Porous ceramic body and method for manufacturing a porous ceramic body

Abstract

To provide a porous ceramic body capable of improving toughness and a method for manufacturing the porous ceramic body.SOLUTION: A porous ceramic body 100 is constituted by laminating a plurality of ceramic layers 101. Each ceramic layer 101 has a thickness of 100 μm or more and 1000 μm or less. Interlayer cavities 103 are formed on each interface 102 between the ceramic layers 101. The interlayer cavities 103 are cavity portions formed in an infinite number of sizes on the interface 102. The interlayer cavity 103 has a height h of 20 μm or more and 50 μm or less at the highest part of the cavity portion in the thickness direction of the porous ceramic body 100. The interlayer cavity 103 is formed substantially evenly and universally between the two ends of one interface 102.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a porous ceramic body having a multilayer structure in which fired products of laminated ceramic papers each form a ceramic layer, and a method for producing the porous ceramic body.

Background Art

[0002] Conventionally, there has been a porous ceramic plate having a multilayer structure in which fired products of laminated ceramic papers each form a ceramic layer. For example, Patent Document 1 below discloses a special heat-resistant ceramics in which silicon carbide layers of 10 μm or more and 100 μm or less are laminated via voids of 1 μm or more and 20 μm or less.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0004] This special heat-resistant ceramics is formed to have a thickness of 10 μm or more and 100 μm or less in order to prevent unevenness or undulation in the thickness of the non-melting sheet forming the silicon carbide layer, and to ensure the bonding strength between the layers of each silicon carbide layer. The thickness of the voids between the layers is formed to be 1 μm or more and 20 μm or less.

[0005] However, the special heat-resistant ceramics described in Patent Document 1 above has a problem that it is extremely brittle and breaks and cracks all at once due to a slight bending deformation.

[0006] The present invention has been made to address the above problems, and an object thereof is to provide a porous ceramic body and a method for producing a porous ceramic body that can improve toughness.

Summary of the Invention

[0007] To achieve the above objective, the present invention is characterized by a multilayer porous ceramic body in which each fired product of stacked ceramic papers forms a ceramic layer, the ceramic layer having a thickness of 100 μm or more and 1000 μm or less, and countless interlayer cavities with a height of 20 μm or more and 50 μm or less are formed between adjacent ceramic layers.

[0008] According to the features of the present invention configured in this way, the porous ceramic body is formed in which each ceramic layer has a thickness of 100 μm or more and 1000 μm or less, and countless interlayer cavities with a height of 20 μm or more and 50 μm or less are formed between adjacent ceramic layers. Therefore, according to the inventors' experimental results, toughness can be improved.

[0009] Furthermore, the present invention can be implemented not only as an invention of a porous ceramic body, but also as an invention of a method for manufacturing this porous ceramic body.

[0010] Specifically, the method for manufacturing a porous ceramic body is a method for manufacturing a multilayer porous ceramic body in which the fired products of each stacked ceramic paper each form a ceramic layer, and includes a paper-making step of making ceramic paper, a laminate-forming step of stacking the ceramic paper and applying pressure in the stacking direction to obtain a ceramic paper laminate in which adjacent ceramic papers are joined together, and a firing step of firing the ceramic paper laminate, wherein the laminate-forming step applies pressure to the stacked ceramic paper to form the thickness of each ceramic paper to be 100 μm or more and 1000 μm or less, and preferably forms countless interlayer cavities with a height of 20 μm or more and 50 μm or less between adjacent ceramic papers. According to this, the method for manufacturing a porous ceramic body can be expected to have the same effects as the porous ceramic body described above. [Brief explanation of the drawing]

