Piezoelectric resonator element, piezoelectric device using the piezoelectric resonator element, method for producing the piezoelectric resonator element, and method for producing the piezoelectric device using the piezoelectric resonator element
10270024 ยท 2019-04-23
Assignee
Inventors
Cpc classification
H03H2003/022
ELECTRICITY
H03H9/13
ELECTRICITY
H10N30/06
ELECTRICITY
International classification
H03H9/13
ELECTRICITY
Abstract
A crystal resonator element 2 has excitation electrodes 23a, 23b formed on front and back main surfaces of a crystal resonator plate. Each of the excitation electrodes is made of a ternary alloy containing silver as a major component, a first additive, and a second additive. The first additive is a metal element having a lower sputtering yield than silver and being resistant to corrosion in an etching liquid. The second additive is an element for forming a solid solution with silver. Outer peripheries of the excitation electrodes are first additive-rich regions 9 in which the first additive is rich.
Claims
1. A piezoelectric resonator element comprising a pair of excitation electrodes for driving a piezoelectric resonator plate, wherein each of the excitation electrodes comprises a ternary alloy containing silver as a major component, a first additive, and a second additive, the first additive being a metal element which has a lower sputtering yield than silver and which is resistant to corrosion in an etching liquid, and the second additive being an element for forming a solid solution with silver, and wherein the first additive is at a higher concentration per unit volume at an outer periphery of each of the excitation electrodes.
2. The piezoelectric resonator element according to claim 1, wherein the alloy contains palladium as the first additive and copper as the second additive.
3. A piezoelectric device comprising the piezoelectric resonator element according to claim 1, wherein the piezoelectric resonator element is accommodated in a holder and hermetically sealed by a lid bonded on the holder.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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BEST MODE FOR CARRYING OUT THE INVENTION
(23) Hereinafter, an embodiment of the present invention is described with reference to the drawings, with a crystal resonator taken as an example of the piezoelectric device. In the present embodiment, a crystal resonator 1 is a surface-mount crystal resonator having a substantially cuboid package structure. For convenience of description, the crystal resonator in
(24) In
(25) In
(26) The lid is a metallic lid member which has a kovar substrate and which is rectangular in plan view. Nickel-plated layers are formed on the front and back surfaces of the lid. On the surface of the lid to be bonded to the holder, a brazing filler metal (not shown) composed of a metal is formed entirely on the nickel-plated layer. In the present embodiment, the brazing filler metal is a silver brazing filler metal.
(27) As shown in
(28) In the crystal resonator plate shown in
(29) Similarly, from an area including a corner of the excitation electrode 23b disposed on the other main surface 202 of the thin portion 20, an extraction electrode 24b is diagonally led to another corner of the short side 211 of the crystal resonator plate. The other end, a terminal end, of the extraction electrode 24b constitutes an adhesive electrode 25b.
(30) The extraction electrodes 24a, 24b and the adhesive electrodes 25a, 25b are provided in pairs, and are arranged not to overlap with each other in plan view.
(31) In the present embodiment, the width of the pair of extraction electrodes 24a, 24b is not constant but increases gradually from the corners of the excitation electrodes 23a, 23b to the adhesive electrodes 25a, 25b. This shape can effectively prevent spurious generation.
(32) In the present embodiment, the excitation electrodes 23a, 23b, the extraction electrodes 24a, 24b, and the adhesive electrodes 25a, 25b have a structure composed of a chromium (Cr) foundation layer and a silver alloy layer laminated thereon. These metal films are formed by sputtering. Patterns of the excitation electrodes, the extraction electrodes, and the adhesive electrodes are formed by photolithography and etching. Application of photolithography enables highly precise formation of the various electrodes even if the external size of the crystal resonator plate is minute.
(33) The silver alloy is a ternary silver alloy containing silver as a major component, a first additive which is a metal element having a lower sputtering yield than silver and being resistant to corrosion in an etching liquid, and a second additive which is an element for forming a solid solution with silver. Specifically, the silver alloy contains silver as the major component, palladium (Pd) as the first additive, and copper (Cu) as the second additive (an AgPdCu alloy). In the present embodiment, the weight ratio of Pd is 1 to 2% and the weight ratio of Cu is 1% or less, relative to the total AgPdCu alloy. The composition of the silver alloy should not be limited to silver-palladium-copper as given above, but may be other compositions. For example, the silver alloy may contain silver as the major component, titanium (Ti) as the first additive, and carbon (C) as the second additive. Additionally, the first additive may be neodymium (Nd).
