of this embodiment is shown, (a) is a top view, (b) is sectional drawing. It is a cross-sectional schematic diagram of a capacitor
- the ceramic composite sheet 1 is formed by laminating a metal foil 2, a dielectric layer 3, and a conductive layer 4.
- a dielectric layer 3 is formed on one side of the metal foil 2, and a conductive layer 4 is formed on the dielectric layer 3.
- the conductive layer 4 of the ceramic composite sheet 1 and the surface of the metal foil 2 of another ceramic composite sheet 1 or the metal foil 2 that does not form the dielectric layer 3 or the conductive layer 4 face each other.
- a winding type or multilayer chip type capacitor is produced.
- the metal foil 2 has a thickness of 5 ⁇ m to 50 ⁇ m, for example.
- the metal foil 2 is mainly made of a conductive material.
- the conductive material is aluminum (Al), nickel (Ni), copper (Cu), silver (Ag), gold (Au), iron (Fe), palladium (Pd), platinum (Pt), zinc (Zn), One kind selected from precious metals and base metals such as tin (Sn) or chromium (Cr), or an alloy thereof.
- the surface of the metal foil 2 is preferably subjected to a roughening treatment such as etching in order to improve the adhesion with the dielectric layer 3 by the anchor effect.
- the dielectric layer 3 has a thickness of 10 to 30 ⁇ m, for example.
- the dielectric layer 3 contains organic resin and dielectric ceramic powder dispersed as main components. Since the dielectric ceramic powder is contained in the dielectric layer 3, the dielectric constant of the ceramic composite sheet 1 can be increased. In addition, since the dielectric layer 3 contains an organic resin, the dielectric gradient of the ceramic composite sheet 1 can be increased and the toughness can be increased.
- the organic resin and the dielectric ceramic powder preferably have an average particle size of more than 0.1 ⁇ m from the viewpoint of improving the withstand voltage of the capacitor.
- the organic resin is one or a mixture of two or more selected from polyamideimide, polyetherimide, polyimide, polyethylene terephthalate, polyethylene naphthalate, polypropylene, polyphenylene sulfide, polyvinylidene fluoride, and the like.
- the dielectric ceramic powder includes a part of Ba substituted with Ca and Sr and a part of Ti substituted with Zr (Ba, Ca, Sr) (Ti, Zr).
- One or a mixture of two or more selected from O 3 ceramics for example, barium titanate (BaTiO 3 ), strontium titanate (SrTiO 3 ), calcium titanate (CaTiO 3 ), titanate magnesium (MgTiO 3) system, calcium zirconate (CaZrO 3) system, calcium titanate zirconate (PCZT) system, barium zirconate (BaZrO 3) system, and titanium oxide (TiO 2) system.
- this dielectric layer 3 The manufacturing process of this dielectric layer 3 is illustrated.
- a mixed solution is prepared by mixing barium titanate with N-methyl-2-poloridone (NMP) as a dispersion solvent at a ratio of 1: 1 by weight.
- NMP N-methyl-2-poloridone
- a mixed solution is prepared by mixing NMP in a ratio of 1: 4 parts by weight of NMP as a dispersion solvent in polyamideimide.
- the dispersion solvent of both mixed liquids can be selected in consideration of the suppression of aggregation of the dielectric ceramic powder, and the same kind is desirable.
- These mixed liquids are mixed at a ratio of 1 part by weight to 0.1 or more and 1.0 or less.
- this mixed solution of barium titanate and polyamideimide is applied to a metal foil 2 such as an aluminum foil subjected to surface roughening treatment to a thickness of 10 ⁇ m to 30 ⁇ m.
- a strip-shaped uncoated portion 2 a is left on one side of the metal foil 2.
- a coating method various known methods such as gravure coating, die coating, and screen printing can be used. After the coating is completed, heat treatment is performed at 100 to 120 degrees Celsius, and the solvent is dried. Note that after the solvent is dried, a press treatment may be performed to increase the density of the dielectric layer 3.
- the content of the dielectric ceramic powder in the dielectric layer 3 is desirably 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin. If it is less than 70 wt%, the effect of increasing the dielectric constant by including the dielectric ceramic powder in the organic resin is reduced.
- the dielectric layer 3 includes many voids, and the withstand voltage is reduced due to the voids. Therefore, when it is going to produce the dielectric material layer 3 with content of dielectric ceramic powder less than 70 wt% with respect to content of organic resin, the process of removing a space
- the dielectric layer 3 becomes a so-called tattered state in which many cracks and voids are generated, and the dielectric strength is lowered in the worst case. It becomes difficult to use.
- the organic resin becomes an adsorbent and a binder during the mixing process of both liquid mixtures. That is, the organic resin covers the particle surface of the dielectric ceramic powder and increases the affinity with the solvent. In addition, the organic resin covering the surface of the dielectric ceramic powder particles bonds the dielectric ceramic powders together with the organic resin as a medium. In addition, when the amount of the dielectric ceramic powder is small, in other words, when the amount of the organic resin is large, a large amount of the organic resin is present between the particles of the dielectric ceramic powder due to the function as a binder. Existed and the organic resin foamed during the mixing process. Therefore, it is considered that the dielectric layer 3 having many voids has been produced after the mixed solution is dried.
- the organic resin functions as an adsorbent and the particle surface of the dielectric ceramic powder is reduced.
- the organic resin cannot cover the function as a binder sufficiently, the dielectric layer 3 after the liquid mixture is dried becomes tattered and there are many cracks and voids. It is thought that it has been.
- the conductive layer 4 has a thickness of 0.5 ⁇ m to 5 ⁇ m, for example.
- the conductive layer 4 includes a conductive material as a main component.
- the conductive material is one or a mixture of two or more selected from natural or artificial graphite, carbon black, carbon nanotubes, graphene, ketjen black, and acetylene black.
- the average particle size of the conductive material is desirably 15 ⁇ m or less, and it is desirable that the conductive layer 4 contains a plate-shaped particle-shaped conductive material.
- the plate-like particle-shaped conductive material is disposed on the surface of the conductive layer 4 in a state where the flat plate surface and the surface of the metal foil 2 are parallel to each other.
- the plate-like conductive material having a particle shape is in surface contact with the metal layer 2, the contact area with the metal foil 2 is widened, and a large adhesion can be obtained.
- a spherical grain-shaped conductive material is included in addition to the tabular grain-shaped conductive material. The spherical particle-shaped conductive material is interposed between the tabular particle-shaped conductive materials, and the conductivity between the tabular particle-shaped conductive materials is increased.
- the flat plate has a flat flat plate surface, the short side length of the flat plate surface is 0.5 to 10 ⁇ m, the long side length is 0.5 to 10 ⁇ m, and the thickness is 0.00.
- the shape of 5 or more and 2 ⁇ m or less includes a sphere, an ellipsoid, a polyhedron, or a shape formed by overlapping and connecting these.
- This conductive layer 4 fixes a conductive material in the layer using an elastomer such as styrene-butadiene rubber (SBR) as a binder.