[0011] [Figure 1]This is a schematic perspective view showing the overall structure of the porous ceramic body according to the present invention. [Figure 2] Figure 1 is a schematic, partially enlarged cross-sectional view showing the cross-sectional state of the porous ceramic body. [Figure 3] Figure 1 shows an example of a digital image of a cross-section of the interface surface used to calculate the formation ratio of interlayer cavities in a porous ceramic body. [Figure 4] This is an example of a digital image that has been grayscaled to represent a cross-section of an interface including an interlayer cavity. [Figure 5] This is a schematic diagram illustrating a grayscale digital image used to explain the process of measuring the thickness of interlayer cavities. [Figure 6] This is a flowchart showing the process flow of the method for manufacturing a porous ceramic body according to the present invention. [Figure 7] Figure 6 is a schematic diagram illustrating the processing steps in the second step, the planarization process. [Figure 8] Figure 6 is a schematic diagram illustrating the processing steps in the third step, the laminated body molding process. [Figure 9] This graph shows the test results (amount of deflection deformation under load) from a three-point bending test performed on a conventional porous ceramic body. [Figure 10] This graph shows the test results (amount of deflection deformation in response to load) of a three-point bending test performed on the porous ceramic body (interlayer cavity height 20 μm) of the present invention. [Figure 11] This graph shows the test results (amount of deflection deformation in response to load) of a three-point bending test performed on the porous ceramic body (interlayer cavity height 50 μm) of the present invention. [Figure 12] This is a schematic diagram illustrating how a three-point bending test is performed using a base, support pins, and pressure pins. [Modes for carrying out the invention]

[0012] Hereinafter, an embodiment of the porous ceramic body and the method for manufacturing the porous ceramic body according to the present invention will be described with reference to the drawings. Figure 1 is a schematic perspective view showing the overall structure of the porous ceramic body 100 according to the present invention. Figure 2 is a schematic partially enlarged cross-sectional view showing the cross-sectional state of the porous ceramic body 100 shown in Figure 1. Note that the schematic diagrams referenced in this specification may be simplified in order to facilitate understanding of the present invention, such as by exaggerating some of the components, and therefore the dimensions and ratios between each component may differ.

[0013] This porous ceramic body 100 is a plate-shaped component used as a support base in a furnace during the firing of ceramic materials, pottery, or glass that constitute electronic components.

[0014] (Composition of porous ceramic body 100) The porous ceramic body 100 is composed of multiple ceramic layers 101 stacked on top of each other. Each ceramic layer 101 is formed by firing ceramic paper 200 (described later) and is composed of a flat ceramic sintered body. Each of these ceramic layers 101 has a thickness of 100 μm or more and 1000 μm or less. Furthermore, each ceramic layer 101 is formed in a porous manner, with an intralayer cavity portion 101a consisting of countless voids inside.

[0015] In this case, the intralayer cavities 101a formed inside each ceramic layer 101 are portions where the organic fibers (not shown) contained in the ceramic paper 200 have disappeared, and adjacent intralayer cavities 101a may be connected to each other, or they may exist independently without being connected to all adjacent intralayer cavities 101a.

[0016] In this embodiment, each of the stacked ceramic layers 101 is composed of the same type of aluminum oxide. Also, each ceramic layer 101 is formed to have a thickness of about 250 μm. And, in this embodiment, the porous ceramic body 100 is composed of 10 ceramic layers 101 stacked in the thickness direction of the porous ceramic body 100. Interlayer cavity portions 103 are formed at each interface 102 between these ceramic layers 101.

[0017] The interface 102 is the boundary portion between two adjacent ceramic layers 101 in the stacking direction in each of the ceramic layers 101 stacked in the thickness direction of the porous ceramic body 100, and is inevitably formed between the stacked ceramic papers 200.

[0018] The interlayer cavity portion 103 is a cavity portion formed at the interface 102. These interlayer cavity portions 103 are formed in countless numbers, large and small, dispersed on the bonding surface between two adjacent ceramic layers 101. These interlayer cavity portions 103 are formed such that the height of the highest portion of the cavity portion in the thickness direction of the porous ceramic body 100 is 20 μm or more and 50 μm or less.

[0019] In this case, the interlayer cavity portion 103 may include cavities having a height h of less than 20 μm or exceeding 50 μm at the interface 102, but cavities having at least a part of a height of 20 μm or more and 50 μm or less mainly exist. Here, the fact that cavities having a height h of 20 μm or more and 50 μm or less mainly exist means that the formation ratio of cavities having a height h of 20 μm or more and 50 μm or less is higher than the formation ratio of cavity portions formed only with a height h of less than 20 μm or only with a height exceeding 50 μm. In this embodiment, the interlayer cavity portion 103 is formed to have a height h of 20 μm. Also, the interlayer cavity portion 103 is formed substantially evenly and uniformly over the entire interface 102.

[0020] The formation ratio of the interlayer cavity 103 can be approximately calculated using a known image processing technique that utilizes a digital image of the cross-section of the interface surface 102. Specifically, the worker cuts the porous ceramic body 100 perpendicular to the surface to expose the cross-section, and then acquires digital image data (hereinafter simply referred to as "image data") of the state of this cross-section at a predetermined magnification (for example, 100x) using a magnifying imaging device such as a scanning electron microscope. In this case, as shown in Figure 3, the worker takes the image including the cross-section of the interface surface 102, which is the subject of the calculation of the formation ratio of the interlayer cavity 103.

