Ceramic sheet sintered compact and method for producing same

Abstract

The present invention addresses the problem of providing a sheet-like lattice body in which separation of a coating layer can be sufficiently suppressed even if the sheet-like lattice body is exposed to a high temperature of 1200°C or higher. The problem is solved by a sheet-like lattice body which comprises (a) a striated part layer composed of a plurality of line parts which each extend in one direction and are arranged at given intervals, and (b) a striated part layer composed of a plurality of line parts which each extend in one direction and are arranged at given intervals so as to be in contact with the top of the line parts of (a) and intersect therewith, wherein, in cases where the lattice body is placed on a horizontal surface, if the uppermost striated part layer is defined as a first striated part layer and the striated part layer immediately below the first striated part layer is defined as a second striated part layer, each of first line parts that constitute the first striated part layer on at least one surface of the lattice body has a coating layer, the coating layer covers the first line part continuously at least from the top part T0 to a point T2, and the ratio of C2 to C1 is 5% or more.

Description

Ceramic sheet sintered body and method for manufacturing the same

[0001] The present invention relates to a sheet-like lattice. More specifically, the present invention relates to a sheet-like lattice including a linear portion having a coating layer, which is used as a setter for firing.

[0002] When firing ceramic electronic components or glass, it is common practice to place the objects to be fired on a setter, also known as a shelf, and then fire them. Such firing processes using setters require high production efficiency, as multiple objects must be fired simultaneously. Therefore, firing is carried out in a multi-tiered configuration, where multiple setters are stacked at predetermined intervals, using a firing jig in which setters are placed on a component called a firing base plate or firing rack.

[0003] To improve production efficiency and increase the number of pieces produced per unit time by shortening the degreasing and firing time of the workpiece, rapid heating and cooling of the workpiece is necessary. A ceramic lattice body that can be used as a firing setter has been proposed to achieve such rapid heating and cooling while also increasing the strength of the setter itself (see Patent Document 1).

[0004] Furthermore, setters are often stored and transported on a stand or in a multi-tiered stack. For example, multi-tiered firing setters may be transported from a storage area over steps to another location using a trolley. Therefore, a grid-like firing setter has been proposed that has a high degree of horizontality to prevent lateral displacement, collapse, and resulting damage even in handling situations involving vigorous movements, such as storage and transport on a stand or in a multi-tiered stack, and especially when transporting multi-tiered setters from a storage area over steps to another location using a trolley, and that can be transported and stacked in an orderly manner (see Patent Document 2).

[0005] Because such setters have a larger surface area compared to flat (plate) shaped setters, when firing objects using such a grid as a setter, components forming the grid may scatter from the surface of the grid and react with the object being fired. When the object being fired reacts with the components forming the grid, it can affect the durability and other properties of the final fired product. Therefore, it has been proposed to provide a coating layer on the surface of the setter to prevent unintended scattering of components from the surface of such grids and their reaction with the object being fired (see Patent Documents 3 and 4).

[0006] International Publication No. 2016 / 117207, International Publication No. 2024 / 034256, International Publication No. 2008 / 149656, Japanese Patent Publication No. 2018-4209

[0007] However, since the firing process exposes the setter to temperatures exceeding 1200°C, even with such a coating layer, there is a risk that the coating layer may peel off after multiple uses, exposing the surface of the setter.

[0008] Therefore, the problem that the present invention aims to solve is to provide a sheet-like grid that can sufficiently suppress the peeling of the coating layer even when exposed to high temperatures of 1200°C or higher. Furthermore, a further problem that the present invention aims to solve is to provide a firing jig that includes the grid.

[0009] As a result of diligent research, the inventors of the present invention have discovered that by covering the linear portions forming a sheet-like grid with a coating layer and making certain parts of the coating layer a specific thickness, the peeling of the coating layer can be sufficiently suppressed, thus completing the present invention.

[0010] The various aspects included in the present invention are as follows. [1] (a) A strip layer composed of a plurality of strip portions in which each strip disposed at a given interval extends in one direction, and (b) A strip layer composed of a plurality of strip portions in which each strip disposed at a given interval so as to contact and cross each strip of the strip portion extends in one direction, A sheet-like lattice body including, When the lattice body is placed on a horizontal plane, the strip layer located at the top is defined as the first strip layer, and the strip layer immediately below the first strip layer is defined as the second strip layer, Each of the first strip portions constituting the first strip layer on at least one surface of the lattice body has a coat layer, The coat layer covers the first strip portion continuously from at least the top T ０ to the point T ２ and covers the first strip portion continuously up to the point T １ The ratio of C ２ to C ０ is 5% or more. However, when the lattice body is placed on a horizontal plane such that the first strip layer is located above the second strip layer, and in a cross-section perpendicular to the longitudinal direction of the first strip portion at a point where the center line of the first strip portion and the center line of the second strip portion constituting the second strip portion intersect in a plan view of the lattice body, Using a straight line passing through both end points where the cross-section of the first strip portion and the cross-section of the second strip portion contact as a reference line, Among the cross-sections of the first strip portion, the position highest in the vertical direction is defined as the top T ０ and the length of the perpendicular from the top T １ to the reference line is defined as the height H of the first strip portion. On the cross-section of the first strip portion, the intersection point of the horizontal line at a height of 80% of the height H and the surface of the first strip portion is defined as the point T ２ and the intersection point of the horizontal line at a height of 20% of the height H and the surface of the first strip portion on the cross-section of the first strip portion is defined as the point T ０ When the midpoint of the perpendicular from the top T １ to the reference line is defined as the point M, The length of the coat layer on the straight line passing through the point M and the point T １ is defined as the thickness C １ of the coat layer at the point T ２ and the length of the coat layer on the straight line passing through the point M and the point T ２ is defined as the thickness C of the coat layer at the point T２ A lattice structure. [2] C ０ C ２ The proportion is 0.01% or more, provided that point M and point T ０ The length of the coating layer along the straight line passing through point T is given by point T. ０ Thickness C of the coating layer ０ The lattice described in [1]. [3] C for L ０ The proportion is 2.0% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the first linear layer, the maximum horizontal length of the cross section of the first linear layer is L, and points M and T ０ The length of the coating layer along the straight line passing through point T is given by point T. ０ Thickness C of the coating layer ０ The lattice body described in [1] or [2]. [4] C for L ２ The proportion is 0.02% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a cross section perpendicular to the longitudinal direction of the first linear layer at the point where the center line of the first linear layer and the center line of the second linear layer intersect in a plan view of the grid, the maximum horizontal length of the cross section of the first linear layer is L, according to any one of [1] to [3]. [5] The grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a cross section perpendicular to the longitudinal direction of the first linear layer at the point where the center line of the first linear layer and the center line of the second linear layer intersect in a plan view of the grid, the length of the line segment connecting the two points where the cross section of the first linear layer and the cross section of the second linear layer contact is shorter than the maximum horizontal length L of the cross section of the first linear layer, according to any one of [1] to [4]. [6] C relative to L ３The proportion is 0.1% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the first linear layer, the intersection point of the second linear layer with a straight line perpendicular to the horizontal plane passing through one endpoint that makes up the maximum horizontal length of the cross section of the first linear layer is point T. ３ Let point T ３ The vertical thickness of the coating layer in C ３ The lattice described in [5]. [7] C １ C ３ The proportion is 10% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the second linear layer, the intersection point of the second linear layer with a straight line perpendicular to the horizontal plane passing through one endpoint that makes up the maximum horizontal length L of the cross section of the first linear layer is point T. ３ Let point T ３ The vertical thickness of the coating layer in C ３ A lattice body according to [5] or [6], wherein the first linear portion and the second linear portion are made of ceramics, according to any one of [1] to [7]. [9] A lattice body according to any one of [1] to [8], wherein the coating layer is made of ceramics, according to any one of [1] to [8].

[10] A lattice body according to any one of [1] to [9], wherein the coating layer comprises one or two components selected from the group consisting of alumina, zirconia, yttria, silica, calcia, magnesia, strontia, mullite and alumina-magnesia spinel composite oxide, calcium zirconate, and barium titanate.

[11] A firing jig comprising a lattice body according to any one of [1] to

[10] .