- SBR styrene-butadiene rubber
- a slurry in which flat graphite and spherical carbon black are mixed at a weight ratio of 10: 1 using pure water as a dispersion solvent, and styrene / butadiene rubber is added at a ratio of 1 as a binder is prepared, and a dielectric is prepared. It is applied on the body layer 3 with a thickness of 0.5 to 5 ⁇ m. When the coating is finished, heat treatment is performed and the solvent is dried.
- the ceramic composite sheet 1 is stacked so that the conductive layer 4 and the metal foil 2 are in contact with each other, and a plurality of sheets are stacked. By applying pressure, the conductive layer 4 and the metal foil 2 are in close contact with each other, and a capacitor is manufactured.
- a pair of long ceramic composite sheets 1 in a strip shape are aligned with the longitudinal direction and the short direction aligned, but with the direction of the uncoated portion 2a reversed. That is, the uncoated portion 2a where the dielectric layer 3 and the conductive layer 4 are not coated is prevented from overlapping. Moreover, it superimposes so that the metal foil 2 of the other ceramic composite sheet 1 may be placed on the conductive layer 4 of one ceramic composite sheet 1.
- the pair of laminated ceramic composite sheets 1 are wound so as to wind the dielectric layer 3 side.
- condenser element 61 by which a pair of ceramic composite sheet 1 was wound is formed.
- an electrode metal is vapor-deposited by metallicon on the end faces of the uncoated portion 2a exposed at both ends of the cylindrical body, and on one end face of the positive electrode side electrode part 5-1, A negative electrode portion 5-2 is formed on the other element end face.
- the electrode metal may be a metal that can be soldered for ease of connection, such as soldering.
- a metal such as zinc or a tin alloy may be used as the solderable metal.
- an alloy of aluminum and zinc, an aluminum and tin alloy, or a zinc and tin alloy may be used as a solderable metal.
- the electrode portions 5-1 and 5-2 are connected to the positive external terminal 64-1 and the negative external terminal 64-2 provided on the terminal plate 67 by lead wires 63. That is, the positive electrode part 5-1 and the positive electrode external terminal 64-1, and the negative electrode part 5-2 and the negative electrode external terminal 64-2 are connected by solder using the lead wire 63. At this time, as shown in FIG. 3D, the lead wire 63 connected to the negative external electrode 64-2 passes through the hollow portion of the capacitor element 61 and the negative external terminal 64-2 is disposed. It is pulled out to the surface and connected to the negative external terminal 64-2.
- the capacitor element 61 is housed in the case 65 and insulated in the case 65.
- the winding type capacitor is manufactured by filling the functional resin 66 and performing a curing process.
- the uncoated portions 2a of the pair of long ceramic composite sheets 1 in a strip shape are cut at predetermined intervals to form tabs 2b in the longitudinal direction.
- the pair of ceramic composite sheets 1 are overlapped with the longitudinal direction and the lateral direction aligned, and the tabs 2b aligned. Moreover, it superimposes so that the metal foil 2 of the other ceramic composite sheet 1 may be placed on the conductive layer 4 of one ceramic composite sheet 1.
- a pair of laminated ceramic composite sheets 1 are wound around the conductive layer 4 side to form a cylindrical capacitor element.
- a positive electrode portion 5-1 protruding from the end face of the capacitor element is formed by a tab 2b-1 of one ceramic composite sheet 1, and the other ceramic composite sheet 1 is formed.
- the tab 2b-2 forms a negative electrode portion 5-2 protruding from the end face of the capacitor element, and the electrode portions 5-1 and 5-2 are formed to face each other.
- FIG. 5 (a) a plurality of rectangular ceramic composite sheets 1 are overlaid so that the uncoated portions 2a face alternately and the dielectric layers 3 and the conductive layers 4 are stacked. .
- FIG. 5B the conductive layer 4 and the metal foil 2 are in close contact with each other without sandwiching the air layer, and the upper and lower ceramic composite sheets 1 are firmly laminated.
- the laminate is molded with resin so that the uncoated portion 2a protruding to one side is exposed.
- a metal such as copper is applied to the exposed surface of the uncoated portion 2a of the laminate to form external electrodes 68a and 68b.
- the external electrodes 68 a and 68 b are formed on the two opposing surfaces of the laminate of the ceramic composite sheet 1. As a result, a multilayer chip capacitor in which a plurality of ceramic composite sheets 1 are laminated is produced.
- a metal foil 6 such as an aluminum foil is superposed on the conductive layer 4 side of the ceramic composite sheet 1.
- the dielectric layer 3 and the conductive layer 4 are not formed like the ceramic composite sheet 1.
- the ceramic composite sheet 1 and the metal foil 6 are overlapped so that the metal foil 6 protrudes on the opposite side of the ceramic composite sheet 1 from the uncoated portion 2a. Then, when heat and pressure are applied to the laminate of the ceramic composite sheet 1 and the metal foil 6, the conductive layer 4 and the metal foil 6 are laminated without sandwiching the air layer.
- the laminate is molded with resin so that one end of the metal foil 6 protruding to one side and the uncoated portion 2a are exposed.
- a metal such as copper is applied to the exposed surface of the uncoated portion 2a of the laminate to form external electrodes 68a and 68b. It is formed on the two opposing surfaces of the laminate of the ceramic composite sheet 1. Thereby, a chip-type capacitor formed by connecting one ceramic composite sheet 1 and one metal foil 6 is produced.
- the dielectric layer 3 containing the organic resin and the dielectric ceramic powder is laminated on the metal foil 2, and the conductive layer 4 is laminated on the dielectric layer 3. I made it.
- the conductive layer 4 is handled as an electrode in the capacitor, it is not necessary to restrict the contained particles of the conductive layer 4 in consideration of the withstand voltage unlike the dielectric layer 3. Therefore, the adhesiveness between the conductive layer 4 and the metal foils 2 and 6 can be enhanced, and both high withstand voltage and suppression of peeling can be achieved.
- a conductive material having a tabular grain shape may be included in the conductive layer 4. Since the flat conductive material is in surface contact with the metal foils 2 and 6, the contact area with the metal foils 2 and 6 is larger than that of the spherical particles, and the conductive layer 4 containing the flat conductive material is made of metal. Strongly adheres to the foils 2 and 6.
- the conductive layer 4 may further include a conductive material having a spherical particle shape.
- the conductivity between the conductive materials having a flat particle shape is increased by interposing the conductive material having a spherical particle shape while maintaining the adhesion to the metal foil, and the metal foils 2 and 6 and the conductive layer are increased.
- the conductivity with 4 is increased.
- the dielectric layer contains dielectric ceramic powder, a capacitor having a high dielectric constant can be produced. Furthermore, since the dielectric layer contains an organic resin, a capacitor having a high dielectric gradient and high toughness can be manufactured.
- the organic resin is a polyamide-imide resin
- the dielectric ceramic powder is a barium titanate powder
- the conductive layer 4 contains graphite and carbon black. I can't.
- the pair of ceramic composite sheets 1 is created by superimposing the aluminum foil 2 of the other ceramic composite sheet 1 on the conductive layer 4 of the ceramic composite sheet 1.