[0021] Next, the worker uses a computer device such as a personal computer capable of processing image data to trim the image data that includes one interface 102 and the surrounding ceramic layer 101.

[0022] Next, the operator uses image processing software (a known computer program) capable of grayscale processing to grayscale the cropped image data. Here, grayscale processing is the process of converting the captured image of the cross-section of the interface surface 102 and its surroundings into grayscale values ​​on a grayscale from 0 (white) to 255 (black). As a result of this process, as shown in Figure 4, the image data is represented with a light gray value close to white for the ceramic layer 101, and with a dark gray value close to black for the intralayer cavity 101a and interlayer cavity 103 within the ceramic layer 101. In this case, the interlayer cavity 103 is often formed to be larger than the intralayer cavity 101a within the ceramic layer 101, so it is represented with a dark gray value closer to black than the intralayer cavity 101a within the ceramic layer 101.

[0023] Next, the worker extracts portions representing the interlayer cavities 103 from the grayscale image data using the image processing software. Specifically, the worker extracts portions from the grayscale image data that have a grayscale value equal to or greater than a predetermined density. This allows the worker to extract portions from the grayscale image data that represent the interlayer cavities 103 extending in the direction of the surface of the porous ceramic body 100.

[0024] Next, the worker measures the thickness of the interlayer cavity 103 using the image processing software. Specifically, as shown in Figure 5, the worker measures the length in the direction perpendicular to the surface direction of the porous ceramic body 100 in the image data of the extracted portion representing the interlayer cavity 103 (i.e., the height h (thickness) of the cavity portion). In this case, the computer device measures the thickness of the portion representing the interlayer cavity 103 at predetermined pitches P (for example, 100 μm) in the surface direction of the porous ceramic body 100 (the direction in which the interface surface 102 is formed).

[0025] Next, the worker identifies the formation ratio of cavity height h in the interlayer cavity 103. Specifically, the worker counts the number of measurement values ​​that fall within the range of 20 μm or more and 50 μm or less for each measurement value measured at the predetermined pitch P along the entire length of the porous ceramic body 100 from one end to the other (i.e., between both ends), and the number of measurement values ​​that fall outside this range. This allows the worker to calculate the formation ratio of cavities in the interlayer cavity 103 where the cavity height h is less than 20 μm or greater than 50 μm, and the formation ratio of cavities where the cavity height h is between 20 μm and 50 μm, respectively.

[0026] Next, the worker evaluates whether the interlayer cavity 103 is acceptable or unacceptable. Specifically, the worker evaluates that the proportion of cavities in the interlayer cavity 103 with a height h of 20 μm or more and 50 μm or less is higher than the proportion of cavities with a height h of less than 20 μm or greater than 50 μm, if the number of measurements within the range of 20 μm or more and 50 μm or less is greater than the proportion of cavities with a height h of less than 20 μm or greater than 50 μm. It goes without saying that this evaluation of whether the interlayer cavity 103 is acceptable or unacceptable may be performed automatically using a computer device.

[0027] The pass / fail evaluation of the interlayer cavity 103 may be performed by evaluating the pass / fail of the interlayer cavity 103 in one cross-section for one interface surface 102, or by evaluating the pass / fail of the interlayer cavity 103 for each cross-section at multiple different locations for one interface surface 102 and then comprehensively evaluating the pass / fail result of the interlayer cavity 103 at one interface surface 102 based on these evaluations.

[0028] Furthermore, the pass / fail evaluation of the interlayer cavity 103 may be performed by evaluating the pass / fail of the interlayer cavity 103 with respect to only one interface 102 formed inside the porous ceramic body 100, or the pass / fail evaluation of the interlayer cavity 103 may be performed for two or more interface 102s and the pass / fail result of the interlayer cavity 103 in one porous ceramic body 100 may be comprehensively evaluated based on these evaluations.

[0029] It goes without saying that the formation ratio of the height h of the cavity portion in the interlayer cavity 103 can be determined manually by the worker using a ruler or similar tool based on image data of the interface surface 102. Alternatively, the formation ratio of the height h of the cavity portion in the interlayer cavity 103 can be determined by dividing the interface surface 102 into predetermined lengths (for example, 1000 μm) and determining the formation ratio for each section. In this case, the pass / fail evaluation of the interlayer cavity 103 at a single interface surface 102 can be comprehensively evaluated based on the pass / fail evaluation of the interlayer cavity 103 for each section.

