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OwnerHirayoshi Tanei, Itaru Ueda +3inventors
InventorsHirayoshi Tanei, Itaru Ueda, Koji Ichikawa, Hiroyuki Tsunematsu, Hatsuo Ikeda
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A multi-layer ceramic substrate having an in-plane shrinkage ratio of 1% or less with 0.1% or less of unevenness, inorganic particles remaining on the external electrodes being 20% or less by mass as a percentage of one or more metals constituting inorganic particles per the total amount of one or more metals constituting the external electrodes and one or more metals constituting the inorganic particles, is produced by (a) preparing a slurry containing ceramic material powder and an organic binder to form low-temperature-sinterable green substrate sheets, (b) laminating the green substrate sheets after forming electrodes thereon, to produce an unsintered multi-layer ceramic substrate, (c) bonding a constraining layer comprising inorganic particles, which are not sintered at the sintering temperature of the unsintered multi-layer ceramic substrate and have an average particle size of 0.3 μm or more, 0.3-4 times that of the ceramic material powder, and an organic binder, to upper and/or lower surfaces of the unsintered multi-layer ceramic substrate having the external electrodes, to form an integral laminate, (d) sintering the laminate, and (e) removing the constraining layer from the sintered laminate.
A multi-layer ceramic substrate obtained by laminating low-temperature-sinterable green substrate sheets comprising a ceramic material, forming external electrodes at least on an upper surface of the resultant unsintered multi-layer ceramic substrate, bonding a constraining layer comprising as main components inorganic particles which are not sintered at the sintering temperature of said unsintered multi-layer ceramic substrate to upper and/or lower surfaces of said unsintered multi-layer ceramic substrate having said external electrodes to form an integral laminate, sintering said integral laminate, and then removing said constraining layer, wherein said multi-layer ceramic substrate has an in-plane shrinkage ratio of 1% or less within 0.1% unevenness, and wherein said inorganic particles remaining on said external electrodes are 20% or less by mass as a percentage of one or more metals constituting said inorganic particles to the total amount of one or more metals constituting said external electrodes and one or more metals constituting said inorganic particles.
A multi-layer ceramic substrate obtained by laminating low-temperature-sinterable green substrate sheets containing a ceramic material, forming external electrodes at least on an upper surface of the resultant unsintered multi-layer ceramic substrate, bonding a constraining layer comprising as main components inorganic particles which are not sintered at the sintering temperature of said unsintered multi-layer ceramic substrate to upper and/or lower surfaces of said unsintered multi-layer ceramic substrate having said external electrodes to form an integral laminate, sintering said integral laminate, and then removing said constraining layer, wherein said multi-layer ceramic substrate has a structure comprising a feldspar crystal based on strontium feldspar and an alumina crystal.
A method for producing a multi-layer ceramic substrate comprising the steps of (a) preparing low-temperature-sinterable green substrate sheets from a slurry containing ceramic material powder and an organic binder, (b) laminating said green substrate sheets after forming electrodes thereon, to form an unsintered multi-layer ceramic substrate, (c) bonding a constraining layer comprising inorganic particles which are not sintered at the sintering temperature of said unsintered multi-layer ceramic substrate and an organic binder to upper and/or lower surfaces of said unsintered multi-layer ceramic substrate having said external electrodes, to form an integral laminate, (d) sintering said integral laminate, and (e) removing said constraining layer from a surface of the sintered laminate, wherein said inorganic particles have an average particle size of 0.3 μm or more, 0.3-4 times the average particle size of said ceramic material powder.
A method for producing a multi-layer ceramic substrate comprising the steps of (a) finely pulverizing a ceramic material comprising 10-60% by mass, calculated as Al2O3, of Al, 25-60% by mass, calculated as SiO2, of Si, 7.5-50% by mass, calculated as SrO, of Sr, and 0-20% by mass, calculated as TiO2, of Ti as main components, the total amount of Al2O3, SiO2, SrO and TiO2 being 100% by mass, which is calcined at 700° C. to 850° C., (b) preparing low-temperature-sinterable green substrate sheets from a slurry containing the resultant fine powder of the calcined body and an organic binder, (c) laminating said green substrate sheets after forming electrodes thereon, to form an unsintered multi-layer ceramic substrate, (d) bonding a constraining layer comprising inorganic particles which are not sintered at the sintering temperature of said unsintered multi-layer ceramic substrate, and an organic binder, to upper and/or lower surfaces of said unsintered multi-layer ceramic substrate having said external electrodes, to form an integral laminate, (e) sintering said integral laminate at 800° C. to 1000° C., and (f) removing said constraining layer from said laminate.
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