- a pair of ceramic composite sheets 1 may be integrated by applying heat and pressure, or a silver paste may be interposed between the ceramic composite sheets 1. .
- various dielectric layers 3 in which the weight ratio of the dielectric ceramic powder and the organic resin was changed were actually produced, the dielectric constant of the dielectric layer 3 was measured, and the state of the dielectric layer 3 was observed.
- barium titanate is used as the dielectric ceramic powder
- NMP N-methyl-2-poloridone
- distribution solvent was used for polyamideimide as organic resin.
- the first mixed liquid in which barium titanate is 65 wt% with respect to polyamideimide the second mixed liquid in which barium titanate is 70 wt% with respect to polyamideimide, and the barium titanate is 80 wt% with respect to polyamideimide.
- a third mixed solution with a percentage of barium titanate of 90 wt% with respect to the polyamideimide a fifth mixed liquid with a barium titanate of 97.5 wt% with respect to the polyamideimide
- a sixth mixed solution in which barium titanate was 98.0 wt% with respect to polyamideimide was obtained.
- FIGS. 7 is a photograph of the dielectric layer 3 obtained with the first and sixth mixed liquids.
- FIG. 8 is a graph showing the relative dielectric constant of the dielectric layer 3 obtained with each liquid mixture.
- the dielectric layer 3 derived from the first mixed liquid in which barium titanate is 65 wt% with respect to the polyamideimide has many voids V.
- foaming was seen in the mixing process of this 1st liquid mixture.
- the dielectric layer 3 derived from the sixth mixed liquid in which barium titanate is 98.0 wt% with respect to the polyamideimide has cracks C, which are in a so-called tattered state. there were.
- no void was found in the dielectric layer 3 derived from the second to fifth mixed liquids in which barium titanate was within 70 to 97.5 wt% with respect to the polyamideimide.
- the content of the dielectric ceramic powder in the dielectric layer 3 is 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin. Can be obtained.
- the relative dielectric constant is 70 wt% when the content of the dielectric ceramic powder in the dielectric layer 3 is 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin.
- % Relative permittivity ( ⁇ s ) averaged 34.5
- 90 wt% relative dielectric constant 52.2 on average 97.
- the relative dielectric constant at 5 wt% is 60.3 on average and increases in proportion to the increase in dielectric ceramic powder.
- the relative dielectric constant is rapidly decreased.
- the content of the dielectric ceramic powder in the dielectric layer 3 is 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin. can get.
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Abstract
Description
本発明は、有機樹脂と誘電性セラミック粉末とを含む誘電体層を金属箔に積層したセラミック複合体シートとこれを備えるコンデンサに関する。 The present invention relates to a ceramic composite sheet in which a dielectric layer containing an organic resin and a dielectric ceramic powder is laminated on a metal foil, and a capacitor including the same.
セラミックコンデンサは、チタン酸バリウム粒子等の誘電性セラミック粉末を主成分とした誘電体層とニッケル等の金属からなる内部電極層とを積層して成る。セラミックコンデンサは、誘電率が高く、また耐熱性も高い。しかしながら、セラミックコンデンサは、誘電体層の靭性が低く、電歪変形して壊れ易い。 The ceramic capacitor is formed by laminating a dielectric layer mainly composed of dielectric ceramic powder such as barium titanate particles and an internal electrode layer made of metal such as nickel. Ceramic capacitors have a high dielectric constant and high heat resistance. However, the ceramic capacitor has low toughness of the dielectric layer, and is easily broken by electrostriction deformation.
金属化フィルムコンデンサは、ポリアミドイミド樹脂等の有機樹脂から成る誘電体フィルムの表面にアルミニウム等の金属を蒸着して成る。金属化フィルムコンデンサは、誘電体層の電位傾度が高く、やわらかくて靭性が高い。しかしながら、金属化フィルムコンデンサは、容量密度が低く、耐熱性が低い。 The metallized film capacitor is formed by depositing a metal such as aluminum on the surface of a dielectric film made of an organic resin such as a polyamide-imide resin. The metallized film capacitor has a high potential gradient of the dielectric layer, and is soft and tough. However, the metallized film capacitor has a low capacity density and low heat resistance.
セラミックコンデンサと金属化フィルムコンデンサの短所を補い合い、互いの長所を引き出すべく、誘電性セラミック粉末と有機樹脂とを含む誘電体層を備えたシート状セラミック複合体コンデンサが開発されている。例えば、誘電性セラミック粉末の分散液と有機樹脂の分散液を混合し、アルミニウム箔等の金属箔に塗布し、熱処理によって溶媒を乾燥させることで、誘電性セラミック粉末と有機樹脂を含む誘電体層を金属箔上に形成し、誘電体層に更に金属箔を重ね合わせて熱及び圧力を加えて密着することで、このシート状セラミック複合体コンデンサは製造される。 In order to compensate for the shortcomings of ceramic capacitors and metallized film capacitors, and to draw out the advantages of each other, sheet-like ceramic composite capacitors having a dielectric layer containing dielectric ceramic powder and organic resin have been developed. For example, a dielectric layer containing a dielectric ceramic powder and an organic resin is prepared by mixing a dispersion of a dielectric ceramic powder and a dispersion of an organic resin, applying the mixture to a metal foil such as an aluminum foil, and drying the solvent by heat treatment. Is formed on the metal foil, and the metal foil is further superposed on the dielectric layer and adhered by applying heat and pressure to produce the sheet-shaped ceramic composite capacitor.
シート状セラミック複合体コンデンサには、誘電体層と金属箔とが剥離し易いという問題があった。その理由は、誘電体層の表面に十分な量の有機樹脂が存在せず、且つ単に有機樹脂の熱可塑性を利用した熱圧着では密着力が不十分であったからである。この問題に対し、一方の金属箔に誘電体層を形成し、他方の金属箔に有機樹脂のスラリーを塗布して有機樹脂膜を形成し、誘電体層と有機樹脂膜を向かい合わせて熱及び圧力を加える方法が提案されている(例えば、特許文献1参照)。スラリー状の有機樹脂膜が介在することで、有機樹脂が金属箔に密着して有機樹脂の内部に空気層がなくなり、また有機樹脂同士を熱圧着するため、密着力が大きくなるものである。 The sheet-shaped ceramic composite capacitor has a problem that the dielectric layer and the metal foil easily peel off. The reason is that a sufficient amount of organic resin does not exist on the surface of the dielectric layer, and the adhesive force is insufficient by the thermocompression bonding simply utilizing the thermoplasticity of the organic resin. To solve this problem, a dielectric layer is formed on one metal foil, an organic resin slurry is applied to the other metal foil to form an organic resin film, and the dielectric layer and the organic resin film face each other with heat and heat. A method of applying pressure has been proposed (see, for example, Patent Document 1). By interposing the slurry-like organic resin film, the organic resin comes into close contact with the metal foil, the air layer disappears inside the organic resin, and the organic resins are thermocompression-bonded, so that the adhesion is increased.