[0030] Furthermore, the evaluation of the pass / fail status of the interlayer cavity 103 at a single interface 102 can be performed not only over the entire length of the cross-section of the interface 102, but also only on a portion of the cross-section of the interface 102. For example, the worker can perform the evaluation over a range of at least one-third of the total length of the interface 102, including the central part in the width direction of the cross-section of a single interface 102.

[0031] (Manufacturing of porous ceramic body 100) Next, the manufacturing method of the porous ceramic body 100 configured in this way will be explained with reference to Figure 6. First, as the first step, the worker manufactures ceramic paper 200. Ceramic paper 200 is the material that forms the ceramic layer 101 in the porous ceramic body 100 and is manufactured by a papermaking process.

[0032] The papermaking process is a conventionally known method in which fibers dispersed in a liquid are filtered to form a long sheet-like paper body (not shown). Specifically, the papermaking process involves adding the raw materials for ceramic paper 200, namely organic fibers and inorganic powder, to water, stirring them to create a slurry-like raw material liquid, filtering these raw materials into a long sheet-like form, and then drying it to obtain a long sheet-like paper body. In this case, the long paper body is dried to a moisture content of 10% or less. Furthermore, in this embodiment, the long paper body is formed to a thickness of 0.3 mm.

[0033] Here, the organic fibers can consist of one or more types of wood pulp, synthetic pulp, polyester fibers, polyamide fibers, polyimide fibers, polyvinyl alcohol-modified fibers, polyvinyl chloride fibers, polypropylene fibers, polybenzimidazole fibers, acrylic fibers, carbon fibers, phenolic fibers, nylon fibers, and cellulose fibers.

[0034] Furthermore, the inorganic powder can consist of one or more types of aluminum oxide, zirconium oxide, silica, mullite, cordierite, silicon carbide, or silicon nitride. The mixing ratio of organic fibers and inorganic powder is appropriately set according to the specifications of the porous ceramic body 100 to be manufactured. In this case, the organic fibers are blended in a ratio of 3% or more and 30% or less by weight of the inorganic powder.

[0035] Next, the worker obtains single sheets of ceramic paper 200 by cutting the long paper roll into appropriate sizes using a cutting machine (not shown). In this case, the worker cuts the long paper roll to shapes and sizes that correspond to the shape and size of the porous ceramic body 100 to be ultimately produced in plan view. The worker also prepares a number of ceramic papers 200 corresponding to the number of ceramic layers 101 to be formed inside the porous ceramic body 100. These papermaking and cutting processes correspond to the papermaking process according to the present invention. Note that if single sheets of ceramic paper 200 are produced directly in the papermaking process, the cutting process is unnecessary.

[0036] Next, the worker performs the second step, which is the flattening of the single sheet of ceramic paper 200. Specifically, as shown in Figure 7, the worker sets the ceramic paper 200 in a press device (not shown) equipped with molds K1 and K2, which are made up of a pair of metal blocks having flat surfaces, and presses it to flatten both the front and back surfaces of the ceramic paper 200. In this case, the worker may press the ceramic paper 200 at room temperature, but flattening can be achieved with greater precision by pressing the ceramic paper 200 with the molds K1 and K2 heated to a temperature of 100°C or higher and 200°C or lower.

[0037] Furthermore, the flatness (planarity) of the planarized ceramic paper 200 should be 0.1 mm or less. The surface roughness of the planarized ceramic paper 200 should preferably be 1.6 μm or less in Ra value. While the planarization of the ceramic paper 200 can be performed by stacking multiple sheets, it is preferable to apply pressure to each sheet individually.

[0038] Next, as the third step, the worker forms a laminate of ceramic paper 200. Specifically, as shown in Figure 8, the worker sets multiple sheets of ceramic paper 200 in a laminated state in a press device (not shown) equipped with molds K3 and K4, which are made up of a pair of metal blocks having flat surfaces, and pressurizes them to integrate the ceramic paper 200. In this case, the worker applies adhesive (for example, thermosetting resin) between adjacent ceramic paper 200 sheets before lamination. Then, the worker presses the laminated ceramic paper 200 by applying pressure from a direction perpendicular to the surface of the press with a predetermined pressure. In this case, the worker presses the laminated ceramic paper 200 with the molds K3 and K4 heated to the temperature at which the adhesive hardens.

