Aluminium nitride sintered body having conductive metallized layer

BACKGROUND OF THE INVENTION

Field of the Invention

0001The present invention relates to an aluminium nitride sintered body, and more specifically to an aluminium nitride sintered body having a conductive metallized layer with an excellent high-temperature adhesion to the aluminium nitride sintered body base material and available for a semiconductor device substrate.

0002Furthermore, the present invention relates to a circuit substrate using an aluminium nitride sintered body as an insulating layer, and more particular to a circuit substrate in which conductive layers are sintered integral and simultaneous with the insulating layer to realize a multilayer interconnection.

Description of the prior Art

0003Owing to excellent and high insulation characteristics, corrosion resistance, thermal shock, high-temperature strength, thermal radiation, and heat conductivity, aluminium nitride (AIN) sintered body has been noticed as various structure materials, various electronic/electric parts materials, etc. Recently, in particular, this AIN sintered body has been used in place of alumina (Al₂O₃) and beryllia (BeO), because Al₂O₃ is not satisfactory in heat radiation and BeO is poisonous and therefore complicated in handling this material. When the AIN sintered body is used, the body is usually joined with some metal members, so that a conductive metallized layer is generally formed on the surface of the AIN sintered body.

0004As a method of forming a metallized layer on the AIN sintered body, there is well known the direct bond copper (DBC) method by which an oxide layer (Al₂O₃) is formed on the surface of the sintered body and thereafter copper (Cu) foil is directly bonded or the thick film method of Copper (Cu), gold (Au), silver (Ag)-palladium (Pd).

0005However, the conductive metallized layer formed on the surface of the AIN sintered body in accordance with the above-mentioned conventional methods is weak in adhesion to the AIN sintered body, in particular at high temperature. Therefore, there exist problems such that it is difficult to bond another member with the formed metallized layer by a high temperature (700°C or higher) bonding method such as brazing, high temperature soldering, etc. or, even if bonded, when the AIN sintered body to which another member is bonded is used at high temperature, the formed metallised layer is peeled off from the surface of the sintered body and eventually another member is dropped off from the metallized layer. In particular, where the AlN sintered body including a conductive metallized layer is used as a heat radiation substrate for electronic circuits, since the substrate is subjected to temperature changes (heat cycles) from low to high or vice versa, there exists another disadvantage such that cracks develop in the metallized layer due to a difference in thermal expansion coefficient between the AIN and the metallized layer forming component.

0006This AIN sintered body is manufactured roughly as follows:

0007An AlN powder is first mixed with a sintering aid such as Y₂O₃, Sm₂O₃, CaO, etc. of a predetermined amount, and further with an acrylic base resin binder, if necessary as an aid. These are sufficiently mixed, formed into an AIN green sheet body (raw compact) of a predetermined shape under pressure, and sintered at a predetermined temperature within a nitrogen atmosphere, for instance.

0008Where the AIN sintered body is used as a substrate for semiconductor devices, it is necessary to further form a conductive film on the surface of this AIN sintered body. Conventionally, this film was a metallized layer of Cu, Au or Ag-Pd formed on the surface of the AIN sintered body in accordance with the DBC (direct bond cupper) method or the thick film method.

0009However, these conventional substrates involve the following problems:

0010The first problem is that the adhesion strength between the metallized layer and the AIN sintered body surface is weak, and therefore peeling occurs between the two as shown in Fig. 1A, thus lowering the substrate reliability, as shown in Fig. 1A.

0011The second problem occurs when a semiconductor element or wire is brazed or soldered at a high temperature onto the formed metallized layer. That is to say, although brazing is effected at about 800°C with a hydrogen-nitrogen mixture gas, since the metallized layer baking temperature is as low as about 600 to 1000°C, the adhesion junction strength between the metallized layer and the AIN sintered body surface is lowered markedly in brazing, thus disabling brazing in practice. Further, the similar problem arises in the case of high temperature soldering.

0012The third problem occurs due to a difference in thermal expansion coefficient between the AIN sintered body and the metallised layer. As is the case of brazing and high temperature soldering, severe heat-cool cycles are applied in use to the substrate on which semiconductor elements such as silicon wafers are mounted. As a result, thermal stresses are generated on junction surfaces between AIN sintered body, metallized layer, brazed layer (or soldered layer), and semiconductor elements due to differences in thermal expansion coefficient between two of these layers, thus resulting in an occurrence of peelings of these elements, as shown in Fig. 1B.

0013The thermal expansion coefficient of the metallized layer is about 2 to 4 times greater than that (about 4.6 x 10^-6/°C) of the AIN sintered body, and roughly equal to or half of that of brazed or soldered layer. Therefore, since there exists a big difference between the AIN sintered body and the metallized layer or the brazed (soldered) layer, microcracks are readily produced on the boundary surface between the AIN sintered body and the metallized layer or the brazed (or soldered) layer during heat cycle. Further, these microcracks develop gradually when the heat cycle is repeated, thus finally causing the peeling-off of the semiconductor element from the sintered body. This problem is serious, in particular, because the reliability of appliances having substrates on which semiconductor elements are mounted will be deteriorated.