[0011] The present invention provides a grid that, by having linear portions with a coating layer of a specific thickness at predetermined locations, not only is the coating layer difficult to peel off, but peeling of the coating layer can also be sufficiently suppressed even when subjected to repeated thermal cycles of exposure to high temperatures of 1200°C or higher and subsequent cooling. Therefore, since the scattering of components of the grid can be prevented for a long period of time, the impact on the fired product can also be reduced for a long period of time. In turn, this can contribute to improving the quality of the fired product, such as its durability.

[0012] Figure 1 is a schematic diagram of a grid according to one embodiment of the present invention. Figure 2 is a schematic diagram of a grid according to one embodiment of the present invention. (a) is a perspective view of the grid observed from above (front surface), and (b) is a perspective view of the grid observed from below (back surface). Figure 3 is a schematic diagram of a grid according to one embodiment of the present invention. (a) is a perspective view of the grid observed from above (front surface), and (b) is a perspective view of the grid observed from below (back surface). Figure 4 is a schematic diagram of a grid according to one embodiment of the present invention. Figure 5 is an enlarged view of the intersection of the first and second linear portions in a plan view of the grid of the present invention. Figure 6 is a schematic diagram for explaining the thickness of each point and the coating layer in the grid of the present invention.

[0013] Sheet-like grid The grid according to the present invention comprises: (a) a linear layer composed of multiple linear sections, each of which is extended in one direction and arranged at a given interval; and (b) a linear layer composed of multiple linear sections, each of which is extended in one direction and arranged at a given interval so as to be adjacent to and intersecting each of the linear sections, wherein when the grid is placed on a horizontal surface, the uppermost linear layer is designated as the first linear layer, and the linear layer directly below the first linear layer is designated as the second linear layer, and each of the first linear sections constituting the first linear layer on at least one surface of the grid has a coating layer, and the coating layer has at least the top T ０ From point T ２ The first linear portion is continuously covered up to C １ C ２ The proportion is 5% or more, which is a characteristic feature.

[0014] Here, in describing each point and thickness, a typical shape of the grid of the present invention will be described with reference to the drawings. Figure 1 shows an example of the grid of the present invention. The grid 1 in Figure 1 has a so-called mesh-like structure. Specifically, the grid 1 has a structure that includes (a) a linear layer composed of multiple linear sections 2 in which each strip is extended in one direction and arranged at a given interval, and (b) a linear layer composed of multiple linear sections 3 in which each strip is extended in one direction and arranged at a given interval so as to be in contact with and intersecting each strip of the linear section 2. Note that in Figure 1, a part of the sheet-like grid 1 is enlarged, and the number, length, and spacing of each strip of the linear sections 2 and 3 are not limited to those shown in Figure 1.

[0015] Furthermore, the angle at which the linear portion 2 and the linear portion 3 intersect is not particularly limited. The angle at which the linear portion 2 and the linear portion 3 intersect may be 20° or more and less than 90°, 45° or more and less than 90°, or 60° or more and less than 90° when viewed in plan with respect to the grid. From the viewpoint of the strength of the sheet-like grid, it is preferable that the angle at which the linear portion 2 and the linear portion 3 intersect is approximately 90° when viewed in plan with respect to the grid of the sheet strips.

[0016] The given spacing between each line in a multi-line section 2 may be designed to be at least partially different or substantially equal when it consists of three or more lines, i.e., when there are two or more spacings. Similarly, the given spacing between each line in a multi-line section 3 may be designed to be at least partially different or substantially equal when it consists of three or more lines, i.e., when there are two or more spacings. The given spacing between each line in a multi-line section 2 and the given spacing between each line in a multi-line section 3 can be designed independently of each other.

[0017] Furthermore, the shapes of the linear sections 2 and 3 can be designed independently. For example, as shown in Figures 2(a) and 2(b), when a grid body is placed with the linear section layer formed by linear section 2 facing downwards, the cylindrical linear section may be made into a so-called semi-circular shape, with the bottom portion being made approximately horizontal, so that the grid body is approximately horizontal. In contrast, linear section 3 may be cylindrical with an approximately circular cross-section. The shapes of each linear section are not limited to these, and the cross-sectional shape of each linear section may be circular, elliptical, triangular, rectangular, etc. When the cross-sectional shape of each linear section is circular, elliptical, triangular, or rectangular, those linear sections form a cylinder, elliptical prism, triangular prism, or rectangular prism. The cross-section may also be approximately rectangular or elliptical. However, since the grid body of the present invention has a workpiece placed on top of it, it is preferable that the size of the cross-section of each linear section constituting the linear section layer is constant.

[0018] Here, the linear layer composed of each linear section may be formed integrally. The integral formation of the linear layer means that multiple linear sections 2 and multiple linear sections 3 are fired and connected at their contact points to form an integrated structure, so as not to be easily separated.

[0019] As shown in Figure 1, when the cross-sections of the linear portion 2 and the linear portion 3 are approximately circular, ideally the linear portion 2 and the linear portion 3 will be in point contact. However, when the linear portion layer composed of each linear portion is formed integrally, in reality, the linear portion 2 and the linear portion 3 will be in contact over a surface having a predetermined extent. An example of a configuration in which the linear portion layer composed of each linear portion is in surface contact is shown in Figure 3. That is, as shown in Figures 3(a) and 3(b), at the contact point between the linear portion 2 and the linear portion 3, one or both linear portions may be partially deformed to conform to the shape of the other linear portion, or one linear portion may be embedded in the other linear portion. Such shapes can be created by forming the linear portions using paste.

[0020] Furthermore, the number of linear layers in the lattice body of the present invention is not particularly limited, as long as it has at least two layers. A typical example of the lattice body of the present invention is one with a two-layer structure, as shown in Figure 1. However, by providing linear sections below the linear layer composed of linear section 2 so as to intersect with linear section 2, a lattice body with three or more linear layers can be created. Similarly, by providing linear sections above the linear layer composed of linear section 3 so as to intersect with linear section 3, a lattice body with three or more linear layers can be created.

[0021] The grid of the present invention is not typically limited to the mesh shape shown in Figures 1 to 3. For example, as shown in Figure 4, the grid 1 of the present invention may be configured as a slatted mat, with a linear layer (support layer) consisting of two linear sections (supports) extended substantially parallel to each other at a given interval, and a linear layer consisting of a plurality of linear sections 3 extended substantially parallel to each other at a given interval, intersecting the two linear sections 2 of the linear layer at both ends. Even when the grid is slatted, the shape of each linear section is not limited, and the cross-sectional shape of each linear section may be circular, elliptical, triangular, rectangular, etc. When the cross-sectional shape of each linear section is circular, elliptical, triangular, or rectangular, those linear sections form a cylinder, elliptical prism, triangular prism, or rectangular prism. The cross-section may also be substantially rectangular or elliptical.

[0022] Cross-section of the grid In explaining the thickness of the coating layer in the grid of the present invention, the method for obtaining the cross-section of the grid is described below. To obtain the cross-section of the grid, the grid of the present invention is placed on a horizontal plane. The grid of the present invention includes multiple linear portions in which each strip is extended in one direction, and at least the linear portion layer in contact with the horizontal plane on which the grid is placed is horizontal in the direction of extension of the linear portions constituting the linear portion layer.

[0023] In this manner, when the grid body of the present invention is placed on a horizontal surface, the uppermost linear layer in the vertical direction is designated as the first linear layer, and the linear layer directly below the first linear layer is designated as the second linear layer. For example, in Figure 1, when the grid body 1 is placed on a horizontal surface with linear layers composed of linear parts 2, the linear layer composed of linear parts 3 is designated as the first linear layer, and the linear layer composed of linear parts 2 is designated as the second linear layer.

[0024] In other words, the first linear layer is the layer on which the object to be fired is actually placed when the grid body of the present invention is placed on a horizontal surface in the same manner as described above and the object to be fired is fired. Therefore, the first linear layer and the second linear layer of the grid body of the present invention can be defined using the front and back surfaces of the grid body, respectively.

[0025] In the definition of the coating layer of the grid body of the present invention, when the linear portion constituting the first linear portion layer is referred to as the first linear portion and the linear portion constituting the second linear portion layer is referred to as the second linear portion, the grid body is placed on a horizontal plane such that the first linear portion layer is located on top of the second linear portion layer, and the cross section is perpendicular to the longitudinal direction of the first linear portion at the point where the center line of the first linear portion and the center line of the second linear portion intersect in a plan view of the grid body.