[0039] Here, the pressure used to press the stacked ceramic paper 200 is such that the thickness of the ceramic layer 101 in the ultimately formed porous ceramic body 100 is 100 μm or more and 1000 μm or less, and the height h of the cavity portion of the interlayer cavity 103 is 20 μm or more and 50 μm or less, and this pressure can be determined experimentally in advance. In this embodiment, the worker stacks 10 sheets of ceramic paper 200 and presses the stacked ceramic paper 200 at a pressure of 7 MPa and a temperature of 180°C for 3 minutes. As a result, the worker can obtain a ceramic paper laminate in which the 10 stacked ceramic papers 200 are integrated with a relatively weak bonding force. The step of pressurizing the stacked ceramic paper 200 to obtain the ceramic paper laminate corresponds to the laminate molding step according to the present invention.

[0040] Next, as the fourth step, the worker performs a degreasing process on the ceramic paper laminate. Here, the degreasing process is a process to remove organic matter contained in the ceramic paper laminate by carbon dioxide gasification. Specifically, the worker places the ceramic paper laminate in an electric furnace (not shown) for degreasing and heats it. In this case, the temperature and time inside the furnace are the temperature and time that can be used to carbon dioxide gasify the organic matter contained in the ceramic paper laminate, and these can be determined experimentally in advance. In this embodiment, the worker heats the ceramic paper laminate at 550°C for 15 minutes. As a result, the worker can obtain a degreased ceramic paper laminate.

[0041] Next, as the fifth step, the worker performs the firing process of the ceramic paper laminate. Here, the firing process is a process to firmly integrate the laminated ceramic paper 200. Specifically, the worker places the ceramic paper laminate in an electric furnace (not shown) for firing and heats it. In this case, the temperature and time inside the furnace are the temperature and time that can sinter each ceramic paper 200 constituting the ceramic paper laminate, and can be determined experimentally in advance. In this embodiment, the worker heats the ceramic paper laminate at 1550°C for about 3 to 5 hours and then slowly cools it.

[0042] This allows the worker to obtain a porous ceramic body 100 in which each ceramic paper 200 is firmly integrated. In this case, the organic fibers present in the ceramic paper 200 disappear, forming an intralayer cavity 101a, and interlayer cavities 103 are formed between adjacent ceramic papers 200.

[0043] (Operation of porous ceramic body 100) The porous ceramic body 100 manufactured as described above is used as a support base in the furnace during firing of ceramic materials, pottery, or glass that constitute electronic components.

[0044] In this case, the porous ceramic body 100 has improved toughness due to the interlayer cavities 103, thus suppressing cracking or chipping when subjected to impact during handling.

[0045] Here, we will explain the experimental results obtained by the inventors. Figure 9 is a graph showing the results of a three-point bending test on a conventional porous ceramic body. Figures 10 and 11 are graphs showing the results of a three-point bending test on the porous ceramic body 100 according to the present invention. In Figures 9 to 11, the vertical axis represents the bending load (N), and the horizontal axis represents the amount of deflection deformation (mm).

[0046] In the conventional porous ceramic body, the height of the interlayer cavity corresponding to the interlayer cavity 103 is formed to be 20 μm or less (specifically, 10 μm), and the thickness of the ceramic layer corresponding to the ceramic layer 101 is formed to be 20 μm. In the porous ceramic body 100, the height h of the interlayer cavity 103 is formed to be 20 μm, and the thickness of the ceramic layer 101 is formed to be 300 μm. Note that the values ​​for the height h of each interlayer cavity 103 and the thickness of each ceramic layer in the conventional porous ceramic body and porous ceramic body 100 are approximate values ​​as precise measurement is impossible, and they have a range of about ±15%. The specimen, before the firing process, is formed in a rectangular shape in plan view with a long side length of 60 mm and a short side length of 30 mm.

[0047] Furthermore, the three-point bending test involves applying a load to the central point of a specimen placed on two support points positioned at a certain distance apart, and measuring the maximum bending stress at which the specimen breaks. This three-point bending test was conducted in accordance with the "Test Method for Room Temperature Bending Strength of Fine Ceramics (R1601:2008)" in the JIS standard.