0014The fourth problem is that the adhesion strength between the metallized layer and the AIN sintered body is small at high temperatures, so that the reliability of the substrate is low at high temperature as in the second problem.

0015Finally, the fifth problem is that thermal energy is not economical when checking the manufacturing processes from the first to the last. In other words, the substrate is completed by first sintering an AIN green body and further sintering the AIN sintered body again to form the metallized layer.

0016By the way, with the advance of miniaturization of electronic appliances, the way how heat generated from semiconductor devices mounted on a circuit substrate can effectively be radiated has become an important problem. Further, heat radiation is an important problem when power semiconductor devices are mounted on a circuit substrate.

0017Conventionally, Al₂O₃ ceramics have widely been adopted as an insulating material for circuit substrates. However, since the Al₂O₃ is low in heat conductivity, there still exists a problem with heat radiation. Therefore, it has been studied to apply AIN ceramics excellent in electrical characteristics such as electric insulating characteristics (as an insulator) and in thermal conductivity to circuit substrates (as disclosed Japanese Published Unexamined Pat. Appl. No. 60-178688).

0018When taking into account the miniaturisation and high densification in electronic appliances, a higher densification is also required for wiring on circuit substrates and therefore a multilayer AIN ceramic substrate has been studied (as disclosed Japanese Published Unexamined Pat. Appl. Nos. 60-253294 and 60-253295). Further, in the Al₂O₃ ceramics, although a technique of simultaneously sintering a plurality of laminated green sheets has been established, it is impossible to simply apply the technique, for Al₂O₃ ceramics to AIN ceramics at it is, because of a difference in fundamental properties between AIN and Al₂O₃.

0019EP-A-0153737 discloses a circuit substrate comprising (a) a sintered aluminium nitride ceramic substrate which may include yttrium, a rare earth metal or an alkali earth metal, and (b) a conductive layer formed on the surface of the ceramic substrate formed from a thick film paste. The conductive layer may include lead, silicon and noble metals such as Ag, Pt, Pd, Au and Cu.

0020As described above, although the demand for AIN ceramic based multilayer interconnection circuit substrates has increased, since warp, conductive path disconnection, peeling-off, etc. will be produced during the process of simultaneous sintering, the AIN multilayer ceramics is out of practical use at present.

0021In summary, with the advance of higher speed, higher densification, and higher output power of semiconductor devices mounted on a substrate, there exists a strong demand for AIN sintered body provided with higher heat conductivity, higher adhesion strength, excellent electric characteristics and additionally with multilayer interconnection owing to simultaneous sintering of the AIN bodies and metallized layers.

0022With these problems in mind, therefore, it is the object of the present invention to provide an aluminium nitride sintered body having a conductive metallized layer high in adhesion strength particularly at high temperature within a reducing atmosphere and therefore high in adhesion reliability of when other members are bonded to the metallized layer by brazing or soldering.

0023It is another object of the present invention to provide a method of forming a metallized layer on the surface of an AIN green body simultaneously when the AIN green body is sintered, in such a way that the thermal expansion coefficient of the metallised layer is approximate to that of the AIN sintered body, the heat resistance and the adhesion strength of the conductive metallized layer are both high.

0024It is the other object of the present invention to provide a circuit substrate using AIN ceramics, which is high in adhesion strength between the conductive layer and the insulating layer, and warp and disconnection resistances, and in particular a circuit substrate having multilayer

0025To achieve the above-mentioned object, an aluminium nitride sintered body according to the present invention comprises: <ul id="ul0001" list-style="none" compact="compact"><li>(a) an insulating layer formed by sintering an aluminium nitride body; and</li><li>(b) a metallized layer formed on said insulating layer, said metallized layer including a mixture of: <ul id="ul0002" list-style="none" compact="compact"><li>(1) a conductive element and/or compound selected from W, Mo, Ta, TiN and ZrN; and</li><li>(2) at least one inorganic filler including a compound containing a IIa, IIIa, IVa, IIIb, lanthanide or actinoide group element of the periodic table.</li></ul></li></ul>

0026The insulating layer includes at least one element selected from the group consisting of alkaline earth and rare-earth elements as a sintering aid to enable atmospheric sintering and to increase adhesion strength between said two layers. The conductor is any one of W, Mo, Ta, TiN and ZrN. Further, the content of the sintering aid in the insulating layer is 20 wt.% or less in oxide conversion, preferably 0.05 wt.% or more.

0027The feature of the present invention exists in combination of the conductor and the component element. Therefore, the ratio of both is not limitative, but selectively determined according to the various objects of improving the adhesion strength between the two layers, the conductivity of the conductor, the deformation of the sintered body in sintering process, and the like.