[0026] Figure 5 is an enlarged view of the intersection of the first linear portion 4 and the second linear portion 5 in a plan view of the grid 1. That is, in Figure 5, the centerlines of the first linear portion 4 and the second linear portion 5 are represented by dashed lines, and the cross section in the definition of the coating layer of the grid 1 of the present invention is the cross section perpendicular to the longitudinal direction of the first linear portion 4 at the point where each dashed line intersects (the plane perpendicular to the plane of paper, represented as X-X' in Figure 5).

[0027] A cross-section of the lattice body 1 of the present invention obtained in this manner is typically shown in Figure 6. However, in Figure 6, the linear portions constituting the lattice body are assumed to have a substantially circular cross-section, and the lengths of each portion may differ from actual proportions in order to understand the present invention.

[0028] Each aspect and thickness in this invention will be explained with reference to Figure 6.

[0029] In the reference line diagram 6, the reference line is defined as the straight line passing through points Y and Y' at both ends where the cross-sections of the first linear section 4 and the second linear section 5 come into contact. As shown in Figure 6, in an ideal grid, the reference line coincides with the upper boundary line of the cross-section of the second linear section 5. In a real grid, the first and second linear sections may have some warping or surface irregularities. In such cases, the reference line does not need to strictly coincide with the upper boundary line of the cross-section of the second linear section. In this invention, the reference line may be the boundary line between the cross-section of the first linear section 4 and the cross-section of the second linear section 5.

[0030] As mentioned above, when the cross-section of the linear portion is approximately circular, ideally each linear portion would be in point contact. However, the reference line may be a straight line that passes through the contact point between the cross-sections of the first linear portion and the second linear portion and coincides with the upper boundary line of the cross-section of the second linear portion. In this specification, Figure 6 shows a cross-section when the first linear portion 4 and the second linear portion 5 are in contact over a surface having a predetermined extent, assuming a more realistic cross-section. In Figure 6, the shaded areas indicate the coating layers applied to the first and second linear portions.

[0031] Top T ０ In the cross-section of the first linear section 4 in Figure 6, the highest point in the vertical direction is the apex T. ０ In Figure 6, the cross-sectional shape of the first linear portion 4 is approximately circular, and the top portion T ０ It is determined to be a single point. If there are multiple points with the highest vertical position in the cross section of the first linear section, the midpoint of the horizontal line segment connecting those points is the apex T. ０ This can be done. For example, if the linear portion 2 in Figure 2 is the first linear portion, then the top portion T ０ This is the midpoint of the horizontal line segment.

[0032] Top T in Figure 6 ０ The height H of the first linear section is defined as the length of the perpendicular from the reference line to the reference line. That is, when the cross-section of the first linear section is circular and the first linear section and the second linear section are in point contact, the height H is equal to the diameter of the first linear section.

[0033] Point T １ and point T ２In Figure 6, point T is the point where the horizontal line at a height of 80% of the height H intersects with the surface of the first linear section 4 on the cross-section of the first linear section. １ Furthermore, on the cross-section of the first linear section 4, the intersection point of the horizontal line at a height of 20% of the height H and the surface of the first linear section is defined as point T. ２ Let it be so. Note that in Figure 6, point T １ and point T １ 'and point T ２ and point T ２ As shown by ', there are at least two points on the cross-section of the first linear portion 4 where a horizontal line at a height of 80% of the height H intersects with the surface of the first linear portion 4, and where a horizontal line at a height of 20% of the height H intersects with the surface of the first linear portion 4. In this specification, simply point T １ When referred to as such, point T １ and point T １ It may be interpreted as referring to either one or both of the above.

[0034] Point T ３ In Figure 6, the line segment that makes up the maximum length in the horizontal direction of the cross-section of the first linear section 4 (one endpoint T of the first linear section 4 in Figure 6) Ｌ and the other endpoint T Ｌ Line segment T connecting ' and Ｌ -T Ｌ Let L be the length of the line segment, and T be the endpoint of the line segment. Ｌ Point T is the point where a straight line passing through the line segment and perpendicular to it (i.e., perpendicular to the horizontal plane) intersects with the cross-section of the second line segment 5. ３ Let's assume that.

[0035] In Figure 6, the cross-section of the first linear section 4 is approximately circular, and L is equal to the wire diameter of the cross-section of the first linear section 4.

[0036] Coating layer thickness C ０ ~C ３ In Figure 6, the top T ０ and point T １ ~T ３ The thickness of the coating layer in C ０ ~C ３ Let's assume that... More specifically, C- ０ ~C ３ The above vertex T is defined as follows: ０Let the midpoint of the perpendicular line from [point] to the reference line be point M. That is, point M is a point at a height of 50% of height H on the perpendicular line from the top T ０ to the reference line. The length of the coating layer on the straight line passing through point M and point T ０ is taken as the thickness C ０ of the coating layer at point T ０ . The length of the coating layer on the straight line passing through point M and point T １ is taken as the thickness C １ of the coating layer at point T １ . The length of the coating layer on the straight line passing through point M and point T ２ is taken as the thickness C ２ of the coating layer at point T ２ . The vertical thickness of the coating layer at point T ３ is taken as C ３ .

[0037] Incidentally, where there may be a plurality of points T １ to T ３ for one cross-section of a stripe portion, the thickness of the coating layer at each point may be the average value at a plurality of points.

[0038] In the present invention, when the lattice body is placed on a horizontal plane, the stripe portion layer located at the topmost is taken as the first stripe portion layer, the stripe portion layer directly below the first stripe portion layer is taken as the second stripe portion layer, and each of the first stripe portions constituting the first stripe portion layer on at least one surface of the lattice body has a coating layer, and the coating layer continuously covers the first stripe portion from at least the top T ０ to point T ２ , and the ratio of C １ to C ２ is 5% or more, which is a lattice body.

[0039] When the lattice body is placed on a horizontal plane, the stripe portion layer located at the topmost is taken as the first stripe portion layer, the stripe portion layer directly below the first stripe portion layer is taken as the second stripe portion layer, and each of the first stripe portions constituting the first stripe portion layer on at least one surface of the lattice body has a coating layer. In the lattice body of the present invention, it may have a coating layer on at least one surface, or may have a coating layer on both surfaces.

[0040] In the present invention, preferably, a coating layer is provided on both surfaces of the lattice body. That is, it is preferable that the strip portions constituting the outermost strip portions on the front and back sides of the lattice body among the strip portions included in the lattice body each have a coating layer. Since such a lattice body can use the front and back sides of the lattice body respectively during the firing of the object to be fired, it is possible to reduce the wear of the coating layer due to the friction between the object to be fired and the lattice body.

[0041] The coating layer covers at least the top T ０ to the point T ２ and continuously covers the first strip portion. As shown by the shaded portion in FIG. 6, the lattice body 1 of the present invention has a coating layer that is continuous from the top T ０ to the point T ２ (and the other point T ２ ') of the cross section of the first strip portion 4.

[0042] In the description of the present invention, as described above, the thicknesses of each point and the coating layer are determined in a cross section perpendicular to the longitudinal direction of the first strip portion at the point where the center line of the first strip portion and the center line of the second strip portion intersect in a plan view with respect to the lattice body. However, the coating layer is not limited to covering only the said cross section. That is, usually, as long as the coating layer is a cross section perpendicular to the longitudinal direction of the first strip portion, the coating layer continuously covers the point corresponding to the top T ０ to the point corresponding to the point T ２ similarly.

[0043] In the present invention, the ratio of C １ to C ２ is 5% or more. The ratio of C １ to C ２ may preferably be 10% or more and 70% or less, and more preferably 15% or more and 35% or less. When the ratio of C １ to C ２ is 5% or more, the coating layer covering the lower part of the first strip portion has an appropriate thickness and can function as an anchor to prevent the peeling of the entire coating layer, so the peeling of the coating layer is suppressed. Furthermore, the reaction between the component forming the lattice body and the object to be fired can be more reliably prevented.

[0044] In the present invention, C １ and C ２ There are no particular restrictions as long as the above proportions are met. C １ For example, it may be 10 μm or more and 500 μm or less, 10 μm or more and 400 μm or less, 10 μm or more and 150 μm or less, or 50 μm or more and 100 μm or less.

[0045] C ２ For example, it may be 1.0 μm or more and 150 μm or less, 2.0 μm or more and 100 μm or less, 5.0 μm or more and 50 μm or less, or 10 μm or more and 20 μm or less.

