Dielectric ceramic, resin-ceramic composite material, electrical part and antenna, and manufacturing method thereof

• US 6,686,406 B2
• Filed: 12/10/2001
• Issued: 02/03/2004
• Est. Priority Date: 04/26/2000
• Status: Expired due to Term

• Current Assignee: Furukawa Electric Company Limited
• Original Assignee: Furukawa Electric Company Limited
• Inventors: Tomomatsu, Isao, Ishiwa, Masayuki
• Primary Examiner(s): BRUNSMAN, DAVID M
• Application Number:
  US10/014,086
• Publication Number:
  US 20020098970A1
• Time in Patent Office: 785 Days
• Field of Search: 501/138, 501/139, 524/403, 343/785, 343/907
• US Class Current: 524/403
• CPC Class Codes: C01G 29/00 Compounds of bismuth
• CPC Class Codes: C01G 29/006 Compounds containing, besides bismuth, two or more other elements, with the exception of oxygen or hydrogen
• CPC Class Codes: C01P 2002/52 containing elements as dopants
• CPC Class Codes: C01P 2006/40 Electric properties
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3215 Barium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3227 Lanthanum oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3229 Cerium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3251 Niobium oxides, niobates, tantalum oxides, tantalates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3284 Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
• CPC Class Codes: C04B 2235/3298 Bismuth oxides, bismuthates or oxide forming salts thereof, e.g. zinc bismuthate
• CPC Class Codes: C04B 2235/72 Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
• CPC Class Codes: C04B 2235/726 Sulfur content
• CPC Class Codes: C04B 2235/727 Phosphorus or phosphorus compound content
• CPC Class Codes: C04B 35/462 based on titanates
• CPC Class Codes: C04B 35/468 based on barium titanates
• CPC Class Codes: C04B 35/4686 based on phases other than BaTiO3 perovskite phase
• CPC Class Codes: C09C 3/12 Treatment with organosilicon compounds C09C3/006 takes precedence
• CPC Class Codes: H01B 3/12 ceramics
• CPC Class Codes: H01Q 1/38 : formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 9/0407 : Substantially flat resonant element parallel to ground plane, e.g. patch antenna dipole H01Q9/285; monopole H01Q9/40

Abstract

A dielectric ceramic containing Bi, Zn, and Sr as constituent elements. A resin-ceramic composite material containing a mixture of the dielectric ceramic powder and an organic polymer resin. An antenna and an electrical part using the composite material, and a manufacturing method thereof.

Claims

1. A resin-ceramic composite material, comprising a mixture of a powder of a dielectric ceramic that includes BaO, Nd₂O₃, TiO₂, Bi₂O₃, Nb, Zn, and Sr as constituent elements, and an organic polymer resin, wherein the organic polymer resin is polyphenylene sulfide.

2. The resin-ceramic composite material according to claim 1, wherein the dielectric ceramic further includes rare earth elements (except Nd) as constituent elements.

3. A resin-ceramic composite material, comprising a mixture of a powder of a dielectric ceramic and an organic polymer resin, wherein the organic polymer resin is polyphenylene sulfide, and

wherein the dielectric ceramic is one, in which, to a main composition expressed by xBaO·

yNd₂O₃·

zTiO₂·

wBi₂O₃, wherein

0.13≦

x≦

0.20;

0.28≦

y≦

0.35;

0.33≦

z≦

0.45;

0.09≦

w≦

0.15; and

x+y+z+w=1,

La, Ce, Pr, Nb, Zn, and Sr as constituent elements are included with amounts ranging 2 to 5 mass % for La, 1 to 2 mass % for Ce, and 0.03 to 1 mass % for each of Pr, Nb, Zn and Sr, and wherein all ceramics as a whole, including the above main composition, make up 100 mass %.

4. The resin-ceramic composite material according to claim 3, wherein a mass average molecular weight of the polyphenylene sulfide is 35,000 or more.

5. The resin-ceramic composite material according to claim 3, wherein a molecular weight at a maximum frequency in molecular weight distribution of the polyphenylene sulfide is 31,000 or more.

6. The resin-ceramic composite material according to claim 3, wherein a mean particle diameter of the ceramic powder used in the resin-ceramic composite material is 6 μ

m or less.