コンデンサは、定格電圧を超える異常電圧が印加されるような過酷な条件下であっても、ショートを起こさぬよう、高い耐電圧を有することが望ましい。そのため、誘電体層の耐電圧を高めるべく、誘電体層に含まれる粒子はある程度の大きさ以上となることが望ましい。誘電体層と金属箔とを密着するためのバインダとして有機樹脂膜を選択した場合、この有機樹脂膜は、コンデンサにおいて誘電体層として機能することになるため、耐電圧向上を望めば、有機樹脂膜に含有させる粒子も誘電体層としてある程度の大きさ以上に規制されることになる。 It is desirable that the capacitor has a high withstand voltage so as not to cause a short circuit even under severe conditions where an abnormal voltage exceeding the rated voltage is applied. Therefore, in order to increase the withstand voltage of the dielectric layer, it is desirable that the particles contained in the dielectric layer have a certain size or more. When an organic resin film is selected as the binder for closely attaching the dielectric layer and the metal foil, the organic resin film functions as a dielectric layer in the capacitor. The particles contained in the film are also regulated to a certain size or more as the dielectric layer.
即ち十分な耐電圧を望めば、有機樹脂膜の表面は、有機樹脂膜内の大きな粒子の存在故、高度に滑らかにすることができず、有機樹脂膜と金属箔との密着性が低下してしまう。そのため、一方の金属箔に誘電体層を形成し、他方の金属箔に有機樹脂のスラリーを塗布して有機樹脂膜を形成し、誘電体層と有機樹脂膜を向かい合わせて熱及び圧力を加える方法では、耐電圧を向上させつつ、有機樹脂膜と金属箔との密着力を十分に高めることはできず、金属箔の剥離を確実に防止できなかった。 That is, if a sufficient withstand voltage is desired, the surface of the organic resin film cannot be made highly smooth due to the presence of large particles in the organic resin film, and the adhesion between the organic resin film and the metal foil is reduced. End up. Therefore, a dielectric layer is formed on one metal foil, an organic resin slurry is applied to the other metal foil to form an organic resin film, and heat and pressure are applied to the dielectric layer and the organic resin film facing each other. In the method, the withstand voltage was improved, and the adhesion between the organic resin film and the metal foil could not be sufficiently increased, and the metal foil could not be reliably peeled off.
本発明は、上記のような従来技術の問題点を解決するため、耐電圧を向上させつつ、金属箔上に誘電体層を積層したセラミック複合体シート同士の剥離をより確実に防止できるセラミック複合体シート、及び当該セラミック複合体シートを備えるコンデンサを提供することにある。 In order to solve the above-described problems of the prior art, the present invention provides a ceramic composite that can more reliably prevent peeling between ceramic composite sheets in which a dielectric layer is laminated on a metal foil while improving withstand voltage. It is providing a capacitor | condenser provided with a body sheet and the said ceramic composite sheet.
上記目的を達成するため、本発明に係るセラミック複合体シートは、金属箔と、前記金属箔上に積層され、有機樹脂と誘電性セラミック粉末とを含む誘電体層と、前記誘電体層上に積層される導電性層と、を備えること、を特徴とする。導電性層は、耐電圧性を必要とする有機樹脂膜のような規制を受けず、金属箔との密着性に重きを置いて設計でき、金属箔の剥離をより確実に防止できる。 In order to achieve the above object, a ceramic composite sheet according to the present invention comprises a metal foil, a dielectric layer laminated on the metal foil and containing an organic resin and a dielectric ceramic powder, and the dielectric layer. And a conductive layer to be laminated. The conductive layer is not subject to restrictions such as an organic resin film that requires voltage resistance, and can be designed with emphasis on adhesion to the metal foil, and can prevent the metal foil from peeling more reliably.
例えば、前記導電性層には、平板状の粒子形状を有する導電性材料が含まれるようにしてもよい。平板状の導電性材料は、金属箔と面接触するため、金属箔との接触面積が球形粒子と比べて大きく、この平板状の導電性材料を含む導電性層は金属箔と強く密着する。 For example, the conductive layer may include a conductive material having a tabular grain shape. Since the flat conductive material is in surface contact with the metal foil, the contact area with the metal foil is larger than that of the spherical particles, and the conductive layer containing the flat conductive material is in close contact with the metal foil.
また、前記導電性層には、更に球形粒子形状を有する導電性材料が含まれるようにしてもよい。金属箔との密着性を維持しつつ、球形粒子形状を有する導電性材料を介することで、平板状の粒子形状を有する導電性材料同士の間に介在し、導電性が高まる。 The conductive layer may further include a conductive material having a spherical particle shape. By interposing the conductive material having a spherical particle shape while maintaining the adhesion with the metal foil, the conductive material is interposed between the conductive materials having a flat particle shape, and the conductivity is increased.
前記誘電体層中の前記誘電性セラミック粉末の含有量は、前記有機樹脂の含有量に対して70wt%以上97.5wt%以下であるようにしてもよい。この下限を下回ると、空隙を多く含む誘電体層となって耐電圧が低下する。一方、この上限を上回ると、ひび割れや空隙を多く含む誘電体層となって耐電圧が低下するどころか、最悪の場合には誘電体層として利用し難くなる。 The content of the dielectric ceramic powder in the dielectric layer may be 70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin. Below this lower limit, the dielectric layer containing a large amount of voids results in a reduction in withstand voltage. On the other hand, if this upper limit is exceeded, it becomes a dielectric layer containing many cracks and voids, and instead of lowering the withstand voltage, it is difficult to use it as a dielectric layer in the worst case.
前記有機樹脂は、ポリアミドイミド樹脂であり、前記誘電性セラミック粉末は、チタン酸バリウム粉末であるようにしてもよい。また、前記導電性層は、黒鉛とカーボンブラックを含むようにしてもよい。 The organic resin may be a polyamide-imide resin, and the dielectric ceramic powder may be a barium titanate powder. The conductive layer may include graphite and carbon black.
このセラミック複合体シートを備えるコンデンサも本発明の一態様であり、本発明のコンデンサは、この複数のセラミック複合体シートを備えること、を特徴とする。 A capacitor including this ceramic composite sheet is also an aspect of the present invention, and the capacitor of the present invention includes the plurality of ceramic composite sheets.
本発明によれば、電極として扱われる導電性層を介して積層できるセラミック複合体シートであるので、セラミック複合体シートの密着力を高めることができる。 According to the present invention, since it is a ceramic composite sheet that can be laminated through a conductive layer treated as an electrode, the adhesion of the ceramic composite sheet can be increased.
以下、本発明に係るセラミック複合体シート及びこれを備える各種コンデンサの実施形態について詳細に説明する。 Hereinafter, embodiments of the ceramic composite sheet according to the present invention and various capacitors including the ceramic composite sheet will be described in detail.