[0046] C １ C ２ The proportion, C １ , and C ２ This can be adjusted by the average particle size of the raw material for the coating layer, as well as the movement speed of the spraying device and the distance between the spraying device and the linear layer when spraying the raw material for the coating layer onto the linear layer.

[0047] By increasing the average particle size of the material that forms the raw material for the coating layer, C １ and C ２ Although it becomes smaller, the contribution to the thickness of the coating layer due to the difference in average particle size is C １ Compared to C ２ The latter is larger. Therefore, by increasing the average particle size of the material that forms the raw material of the coating layer, C １ C ２ The proportion can be reduced.

[0048] By slowing down the movement speed of spraying equipment, etc., C １ and C ２ Although it becomes larger, the contribution of the difference in the movement speed to the thickness of the coat layer is C １ Compared to C ２ The latter is larger. Therefore, by slowing down the movement speed of the spraying device, etc., C １ C ２ The proportion can be increased.

[0049] By reducing the distance between the spraying device and the linear layer, C１ and C ２ Although it becomes larger, the contribution of the difference in distance to the thickness of the coat layer is C ２ Compared to C １ The latter is larger. Therefore, by reducing the distance between the spraying device and the linear layer, C １ C ２ The proportion can be reduced.

[0050] In one embodiment of the present invention, C ０ C ２ The percentage may be 0.01% or more. ０ C ２ The proportion may preferably be 0.1% or more and 60% or less, more preferably 0.5% or more and 55% or less, even more preferably 1.0% or more and 50% or less, even more preferably 3.0% or more and 40% or less, and even more preferably 5.0% or more and 20% or less. ０ C ２ If the proportion is 0.01% or more, the coating layer covering the lower part of the first ridge will have an appropriate thickness and can function as an anchor to prevent the peeling of the entire coating layer, thus suppressing the peeling of the coating layer.

[0051] In this embodiment, C ０ and C ２ There are no particular restrictions as long as the above proportions are met. C ２ This is determined as appropriate within the above range, C ０ For example, it may be 10 μm or more and 500 μm or less, 15 μm or more and 200 μm or less, 20 μm or more and 100 μm or less, or 25 μm or more and 75 μm or less.

[0052] C ０ C ２ The proportion, C ０ , and C ２ This can be adjusted by the average particle size of the raw material for the coating layer, as well as the movement speed of the spraying device and the distance between the spraying device and the linear layer when spraying the raw material for the coating layer onto the linear layer.

[0053] By increasing the average particle size of the material that forms the raw material for the coating layer, C ０ It becomes larger. On the other hand, by increasing the average particle size of the material that makes up the coating layer, generally C ２ The size decreases. This is thought to be because the larger the average particle size of the raw material for the coating layer, the more difficult it becomes for the material to be sprayed or otherwise reach below the fringe. Therefore, by increasing the average particle size of the raw material for the coating layer, C ０ C ２ The proportion can be reduced.

[0054] By slowing down the movement speed of spraying equipment, etc., C ０ and C ２ Although it becomes larger, the contribution of the difference in the movement speed to the thickness of the coat layer is C ０ Compared to C ２ The latter is larger. Therefore, by slowing down the movement speed of the spraying device, etc., C ０ C ２ The proportion can be increased.

[0055] By reducing the distance between the spraying device and the linear layer, C ０ and C ２ Although it becomes larger, the contribution of the difference in distance to the thickness of the coat layer is C ２ Compared to C ０ The latter is larger. Therefore, by reducing the distance between the spraying device and the linear layer, C ０ C ２ The proportion can be reduced.

[0056] In one embodiment of the present invention, C relative to L ０ The ratio of C to L is usually 0.3% or more, 0.6% or more, or 1.0% or more, and preferably 2.0% or more. ０ The ratio of C to L may more preferably be 2.5% to 100%, even more preferably 3.0% to 25%, and even more preferably 3.5% to 15%. ０By having a ratio of 0.3% or more, 0.6% or more, or 1.0% or more, preferably 2.0% or more, the surface of the linear portion can be covered with a coating layer of appropriate thickness, thereby preventing peeling of the coating layer and more reliably preventing the reaction between the components forming the grid and the fired material.

[0057] Here, L is the length of the line segment that makes up the maximum horizontal length of the cross-section of the first linear section, and L can be adjusted as appropriate when forming the linear section. For example, L can be increased by increasing the nozzle diameter of the nozzle that dispenses the paste for forming the linear section.

[0058] On the other hand, the thickness of the coating layer C ０ As mentioned above, this can be adjusted by the average particle size of the raw material for the coating layer, as well as the movement speed of the spraying device and the distance between the spraying device and the filament layer when spraying the raw material for the coating layer onto the filament layer.

[0059] In one embodiment of the present invention, C relative to L ２ The proportion of C relative to L may be 0.02% or more. ２ The ratio may preferably be 0.04% to 15.2%, and more preferably 0.05% to 10.0%. In a further embodiment, C relative to L ２ The ratio of C to L may more preferably be 0.1% to 15.2%, and may be 0.2% to 10.0%. ２ If the proportion is 0.02% or more, the coating layer covering the lower part of the first ridge will have an appropriate thickness and can function as an anchor to prevent the peeling of the entire coating layer, thus suppressing the peeling of the coating layer.

[0060] C relative to L ２ The ratio is also determined by the length of the line segment that makes up the maximum length in the horizontal direction of the cross-section of the first linear section, L, and the thickness of the coating layer C. ２As determined by the above, this can be adjusted by appropriately changing the nozzle diameter of the nozzle that dispenses the paste for forming the fringe, the average particle size of the material that forms the coating layer, and the movement speed of the spraying device and the distance between the spraying device and the fringe layer when spraying the material that forms the coating layer onto the fringe layer.

[0061] Furthermore, in one aspect of the present invention, a grid body is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid body, the length of the line segment connecting the two ends where the cross-sections of the first and second linear layers contact in a cross-section perpendicular to the longitudinal direction of the first linear layer at the point where the centerlines of the first and second linear layers intersect is shorter than the maximum horizontal length of the cross-section of the first linear layer.

[0062] In other words, as shown in Figure 6, the length of the line segment Y-Y' connecting the two ends so that the cross-section of the first linear section 4 and the cross-section of the second linear section 5 are in contact is the line segment T which is the maximum horizontal length of the cross-section of the first linear section 4. Ｌ -T Ｌ It can be made shorter than the length of ' (i.e., length L). By making the grid body this shape, the lower part of the first linear portion 4 (Y-T Ｌ Between and Y'-T Ｌ The coating layer formed on the surface of the first linear portion 4 between the layers can function as an anchor to prevent the entire coating layer from peeling off, thus suppressing the peeling of the coating layer. The cross-sectional shape of the first linear portion is not particularly limited as long as it satisfies the above relationship of line segments, and the cross-sectional shape of the first linear portion may be substantially circular or substantially polygonal. From the viewpoint of ease of forming the linear portion and forming a continuous and uniform coating layer, it is preferable that the cross-sectional shape of the first linear portion be substantially circular.

[0063] In one embodiment of the present invention, C relative to L ３ The proportion of C relative to L may be 0.1% or more. ３The proportion may preferably be 0.5% to 40%, more preferably 1.0% to 40%, even more preferably 1.2% to 20%, and even more preferably 1.2% to 5.0%. ３ Point T on the second line section. ３ The thickness of the coating layer formed is C relative to L. ３ By having a ratio of 0.1% or more, it is possible to prevent the scattering of components from the surface of the second linear portion.

[0064] As mentioned above, the length L of the line segment that makes up the maximum length in the horizontal direction of the cross-section of the first linear portion can be adjusted by the nozzle diameter of the nozzle that dispenses the paste for forming the linear portion.

[0065] On the other hand, the thickness C of the coating layer on the second stripe section. ３ The thickness C of the coating layer on the first stripe is... ０ Similarly, this can be adjusted by appropriately changing the average particle size of the raw material for the coating layer, as well as the movement speed of the spraying device and the distance between the spraying device and the grid when spraying the raw material for the coating layer onto the grid.

[0066] In one embodiment of the present invention, C １ C ３ The percentage may be 10% or more. C １ C ３ The proportion may preferably be 15% or more and 105% or less, and more preferably 19% or more and 75% or less. １ C ３ A proportion of 10% or more indicates that a coating layer of appropriate thickness is formed not only in the first ridge section but also in the second ridge section, preventing the scattering of lattice components and peeling of the coating during firing.