[0048] Specifically, the three-point bending test in this application is performed using a base 300, support pins 302 and pressure pins 303, as shown in Figure 12. The base 300 is a component for supporting the conventional porous ceramic body and the porous ceramic body 100, which are the test subjects, via the support pins 302, and is constructed by forming a U-shaped block from a metal material such as steel. The dimensions of each part of the base 300 are as shown in Figure 12, but the length in the depth direction, which is not shown in Figure 12, is 30 mm.

[0049] The base 300 has a horizontally formed upper surface with two V-shaped grooves 301 spaced 30 mm apart, and a support pin 302 is supported within each groove 301. The support pin 302 is a component for supporting the object to be placed on, and is made of a metal material such as steel formed into a cylindrical shape with a diameter of 4 mm and a length of 30 mm. The pressing pin 303 is a component for applying a load to the object to be placed on the two support pins 302, and is made of a metal material such as steel formed into a cylindrical shape with a diameter of 4 mm and a length of 30 mm.

[0050] The tester positions the specimen horizontally while it is suspended on two support pins 302, and then applies a load to the specimen via the pressure pin 303 by operating a loading device (not shown). In this case, the operator applies a load of up to 20 kN to the specimen at a speed of 0.5 mm / min. The tester then calculates the bending strength of the specimen using the formula shown in Equation 1 below. (Math 1) Bending strength = (3 × P × L) / (2 × w × t) 2 ) Here, P is the maximum load (N) at which the specimen breaks, L is the distance between supports (mm), w is the width of the specimen (mm), and t is the thickness of the specimen (mm).

[0051] According to these experimental results, in conventional porous ceramic materials, as shown in Figure 9, when a load of about 50 N is applied, the porous ceramic material hardly stretches and breaks instantly. On the other hand, in the porous ceramic material 100 according to the present invention, as shown in Figure 10, when a load of about 40 N is applied to the porous ceramic material 100, it stretches and then breaks instantly. In other words, it can be seen that the porous ceramic material 100 according to the present invention has improved toughness, although the maximum load is lower compared to conventional porous ceramic plates.

[0052] This tendency for the toughness of the porous ceramic body 100 to improve was similarly observed when the height h of the interlayer cavity 103 was 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, and 100 μm. However, as shown in Figure 11, increasing the height h of the interlayer cavity 103 (to 50 μm) also tends to decrease the maximum load. Therefore, a height h of 20 μm or more and 50 μm or less is preferable, and more preferably... 20 μm It is preferable that the size is greater than or equal to 30 μm or less.

[0053] On the other hand, if the thickness of the ceramic layer 101 in the porous ceramic body 100 is 100 μm or less, it is difficult to mold the ceramic layer 101. Also, if the thickness of the ceramic layer 101 is 100 μm or less or 1000 μm or more, the effect of improving toughness tends to decrease. Therefore, the thickness of the ceramic layer 101 in the porous ceramic body 100 is preferably 100 μm or more and 1000 μm or less, and more preferably 100 μm It is preferable that the size is greater than or equal to 500 μm or less.

[0054] As can be understood from the above description of operation, according to the above embodiment, the porous ceramic body 100 is formed with each ceramic layer 101 having a thickness of 250 μm, and countless interlayer cavities 103 of 20 μm are formed at the interlayer interface 102 between adjacent ceramic layers 101. Therefore, according to the inventors' experimental results, toughness can be improved.

[0055] Furthermore, the implementation of the present invention is not limited to the embodiments described above, and various modifications are possible as long as they do not depart from the objective of the present invention.

[0056] For example, in the above embodiment, the porous ceramic body 100 was composed of 10 ceramic layers 101. However, the porous ceramic body 100 can be composed of at least 2 ceramic layers 101.

[0057] Furthermore, in the above embodiment, the porous ceramic body 100 was constructed by laminating ceramic layers 101 of the same thickness. However, the porous ceramic body 100 can also be constructed by laminating ceramic layers 101 of different thicknesses. In this case, the porous ceramic body 100 can be constructed of ceramic layers 101 of different thicknesses by laminating ceramic papers 200 of different thicknesses.

[0058] Furthermore, in the above embodiment, the porous ceramic body 100 was constructed by laminating ceramic layers 101 of the same shape. However, the porous ceramic body 100 can also be constructed by laminating ceramic layers 101 of different shapes. In this case, the porous ceramic body 100 can be constructed of ceramic layers 101 of different shapes by laminating ceramic papers 200 of different shapes. Therefore, the porous ceramic body 100 according to the present invention can be constructed not only as a plate-shaped support base but also as a ceramic battery / electronic device component, filter, or ceramic.