(セラミック複合体シート)
図1に示すように、セラミック複合体シート1は、金属箔2と誘電体層3と導電性層4を積層して成る。金属箔2の片面に誘電体層3が形成され、誘電体層3に導電性層4が形成される。このセラミック複合体シート1の導電性層4と、他のセラミック複合体シート1の金属箔2の面、若しくは誘電体層3や導電性層4を形成しない金属箔2とを向かい合わせにして重ね合わせ、巻回型や積層チップ型等のコンデンサが作製される。
(Ceramic composite sheet)
As shown in FIG. 1, the
金属箔2は、例えば5μm以上50μm以下の厚みを有する。この金属箔2は、導電材料を主たる材質とする。導電性材料は、アルミニウム(Al)、ニッケル(Ni)、銅(Cu)、銀(Ag)、金(Au)、鉄(Fe)、パラジウム(Pd)、白金(Pt)、亜鉛(Zn)、スズ(Sn)、又はクロム(Cr)等の貴金属及び卑金属から選ばれる一種、若しくはこれらの合金である。金属箔2の表面には、アンカー効果による誘電体層3との密着性向上のため、エッチング等の粗面化処理が施されることが望ましい。
The
誘電体層3は、例えば10以上30μm以下の厚みを有する。この誘電体層3は、有機樹脂と誘電性セラミック粉末を主たる成分として分散させて含有する。誘電体層3に誘電性セラミック粉末を含有させるので、セラミック複合体シート1の誘電率を高めることができる。また、誘電体層3に有機樹脂を含有しているので、セラミック複合体シート1の誘電傾度を高めることができ、靱性も高めることができる。有機樹脂と誘電性セラミック粉体は、コンデンサの耐電圧向上の観点から、平均粒径0.1μm超が望ましい。
The
有機樹脂は、ポリアミドイミド、ポリエーテルイミド、ポリイミド、ポリエチレンテレフタレート、ポリエチレンナフタレート、ポリプロピレン、ポリフェニレンサルファイド、ポリフッ化ビニリデン等から選ばれる一種又は二種以上の混合である。 The organic resin is one or a mixture of two or more selected from polyamideimide, polyetherimide, polyimide, polyethylene terephthalate, polyethylene naphthalate, polypropylene, polyphenylene sulfide, polyvinylidene fluoride, and the like.
誘電性セラミック粉末は、チタン酸バリウム(BaTiO3)系セラミックのほか、Baの一部をCaやSrで置換するとともにTiの一部をZrで置換した(Ba,Ca,Sr)(Ti,Zr)O3系セラミック等から選ばれる一種又は二種以上の混合であり、例えば、チタン酸バリウム(BaTiO3)系、チタン酸ストロンチウム(SrTiO3)系、チタン酸カルシウム(CaTiO3)系、チタン酸マグネシウム(MgTiO3)系、ジルコン酸カルシウム(CaZrO3)系、チタン酸ジルコン酸カルシウム(PCZT)系、ジルコン酸バリウム(BaZrO3)系、酸化チタン(TiO2)系が挙げられる。 In addition to barium titanate (BaTiO 3 ) -based ceramics, the dielectric ceramic powder includes a part of Ba substituted with Ca and Sr and a part of Ti substituted with Zr (Ba, Ca, Sr) (Ti, Zr). ) One or a mixture of two or more selected from O 3 ceramics, for example, barium titanate (BaTiO 3 ), strontium titanate (SrTiO 3 ), calcium titanate (CaTiO 3 ), titanate magnesium (MgTiO 3) system, calcium zirconate (CaZrO 3) system, calcium titanate zirconate (PCZT) system, barium zirconate (BaZrO 3) system, and titanium oxide (TiO 2) system.
この誘電体層3の製造工程を例示する。例えばチタン酸バリウムに分散溶媒としてN-メチル-2-ポロリドン(NMP)を重量部で1:1の割合で混合した混合液を調製する。また、ポリアミドイミドに分散溶媒としてNMPを重量部1:4の割合でNMPを多く混合した混合液を調製する。両混合液の分散溶媒は、誘電性セラミック粉末の凝集抑制を考慮して選択でき、同種のものが望ましい。この両混合液を重量部1:0.1以上1.0以下の割合で混合する。
The manufacturing process of this
そして、このチタン酸バリウムとポリアミドイミドの混合液を、粗面化処理を施したアルミニウム箔等の金属箔2に10μm以上30μm以下の厚さで塗布する。但し、金属箔2の一辺に帯状の未塗工部分2aを残しておく。塗布の方法としては、グラビア塗工、ダイ塗工、スクリーン印刷等の各種公知の手法を用いることができる。塗工終了の後、摂氏100度以上120度以下で熱処理を行い、溶媒を乾燥させる。なお、溶媒を乾燥させた後、プレス処理を施し、誘電体層3の密度を上げてもよい。
Then, this mixed solution of barium titanate and polyamideimide is applied to a
ここで、誘電体層3中の誘電性セラミック粉末の含有量は、有機樹脂の含有量に対して70wt%以上97.5wt%以下であることが望ましい。70wt%未満となると、有機樹脂に誘電性セラミック粉末を含ませて誘電率を高める効果が低くなる。また、誘電体層3は空隙を多く含み、この空隙に起因して耐電圧が低下する。そのため、誘電性セラミック粉末の含有量を、有機樹脂の含有量に対して70wt%未満の誘電体層3を作製しようとすると、空隙を除去する工程を追加するか、空隙がない部分のみを用いる必要が生じ、歩留まりが悪化する。一方、97.5wt%超となると、誘電体層3が多数のひび割れや空隙が生じる所謂ボロボロな状態となり、耐電圧が低下するどころか、最悪の場合には塗工すらできず誘電体層3として利用し難くなる。
Here, the content of the dielectric ceramic powder in the
推測であり、このメカニズムに限定されるものではないが、誘電性セラミック粉末の含有量に空隙やひび割れの観点で下限及び上限が存在することとなったのは次の理由によるものと考えられる。 It is speculated and not limited to this mechanism, but it is considered that the lower limit and the upper limit existed in terms of voids and cracks in the content of the dielectric ceramic powder because of the following reasons.