(34) Presence of palladium as the first additive makes the surfaces resistant to oxidation and thereby enhances the oxidation resistance and the chemical resistance. Hence, when patterns of the various electrodes are formed in predetermined shapes, for example, by photolithography, side surfaces of each metal film under a resist are rich in palladium during metal etching and can therefore inhibit excessive side etching. This is because palladium per se has excellent weatherability such as oxidation resistance and chemical resistance, and can exhibit its excellent weatherability also in the silver alloy containing palladium.
(35) Besides, palladium is a metal element having a lower sputtering yield than silver, and mixes evenly with silver while targets are formed by sputtering. Thus, palladium is desirable in making outer peripheries of the electrodes in a palladium-rich state.
(36) Copper, as the second additive, forms an interstitial solid solution with silver by allowing copper atoms to enter gaps in a silver crystal lattice. This eventually inhibits movement of silver atoms and can thereby prevent aggregation of silver particles due to thermal history. It is therefore possible to enhance thermal resistance and to prevent delamination or disconnection of the electrodes.
(37) In
(38) Incidentally, in the case of the conventional crystal resonator element 10, if a central portion of the crystal resonator element 10 (see
(39) In the present invention, on the other hand, the outer peripheries of the pair of excitation electrodes 23, the outer peripheries of the pair of extraction electrodes 24, and the outer peripheries of the pair of adhesive electrodes 25 are rich in palladium. Since palladium has a higher Vickers hardness than silver, it is possible to prevent delamination of the electrodes from the outer peripheries of the electrodes 23, 24, 25.
(40) The adhesive electrodes 25a, 25b provided at an end of the long sides of the crystal resonator element 2 are conductively bonded on the crystal resonator element-mounting pads 5, 5 via the conducting adhesives 6, 6. In the present embodiment, the conducting adhesives 6 are silicone-based conductive resin adhesives, but may also be non-silicone-based conducting adhesives. Incidentally, the means for conductively bonding the crystal resonator element and the crystal resonator element-mounting pads is not limited to conducting adhesives, and other bonding means are also applicable. For example, the crystal resonator element and the crystal resonator element-mounting pads may be conductively bonded by thermocompression bonding with application of ultrasonic waves via conductive bumps (so-called FCB, or Flip Chip Bonding).
(41) Turning next to
(42) Metal Film Formation Step
(43) First of all, as shown in
(44) Each metal film M has a layer structure composed of a chromium foundation layer and a silver alloy (AgPdCu alloy) layer laminated thereon, the silver alloy containing silver as the major component, a trace amount of palladium (the first additive), and a trace amount of copper (the second additive). Palladium, as the first additive, is a metal element having a lower sputtering yield than silver and being resistant to corrosion in an etching liquid. Copper, as the second additive, is an element for forming a solid solution with silver. The chromium layer is so much thinner than the silver alloy layer that illustration of the chromium layer is omitted in all cross-sectional views.
(45) Resist Formation Step
(46) Next, resists R are formed on the metal films M covering the entirety of the front and back main surfaces of the quartz crystal wafer 200 (
(47) Light Exposure & Development Step
(48) Then, as shown in
(49) Metal Etching Step
(50) Next, as shown in
(51) During the metal etching step, silver and copper contained in the uncovered regions of the metal films M dissolve into the etching liquid, whereas palladium contained in the metal films M is less likely to dissolve into the etching liquid, so that the ratio of palladium increases in the metal films M. Eventually, the amount of palladium at the side surfaces of the metal films M under the residual resists becomes greater than in the rest of the metal films M except the side surfaces. In other words, the palladium concentration at the outer peripheries of the excitation electrodes is higher (palladium-rich), per unit volume, than the inner regions of the excitation electrodes surrounded by the side surfaces (
(52) Resist Stripping Step
(53) Lastly, the residual resists R are removed to give a quartz crystal wafer 210 on which a multiplicity of crystal resonator elements 2, 2, . . . , 2 are formed in an integrated manner. Each crystal resonator element has the excitation electrodes 23a, 23b whose outer peripheries are rich in palladium (
(54) According to the above-described method of the present invention for producing the crystal resonator element, it is possible to produce crystal resonator elements in each of which the outer peripheries of the excitation electrodes are rich in palladium. This is achievable because silver can be selectively etched away at the side surfaces of the metal films whose top surfaces are covered by the resists, by the steps including: forming the metal films M each composed of the above-mentioned ternary alloy on the front and back surfaces of the crystal resonator plate in the metal film formation step, forming resists on the top surfaces of the metal films M, and then etching the metal films with use of an etching liquid which is corrosive to silver and copper in the metal etching step.
