Skyworks Solutions, Inc. (Irvine, CA)

The following are disclosed examples of materials with high thermal conductivity and high dielectric constants. A two-phase composite ceramic can be constructed with an aluminum oxide component that is contiguous and another phase embedded in the permanent phase. Example secondary phases include calcium titanate, strontium titanate or titanium dioxide.

Field

This disclosure generally relates to composite ceramic materials having high thermal conductivity and a large dielectric constant.

Description of the Related Art

A variety of new applications for high dielectric materials demand dielectric materials to be heated and then cooled quickly during use. This may lead to the possibility of thermal shock of the material, in particular when the heatingand cooling is used on monolithic polycrystalline ceramic dielectrics. The term “thermal gradient” refers to a variation in temperature that causes the material to expand and contract in different ways. This differential in the amount of expansion for different parts of the material could cause increased stress and/or strain between the parts. If the stress or strain is too great, be it afterrepeated stress/strain or an initial strain/stress that is high cracks may form in the material. Cracks can eventually lead to structural failure. Thermal shock can result in physical harm to high dielectric materials and make it inoperable for its intended purpose. The heat generated by the material may also cause harm to other components.

Applications that require extremely high energy levels, like lighting systems, or any other application require extremely high thermal conductivity material to work at their best. But, the main issue is that the majority of high-temperature conductivity ceramics are expensive, very harmful, and/or have lower dielectric constants.

In this document are described embodiments of a dual phase composite ceramic material. The material comprises one primary and at most one secondary phase. These two can form the dual phase composite.

In certain embodiments, the primary phase can include aluminum oxide. The primary phase may be contiguous in certain examples. In some instances, the dual-phase composite can be characterized by a dielectric constant greater than 25. Certain embodiments may have a thermal conductivity greater than 30 Wm.sup.-1K.sup.-1.

The secondary phase may be non-reactive with aluminum dioxide in certain embodiments. In some embodiments the secondary phase may contain more than one composition. In some embodiments, the secondary phase can be selected from the groupconsisting of CaTiO.sub.3, TiO.sub.2, LaAlO.sub.3, La.sub.2MgTiO.sub.6, YAlO.sub.3, SmAlO.sub.3, Mg.sub.4Nb.sub.2O.sub.9, and La.sub.4Ti.sub.3O.sub.12.

Some versions of the composite with dual phases may have a temperature drift of less than 1000 ppm/Degree Celsius.

Additionally, disclosed are embodiments of a method for forming an elastomeric dual-phase ceramic material that involves mixing materials to form out a primary generally contiguous phase and a second non-contiguous phase, the materials that form the primary phase are generally inert with the materials of the secondary phase, and then sintering the materials to form an emulsion ceramic comprising the main generally contiguous phase as well as the secondary non-contiguous phase, the ceramic has an dielectric constant of more than 20 and a thermal conductivity greater than 20 Wm.sup.-1K.sup.-1.

In certain embodiments, the primary phase may comprise aluminum oxide while the secondary phase includes a metallic oxide. In some embodiments, the composite ceramic may have a thermal conductivity of more than 30 Wm.sup.-1K.sup.-1. Certain embodiments may include aluminum oxide, while the secondary phase can comprise materials with an extremely large dielectric constant.

In addition, there are examples of radiofrequency components composed of a ceramic material comprising a primary phase, the primary phase being generally contiguous, with at least one secondary phase located in the primary phase to form a dual-phase composite, the dual-phase composite having a dielectric constant of greater than 20 and a thermal conductivity higher than 20 Wm.sup.-1K.sup.-1.

In some embodiments, the primary phase can include aluminum oxide and the secondary phase is selected from the group consisting of CaTiO.sub.3, TiO.sub.2, LaAlO.sub.3, La.sub.2MgTiO.sub.6, YAlO.sub.3, SmAlO.sub.3, Mg.sub.4Nb.sub.2O.sub.9, andLa.sub.4Ti.sub.3O.sub.12. In certain embodiments the primary phase could comprise aluminum oxide, while the secondary phase includes a high dielectric constant material.

In certain embodiments, the radiofrequency component can be incorporated into solid state lighting. The radiofrequency component could be integrated into a cell tower in certain examples. In some embodiments, the radiofrequency component canbe employed at frequencies greater than 100 MHz.

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