7. The resin-ceramic composite material according to claim 3, wherein an inorganic filler with a dielectric dissipation factor of not more than 0.001, a dielectric constant of not more than 6, and a temperature dependency of dielectric constant of not more than ±

100 ppm/°

C., is added as a third constituent.

8. The resin-ceramic composite material according to claim 3, wherein a lubricity auxiliary is added to the resin-ceramic composite material.

9. An electrical part, which is prepared using the resin-ceramic composite material of claim 3.

10. The electrical part according to claim 9, wherein a surface of the resin-ceramic composite material is plated.

11. An antenna, whose dielectric is formed with the resin-ceramic composite material of claim 3.

12. The antenna according to claim 11, wherein a surface of the resin-ceramic composite materiel is plated.

13. A resin-ceramic composite material, comprising a mixture of a dielectric ceramic powder, and polyphenylene sulfide with a weight average molecular weight of not less than 35,000 and a molecular weight at a maximum frequency in molecular weight distribution of not less than 31,000, wherein the dielectric ceramic is one, in which, to a main composition expressed by xBaO·

yNd₂O₃·

zTiO₂·

wBi₂O₃, wherein

0.13≦

x≦

0.20;

0.28≦

y≦

0.35;

0.33≦

z≦

0.45;

0.09≦

w≦

0.15; and

x+y+z+w=1,

La, Ce, Pr, Nb, Zn, and Sr as constituent elements are included with amounts ranging 2 to 5 mass % for La, 1 to 2 mass % for Ce, and 0.03 to 1 mass % for each of Pr, Nb, Zn and Sr, wherein all ceramics as a whole, including the above main composition, make up 100 mass %.

14. A method for producing an electrical part with a resin-ceramic composite material, comprising steps of:

molding the resin-ceramic composite material obtained by mixing a dielectric ceramic powder with a mean particle diameter of not more than 6 μ

m, and polyphenylene sulfide, by an injection-molding, wherein the dielectric ceramic powder is one, in which, to a main composition expressed by xBaO·

yNd₂O₃·

zTiO₂·

wBi₂O₃, wherein

0.13≦

x≦

0.20;

0.28≦

y≦

0.35;

0.33≦

z≦

0.45;

0.09≦

w≦

0.15; and

x+y+z+w=1,

La, Ce, Pr, Nb, Zn, and Sr as constituent elements are included with amounts ranging 2 to 5 mass % for La, 1 to 2 mass % for Ce, and 0.03 to 1 mass % for each of Pr, Nb, Zn and Sr, and wherein all ceramics as a whole, including the above main composition, make up 100 mass %;

removing a surface skin layer consisting of only polyphenylene sulfide that is formed on the surface of the molded article; and

plating thereon.

15. A method for producing an antenna with a resin-ceramic composite material, comprising steps of:

molding the resin-ceramic composite material obtained by mixing a dielectric ceramic powder with a mean particle diameter of not more than 6 μ

m, and polyphenylene sulfide, by an injection-molding, wherein the dielectric ceramic powder is one, in which, to a main composition expressed by xBaO·

yNd₂O₃·

zTiO₂·

wBi₂O₃, wherein

0.13≦

x≦

0.20;

0.28≦

y≦

0.35;

0.33≦

z≦

0.45;

0.09≦

w≦

0.15; and

x+y+z+w=1,

La, Ce, Pr, Nb, Zn, and Sr as constituent elements are included with amounts ranging 2 to 5 mass % for La, 1 to 2 mass % for Ce, and 0.03 to 1 mass % for each of Pr, Nb, Zn and Sr, and wherein all ceramics as a whole, including the above main composition, make up 100 mass %;

removing a surface skin layer consisting of only polyphenylene sulfide that is formed on the surface of the molded article; and

plating thereon.

16. A resin-ceramic composite material, comprising a mixture of dielectric ceramic powder and polyphenylene sulfide, wherein the dielectric ceramic includes BaO, Nd₂O₃, TiO₂, Bi₂O₃, Nb, Zn, and Sr as constituent elements, and wherein an inorganic filler with a dielectric dissipation factor of not more than 0.001, a relative dielectric constant of not more than 6, and a temperature dependency of dielectric constant of not more than ±

100 ppm/°

C., is added as a third constituent.