Modified Sintered Materials
This invention relates to the production of low dielectric loss ceramic materials, particularly ceramic materials useful in dielectric resonators. In current microwave communication, technology dielectric resonators (DRs) are key elements for filters, low phase noise oscillators and frequency standards DRs possess resonator quality factors (Q) comparable to cavity resonators, strong linearity at high power levels, weak temperature coefficients, high mechanical stability and small size.
Ceramic dielectric materials are used to form thermally stable DRs as key components in a number of microwave subsystems which are used in a range of consumer and commercial market products. These products range from Satellite TV receiver modules (frequency converter for Low Noise Broadcast (LNB)), Cellular Telephones, PCN's. (Personal Communication Networks Systems) and VSAT (Very Small Aperture Satellite) systems for commercial application to emerging uses in transportation and automobile projects, such as sensors in traffic management schemes and vehicle anti-collision devices. Dielectric Resonators may be used to determine and stabilise the frequency of a microwave oscillator or as a resonant element in a microwave filter. New systems of satellite TV transmission, based on digital encoding and compression of the video signals, determine the need for improved DR components The availability of advanced materials will also enable necessary advances in the performance of DRs used for other purposes as referred to above.
In this specification, the term 'ceramic' means any solid inorganic particulate material, the particles of which can be caused to sinter together by the application of heat. The term ceramic has been used also to describe single crystals of inorganic materials such as alumina, titania, etc.
Low dielectric loss materials are highly desirable in the area of communications over a wide frequency range. As an example, resonators using dielectric sintered ceramics may be used in base stations required for mobile communications The materials used are often complex mixtures of elements
One ofthe earliest resonator materials was Barium Titanate (BaTiO^ or BaTi^Og see, for example, T Negas et al American Ceramic Society Bulletin, vol 72, pp 80-89 1993) The dielectric loss of a material is referred to as the tan delta and the inverse of this quantity is called the Q (Quality Factor) The Q factor of a resonator is determined by choosing a resonance and then dividing the resonant frequency by the band width 3dB below the peak
The losses in ceramic materials may be associated with molecules or defects which can be spatially oriented (Debye loss), due to the inertia of free charges, e g electrons in a metal or resonant absorption at certain frequencies It is considered that extrinsic factors such as impurities and e g oxygen vacancy concentration as well as microstructure are of overriding importance Single crystals or 'perfect' crystals have a lower loss than corresponding poly-crystalline materials The difference between a 'perfect' single crystal and a polycrystalline ceramic are thought to be due to the huge differences in microstructure and perfection between the two and are clear indicators why it is considered impossible to achieve a dielectric loss approaching that of single crystal counterparts in sintered materials
A single crystal is made from a melt The melting temperatures of these crystals is extremely high For example, the melting point of alumina is 2072C, of magnesia 2852C, of zirconia 2700C, of yttria 24 IOC and titania 1850C
The particulate ceramic material can be shaped in a variety of ways, for example, by uniaxial powder pressing, by isostatic pressing, by slip-casting or by polymer processing and extrusion The resultant shape is then sintered at high temperature and this is associated with a shrinkage and a decrease in the volume ofthe body The sintering step can take place in air or in special atmospheres be they oxidising, reducing or inert
Sintering a ceramic involves taking a fine powder of the material, pressing it into the desired shape and then heating it to temperatures less than their melting point (usually about 75% of the melting point) The powders sinter together in an effort to reduce surface energy and this is accomplished by the reduction in
surface area until the porosity is reduced substantially or entirely The sintering process involves less expensive capital equipment and is less energy intensive
The major problem with dielectric ceramics is that their dielectric loss is much higher than single crystals Single crystal materials can exhibit very low loss and this is usually attributed to the absence of grain boundaries and the greater perfection in their structure The problem with single crystals is that they are time consuming to manufacture and they are extremely expensive For example, a single crystal of alumina in cylindrical form is around 10,000 times more expensive than an identically shaped sintered alumina