まず有機樹脂は両混合液の混合過程で吸着剤及び結合剤となる。即ち、有機樹脂は、誘電性セラミック粉末の粒子表面を覆い、溶媒との親和性を高める。また、誘電性セラミック粉末の粒子表面を覆った有機樹脂は、有機樹脂同士を媒介として、誘電性セラミック粉末同士を結合させる。また、両混合液の混合過程において、誘電性セラミック粉末の量が少ないと、換言すると有機樹脂の量が多いと、結合剤としての機能により、誘電性セラミック粉末の粒子間に多くの有機樹脂が存在し、混合過程で有機樹脂が泡立ってしまった。そのため、混合液を乾燥させた後には、空隙が多く存在する誘電体層3が作製されてしまったものと考えられる。
First, the organic resin becomes an adsorbent and a binder during the mixing process of both liquid mixtures. That is, the organic resin covers the particle surface of the dielectric ceramic powder and increases the affinity with the solvent. In addition, the organic resin covering the surface of the dielectric ceramic powder particles bonds the dielectric ceramic powders together with the organic resin as a medium. In addition, when the amount of the dielectric ceramic powder is small, in other words, when the amount of the organic resin is large, a large amount of the organic resin is present between the particles of the dielectric ceramic powder due to the function as a binder. Existed and the organic resin foamed during the mixing process. Therefore, it is considered that the
一方、両混合液の混合過程において、誘電性セラミック粉末の量が多いと、換言すると有機樹脂の量が少ないと、有機樹脂は吸着剤としての機能は発揮して誘電性セラミック粉末の粒子表面を覆うが、有機樹脂は結合剤としての機能を十分に発揮することができず、そのため、混合液を乾燥させた後の誘電体層3はボロボロになり、ひび割れや空隙が多く存在することとなってしまったと考えられる。
On the other hand, when the amount of the dielectric ceramic powder is large in the mixing process of both the mixed liquids, in other words, when the amount of the organic resin is small, the organic resin functions as an adsorbent and the particle surface of the dielectric ceramic powder is reduced. Although the organic resin cannot cover the function as a binder sufficiently, the
導電性層4は、例えば0.5μm以上5μm以下の厚みを有する。この導電性層4は、導電性材料を主たる成分とする。導電性材料としては、天然又は人造の黒鉛、カーボンブラック、カーボンナノチューブ、グラフェン、ケッチェンブラック、アセチレンブラックから選ばれる一種又は二種以上の混合である。導電性材料の粒径は、平均15μm以下が望ましく、また導電性層4には平板状の粒子形状の導電性材料が含まれていることが望ましい。平板状の粒子形状の導電性材料は、平板面と金属箔2の表面とが平行した状態で、導電性層4の表面に配置される。したがって、平板状の粒子形状の導電性材料は、金属層2と面接触するので、金属箔2との接触面積が広くなり、大きな密着力を得られる。更に望ましくは、平板状の粒子形状の導電性材料に加えて、球形粒子形状の導電性材料が含まれる。平板状の粒子形状の導電性材料間に球形粒子形状の導電性材料が介在し、平板状の粒子形状の導電性材料同士の導電性が高まる。
The
尚、平板とは、平面状の平板面を有しており、この平板面の短辺長が0.5以上10μm以下、長辺長が0.5以上10μm以下であり、厚さが0.5以上2μm以下の形状をいい、球形には、真球、楕円体、多面体、又はこれらが重複して接続し合って形作られた形状が含まれる。 The flat plate has a flat flat plate surface, the short side length of the flat plate surface is 0.5 to 10 μm, the long side length is 0.5 to 10 μm, and the thickness is 0.00. The shape of 5 or more and 2 μm or less includes a sphere, an ellipsoid, a polyhedron, or a shape formed by overlapping and connecting these.
この導電性層4は、スチレン・ブタジエンゴム(SBR)等のエラストマーを結合剤として導電性材料を層内に固定化する。例えば、純水を分散溶媒として平板状の黒鉛と球形状のカーボンブラックを重量部10:1の割合で混合し、スチレン・ブタジエンゴムを結合剤として1の割合で添加したスラリーを作製し、誘電体層3上に0.5以上5μm以下の厚さで塗布する。塗工を終了すると、熱処理を行い、溶媒を乾燥させる。
This
(コンデンサ)
以上のセラミック複合体シート1を、図2に示すように、導電性層4と金属箔2とが接触するように向き合わせて複数枚を積み重ね、セラミック複合体シート1の積層体に、熱及び圧力をかけることで、導電性層4と金属箔2とが密着し、コンデンサが作製される。
(Capacitor)
As shown in FIG. 2, the ceramic
(第1の巻回型コンデンサ例)
例えば、図3の(a)に示すように、帯状に長い一対のセラミック複合体シート1を、長手方向及び短手方向を揃え、但し未塗工部分2aの向きを逆にして重ね合わせる。即ち、誘電体層3及び導電性層4を塗工していない未塗工部分2aが重ならないようにする。また、一方のセラミック複合体シート1の導電性層4に他方のセラミック複合体シート1の金属箔2が載るように重ね合わせる。
(First winding type capacitor example)
For example, as shown in FIG. 3A, a pair of long ceramic
図3の(b)に示すように、積層した一対のセラミック複合体シート1を誘電体層3側を巻き込むように巻回する。これにより、一対のセラミック複合体シート1が巻回された円筒状のコンデンサ素子61が形成される。
As shown in FIG. 3B, the pair of laminated ceramic
図3の(c)に示すように、この円筒体の両端部に露出した未塗工部分2aの端面にメタリコンによって電極金属を蒸着させ、一方の素子端面には正極側電極部5-1、他方の素子端面には負極側電極部5-2を形成する。このように各素子端面は異なる電極で構成されている。この場合、電極金属としては、半田付けなど、接続の容易性から半田付け可能な金属を用いればよい。この半田付け可能な金属にはたとえば、亜鉛、錫合金などの金属を用いればよい。その他、半田付け可能な金属にはたとえば、アルミニウムと亜鉛の合金、アルミニウムと錫合金、亜鉛と錫合金などを用いてもよい。
As shown in FIG. 3 (c), an electrode metal is vapor-deposited by metallicon on the end faces of the
電極部5-1、5-2は、端子板67に設けられた正極側外部端子64-1、負極側外部端子64-2とリード線63により接続されている。すなわち、正極側電極部5-1と正極側外部端子64-1、負極側電極部5-2と負極側外部端子64-2は、リード線63を用いて半田により接続されている。このとき、図3の(d)に示すように、負極側外部電極64-2に接続したリード線63は、コンデンサ素子61の中空部を通って、負極側外部端子64-2が配置される面に引き出され、負極側外部端子64-2と接続される。
The electrode portions 5-1 and 5-2 are connected to the positive external terminal 64-1 and the negative external terminal 64-2 provided on the
図3の(d)に示すように、リード線63を正極側外部端子64-1、負極側外部端子64-2と接続した後、コンデンサ素子61をケース65に収納し、ケース65内に絶縁性樹脂66を充填して硬化処理を施して巻回型コンデンサが作製される。
As shown in FIG. 3D, after the
(第2の巻回型コンデンサ例)
図4の(a)に示すように、帯状に長い一対のセラミック複合体シート1の未塗工部分2aを所定の間隔で切り除いて、長手方向にタブ2bを形成する。この一対のセラミック複合体シート1を長手方向及び短手方向を揃え、またタブ2bの方向を揃えて重ね合わせる。また、一方のセラミック複合体シート1の導電性層4に他方のセラミック複合体シート1の金属箔2が載るように重ね合わせる。
(Second winding type capacitor example)
As shown in FIG. 4A, the
図4の(b)に示すように、積層した一対のセラミック複合体シート1を導電性層4側を巻き込むように巻回し、円筒状のコンデンサ素子を形成する。このコンデンサ素子の一方端部には、一方のセラミック複合体シート1のタブ2b-1によって、コンデンサ素子の端面から突出した正極側電極部5-1が作られ、また他方のセラミック複合体シート1のタブ2b-2によって、コンデンサ素子の端面から突出した負極側電極部5-2が作られ、電極部5-1、5-2は互いに対向するように形成する。
As shown in FIG. 4B, a pair of laminated ceramic
このコンデンサ素子の電極部5-1、5-2と、封口板に設けられた外部端子と接続した後、ケースに収容し、封止樹脂を充填して硬化処理を施して、巻回型コンデンサが作製される。 After being connected to the electrode portions 5-1 and 5-2 of this capacitor element and the external terminals provided on the sealing plate, they are housed in a case, filled with a sealing resin and subjected to a curing treatment, and a wound capacitor Is produced.