[0059] Furthermore, in the above embodiment, in the first step of the papermaking process in the manufacturing process of the porous ceramic body 100, a slurry-like raw material liquid was used, which consisted of water into which the raw materials for ceramic paper 200, specifically organic fibers and inorganic powder, were added. However, in this papermaking process, inorganic fibers can also be used in place of or in addition to organic fibers. In this case, the inorganic fibers can consist of one or more types, such as glass fibers, rock wool, potassium titanate fibers, ceramic fibers, silica fibers, silica-alumina fibers, kaolin fibers, bauxite fibers, kayanoid fibers, boron fibers, magnesia fibers, and metal fibers.

[0060] Furthermore, in this papermaking process, a binder can be included in the raw material liquid. In this case, synthetic latex, thermoplastic resin, or thermoplastic elastomer can be used as the binder. Examples of thermoplastic resins include vinyl chloride resin, polyester resin, acrylic resin, polyolefin resin, or fluoropolymer resin. Examples of thermoplastic elastomers include styrene-based, olefin-based, PVC-based, polyurethane-based, polyester-based, polyamide-based, or acrylic-based materials. The binder should be mixed into the raw material liquid in a proportion of 5% by weight or more and 15% by weight or less.

[0061] In this case, the method for manufacturing the porous ceramic body 100 is as follows: Flattening process In this method, the material can be pressed and cooled at a temperature above the temperature at which the binder softens. As a result, the manufacturing method of the porous ceramic body 100 can maintain the shape of the flattened ceramic paper 200 for a long period of time, making it easier to store or transport the ceramic paper 200. Furthermore, by including the binder in the raw material liquid, the manufacturing method of the porous ceramic body 100 can increase the integrity of the ceramic paper 200 itself, making the cutting process easier.

[0062] Furthermore, in the manufacturing method of the porous ceramic body 100, in the laminate molding process in the third step, the material is pressed at a temperature above the temperature at which the binder softens and then cooled. As a result, the manufacturing method of the porous ceramic body 100 can increase the adhesion of the laminated ceramic paper 200, suppressing peeling or deformation of each layer and forming a single, integrated product, which facilitates handling in subsequent processes or as a finished product. In addition, the manufacturing method of the porous ceramic body 100 can also eliminate the need to apply adhesive during the lamination process of the ceramic paper 200.

[0063] Furthermore, in the above embodiment, the ceramic paper 200 was flattened in the second step of the manufacturing process of the porous ceramic body 100. However, the ceramic paper flattening step can be omitted if the ceramic paper 200 after the papermaking step in the first step is sufficiently flat. For example, the ceramic paper flattening step can be omitted when it is desired to form a high height h in the interlayer cavity 103, or when pressing with high pressure is performed in the laminate molding step in the fourth step. [Explanation of symbols]

[0064] P...Interval for measuring the thickness of the interlayer cavity, K1~K4...Mold, h...Height of the interlayer cavity, 100...Porous ceramic body, 101...Ceramic layer, 101a...Intralayer cavity, 102...Interface, 103...Interlayer cavity 200... Ceramic paper, 300...base, 301...groove, 302...support pin, 303...pressure pin.

Claims

1. A porous ceramic body having a multilayer structure in which the fired products of each stacked ceramic paper each form a ceramic layer, The ceramic layer is formed with a thickness of 100 μm or more and 1000 μm or less. A porous ceramic body characterized in that countless interlayer cavities with a height of 20 μm or more and 50 μm or less are formed between adjacent ceramic layers.

2. A method for manufacturing a porous ceramic body having a multilayer structure in which each fired product of stacked ceramic papers forms a ceramic layer, A papermaking process for producing the aforementioned ceramic paper, A laminate molding process is performed to obtain a ceramic paper laminate in which the ceramic papers are stacked and pressure is applied in the stacking direction so that adjacent ceramic papers are joined together, The process includes a firing step for firing the ceramic paper laminate, The aforementioned laminate molding process is, A method for manufacturing a porous ceramic body, characterized by applying pressure to the stacked ceramic papers to form each ceramic paper with a thickness of 100 μm or more and 1000 μm or less, and forming countless interlayer cavities with a height of 20 μm or more and 50 μm or less between adjacent ceramic papers.

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