We have now discovered sintered ceramic materials with a low dielectric loss and a method for making them
According to the invention there is provided a sintered material comprising a major part of alumina and a minor part of metal or semi-metal oxide
The metal or semi-metal oxide, which forms the minor part of the materials of the invention, are preferably oxides of elements of Group III and IV of the periodic table such as Ti, Nb, Y and Zr The minor part is preferably present in an amount of less than 5% by weight of the total weight of the composition and, more preferably, less than 2% by weight
The materials ofthe present invention can be made in any conventional way, e g by mixing the powders of alumina and the minor component, for example, of particle size of 0 01 to 2 microns and pressing the mixture into a shape and then heating to a temperature below its melting point, typically 75% of the melting point The powders sinter together until the porosity is substantially or entirely reduced. Preferably the temperature of sintering for powders such as alumina is less than 1600°C and more preferably between 1500°C and 1600°C
It is very surprising that the addition of oxides with a low Q factor to alumina can increase the Q factor of the resulting material very considerably and can approach the value of single crystals It was considered that any material with grain boundaries must inevitably show high dielectric loss
The dielectric loss of polycrystalline sintered alumina has been measured by several workers and the results vary widely For example, Ceramic Source, vol 6 1990, American Ceramic Society (publ) reports the loss of alumina as Q - 1000 at 10GHz and 25°C
The highest Q previously measured in alumina at room temperature (i e approximately 25°C) is by Woode et al (RA Woode, EN Ivanov, ME Tobar and DG Blair 'Measurement of dielectric loss tangent of alumina at microwave frequencies and room temperature' Electronics Letters, vol 30 no 25, 8 Dec 1994) who measured a Q of 23,256 This Article noted that purity alone was a poor indicator of the dielectric loss tangent We have found that although an impure alumina will give a poor Q, a very pure alumina is not a guarantee of a high Q Pure alumina can have compounds added to it in order to assist the sintering process. These additions should not adversely influence the Q So, for example, magnesia may be added to a very pure alumina and this will assist the sintering but will not adversely affect the Q if added in small quantities However, adverse effects are observed with impurities such as alkali salts (sodium and potassium) and metallic elemental impurities such as iron
The invention also comprises a sintered ceramic material comprising an alumina and minor amount of a metal or semi-metal oxide which has a Q value greater than 25,000, more preferably greater than 30,000 and even more preferably greater than 45,000 at 10GHz and at 25°C
The invention is described in the following Examples
The aluminas used were commercially available aluminas and the analyses of the powders used in the examples are given in Table 1 with the impurities given in parts per million based on the total weight ofthe sample
able 1 Chemical analyses of powders used
Examples
Examples 1 to 3 are comparative examples
Powders A-C inclusive were pressed in a 13 5 mm diameter stainless steel die press at a pressure of 100 MPa. The pressed samples were sintered in air at a temperature of 1550°C for 300 mins The sample density was then measured and the dielectric constant and dielectric loss experiments were carried out using a parallel plate resonator and employing a modified Haaki-Coleman technique described in B W Haki and P.D Coleman 'A dielectric resonator method of measuring inductive capacities in the millimeter range', IFEE Trans Microwave Theory Tech Vol 8, p 402-410 (1960) Here the dielectric puck is placed not directly onto the lower copper plate but onto a low loss material with a much lower dielectric constant We have used a quartz crystal 4mm thick and 10mm in diameter The sample dimensions were approximately 10mm diameter, 4mm thick discs The measurements were made using a Hewlett Packard HP8719C vector network analyser with 1Hz resolution and the TE01 1 mode was examined. All dielectric measurements were carried out at room temperature in air at a relative humidity of approximately 30% No special precautions were taken to prevent the adsorption of water to the sample surface The loss measurements are presented in terms of the Q factor, i e tan delta 1, the measuring frequency was 9-10 GHz at a temperature of 25°C
Example 1
Sample A showed a Q of 3,500 while B had a Q factor less than 1000
B
3,500 <1000
Example 2
The chemically purer powder C was made into dense discs. Sample C2, was subjected to a sintering temperature of 1600°C for 300 mins.