BRIEF DESCRIPTION OF THE INVENTION

0028The features and advantages of the aluminium nitride sintered body having a conductive layer according to the present invention will be more clearly appreciated from the following description taken- in conjunction with the accompanying tables and drawings. <ul id="ul0003" list-style="none" compact="compact"><li>Fig. 1A is an illustration for assistance in explaining peeling-off occurring due to lack of adhesion strength between AIN sintered bodies and metallized layers in a prior art AIN sintered body having conductive metallized layer;</li><li>Fig. 1B is an illustration for assistance in explaining peeling-off occuring due to a difference in thermal expansion coefficient and shrinkage coefficient between AIN sintered bodies and metallized layers in the prior art AIN sintered body having conductive metallized layer;</li><li>Fig. 2A is an illustration showing an AIN sintered body having a conductive layer according to the present invention in a model form;</li><li>Fig. 2B is an illustration showing two AIN green sheets each having two conductive paste patterns being stacked one above the other before simultaneous sintering; and</li><li>Fig. 3 is an illustration for assistance in explaining a generation of warp due to simultaneous sintering.</li></ul>

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

0029An embodiment of the aluminium nitride sintered body according to the present invention for providing a stronger adhesion strength comprises a conductive metallized layer on at least a part of an insulating layer of AIN sintered body, the conductive metallized layer including: <ul id="ul0004" list-style="none" compact="compact"><li>(a) at least one element selected from the first group consisting of molybdenum, tungsten and tantalum; and</li><li>(b) at least one element selected from the second group consisting of IIa group elements, IIIa and IIIb group elements, IVa group elements, rare-earth elements, and actinoide elements in periodic law table, as the conductive phase composing component elements.</li></ul>

0030As described above, the AIN sintered body according to the present invention is characterized by the combination of component elements for composing the phase of the conductive metallized layer formed on the sintered body base material (corresponding to the insulating layer) surface, so that the properties of the AIN sintered body base material itself are not particularly limited.

0031In the component elements of the conductive metallized layer, the elements belonging to the first group of molybdenum (Mo), tungsten (W) and tantalum (Ta) are excellent in heat resistance and further approximate to the AIN sintered body base material in thermal expansion coefficient, so that these elements serve to improve the heat resistance characteristics and the cyclic heat resistance characteristics.

0032These elements are included in a filler of the metallised layer as a single element or a combination of two or more elements. In more detail, these elements belonging to the first group can exist in the metallized layer in the form of individual elements, as a compound or as a solid solution including each element, or a mixture of two or more of the above mentioned individual elements, compounds and solid solutions.

0033The compounds are oxides of these elements, nitrides thereof, carbides thereof, acid nitrides thereof, borides thereof, silicides thereof, etc. In addition to the above-mentioned elements, these compounds can be composite compounds or solid solutions which include at least one of elements belonging to the second group (described later) and/or at least one of elements other than those belonging to the second group.

0034That is, when taking the case of Mo as the component element, Mo exists in the composed phase of the conductive metallized layer in the form of Mo or Mo-Al solid solution.

0035Further, in the component elements of the conductive metallized layer, the elements belonging to the second group of the Illb group elements (B, Al, Ga, In, Tl), the IVa group elements (Ti, Zr, Hf), IIIa group elements (Sc, Y), the rare earth elements (Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu) and the actinoid (Ac, Th, Pa. U, Np, Pu, Am, Cm, Bk, Cf, Es, Fm, Md; No; Lr) are excellent in weatness relative to AIN, so that these elements serve to improve the adhesion between the conductive metallized layer and the AIN sintered body. Further, Al, Ti, Zr, Hf, Y, Ce, Dy, Th, Sm are particularly preferable as the elements belonging to the second group.

0036In the same way as in the component elements belonging to the first group, these elements belonging to the second group are included in the composed phase of the metallized layer in the form of a single element or a mixture of two or more elements. That is, these elements exist in the metallized layer in the form of each element, a compound or solid solution including each element or a mixture of two or more elements selected from the group consisting of these elements, compounds and solid solutions.

0037In the case of Ti as the component phase, Ti exists in the composed phase of the conductive metallized layer in the form of TiN, TiO₂, etc.

0038In the present invention, the composition ratio of elements belonging to the first group and those belonging to the second group is not defined specifically. The ratio is appropriately determined according to the kind of elements used or the combination. For instance, it is preferable that the ratio of the sum total of the elements belonging to the first group to that of the elements belonging to the second group is 90/10 to 10/90 in atomic ratio.

0039The AIN sintered body according to the present invention can be manufactured as follows:

0040A paste or liquid including elements selected from the first and second groups is applied to a desired surface of the AIN sintered bodv base material manufactured in the conventional method. In practice, the paste can be obtained by dispersing a single element or compound powder of the above-mentioned elements into an adhesive agent such as ethylcellulose, nitrocellulose, etc. The above raw material powder is single element powder of each of the above-mentioned elements or conductive non-organic compounds including each element such as the oxides, nitrides, carbides, silicides, borides, acid nitrides, boric nitrides, silicic nitrides, hydrides, chlorides, fluorides, bromides, iodides, nitrate, nitrite, sulfates, sulfites, borates, phosphates, phosphites, carbonates, oxalates chlorates, silicates, hydroxides, ammonium salts, or other inorganic compounds or organic compounds (e.g. alkoxycid, sol-gel, etc.), which can be changed into a conductive material when baked. It is preferable that the elements selected from the first and second groups or the compounds including the elements of 5 wt.% or more in total are included in the paste or the liquid.