(第1のチップ型コンデンサ例)
図5の(a)に示すように、未塗工部分2aが交互に逆に向き、誘電体層3と導電性層4が積み重ねるように、矩形状のセラミック複合体シート1を複数枚重ね合わせる。図5の(b)に示すように、導電性層4と金属箔2とが空気層を挟むことなく密着し、上下のセラミック複合体シート1同士が強固に積層される。
(First chip type capacitor example)
As shown in FIG. 5 (a), a plurality of rectangular ceramic
図5の(c)に示すように、一方に突き出た未塗工部分2aが露出するように積層体を樹脂でモールドする。積層体の未塗工部分2aの露出面に、銅などの金属を塗布し、外部電極68a、68bを形成する。外部電極68a,68bは、セラミック複合体シート1の積層体の対向する2つ面に形成されたことになる。これにより、複数枚のセラミック複合体シート1が積層された積層チップ型コンデンサが作成される。
As shown in FIG. 5C, the laminate is molded with resin so that the
(第2のチップ型コンデンサ例)
図6の(a)及び(b)に示すように、セラミック複合体シート1の導電性層4側にアルミニウム箔等の金属箔6を重ね合わせる。金属箔6は、セラミック複合体シート1のように誘電体層3や導電性層4は形成されていない。セラミック複合体シート1の未塗工部分2aとは反対側に金属箔6がはみ出るように、セラミック複合体シート1と金属箔6を重ね合わせる。そして、セラミック複合体シート1と金属箔6の積層体に熱及び圧力を加えると、導電性層4と金属箔6とが空気層を挟むことなく積層される。
(Second chip type capacitor example)
As shown in FIGS. 6A and 6B, a
図6の(c)に示すように、一方に突き出た金属箔6の一端および未塗工部分2aが露出するように樹脂で積層体をモールドする。積層体の未塗工部分2aの露出面に、銅などの金属を塗布し、外部電極68a、68bを形成する。セラミック複合体シート1の積層体の対向する2つ面に形成されたことになる。これにより、一枚のセラミック複合体シート1と一枚の金属箔6とを接続して成るチップ型コンデンサが作成される。
6 (c), the laminate is molded with resin so that one end of the
(作用効果)
以上のように、このセラミック複合体シート1は、金属箔2上に有機樹脂と誘電性セラミック粉末とを含む誘電体層3を積層し、誘電体層3上に導電性層4を積層するようにした。
(Function and effect)
As described above, in this ceramic
導電性層4は、コンデンサにおいて電極として扱われるため、導電性層4の含有粒子を誘電体層3のように耐電圧を考慮して大きく規制する必要がない。そのため、導電性層4と金属箔2、6との密着性を高めることができ、高い耐電圧と剥離抑制とを両立できる。
Since the
特に、平板状の粒子形状を有する導電性材料が導電性層4に含まれるようにすればよい。平板状の導電性材料は金属箔2、6と面接触するため、金属箔2、6との接触面積が球形粒子と比べて大きく、この平板状の導電性材料を含む導電性層4は金属箔2、6と強く密着する。
In particular, a conductive material having a tabular grain shape may be included in the
また、導電性層4には、更に球形粒子形状を有する導電性材料が含まれるようにすればよい。金属箔との密着性を維持しつつ、球形粒子形状を有する導電性材料を介することで、平板状の粒子形状を有する導電性材料同士の導電性が高まり、金属箔2、6と導電性層4との導電性が高まる。
The
また、誘電体層に誘電性セラミック粉末を含有しているので、誘電率が高いコンデンサを作製することができる。さらに、誘電体層に有機樹脂を含有しているので、誘電傾度が高く、また、靱性が高いコンデンサを作製することができる。 Also, since the dielectric layer contains dielectric ceramic powder, a capacitor having a high dielectric constant can be produced. Furthermore, since the dielectric layer contains an organic resin, a capacitor having a high dielectric gradient and high toughness can be manufactured.
尚、本実施形態では、有機樹脂は、ポリアミドイミド樹脂であり、誘電性セラミック粉末は、チタン酸バリウム粉末であり、導電性層4は、黒鉛とカーボンブラックを含むようにしたが、これに限られない。
In this embodiment, the organic resin is a polyamide-imide resin, the dielectric ceramic powder is a barium titanate powder, and the
また、本実施形態では、セラミック複合体シート1の導電性層4に他方のセラミック複合体シート1のアルミニウム箔2が載るように重ね合わせて一対のセラミック複合体シート1を作成したが、密着性をさらに高めるために、一対のセラミック複合体シート1を重ね合わせた状態で、熱及び圧力を加えて一体化させてもよく、セラミック複合体シート1同士の間に銀ペーストを介在させてもよい。
Further, in this embodiment, the pair of ceramic
また、誘電性セラミック粉末と有機樹脂の重量比率を変えた各種の誘電体層3を実際に作製し、誘電体層3の誘電率を計測するとともに、誘電体層3の状態を観察した。誘電体層3の作製に際し、誘電性セラミック粉末としてチタン酸バリウムを用い、チタン酸バリウムに分散溶媒としてN-メチル-2-ポロリドン(NMP)を重量部で1:1の割合で混合した混合液を調製した。また、有機樹脂としてポリアミドイミドを用い、ポリアミドイミドに分散溶媒としてNMPを重量部1:4の割合でNMPを多く混合した混合液を調製した。
Further, various
そして、この両混合液を次の重量比率となるように混合して、各種の混合液を得た。即ち、ポリアミドイミドに対してチタン酸バリウムが65wt%となる第1の混合液、ポリアミドイミドに対してチタン酸バリウムが70wt%となる第2の混合液、ポリアミドイミドに対してチタン酸バリウムが80wt%となる第3の混合液、ポリアミドイミドに対してチタン酸バリウムが90wt%となる第4の混合液、ポリアミドイミドに対してチタン酸バリウムが97.5wt%となる第5の混合液、及びポリアミドイミドに対してチタン酸バリウムが98.0wt%となる第6の混合液を得た。 And these both liquid mixtures were mixed so that it might become the following weight ratio, and various liquid mixture was obtained. That is, the first mixed liquid in which barium titanate is 65 wt% with respect to polyamideimide, the second mixed liquid in which barium titanate is 70 wt% with respect to polyamideimide, and the barium titanate is 80 wt% with respect to polyamideimide. A third mixed solution with a percentage of barium titanate of 90 wt% with respect to the polyamideimide, a fifth mixed liquid with a barium titanate of 97.5 wt% with respect to the polyamideimide, and A sixth mixed solution in which barium titanate was 98.0 wt% with respect to polyamideimide was obtained.
