Ceramic electronic component including ceramic nanosheets having multimodal lateral size distribution and method of manufacturing the same and electronic device

Patent metadata

Field	Value
Publication number	US-11120944-B2
Application number	US-201816169800-A
Country	US
Kind code	B2
Filing date	Oct 24, 2018
Priority date	Oct 27, 2017
Publication date	Sep 14, 2021
Grant date	Sep 14, 2021

Abstract

A ceramic electronic component includes a pair of electrodes facing each other and a dielectric layer disposed between the pair of electrodes and including a plurality of ceramic nanosheets, where the plurality of ceramic nanosheets has a multimodal lateral size distribution expressed by at least two separated peaks, a method of manufacturing the same, and an electronic device including the ceramic electronic component.

First claim

What is claimed is:

1. A ceramic electronic component, comprising:
a pair of electrodes facing each other, and
a dielectric layer between the pair of electrodes and including a nanosheet monolayer film in which a plurality of ceramic nanosheets is arranged in a monolayer,
wherein the plurality of ceramic nanosheets have a multimodal lateral size distribution expressed by at least two separated peaks,
wherein the plurality of ceramic nanosheets includes:
a first ceramic nanosheet group, the first ceramic nanosheet group showing a lateral size distribution in a region of at least a pan of about 1 micrometer to about 10 micrometers and having a first peak shown in a lateral size greater than or equal to about 1.5 micrometers,
a second ceramic nanosheet group, the second ceramic nanosheet group having an average lateral size smaller than that of the first ceramic nanosheet group and having a second peak separated from the first peak and shown in a lateral size smaller than the lateral size of the first peak.

2. The ceramic electronic component of claim 1 , wherein
the lateral size at the first peak is about 1.5 micrometers to about 10 micrometers, and
the lateral size at the second peak is less than or equal to about 1.0 micrometers.

3. The ceramic electronic component of claim 1 , wherein a ratio of the lateral sizes at the first peak and the second peak is about 2:1 to about 10:1.

4. The ceramic electronic component of claim 1 , wherein
the lateral size at the first peak is from about 2.0 micrometers to about 5.0 micrometers,
the lateral size at the second peak is from about 0.5 micrometers to about 1.0 micrometers, and
a ratio of the lateral size at the first peak and the lateral size at the second peak is from about 2.4:1 to about 6:1.

5. The ceramic electronic component of claim 1 , wherein the first ceramic nanosheet group and the second ceramic nanosheet group are included at a volume ratio of about 5:1 to about 100:1.

6. The ceramic electronic component of claim 1 , wherein the plurality of ceramic nanosheets has a bimodal lateral size distribution expressed by two separated peaks.

7. The ceramic electronic component of claim 1 , wherein the dielectric layer has a porosity less than or equal to about 9.0%,
wherein the porosity is a ratio of a pore area with respect to a total area of the dielectric layer.

8. The ceramic electronic component of claim 1 , wherein the plurality of ceramic nanosheets has a permittivity greater than or equal to about 50.

9. The ceramic electronic component of claim 1 , wherein the plurality of ceramic nanosheets includes Ca 2 Nb 3 O 10 , Ca 2 NaNb 4 O 13 , Ca 2 Na 2 Nb 5 O 16 , Sr 2 Nb 3 O 10 , SrBi 4 Ti 4 O 15 , Ti 2 NbO 7 , LaNb 2 O 7 , or a combination thereof.

10. The ceramic electronic component of claim 1 , wherein the ceramic nanosheet is a structure exfoliated from the ceramic powder.

11. The ceramic electronic component of claim 1 , wherein the dielectric layer includes one or at least two of the nanosheet monolayer film including the plurality of ceramic nano sheets.

12. The ceramic electronic component of claim 1 , wherein the dielectric layer has a thickness less than or equal to about 0.5 micrometer.

13. The ceramic electronic component of claim 1 , wherein the dielectric layer includes
a first dielectric layer including the plurality of ceramic nanosheets and
a second dielectric layer disposed on the first dielectric layer and including a bulk ceramic dielectric material.