0041Thereafter, the paste or liquid applied on the surface of the AIN sintered body is dried and heat treated to form a metallized layer. The heating temperature is usually 1100 to 1800°C, although being different from the kind and the combination of the component elements. The treatment gas is nitrogen gas, dry forming gas, wet forming gas, etc. The treatment time is 0.5 to 2 hours, preferably. Where necessary, a plurality of these AIN sintered bodies on each surface of which the paste is applied to form a conductive layer are stacked one above the other for simultaneous sintering so as to provide multilayer interconnection.

0042Further, in order to bond another member to the AIN sintered body having the conductive metallized layer, Ni plating, for instance, is effected on the conductive metallized layer and then the plating layer is annealed at 600 to 850°C within a forming gas, before brazing or soldering. Further, it is possible to form an excellent metallized layer on the surface of the AIN sintered body by applying the paste already explained to an AIN green body and then sintering the both at the same time.

0043In more detail, in the method of manufacturing an AIN sintered body including a conductive metallized layer a paste including at least one selected from the first group consisting of molybdenum (Mo), tungsten (W), tantalum (Ta), and compounds having at least one of these elements, and at least one selected from the second group consisting of III group elements in periodic law table, IVa group elements, rare earth elements (the rare earth elements are lanthanum family including Sc and Y), actinoide family elements, and compounds including at least one of these elements, is applied to an AIN green sheet body; and the whole is sintered simultaneously. Fig. 2A shows a model in which a conductive metallized layer including a first group metal element and a second group filler element is formed on an AIN sintered body including an assistant by simultaneous sintering. Fig. 2B shows an example in which two AIN green sheets each having two conductive paste layers are stacked one above the other before simultaneous sintering.

0044First, the AIN green sheet body to which the present invention is applied is a raw compact obtained by mixing AIN powder of predetermined grain size with sintering assistant powder such as YF₃, Sm₂O₃, Y₂O₃ or CaCO₃ and a binder such as wax or plastic at a predetermined ratio and by forming the mixture at room temperature under pressure or by forming the mixture into a sheet in accordance with doctor blade method. The grain sizes of the AIN powder and the sintering assistant powder, the mixture ratio of both the powder and the forming pressure, etc. are all appropriately selected under consideration of the characteristics of the AIN sintered body according to the usage.

0045In the method of the present invention, however, it is preferable to adopt an AIN green sheet body such that the heat conductivity changes to 50 W/m.K or more after having been sintered.

0046As the method of applying the paste of composition already described to the AIN green sheet body, various known methods such as screen printing, brush application, spin roller application and the like may be adopted.

0047The paste is composed of two components belonging to two groups I (conductor) and II (component elements) both conversed into a metallized layer after having been sintered and a medium for dispersing these components.

0048The component belonging to the first group I is at least one selected from the group consisting of Mo, W, Ta, compounds including at least one of these elements.

0049These components can be used as a single component or a mixture obtained by combining two or more components selected appropriately.

0050In order to increase the conductivity of the metallized layer to be formed, it is preferable to use one metal of Mo, W or Ta

0051The component belonging to the second group II is at least one selected trom tne group consisting of III group elements in periodic law table, IVa group elements, rare earth elements (the rare earth elements are lanthanum family including Sc and Y), actinoide family elements, and compounds including at least one of these elements.

0052The III group elements are Al, Ga, In, for instance. In particular, Al is preferable. The IVa group elements are Ti, Zr, Hf, for instance. In particular, Ti is preferable because an excellent metallized layer can be formed irrespective of the kind of the components belonging to the first group I. The rare earth elements are Sc, Y, La, Ce, Pr, Nd, Sm, Gd, etc. In particular, Y and Sm are preferable. The actinoide family elements are Ac, Th, etc. However, Ac is preferable, in particular.

0053In practice, the component belonging to the second group II is a single metal of the III group elements, IVa group elements, rare-earth elements, and actinoide family elements, these oxides, nitrides, carbides, borides, silicides, acid nitrides, carbon nitrides, halogenides, hydrides, hydroxides, nitrides, nitrates, sulfites, sulfates, borates, carbonates, silicates, phosphates, phosphites, hydrochloride, chlorates, oxalates, salts such as ammonium salt, alkoxycids such as ATRON NTa - 700 (Trademark of NIHON SODA Co., Ltd.), organic metal compounds such as sol/gel, and mixtures of two or more of the above components. These components can be used as a single component or a mixture by combining two or more components selected appropriately.

0054The paste according to the present invention can be prepared by uniformly dispersing the components belonging to two groups I and II into the medium. The medium used is ethylcellulose or nitrocellulose, for instance. The solvant for the medium is terpineol, tetralin, butyrcarbitol, etc., for instance.

0055It is considered that the component belonging to the first group I is effective to mainly maintain the conductivity and the heat resistance of the formed metallized layer at high level and the component belonging to the second group II is effective to maintain the strength of the metallized layer by binding the components belonging to the first group I.