(55) Next, the method for producing the crystal resonator 1 according to the present invention is described with reference to
(56) After the bonding step, an ion beam IB (argon ions Art) is emitted from an ion gun IG to the excitation electrode 23a of the crystal resonator (
(57) In the fine adjustment step, the outer peripheries of the excitation electrodes are rich in the first additive, palladium. Palladium has a lower sputtering yield than silver, and thus is resistant to sputtering by ion beam irradiation than silver. Owing to this arrangement, it is possible to prevent a decrease in the external dimension of the excitation electrodes.
(58) After the fine adjustment step, the lid is bonded on the holder 3 to seal the crystal resonator element 2 hermetically in the recess 8 (sealing step). This is the final step in the method for producing the crystal resonator according to the present invention.
(59) According to the crystal resonator of the present invention described above, addition of palladium to silver makes the surfaces resistant to oxidation and can thereby enhance weatherability. Besides, copper, which is an element for forming a solid solution with silver, can enhance hardness of the electrodes and can improve thermal resistance of the crystal resonator using the crystal resonator element. These functions and effects are demonstrated by results of reliability tests on examples of the present invention in comparison with conventional examples, as shown in
(60) The graphs in
(61) The graphs in
(62) The graphs in
(63) As understood from the above results, the present invention can provide a piezoelectric device which is excellent in thermal resistance and weatherability.
(64) The graphs in
(65) Let us assume the reason for the above results. In the conventional examples (the foundation layer is covered by a pure Ag layer), oxide films are formed on the surfaces of the excitation electrodes and the extraction electrodes (including the adhesive electrodes in the present embodiment), which is likely to deteriorate the adhesion property between the extraction electrodes (specifically, the adhesive electrodes) and the conducting adhesives and to make the crystal resonators unstable. At this state, the conductivity resistance increases at the bonding interface between the extraction electrodes and the conducting adhesives, which is further likely to deteriorate the equivalent resistance in the crystal resonators. Eventually, the conventional crystal resonators show unstable characteristics in excitation power dependency.
(66) In contrast, according to the present invention, the excitation electrodes, the extraction electrodes, and the adhesive electrodes contain Pd as the first additive, which makes the surfaces of the excitation electrodes, the extraction electrodes, and the adhesive electrodes resistant to oxidation. As a result, the adhesion property between the adhesive electrodes and the conducting adhesives improves and stabilizes the crystal resonators. At this state, the conductivity resistance decreases at the bonding interface between the adhesive electrodes and the conducting adhesives, which in turn reduces the equivalent resistance in the crystal resonators. Eventually, the present invention can provide a crystal resonator having a good excitation power dependency.
(67) In the above embodiment of the present invention, a surface-mount crystal resonator is employed as an example. In addition, the present invention is applicable to other piezoelectric devices such as a crystal filter and a crystal oscillator.
(68) The present invention can be embodied and practiced in other different forms without departing from the spirit and essential characteristics of the invention. Therefore, the above-described embodiment is considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description. All variations and modifications falling within the equivalency range of the appended claims are intended to be embraced therein.
(69) This application claims priority to Japanese Patent Application No. 2013-218778 filed on Oct. 22, 2013, and Japanese Patent Application No. 2014-154231 filed on Jul. 29, 2014. The contents of these applications are incorporated herein by reference in their entirety.
INDUSTRIAL APPLICABILITY
(70) The present invention is applicable to mass production of piezoelectric resonator elements and piezoelectric devices.
DESCRIPTION OF THE REFERENCE NUMERALS
(71) 1 crystal resonator 2 crystal resonator element 3 holder 23, 23a, 23b excitation electrode 9 first additive-rich region