[0067] C １ C ３ The proportion, C １ , and C ３ This can be adjusted by the average particle size of the raw material for the coating layer, and the movement speed of the spraying device, etc., when spraying the raw material for the coating layer onto the linear layer.

[0068] By increasing the average particle size of the material that forms the raw material for the coating layer, C １ and C ３ It becomes smaller. However, C ３ The first linear portion and the coating layer formed on the first linear portion form a point T on the second linear portion. ３ Because it is hidden, point T by spraying device, etc. ３ It is thought that the deposition of the raw material for the upper coating layer does not progress. Therefore, the contribution of the difference in average particle size to the thickness of the coating layer is C ３ Compared to C １ The latter is larger. Therefore, by increasing the average particle size of the material that forms the raw material of the coating layer, C １ C ３ The proportion can be increased.

[0069] By slowing down the movement speed of spraying equipment, etc., C １ and C ３ Although it becomes larger, the contribution of the difference in the movement speed to the thickness of the coat layer is C １ Compared to C ３ The latter is larger. Therefore, by slowing down the movement speed of the spraying device, etc., C １ C ３ The proportion can be increased.

[0070] Furthermore, by reducing the distance between the spraying device, etc. and the linear layer, C １ and C ３ Although it becomes larger, the contribution of the difference in distance to the thickness of the coat layer is C １ and C ３ The same applies to C. １ C ３ Regarding the proportion, the distance between the spraying device, etc., and the linear layer has a smaller contribution compared to the other ratios mentioned above.

[0071] Up to this point, regarding the various aspects of the present invention, we have described the ratio of the thickness of the coating layer based on each point and length in a cross section perpendicular to the longitudinal direction of the first linear portion at the point where the center line of the first linear portion and the center line of the second linear portion intersect in a plan view of the grid body, with the grid body placed on a horizontal plane such that the first linear portion layer is located on the second linear portion layer. However, it should be noted that these ratios are the same not only for the cross section but also for the entire linear portion.

[0072] In other words, in the lattice body of the present invention, when the lattice body is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and a cross-section perpendicular to the longitudinal direction of the first linear layer is observed at any point on the first linear layer, the thickness C of the coating layer on the first linear layer is usually ０ , C １ , and C ２ The thickness of the coating layer in the corresponding area satisfies the ratio described in the above embodiment.

[0073] Furthermore, in specifying each length, the grid body may be placed on a horizontal plane such that the first linear layer is located on the second linear layer, and the cross-section perpendicular to the longitudinal direction of the first linear layer may be observed at any multiple points where the centerlines of the first linear layer and the centerlines of the second linear layer intersect in a plan view of the grid body, the predetermined length at each cross-section may be measured, and the length may be specified as the average value of the measured lengths. When calculating the average value in this way, the arbitrary multiple points may be, for example, two, three, five, or ten points.

[0074] In one embodiment of the present invention, the first and second rib portions may be made of ceramics. A lattice body in which the first and second rib portions are made of ceramics can be obtained by using ceramic raw material powder as a raw material when manufacturing the first and second rib portions. Because the first and second rib portions are made of ceramics, it can be used appropriately even in firing processes that are exposed to high temperatures of 1200°C or higher.

[0075] The ceramic raw material powder in the first and second linear sections is not particularly limited and may contain various ceramic materials. Examples of ceramic materials used as ceramic raw material powder include alumina (Al ２ O ３ ), Zirconia (ZrO ２ ), magnesium oxide (MgO), mullite (3Al ２ O ３ -2SiO ２ ), silicon carbide (SiC), silicon nitride (Si ３ N ４ ), aluminum nitride (AlN), boron carbide (B ４ C), Cordierite (MgO / Al ２ O ３ / SiO ２ ), aluminum titanate (Al ２ TiO ５ ), magnesium titanate (MgTiO ３ ), Titanium Diboride (TiB ２ Examples include one or more combinations of these ceramic materials. Furthermore, a lattice body manufactured using raw material powders that are one or more combinations of these ceramic materials will naturally have a composition that can arise from these materials.

[0076] Furthermore, the first and second linear sections may be made of ceramics of the same composition, or they may be made of ceramics of different compositions. Also, if the lattice body consists of three or more linear sections, the composition of the linear sections other than the first and second linear sections is not particularly limited. It is preferable that the linear sections other than the first and second linear sections are made of ceramics.

[0077] In one embodiment of the present invention, the coating layer may be a lattice made of ceramics. Because the coating layer is made of ceramics, it can be used appropriately even in firing processes exposed to high temperatures of 1200°C or higher.

[0078] In this embodiment, the coating layer may contain one or two components selected from the group consisting of alumina, zirconia, yttria, silica, calcia, magnesia, strontia, mullite, and alumina-magnesia spinel composite oxide, calcium zirconate, and barium titanate. The coating layer is preferably zirconia (ZrO ２ ) may include.

[0079] In one embodiment of the present invention, a firing jig is provided that includes the above-described grid. Such a firing jig may include, in addition to the above-described grid, a base plate, a frame, and the like.

[0080] A method for manufacturing a lattice body according to the present invention is described below as an example. The method for manufacturing a lattice body includes (1) the step of forming an uncoated lattice body including a plurality of linear layers, and (2) the step of forming a coating layer on the uncoated lattice body to obtain a coated lattice body.

[0081] Furthermore, (1) the step of forming an uncoated lattice body including multiple linear layers includes (1-i) the step of creating a lattice-like precursor from a raw material paste containing ceramic raw material powder and a medium, which includes a first linear coating body with multiple linear stripes arranged at given intervals and each stripe extended in one direction, and a second linear coating body with multiple linear stripes arranged at given intervals so as to be in contact with and intersecting each stripe of the first linear coating body, each stripe extended in one direction, and (1-ii) the step of firing the lattice-like precursor. These steps may be simply abbreviated as the molding step and the firing step in the following description. Note that the first linear coating body and the second linear coating body in the description of the method for manufacturing the uncoated lattice body refer to the first coating body, second coating body, third coating body, etc., in the order of the coating bodies created in the molding step, and do not necessarily correspond to the first linear portion and second linear portion of the present invention.

[0082] (2) The step of forming a coating layer on an uncoated lattice to obtain a coated lattice includes (2-i) a step of spraying the raw material for the coating layer onto the surface of the uncoated lattice to form a coating layer precursor, and (2-ii) a step of firing the coating layer precursor as necessary. These steps may be abbreviated as the spraying step and the coating layer firing step in the following description.

[0083] (1) Step of forming an uncoated lattice body including multiple linear layers (1-i) Molding step The ceramic raw material powder constituting the raw material paste in the molding step is not particularly limited and may contain various ceramic materials. As described above regarding the linear portion of the lattice body, an example of a ceramic material used as ceramic raw material powder is alumina (Al ２ O ３ ), Zirconia (ZrO ２ ), magnesium oxide (MgO), mullite (3Al ２ O ３ -2SiO ２ ), silicon carbide (SiC), silicon nitride (Si ３ N ４ ), aluminum nitride (AlN), boron carbide (B ４ C), Cordierite (MgO / Al ２ O ３ / SiO ２ ), aluminum titanate (Al ２ TiO ５ ), magnesium titanate (MgTiO ３ ), Titanium Diboride (TiB ２ Examples include one or more combinations of the following. The mass ratio of ceramic raw material powder in the raw material paste is usually 20% by mass or more and 85% by mass or less, and preferably 30% by mass or more and 75% by mass or less, relative to the total mass of the paste.

[0084] The average particle size of the ceramic raw material powder used in the raw material paste is usually in the range of 0.1 to 20 μm, preferably in the range of 0.2 to 10 μm. Here, the average particle size of the ceramic raw material powder is the value of the volume cumulative median diameter (D50) obtained by laser diffraction and scattering method. By having the average particle size of the ceramic raw material powder within the above range, it becomes possible to obtain a lattice body with increased structural strength and stability after firing, and with a reduced possibility of collapse.

[0085] Water is typically used as the medium for the raw material paste used to create the molded article. Other media that can be used include alcohol, acetone, and ethyl acetate. Two or more of these media may be mixed. The mass percentage of the medium in the raw material paste is usually 10% to 60% by mass, and preferably 15% to 55% by mass, relative to the total mass of the paste.