0056The relationship in quantity between components belonging to groups I and II changes according to the kinds of the selected components. In usual, the component ratio (I/II) by weight of the first group I to the second group II is 1/100 to 10/1.

0057Further, with respect to the component belonging to the second group II, the weight ratio of I/II is preferably 1/2 to 2/1 in the IV group elements, but 1/5 to 1/1 in the III group elements.

0058If the component belonging to the group I is too much as compared with that belonging to the group II, the strength of the formed metallized layer is lowered. In contrast with this, if the component belonging to the group I is too small, the conductivity of the formed metallised layer is unsatisfactory.

0059The various amount of the components belonging to the groups I and II into the medium is determined on the basis of the consistency of the prepared paste. If the component belonging to the first group I is too much, the paste becomes viscous, so that it is difficult to uniformly apply the paste on the surface of the AIN green sheet body. In contrast with this, if too little, the paste becomes non-viscous, so that the applied past drops from the surface of the AIN green sheet body. It is preferable to disperse the component belonging to the first group I to that belonging to the second group II so that a viscocity of the paste lies between 1.0 to 2.5x10⁴ Pa.s (1.0 to 2.5 x 10⁵ poise).

0060In the method according to the present invention, after the paste has been applied on the surface of the AIN green sheet body, the whole body is sintered simultaneously. Prior to the above-mentioned simultaneous sintering, it is preferable to effect a degreasing treatment at temperature from 50 to 700°C, for instance, in order to eliminate the binder component of the AIN green sheet body and the medium of the paste.

0061The sintering is effected within a nitrogen atmosphere for instance. The sintering temperature and time are determined so that the AIN sintered body has desired characteristics such that the heat conductivity is 50 W/m.K or more. In practice, the sintering temperature is 1600 to 2000°C, preferably 1700 to 1800°C, the sintering time is 0.2 to 5 hours, preferably 0.5 to 1.5 hours.

0062As described above, it is possible to form a metallized layer as a conductive thin layer on the AIN sintered body by applying the paste on the surface of the AIN green sheet body.

0063To confirm the features (heat conductivity, resistivity, adhesion strength, etc.) of the AIN sintered body according to the present invention, various tests have been made in various ways as follows;

(1) First Test Results

Example 1A:

0064Raw material paste was prepared by mixing modybdenum (Mo) powder, titanium nitride (TiN) powder and ethylcellulose at weight ratio of 8 : 2 : 1. The prepared paste was applied on the surface of the AIN sintered body base material including 3 wt.% Y₂O₃. The applied paste was dried and heated within N₂ gas at about 1700°C for 1 hour to form a conductive metallized layer. As the result of examination of the obtained conductive metallized layer in accordance with an X-ray diffraction method, Mo, AIN, YAG and TiN were observed as the composition phase.

0065Next, in order to evaluate the adhesion strength of the conductive metallised layer to the AIN sintered body, Ni was plated on the metallized layer and annealed at about 800°Cwithin a forming gas. An end of a covar (Registered Trade Mark) (Ni-Co-Fe alloy) wire was soldered to the metallized layer. The wire was pulled in the direction vertical to the metallized surface to measure the adhesion strength. The measured result was 2 kg/mm² or more, as shown in Table 1.

Examples 2A to 12A:

0066In the same way as in the Example 1, many AlN sintered bodies having various conductive metallised layers were manufactured by changing the kinds of elements belonging to the first and second groups in various ways. The evaluation results of these examples are listed in the Table 1 in terms of the composition of raw paste material for the metallized layer, the metallized conditions and the obtained layer composition phase.

0067This table 1 indicates that the AlN sintered body according to the present invention is formed with a conductive metallized layer having a high adhesion strength to the AlN sintered body base material even after brazing or soldering process. Therefore, if another member is bonded, the reliability is high, so that it is possible to utilize the AlN sintered body according to the present invention for various usage. In particular, since the AlN sintered body has a very high heat conductivity (about 5 times higher than that of Al₂O₃) and additionally a thermal expansion coefficient extremely approximate to that of Si which constitues semiconductor devices, the AlN sintered body having the conductive metallized layer according to the present invention is usable as semiconductor substrate material.

0068As described above, since the aluminium nitride sintered body according to the present invention is provided with a conductive metallized layer extremely high in adhesion strength at high temperature to the AlN sintered body base material, it is possible to bond other members to the sintered body by brazing or soldering. In addition, the metallized layer will not be peeled off even if the sintered body to which other members are bonded is used under heat cycle environment in which temperature changes from low to high or vice versa. Therefore, the AlN sintered body according to the present invention is available for recent high-integration, high-power circuit substrates, ignitors, high-frequency transistors, laser tubes, magnetrons, or various heaters, thus the industrial value being extremely high.

(2) Second Test Results

Example 1B:

0069Mo powder of 0.5 to 1.0 µm in particle diameter was prepared as a component belonging to the group I, and TiN powder of 1.0 to 2.0 µm in particle diameter was prepared as a component belonging to group II. The weight ratio of Mo was 50, and that of TiN was 50. A mixed powder of 100 weight ratio was dispersed into ethylcellulose of 7 weight ratio to obtain a paste of 2.0 x 10⁴ Pa.s (2.0 x 10⁵ poise).

