Low-Temperature Sintering and Microwave Dielectric Properties of Zn2SiO4 Ceramic Added with Crystalline Zinc Borate

The physical and dielectric properties of composites of known microwave materials, Zn2SiO4 and Zn3B2O6, prepared by solid-state reaction, were investigated with the purpose of developing a low-loss dielectric material for low-temperature co-fired ceramic applications. An off-stoichiometric phase of Zn2SiO4 with extra SiO2 was used to avoid the occurrence of unreacted ZnO. During sintering, zinc borate was found to partially react with residual SiO2 to form Zn2SiO4. The residual zinc borate was converted to a boron-rich glassy phase which helped to reduce the sintering temperature of the composite. Good relative sintering density (>90%) at temperatures below the melting temperature of zinc borate is indicative of a sintering mechanism of diffusion-based mass transfer. Composites containing 15 wt.% zinc borate, 2.5 wt.% lithium carbonate and 20 wt.% zinc borate in zinc silicate had dielectric constants of 6.8 and 6.1, quality factors (Q×f) of 48,800 and 94,300 GHz when sintered at 900°C and 950°C, respectively. These quality factor results are close to the best values reported for zinc silicate at these sintering temperatures.