[0086] The raw material paste for creating the molded body may optionally contain a sintering aid. Depending on the purpose, any known sintering aid may be used in an appropriate amount, or it may not be used at all.

[0087] The raw material paste may contain a binder. Examples of binders, though not particularly limited, include polyvinyl alcohol, polyethylene glycol, polyethylene, oxide, dextrin, sodium lignosulfonate and ammonium, carboxymethylcellulose, ethylcellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, hydroxyethyl methylcellulose, sodium alginate and ammonium, epoxy resins, phenolic resins, gum arabic, polyvinyl butyral, acrylic polymers such as polyacrylic acid and polyacrylamide, thickening polysaccharides such as xanthan gum and guar gum, gelling agents such as gelatin, agar and pectin, vinyl acetate resin emulsion, wax emulsion, and inorganic binders such as alumina sol and silica sol. Two or more of these may be used in mixture form. The mass percentage of the binder in the raw material paste may be, for example, 0% to 40% by mass, preferably 1% to 40% by mass, and more preferably 3% to 30% by mass, relative to the total mass of the raw material paste.

[0088] The viscosity of the raw material paste is preferably high at the temperature at which the filament coating is applied, as this allows for the successful manufacture of the filament coating. The viscosity of the raw material paste is not particularly limited, but it is preferably 1.5 MPa·s to 5.0 MPa·s at the temperature at which it is applied (typically room temperature such as about 25°C), and more preferably 1.7 MPa·s to 3.0 MPa·s. The viscosity of the raw material paste here refers to the measurement taken 4 minutes after the start of measurement using a cone-plate type rotary viscometer or rheometer at a rotation speed of 0.3 rpm.

[0089] The raw material paste may contain viscosity modifiers such as thickeners, flocculants, and thixotropic agents.

[0090] Examples of thickeners, though not limited to them, include polyethylene glycol fatty acid esters, alkylallyl sulfonic acid, alkylammonium salts, ethyl vinyl ether / maleic anhydride copolymer, fumed silica, and proteins such as albumin. In many cases, binders are classified as thickeners because they have a thickening effect, but if more precise viscosity adjustment is required, a separate thickener that is not classified as a binder can be used.

[0091] Examples of flocculants, though not particularly limited, include polyacrylamide, polyacrylic acid esters, aluminum sulfate, and polyaluminum chloride. Examples of thixotropic agents include fatty acid amides, oxidized polyolefins, and polyether ester-type surfactants.

[0092] To stabilize the discharge volume from the dispensing device, the raw material paste may contain, for example, plasticizers, lubricants, dispersants, sedimentation inhibitors, pH adjusters, etc.

[0093] Examples of plasticizers, though not particularly limited, include glycol-based plasticizers such as trimethylene glycol and tetramethylene glycol, glycerin, butanediol, phthalates, adipic acids, and phosphoric acids.

[0094] Examples of lubricants, though not limited to them, include hydrocarbons such as liquid paraffin, microwax, and synthetic paraffin, as well as higher fatty acids and fatty acid amides.

[0095] Examples of dispersants, though not particularly limited, include sodium polycarboxylate or ammonium salts, acrylic acid-based agents, polyethyleneimines, and phosphoric acid-based agents.

[0096] Examples of settling inhibitors, though not limited to them, include polyamide amine salts, bentonite, and aluminum stearate.

[0097] Examples of pH adjusters, though not limited to them, include sodium hydroxide, aqueous ammonia, oxalic acid, acetic acid, and hydrochloric acid.

[0098] The raw material paste obtained in this way is dispensed from the dispensing device onto a flat substrate to form a first striped coating body consisting of multiple strips, each strip arranged at a given interval and extended in one direction.

[0099] Various known devices such as small extruders and printing presses can be used as dispensing devices. These dispensing devices typically include a dispenser with a nozzle. After the first striped coating is dispensed, an operation can be performed to remove the medium contained in the first striped coating, dry it, and increase its viscosity. The medium can be removed by blowing hot air onto the first striped coating or by irradiating it with infrared light. The proportion of medium in the first striped coating after the medium removal operation may be reduced to preferably 50% by mass or less, more preferably to 30% by mass or less. By performing such a medium removal operation, the viscosity of the first striped coating becomes extremely high, and its shape retention is further enhanced.

[0100] Next, a raw material paste is used to form a second linear coating body, which consists of multiple stripes, each extended in one direction, arranged at a given interval so as to be in contact with and intersecting each strip of the first linear coating body. The raw material paste for forming the second linear coating body may be the same as or different from the raw material paste for forming the first linear coating body, but it is more preferable that they be the same from the viewpoint of efficiency in forming the linear coating body and the integrity of the structure and physical properties of the uncoated grid produced.

[0101] The specific shapes of the multiple-stripe first-stripe coated body and the multiple-stripe second-stripe coated body formed as a molded body can be constructed to conform to a desired shape of a sheet-like grid body including a first-stripe layer composed of multiple first-stripe sections and a second-stripe layer composed of multiple second-stripe sections according to the various embodiments described above.

[0102] In an additional embodiment, a raw material paste may be used to optionally form a third striped coating body consisting of multiple stripes, each extended in one direction, arranged at a given interval so as to be in contact with each stripe of the second striped coating body and intersecting the first and second striped coating bodies. The raw material paste for forming the optional third striped coating body may be the same as or different from the raw material paste for forming the first / second striped coating body, but it is more preferable that they be the same from the viewpoint of efficiency in striped coating body formation and the integrity of the structure and physical properties of the uncoated grid body produced.

[0103] (1-ii) Firing process The grid-like precursor, which includes the multiple first stripe coated bodies and the multiple second stripe coated bodies obtained in this way, is peeled off the substrate (workbench for forming the grid-like precursor) and placed in a firing jig (firing furnace), and then the grid-like precursor is fired to obtain an uncoated grid body. The obtained grid body includes (a) a stripe layer composed of multiple stripe portions (fired products of the multiple first stripe coated bodies) in which each stripe is extended in one direction and arranged at a given interval, and (b) a stripe layer composed of multiple stripe portions (fired products of the multiple second stripe coated bodies) in which each stripe is extended in one direction and arranged at a given interval so as to be in contact with and intersecting each stripe of the stripe portions. By firing, the uncoated grid body is constructed as an integral structure. Such construction of the uncoated grid body as an integral structure does not usually involve physical bonding of each member by adhesive.

[0104] In the firing process, a ceramic plate may be placed on the second striped coating body of the molded body containing the multiple first striped coating bodies and the multiple second striped coating bodies obtained as described above (or on the third striped coating body in the embodiment where a third striped coating body is formed on the second striped coating body). By placing the ceramic plate on the second striped coating body in this way, warping that occurs after firing can be suppressed.

[0105] The firing process may be carried out in an air atmosphere (at atmospheric pressure) or under pressure using an inert gas such as nitrogen, as necessary. The firing temperature should be selected appropriately according to the type of raw material powder used for the ceramic material. The same applies to the firing time. Non-limiting examples of firing temperatures include 500°C or higher, 800°C or higher, or 1000°C or higher, and 4000°C or lower, 3500°C or lower, or 3000°C or lower. Non-limiting examples of firing times include 30 minutes or more, 1 hour or more, or 2 hours or more, and 24 hours or less, 12 hours or less, or 6 hours or less.

[0106] In the firing process, a device commonly referred to as a "firing furnace" or "firing kiln" is used. When firing is mainly performed in an inert atmosphere, a jig more preferably called a "crucible" is used to prevent contamination within the device. A crucible usually consists of a storage body (forming the storage space for the objects to be fired) and a lid. In addition to the body and lid, the crucible may have accessories such as sealants. The outline of the storage space of the crucible is not particularly limited and can take various forms such as cubes, rectangular prisms, cylinders, and elliptical cylinders, but it is preferable that its inner bottom surface is substantially flat. The crucible may have an inlet for inert gas such as nitrogen. While not particularly limited, generally, materials such as mullite and zirconia are often fired in an atmospheric furnace (air furnace) because the firing takes place in an air atmosphere, while carbides and nitrides such as silicon nitride and silicon carbide are often fired in a crucible because the firing takes place in an inert atmosphere.