0070The paste prepared as above was applied with a roller on one surface of an AlN green sheet including 3 wt.% Y₂O₃ as a sintering assistance to form a 15 µm thick layer.

0071The green sheet on which the paste was applied was baked at 700°C for 180 minutes within a nitrogen atmosphere for degreasing treatment and then sintered at 1800°C for about 60 minutes in a nitrogen stream.

0072A metallized layer was formed on the surface of the AIN sintered body. The fact that this metallized layer component phase is Mo and TiN was confirmed by X-ray diffraction method.

0073Ni plating of about 3 to 5 µm in thickness was formed in accordance with electroless plating technique on the obtained metallized layer. After the plating layer had been annealed at 800°C within a homing gas, a covar (Registered Trade Mark) wire (dia: 0.5 mm) tensile strength: 55 kg/mm²) was brazed by use of silver solder. The brazing temperature was 800°C, and the atmosphere was a mixture gas of 50 vol.% hydrogen and 50 vol.% nitrogen.

0074Thereafter, the AIN sintered body sheet was fixed and then the covar wire was pulled at room temperature (20°C) to observe the peeled-off resistance of the metallized layer from the sintered sheet. The brazed portion between the metallized layer and the covar wire was broken at a tensile strength of 5 kg/mm², so that it was proved that the adhesion strength between the two was 5 kg/mm² or more.

Examples 2B to 5B:

0075Various pastes were prepared by selecting the component belonging to the group I and that belonging to the group II as listed in the Table 2. Each of these paste was applied to the surface of the AIN green sheet the same as in Example 1B; the green sheets on which the pastes were applied were treated for degreasing and then sintered under the conditions as listed.

0076The adhesion strength between the metallized layer and the AIN sintered body sheet was measured for each of the sintered body sheets in the same way as in Example 1B. The measured results are listed in Table 2 together.

Comparison 1 B:

0077Each of Au, Cu and Ag-Pd layers was baked on the surface of three AIN sintered sheet with a heat conductivity of 70 to 130 W/m.K in accordance with a thick film method. A copper pin covered by nickel plating was soldered to each of the obtained metallized layer, and then pulled to measure the adhesion strength between the metallized layer and the AIN sintered body sheet. The measured result was about 1 kg/mm² for all the layers.

Comparison 2B:

0078A paste of Example 3B was applied to the AIN sintered sheet with a heat conductivity of 70 to 130 W/m.K and baked at 1700°C. A covar (Registered Trade Mark) pin was brazed to the obtained metallized layer at 700 to 800°C and pulled. The adhesion strength was 2.0 kg/mm².

Comparison 3B:

0079A metallized layer was formed in the same way as in Comparison 28 by the use of the paste of Example 28. The adhesion strength was roughly equal to that of Comparison 2B.

0080As described above, the method according to the present invention is high in industrial value as follows: (1) it is possible to form a conductivity metallized layer with a high adhesion strength between the layer and the AIN sintered body surface; (2) the formed metallized layer serves to function as a thermal shock layer, because the metallized layer includes a high melting point metal such as Mo, W, Ta and thereby is excellent in heat resistance and approximate to the AIN sintered body in thermal expansion coefficient; and (3) the method is advantageous from thermal economical standpoint because the applied paste is changed to a metallized layer simultaneously when the AIN green body sheet is sintered.

0081The AIN sintered body manufactured in accordance with the present invention is applicable to various parts, appliances, etc. such as ignitor, high-frequency transformer, circuit board parts as capacitors, laser insulation tube, power tube insulating cover, high-frequency electromagnetic wave travelling tube window, high-energy beam irradiating window, magnetron member, tube heater, surface heater, sheath heater, soldering iron, iron press plate, moxa cautery appliance, coffee maker heater, trousers presser, hot plate, stool seat, cooking pan, thermal copy printer head, plug, thermo-couple protective tube, crucible scissors end, metal melting crucible, crystal pulling crucible, etc.

0082Here, an embodiment of the circuit substrate according to the present invention will be described. The present invention provides a circuit substrate formed with an insulating layer including AIN as the main component and at least one element selected from the group consisting of rare earth elements (including Y and lanthanide elements) and alkaline earth elements; and a conductive layer including at least one of a mixture and a compound including alumina and at least one of rare earth elements, and alkaline earth elements in addition to a conductive substance.

0083The above-mentioned circuit substrate can be obtained by forming a conductive pattern on an AIN green sheet by use of a conductive paste mixed with at least one of the mixture and the compound, before the simultaneous sintering.