これら第1乃至第6の混合液を、アルミニウム箔にドクターブレード方法にて塗布し、摂氏90度で30分間熱処理を行って溶媒を乾燥させ、各誘電体層3を得て、状態を写真撮影するとともに、比誘電率を測定した。この結果を図7及び図8に示す。図7は、第1及び第6の混合液で得られた誘電体層3を撮影した写真である。図8は、各混合液で得られた誘電体層3の比誘電率を示すグラフである。
These first to sixth mixed liquids are applied to an aluminum foil by a doctor blade method, subjected to heat treatment at 90 degrees Celsius for 30 minutes to dry the solvent, obtain each
図7(a)に示すように、ポリアミドイミドに対してチタン酸バリウムが65wt%となる第1の混合液を由来とする誘電体層3は、多くの空隙Vが存在している。尚、この第1の混合液の混合過程では泡立ちが見られた。図7(b)に示すように、ポリアミドイミドに対してチタン酸バリウムが98.0wt%となる第6の混合液を由来とする誘電体層3は、ひび割れCが生じ、所謂ボロボロの状態であった。一方、ポリアミドイミドに対してチタン酸バリウムが70以上97.5wt%以下に収まる第2乃至第5の混合液を由来とする誘電体層3には空隙が見られなかった。
As shown in FIG. 7A, the
この状態観察の結果より、誘電体層3中の誘電性セラミック粉末の含有量は、有機樹脂の含有量に対して70wt%以上97.5wt%以下とすることが望ましく、これにより更に高い耐電圧を得ることができる。
From the result of this state observation, it is desirable that the content of the dielectric ceramic powder in the
また、図8に示すように、比誘電率は、誘電体層3中の誘電性セラミック粉末の含有量が、有機樹脂の含有量に対して70wt%以上97.5wt%以下であれば、70wt%のときの比誘電率(εs)が平均34.5となり、80wt%のときの比誘電率が平均43.1となり、90wt%のときの比誘電率が平均52.2となり、97.5wt%のときの比誘電率が平均60.3となり、誘電性セラミック粉末の増加に比例して増加する。一方、この70wt%以上97.5wt%以下の範囲を逸脱すると、比誘電率は、急激に減少してしまう。
Further, as shown in FIG. 8, the relative dielectric constant is 70 wt% when the content of the dielectric ceramic powder in the
この結果により、誘電体層3中の誘電性セラミック粉末の含有量は、有機樹脂の含有量に対して70wt%以上97.5wt%以下とすることが望ましく、これにより、より高容量のコンデンサが得られる。
As a result, it is desirable that the content of the dielectric ceramic powder in the
1 セラミック複合体シート
2 金属箔
2a 未塗工部分
2b タブ
3 誘電体層
4 導電性層
5-1 正極側電極部
5-2 負極側電極部
6 金属箔
61 コンデンサ素子
63 リード線
64-1 正極側外部端子
64-2 負極側外部端子
65 ケース
66 封止樹脂
67 端子板
68a 外部電極
68b 外部電極
DESCRIPTION OF
Claims (7)
前記金属箔上に積層され、有機樹脂と誘電性セラミック粉末とを含む誘電体層と、
前記誘電体層上に積層される導電性層と、
を備えること、
を特徴とするセラミック複合体シート。 Metal foil,
A dielectric layer laminated on the metal foil and comprising an organic resin and a dielectric ceramic powder;
A conductive layer laminated on the dielectric layer;
Providing
A ceramic composite sheet characterized by
を特徴とする請求項1記載のセラミック複合体シート。 The conductive layer includes a conductive material having a tabular particle shape,
The ceramic composite sheet according to claim 1.
を特徴とする請求項2記載のセラミック複合体シート。 The conductive layer further includes a conductive material having a spherical particle shape;
The ceramic composite sheet according to claim 2.
前記有機樹脂の含有量に対して70wt%以上97.5wt%以下であること、
を特徴とする請求項1乃至3の何れかに記載のセラミック複合体シート。 The dielectric ceramic powder content in the dielectric layer is:
70 wt% or more and 97.5 wt% or less with respect to the content of the organic resin,
The ceramic composite sheet according to any one of claims 1 to 3.
前記誘電性セラミック粉末は、チタン酸バリウム粉末であること、
を特徴とする請求項1乃至4の何れかに記載のセラミック複合体シート。 The organic resin is a polyamideimide resin,
The dielectric ceramic powder is a barium titanate powder;
The ceramic composite sheet according to any one of claims 1 to 4, wherein:
を特徴とする請求項3記載のセラミック複合体シート。 The conductive layer includes graphite having a flat particle shape and carbon black having a spherical particle shape;
The ceramic composite sheet according to claim 3.
を特徴とするコンデンサ。 Comprising a plurality of ceramic composite sheets according to any one of claims 1 to 6,
Capacitor characterized by.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2023503212A (en) * | 2020-09-21 | 2023-01-27 | ティーディーケイ・エレクトロニクス・アクチェンゲゼルシャフト | capacitor |
| JP2023046075A (en) * | 2021-09-22 | 2023-04-03 | 京セラ株式会社 | Method for manufacturing film capacitor element |
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| JPS49103154A (en) * | 1973-02-05 | 1974-09-30 | ||
| JPS5061435A (en) * | 1973-10-02 | 1975-05-27 | ||
| JPH0917689A (en) * | 1995-06-28 | 1997-01-17 | Hokuriku Electric Ind Co Ltd | Printing capacitor and its manufacture |
| JP2010539285A (en) * | 2007-09-14 | 2010-12-16 | オークミツイ,インク., | Polymer-ceramic composite with excellent TCC |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JPS49103154A (en) * | 1973-02-05 | 1974-09-30 | ||
| JPS5061435A (en) * | 1973-10-02 | 1975-05-27 | ||
| JPH0917689A (en) * | 1995-06-28 | 1997-01-17 | Hokuriku Electric Ind Co Ltd | Printing capacitor and its manufacture |
| JP2010539285A (en) * | 2007-09-14 | 2010-12-16 | オークミツイ,インク., | Polymer-ceramic composite with excellent TCC |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2023503212A (en) * | 2020-09-21 | 2023-01-27 | ティーディーケイ・エレクトロニクス・アクチェンゲゼルシャフト | capacitor |
| JP7464704B2 (en) | 2020-09-21 | 2024-04-09 | ティーディーケイ・エレクトロニクス・アクチェンゲゼルシャフト | Capacitor |
| US11996239B2 (en) | 2020-09-21 | 2024-05-28 | Tdk Electronics Ag | Capacitor |
| JP2024081735A (en) * | 2020-09-21 | 2024-06-18 | ティーディーケイ・エレクトロニクス・アクチェンゲゼルシャフト | Capacitor |
| JP7653559B2 (en) | 2020-09-21 | 2025-03-28 | ティーディーケイ・エレクトロニクス・アクチェンゲゼルシャフト | Capacitor |
| JP2023046075A (en) * | 2021-09-22 | 2023-04-03 | 京セラ株式会社 | Method for manufacturing film capacitor element |
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| JP7180048B2 (en) | 2022-11-30 |
| JPWO2018168845A1 (en) | 2020-01-16 |
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