[0107] The components of a firing jig, including the surface exposed to the firing atmosphere, are not particularly limited, but may be formed from one or more of the various known ceramic raw materials. The housing body and furnace lid (lid) or furnace top of a firing jig, such as a crucible, and the surface exposed to the firing atmosphere, may be made of the same material or different materials.

[0108] (2) Steps to obtain a coated grid by forming a coating layer on an uncoated grid (2-i) Spraying step In the spraying step, a slurry is prepared by mixing ceramic raw material powder, which will be the raw material for the coating layer, with a medium, and by spraying it onto the uncoated grid formed in (1) above using a spraying device, a coating layer precursor can be formed on the surface of the uncoated grid. Alternatively, in the spraying step, the ceramic raw material can be directly sprayed onto the uncoated grid formed in (1) above using a thermal spraying device. The spraying of the slurry that will be the coating layer precursor onto the uncoated grid can be performed by moving the spraying device (thermal spraying device) at a predetermined moving speed. The distance between the tip of the spraying device (thermal spraying device) and the uncoated grid can also be set to a predetermined distance.

[0109] The ceramic raw material powder used as the raw material for the coating layer is not particularly limited and may contain various ceramic materials, similar to the ceramic raw material powder used when forming the lattice. Examples of ceramic materials that can be used as ceramic raw material powder include alumina (Al ２ O ３ ), Zirconia (ZrO ２ ), magnesium oxide (MgO), mullite (3Al ２ O ３ -2SiO ２ ), silicon carbide (SiC), silicon nitride (Si ３ N ４ ), aluminum nitride (AlN), boron carbide (B ４ C), Cordierite (MgO / Al ２ O ３ / SiO ２ ), aluminum titanate (Al ２ TiO ５ ), magnesium titanate (MgTiO ３ ), Titanium Diboride (TiB ２ Examples include one or more combinations of the following:

[0110] The average particle size of the ceramic raw material powder used as the raw material for the coating layer is usually in the range of 0.1 μm to 100 μm, preferably in the range of 1 μm to 30 μm, and more preferably in the range of 5 μm to 25 μm. The larger the average particle size of the ceramic raw material powder used as the raw material for the coating layer, the thicker the coating layer formed on the surface of the lattice (for example, point T of the lattice of the present invention). ０ Thickness C of the coating layer ０ ) also tends to increase. Note that the average particle size of the ceramic raw material powder here is the value of the volume cumulative median diameter (D50) obtained by laser diffraction and scattering method.

[0111] Water is typically used as the medium for the slurry to form the coat layer precursor. Other media that can be used include alcohol, acetone, and ethyl acetate. Two or more of these media may be mixed. The mass percentage of the medium in the slurry is usually 10% to 60% by mass, and preferably 15% to 55% by mass, relative to the mass of the slurry.

[0112] The slurry for forming the coat layer precursor may contain a binder. Examples of binders, though not particularly limited, include polyvinyl alcohol, polyethylene glycol, polyethylene, oxide, dextrin, sodium lignosulfonate and ammonium, carboxymethylcellulose, ethylcellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, hydroxyethyl methylcellulose, sodium alginate and ammonium, epoxy resins, phenolic resins, gum arabic, polyvinyl butyral, acrylic polymers such as polyacrylic acid and polyacrylamide, thickening polysaccharides such as xanthan gum and guar gum, gelling agents such as gelatin, agar and pectin, vinyl acetate resin emulsion, wax emulsion, and inorganic binders such as alumina sol and silica sol. Two or more of these may be used in mixture form. The mass percentage of the binder in the slurry may be, for example, 0% to 40% by mass, preferably 1% to 40% by mass, and more preferably 3% to 30% by mass, relative to the total mass of the raw material paste.

[0113] The slurry for forming the coat layer precursor may contain a dispersant. The dispersant is not particularly limited, but examples include one or more types of sodium polycarboxylate or ammonium salts, acrylic acid-based compounds, polyethyleneimines, and phosphate-based compounds. The optional components that the slurry may contain are not limited to binders and dispersants, but may include other known substances.

[0114] A slurry for forming a coating layer precursor can be obtained by mixing the above-mentioned ceramic raw material powder and medium, as well as optionally selected binders and dispersants, using a ball mill.

[0115] The movement speed of the spraying device is not particularly limited, but from the viewpoint of forming a precursor of a coating layer of appropriate thickness on the surface of the grid, it may be 300 mm / sec to 600 mm / sec. The slower the movement speed of the spraying device, the thinner the coating layer formed on the surface of the grid (for example, point T of the grid of the present invention). ０ Thickness C of the coating layer ０ The thickness tends to increase. It is preferable that the slurry is sprayed by the spraying device over the entire surface to be sprayed. Here, the moving speed of the spraying device is the relative speed between the spraying device and the target grid, and the spraying device itself may be moved, the grid may be moved, or both may be moved.

[0116] The distance between the tip of the spraying device (spray nozzle) and the grid is not particularly limited, but may be 100 mm to 200 mm. Generally, the shorter the distance between the tip of the spraying device and the grid (i.e., the closer the spraying device and the grid are), the thicker the coating layer (for example, point T of the grid of the present invention). ０ Thickness C of the coating layer ０ ) tends to become thicker.

[0117] When ceramic raw materials are sprayed directly onto a grid using a thermal spraying device, it is not necessary to form the slurry described above, and the ceramic raw material powder that will be used for the coating layer can be used as is. Furthermore, the movement speed of the thermal spraying device and the distance between the tip (nozzle) of the thermal spraying device and the grid are the same as when using the spraying device described above.

[0118] (2-ii) Coating layer firing process: When a coating layer precursor is formed using a slurry, a lattice body with a coating layer can be obtained by further firing the lattice body on which the coating layer precursor has been formed. Before firing, the lattice body on which the coating layer precursor has been formed can be dried in order to volatilize the medium contained in the coating layer precursor.

[0119] The drying may be carried out at a temperature of, for example, 50°C or higher, 75°C or higher, 100°C or higher, or 125°C or higher, and the drying time may be 30 minutes or more, 1 hour or more, 12 hours or more, or 24 hours or more.

[0120] The coating layer firing process may be carried out in an air atmosphere (at atmospheric pressure) or under pressure using an inert gas such as nitrogen, as necessary. The firing temperature should be selected appropriately according to the type of raw material powder used for the ceramic material. The same applies to the firing time. Non-limiting examples of firing temperatures include 500°C or higher, 800°C or higher, or 1000°C or higher, and 4000°C or lower, 3500°C or lower, or 3000°C or lower. Non-limiting examples of firing times include 30 minutes or more, 1 hour or more, or 2 hours or more, and 24 hours or less, 12 hours or less, or 6 hours or less.

[0121] The present invention will be described in more detail below with reference to examples. However, the present invention is not limited to the following examples.

[0122] Manufacturing of Lattice Structures (1) Preparation of Paste for Forming Linear Coatings 65.3 parts of 3 mol% yttria-added partially stabilized zirconia powder with an average particle size of 0.8 μm, 5.0 parts of hydroxypropyl methylcellulose (average degree of polymerization: 300,000 g / mol) as an aqueous binder, 2.5 parts of glycerin as a plasticizer, 1.1 parts of a polycarboxylic acid-based dispersant (molecular weight 12,000), and 26.1 parts of water were mixed and degassed to prepare a paste. The viscosity of the paste was 2.3 MPa·s at 25°C.

[0123] (2) Formation of the filamentous coating A first filamentous coating was formed on a resin substrate using the paste described above as a raw material and a dispenser equipped with a nozzle having the nozzle diameter shown in Table 1. Next, hot air was blown onto the first filamentous coating using a dryer to remove water and dry the first filamentous coating. After drying, the water content of the first filamentous coating was 10%. Subsequently, a second filamentous coating was formed intersecting the first filamentous coating. The intersection angle of the two filamentous coatings was set to 90°. Hot air was blown onto the second filamentous coating using a dryer to remove water and dry the second filamentous coating. After drying, the water content of the second filamentous coating was 8%. By repeating these operations, a lattice-like precursor was obtained, which is a filamentous coating consisting of a four-layer lattice structure in which two laminates of vertically intersecting first and second filamentous coatings are stacked so that their openings coincide.