Example 3
The same alumina powder as used in C, was sintered at 1500°C for 300 minutes.
Examples 4 to 7 and 10 to 12 are examples of the invention and Examples 8 and 9 are comparative examples.
Examples 4 to 6
In the second series of experiments, Alumina C was doped with TK^. The addition of Tiθ2 influences the sintering temperature at which the material achieves high density and for this reason the aluminas doped with Tiθ2 were sintered at 1500°C. To check the effect of a reduction in the sintering temperature on the pure alumina, alumina C was also sintered at 1500°C. Tiθ2 sintered in air to full density displays a very poor Q which was measured at 1,500. This is due to the fact Tiθ2 is easily reduced. Small deviations from stoichiometric Tiθ2 causes a random distribution of point defects. As the defect
concentration increases, their interaction increases and ordering can occur.
Long range ordering produces shear structures At compositions around TiO] 9, Magnelli phases exist but this degree of reduction is severe and is associated with a darkening of the material to blue-black A slight reduction to TiO j ^g causes defects to order on the (132) planes in a series of shear structures. In the 100% Tiθ2 samples studied here, sintering in air has caused a slight reduction resulting in a dense ceramic with a brown-tan colour The dielectric loss has suffered in comparison with the single crystal Q value which was measured at 7,000
Example 4
A pure alumina (alumina C) was doped by 0.5% weight of Titanium dioxide powder (Sample name CTO.5) The mixture was sintered at 1500°C as in Example 3 and the Q measured as in Example 1 , and was found to be 47,000
cm 5
47.000
Example 5
A pure alumina (alumina C) was doped with 1% by weight of Tiθ2 (sample name CTI 0) and sintered at 1500°C, i.e at the same temperature as that used for samples C in Example 3 The Q was found to be 35,000.
CT1.0
Q 35,000
Example 6
A pure alumina (alumina C) was doped with 5% by weight of Ti02 (sample name CT5 0) and sintered at 1500°C, i.e at the same temperature as that used for samples C in Example 3 The Q was found to be 12,650
CT5 0
12.650
Example 7
A pure alumina (alumina C) was doped with 10% by weight of TiO^ (sample name CT10 0) and sintered at 1500°C, i e at the same temperature as that used for samples C in Example 3 The Q was found to be 7,300
CT100
7.300
Example 8
A pure Ti02 was sintered to full density in air at 1400°C The purpose of this example is to demonstrate that the Q of Ti02 is much lower than the Q of A 1203 and hence demonstrate that it might be expected that any addition of Tiθ2 to AI2O3 would have the effect of decreasing the Q rather than enhancing the Q Using a mixtures rule, common in the description of dielectrics, it might be expected that at 0 5% Tiθ2 in AI2O3 the Q should be 33,500 when in fact the measured Q is 47,500
By was of comparison, three single crystals (SCl-3) of sapphire (A1203) were tested under identical conditions As expected, the Q of the single crystals was higher than the Q of the sintered aluminas but, surprisingly, the Q factors for the sintered aluminas were only a factor of approximately two lower
SCl SC2 SC3
100.000 100.000 100,000
Examples 10, 11 and 12
Dopants other than Tiθ2 close to Ti in the periodic table, i e Nb, Zr and Y, were also added to alumina C The dopants were added at the 0 25, 0 5, 1 and 5wt% level a total of 12 different compositions All samples were sintered at 1500°C for 300 mins in air In none of the measurements did the Q factor exceed the highest value for the Tiθ2 addition However, there are indications of increases in the Q which is surprising as all three dopants have a higher dielectric loss in comparison with A1203
Examples
Example 10 Example 1 1 Example 12 Dopant b70, Y O, ZiO,
Q (0.25% dopant) 26.000
Q (0 5% dopant) 30.000 25.400 28.400
Q (1 0% dopant) 14.000 36.000 16.600
Q (5 0% dopant) 30.000 30.000 17.000