0084In the present invention, since at least one of the mixture and the compound are included in the conductive layer, it is possible to improve the peeling-off resistance of the conductive layer and the warp resistance of the substrate. The conductive substance included in the conductive layer is not particularly limited, if the material is resistant against the AIN ceramic sintering temperature. W, Mo, ZrN, TiN, etc. are preferable. Further, the content of the mixture and/or the compound of alumina and at least one element of rare earth elements and alkaline earth elements is preferably 0.05 to 20 wt.% in oxide conversion in the conductive layer. If the content is too high, the electric conductivity of the conductive layer decreases. If the content is too low, it is impossible to effectively prevent the peeling-off of the conductive layer and the warp of the substrate. The alkaline earth elements and the rare earth elements are preferably Ca, Ba, Sr and Y, La, Ce.

0085Further, the AIN insulating layer is a sintered body including AIN as the main component and a sintering aids including at least one of rare earth elements (Y and lanthanides) and alkaline earth elements. The rare earth element and/or the alkaline earth element is essential to sinter the AIN layer at atmospheric pressure. However, where AIN ceramics including the rare earth element and the alkaline earth element is used as an insulating body, the aforementioned problems such as substrate warp, conductive path disconnection, etc. become noticeable. To solve these problems, the conductive layer as described above is adopted, which realize a multi layer interconnection ceramic circuit substrate by making the best use of the AIN ceramics inclusing the rare earth element and/or the alkaline earth element. It is preferable that the content of the rare earth element and the alkaline earth element in the insulating layer is 0.01 to 15 wt.% in oxide convention. Further, when taking the AIN heat conductivity into account, it is preferable to mix the rare earth element with the alkaline earth element such as Y - Ca, for instance.

0086The method of manufacturing the circuit substrate according to the present invention will be described hereinbelow. First, an AIN green sheet is formed. To obtain the AIN green sheet, AIN powder, a sintering aids, and a binder are sufficiently mixed together with a solvent, and then the mixture is formed into a sheet in accordance with doctor blade method, for instance. The mean particle size (mean dia.) of the used AIN powder is 5 µm or less, preferably 4 µm or less when taking into account the sintering. In practice, the powder of 0.5 to 2 µm is used. The oxygen concentration in the AIN powder is important, because the heat conductivity is reduced when the content of oxygen is high. Therefore, the content of oxygen in the AIN powder should be 5 wt.% or less, preferably 3 wt.% or less. In practice, the oxygen content is 0.1 to 3 wt.%.

0087The added sintering aids is rare earth element and alkaline earth element such as Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Dy and Ca, Sr, Mg. These elements contribute to the densification of the AIN ceramics and the high thermal conductivity because oxygen in the AIN powder is trapped by subphase of the grain boundary. As elements having such an effect as described above, Y, La, Ce, Ca, Sr, Ba are particularly preferable. The sintering aids is added in the form of oxide, carbonate, nitrade, halide, acetylide, carbide, fluoride, hydride, nitride, etc.

0088Subsequently, the conductive paste sintered into a conductive layer is printed on the AIN layer with a pattern. In this process, viaholes are formed in the green sheet to electrically connect two upper and lower conductive layers each sandwiched by two green sheets. The conductive material in the conductive paste should maintain the electric conductivity even after the simultaneous sintering. The preferable material is W, Mo, ZrN, and TiN. To this conductive paste, at least one of the mixture and/or the compound of alumina and at least one of rare earth elements and alkaline earth elements, are added as a filler. The additive forms an aluminate liquid phase when the AIN sheet is sintered simultaneously. Further, since the AIN ceramics is sintered with liquid phase, an aluminate liquid phase is produced in the insulating layer during sintering. Here, it should be noted that since an aluminate liquid phase is also produced in the conductive layer, the liquid phase in the insulating layer is prevented from being sucked up into the conductive layer in the arrow direction as shown in Fig. 3, and therefore it is possible to prevent the composition of the insulating layer from being made non-uniform due to partial suction of liquid phase, that is, to prevent the circuit substrate from being bent. In this connection, if liquid phase in the insulating layer moves into the conductive layer as shown in Fig. 3, this is not preferable because a difference in shrinkage is produced between the conductive layer and the insulating layer and therefore the wetness is degraded. Further, it is possible to mix the sintering aids (compound) with alumina or else to add a previously formed aluminate in order to form liquid phase in the conductive layer. When a mixture of the aids and alumina is added, it is preferable to mix the two at such a ratio as to form aluminate. That is, the amount of alumina is preferably 0.03 to 10 wt.% so that the aluminate can be formed. Further, it is preferable to use an additive element of the same kind as the AIN ceramic sintering aids.

0089As described above, it is possible to obtain an AIN ceramic circuit substrate having wiring patterns by simultaneously sintering the green sheets on which conductive paste is applied. The presence of the additive in the conductive layer heightens the adhesion between the conductive layer and the insulating layer and prevents the substrate from being bent during the manufacturing steps.

(3) Third Test Results

Example 1:

0090A raw material of green sheet was prepared by adding a sintering aid of 1.2 µm mean dia. Y₂0₃ of 3 wt.% to 1.5 µm mean particle size AIN powder including 1.4 wt.% oxygen as impurity and by wet-blending the two for 24 hours with a ball mill. An organic binder was dispersed into this prepared raw material together with an organic solvent to form a slurry. The slurry was formed into a green sheet with a uniform thickness of 100 to 400 µm in accordance with doctor blade method. The green sheet was cut into an about 130 x 130 mm square insulating body, and a 300 µm dia. hole was formed to connect electric circuits formed on the insulating layers.