14. The ceramic electronic component of claim 1 , wherein the dielectric layer includes:
a first dielectric layer including the plurality of ceramic nanosheets,
a second dielectric layer disposed on the first dielectric layer and including a bulk ceramic dielectric material, and
a third dielectric layer disposed on the second dielectric layer and including the plurality of ceramic nanosheets.

15. The ceramic electronic component of claim 1 , wherein the dielectric layer includes:
a plurality of grains including a bulk ceramic dielectric material, and
a grain boundary including the plurality of ceramic nanosheets.

16. The ceramic electronic component of claim 1 , wherein the ceramic electronic component is a multi-layer ceramic capacitor, and
wherein the multi-layer ceramic capacitor has a structure in which a unit capacitor including the pair of electrodes and the dielectric layer is laminated in plural.

17. A method of manufacturing a ceramic electronic component, the method comprising:
synthesizing a layered ceramic powder,
preparing a plurality of ceramic nanosheets having different lateral size distributions by exfoliating the layered ceramic powder,
forming the plurality of ceramic nanosheets, in a monolayer on a first electrode to provide a dielectric layer including a nanosheet monolayer film, and
forming a second electrode on the dielectric layer,
wherein the plurality of ceramic nanosheets has a multimodal lateral size distribution expressed by at least two separated peaks,
wherein the preparing the plurality of ceramic nanosheets includes:
preparing a first ceramic nanosheet group having a lateral size distribution in a region of at least a part of about 1 micrometer to about 10 micrometers and showing a first peak in a lateral size greater than or equal to about 1.5 micrometers,
preparing a second ceramic nanosheet group having an average particle size smaller than that of the first ceramic nanosheet group and showing a second peak in a lateral size smaller than the lateral size of the first peak, and
mixing the first ceramic nanosheet group and the second ceramic nanosheet group.

18. The method of claim 17 , wherein each of the preparing the first ceramic nanosheet group and the preparing the second ceramic nanosheet group includes performing at least one of a heat treatment and a centrifuging,
wherein the preparing the first ceramic nanosheet group performs a heat treatment at a higher temperature than that in the preparing the second ceramic nanosheet group, and
wherein the preparing the first ceramic nanosheet group performs a centrifuging at a slower speed than that in the preparing the second ceramic nanosheet group.

19. The method of claim 17 , wherein the mixing the first ceramic nanosheet group and the second ceramic nanosheet group is performed by mixing the first ceramic nanosheet group and the second ceramic nanosheet group at a volume ratio of about 5:1 to about 100:1.

20. The method of claim 17 , wherein the providing the dielectric layer includes:
preparing a ceramic nanosheet solution including the plurality of ceramic nanosheets, and
coating the ceramic nanosheet solution on the first electrode by a Langmuir-Blodgett method, a Layer-by-Layer method, a spin coating, a slit coating, a bar coating, or a dip coating to provide the nanosheet monolayer film.

21. The method of claim 20 , wherein the providing the dielectric layer includes repeatedly performing the forming the nanosheet monolayer film for a plurality of times to provide a plurality of nanosheet monolayer films.

22. An electronic device comprising a ceramic electronic component, the ceramic electronic component comprising:
a pair of electrodes facing each other, and
a dielectric layer between the pair of electrodes and including a nanosheet monolayer film in which a plurality of ceramic nanosheets is arranged in a monolayer,
wherein the plurality of ceramic nanosheets have a multimodal lateral size distribution expressed by

Assignees

• Samsung Electronics Co Ltd
• Nat Inst Materials Science

Inventors

• Park Hyeon Cheol
• Sasaki Takayoshi
• Osada Minoru
• Kwak Chan
• Yang Daejin
• Jung Doh Won
• Cho Youngjin

Classifications

• H01G4/1254

  based on niobium or tungsteen, tantalum oxides or niobates, tantalates · CPC title

• H01G4/1209 Primary

  characterised by the ceramic dielectric material (H01G4/1272, H01G4/1281 take precedence) · CPC title

• H01G4/1218

  based on titanium oxides or titanates (H01G4/1245 takes precedence) · CPC title

• 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)} · CPC title

• H01G4/005

  Electrodes · CPC title