0091On the other hand, a conductive paste to which filler is added was prepared by mixing 1.1 µm mean particle size tungsten of 97.0 wt.%, 1 µm mean particle size Al₂O₃ of 1.288 wt.%, and 1.2 µm mean particle size of Y₂O₃ of 1.712 wt.% and by dispersing the mixture.

0092This tungsten paste to which an inorganic filler had been added was screen-printed on the green sheet in which a viahole had already been formed. A plurality of these were hot pressed to obtain laminated green sheets. The laminated green sheets were treated within a N₂ atmosphere to remove the binder, and thereafter sintered at 1800°C for 1 hour within a N₂ atmosphere to obtain a multilayer ceramic substate.

0093A disc with a diameter of 100 mm and a thickness of 2.5 mm was cut away from part of the obtained substrate at which no conductive portion is included in order to measure the thermal conductivity in accordance with laser flash method with this disc as a test piece.

0094The parallelism between both sides of the substrate representative of the presence or absence of substrate warp was obtained by measuring a maximum warp value at the center and the peripheral edges of the substrate with the diagonal line of the multilayer sintered body substrate as its standard.

0095The resistance (m ohm/mm square) of the conductive layer was measured without effecting metal plating to check the effect of inorganic filler addition.

0096Further, after Ni plating had been effected on a 2 x 2 mm conductive area of the obtained substrate, a wire was soldered on the Ni plating surface for tensile strength test, that is, the adhesion strength between the Al substrate and the conductive layer was measured. These test results are all listed in Tables 3A, 38 and 4.

0097Various AIN multilayer ceramic substrates were formed as in the first example 1 by changing the kind of AIN powder, the kind of AIN substrate sintering aid powder, the kind of sintering additive filler, the amount of the above substances, the kind of conductive materials, etc. in various manners. The thermal conductivity, the tensile strength, the parallelism, the surface resistance of conductive layer of each of these Examples were measured. The test results are listed in Tables 3A, 3B and 4.

0098These tables indicate that the Examples according to the present invention can improve the adhesion strength between the conductive layer and the substrate. That is to say, the tensile strength is 6.8 kg/2x2 mm in Example 1, but 3.5 kg/2x2 mm in Comparison 1, indicating an insufficient adhesion strength.

0099In addition, Table 4 indicates that the warp represented by the parallelism between both sides of the substrate is small and further the resistivity is low, in spite of the fact that an additive is included, in the simultaneous sintered body according to the present convention.

0100As described above, in the aluminium nitride substrate according to the present invention, the thermal conductivity of the insulating body is high; adhesion of the conductive layer is strong; the deformation of the substrate is small during the sintering process; and the surface resistance of conductive layer is low; the tensile strength is high, thus indicating practical and excellent characteristics of the substrates of a high industrial utilization. <tables id="tabl0001" num="0001"><img file="EP0235682B2_D0001.tif" /></tables><tables id="tabl0002" num="0002"><img file="EP0235682B2_D0002.tif" /></tables><tables id="tabl0003" num="0003"><img file="EP0235682B2_D0003.tif" /></tables><tables id="tabl0004" num="0004"><img file="EP0235682B2_D0004.tif" /></tables><tables id="tabl0005" num="0005"><img file="EP0235682B2_D0005.tif" /></tables><tables id="tabl0006" num="0006"><img file="EP0235682B2_D0006.tif" /></tables><tables id="tabl0007" num="0007"><img file="EP0235682B2_D0007.tif" /></tables><tables id="tabl0008" num="0008"><img file="EP0235682B2_D0008.tif" /></tables><tables id="tabl0009" num="0009"><img file="EP0235682B2_D0009.tif" /></tables><tables id="tabl0010" num="0010"><img file="EP0235682B2_D0010.tif" /></tables><tables id="tabl0011" num="0011"><img file="EP0235682B2_D0011.tif" /></tables><tables id="tabl0012" num="0012"><img file="EP0235682B2_D0012.tif" /></tables><tables id="tabl0013" num="0013"><img file="EP0235682B2_D0013.tif" /></tables><tables id="tabl0014" num="0014"><img file="EP0235682B2_D0014.tif" /></tables><tables id="tabl0015" num="0015"><img file="EP0235682B2_D0015.tif" /></tables><tables id="tabl0016" num="0016"><img file="EP0235682B2_D0016.tif" /></tables><tables id="tabl0017" num="0017"><img file="EP0235682B2_D0017.tif" /></tables><tables id="tabl0018" num="0018"><img file="EP0235682B2_D0018.tif" /></tables><tables id="tabl0019" num="0019"><img file="EP0235682B2_D0019.tif" /></tables><tables id="tabl0020" num="0020"><img file="EP0235682B2_D0020.tif" /></tables><tables id="tabl0021" num="0021"><img file="EP0235682B2_D0021.tif" /></tables><tables id="tabl0022" num="0022"><img file="EP0235682B2_D0022.tif" /></tables>