[0124] (3) After drying in the firing process, the lattice-like precursor was peeled off from the resin substrate and placed in an atmospheric firing furnace. Degreasing and firing were carried out in this furnace to obtain a mesh-like zirconia sheet. The firing temperature was 1450°C and the firing time was 3 hours. In the obtained mesh-like zirconia sheet, the intersection angle between the first and second ridges was 90°. The size of the mesh-like zirconia sheet was 150 mm in length and 150 mm in width, with 4 layers and 215 first ridges.

[0125] (4-i) Preparation of slurry for coating layer formation A slurry for coating layer formation was obtained by mixing 90.7 parts of raw material powder having the average particle size listed in Table 1, 3.3 parts of water, 5.6 parts of polyvinyl alcohol as a binder, and 0.4 parts of a polycarboxylic acid-based dispersant as a dispersant in a ball mill for 3 hours.

[0126] (4-ii) Thermal spray raw materials for coating layer formation. Raw material powders having the average particle size listed in Table 1 were used as thermal spray raw materials.

[0127] (5) Forming the coating layer Using a spraying device or thermal spraying device, the slurry obtained in (4-i) or the zirconia powder described in (4-ii) was sprayed onto the mesh-like zirconia sheet obtained in (3). The movement speed of the spraying device or thermal spraying device and the distance between the spraying device or thermal spraying device and the mesh-like zirconia sheet were as shown in Table 1. When slurry was sprayed, the grid after slurry spraying was dried at 100°C for 3 hours using a constant-temperature dryer, and then fired in an atmospheric firing furnace at 1400°C for 5 hours.

[0128] Measurement of the coating layer thickness in cross-section The obtained grid was left to cool to room temperature. The grid was placed so that the surface with the coating layer was facing upwards. In the following explanation of the method for measuring the thickness of the coating layer, in this state, the uppermost linear layer will be referred to as the first linear layer, the linear layer directly below the first linear layer will be referred to as the second linear layer, the linear parts constituting the first linear layer will be referred to as the first linear parts, and the linear parts constituting the second linear layer will be referred to as the second linear parts. When the grid is observed from above, the grid was cut out using a cutting tool to obtain a cross-section perpendicular to the longitudinal direction of the first linear part at an arbitrary point where the center line of the first linear part and the center line of the second linear part constituting the second linear part intersect, thereby exposing the cross-section of the grid. After exposing the cross-section, the grid was immersed in resin to cover the cross-section with resin, and then the resin covering the cross-section was hardened to obtain a hardened resin sample in which the grid was embedded. Furthermore, the cured resin sample was polished using a polishing machine to expose the cross-section of the lattice, and the cross-section was polished to a mirror finish to obtain a sample for SEM observation. The SEM observation sample was observed using an SEM, and the thickness of each coating layer was measured.

[0129] Thermal Cycle Test The sheets of the obtained examples and comparative examples were subjected to a thermal cycle test as follows: (1) A sample sheet was placed in a firing furnace, and the furnace was heated at 3°C / min until the furnace temperature reached 1350°C. (2) The furnace temperature of 1350°C was maintained for 30 minutes. (3) After that, heating was stopped, and the furnace temperature was allowed to cool down to room temperature (30°C). Steps (1) to (3) above constituted one cycle, and this was repeated 150 times.

[0130] The peelability of the coating layer was evaluated before and after the thermal cycling test in the obtained examples and comparative examples as follows. Cloth tape (No. 1590) manufactured by Teraoka Seisakusho Co., Ltd. was cut to 100 mm x 50 mm. After uniformly attaching the cloth tape to the sample, the cloth tape was peeled off the sample. Using a digital microscope (Keyence, product name "VHX-5000"), the number of peeled pieces of the coating layer attached to the adhesive surface of the peeled cloth tape was counted. The number of peeled pieces was counted using a measuring tool in the digital microscope, and peeled pieces with a major axis of 0.1 mm or more were counted. Due to the specifications of the digital microscope and measuring tool, the adhesive surface of the cut cloth tape was divided into six sections, and each section was defined as one field of view. Peeled pieces were counted using the measuring tool in each of these fields of view (approximately 33 mm x 25 mm), and the total number of counts for the six fields of view was summed to determine the number of peeled pieces of the coating layer attached to the entire adhesive surface of the cloth tape.

[0131] The sample sheets were evaluated according to the following criteria based on the number of peeling fragments in the coating layer: Peeling evaluation criteria before thermal cycling test A: Number of peeling fragments is 0 to 10 B: Number of peeling fragments is 11 to 50 C: Number of peeling fragments is 51 or more Peeling evaluation criteria after thermal cycling test A: Number of peeling fragments is 0 to 50 B: Number of peeling fragments is 51 to 100 C: Number of peeling fragments is 101 or more

[0132] Table 1 shows the thickness of each coating layer, the nozzle diameter of the dispenser used to form the striped coating body, the average particle size of the raw material powder used to form the coating layer, the movement speed of the spraying or thermal spraying device, the distance between the spraying device (nozzle) or thermal spraying device (nozzle) and the grid body, and the number and evaluation of the peeled coating pieces before and after the thermal cycling test for each example and comparative example.

[0133] From Table 1, C １ C ２ When the proportion is 5% or more, it can be seen that the number of peeled-off pieces of the coating layer decreases both before and after the thermal cycling test.

[0134] According to the present invention, compared to conventional grid-shaped setters used for firing works, the coating layer is less likely to peel off from the linear portions. Furthermore, even when the firing process, which involves exposure to high temperatures of 1200°C or higher, is repeated multiple times, the coating layer remains less likely to peel off from the linear portions. Therefore, by preventing the coating layer from peeling off and exposing the surface of the grid, the scattering of components from the surface of the grid can be suppressed, thus preventing a decrease in the durability of the fired work. Such unexpected and remarkable effects are not only applicable to the firing of glass products, but also contribute to improving the manufacturing efficiency of ceramic electronic components, etc., where the durability of the fired work affects the yield of the final product.

[0135] 1: Lattice 2: Linear section 3: Linear section 4: First linear section 5: Second linear section

Claims

1. (a) A strip layer composed of a plurality of strips extending in one direction and arranged at a given interval, and (b) a strip layer composed of a plurality of strips extending in one direction and arranged at a given interval so as to contact and intersect each other on top of each strip of the strip portion, A sheet-like lattice body, When the lattice body is placed on a horizontal plane, the strip layer located at the top is defined as the first strip layer, and the strip layer immediately below the first strip layer is defined as the second strip layer. Each of the first strips constituting the first strip layer on at least one surface of the lattice body has a coat layer, The coat layer covers the first strip continuously from at least the top T ０ to point T ２ and covers the first strip continuously up to point T １ The ratio of C to C ２ is 5% or more. However, when the lattice body is placed on a horizontal plane such that the first strip layer is located above the second strip layer, and in a cross-section perpendicular to the longitudinal direction of the first strip at a point where the center line of the first strip and the center line of the second strip constituting the second strip intersect in a plan view of the lattice body, Using the straight line passing through the two end points where the cross-section of the first strip and the cross-section of the second strip contact as the reference line, Among the cross-sections of the first strip, the highest position in the vertical direction is defined as the top T ０ and the length of the perpendicular from the top T ０ to the reference line is defined as the height H of the first strip. On the cross-section of the first strip, the intersection point of the horizontal line at a height of 80% of the height H and the surface of the first strip is defined as point T １ and the intersection point of the horizontal line at a height of 20% of the height H and the surface of the first strip on the cross-section of the first strip is defined as point T ２ . When the midpoint of the perpendicular from the top T ０ to the reference line is defined as point M, The length of the coat layer on the straight line passing through point M and point T １ is defined as the thickness C １ of the coat layer at point T １ , and the length of the coat layer on the straight line passing through point M and point T ２ is defined as the thickness C ２ of the coat layer at point T ２ The lattice body.

2. C ０ C ２ The proportion is 0.01% or more, provided that point M and point T ０ The length of the coating layer along the straight line passing through point T is given by point T. ０ Thickness C of the coating layer ０ The lattice body according to claim 1.

3. C relative to L ０ The proportion is 2.0% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the first linear layer, the maximum horizontal length of the cross section of the first linear layer is L, and points M and T ０ The length of the coating layer along the straight line passing through point T is given by point T. ０ Thickness C of the coating layer ０ The lattice body according to claim 1.

4. C relative to L ２ The proportion is 0.02% or more, provided that the grid body is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a cross section perpendicular to the longitudinal direction of the first linear layer at the point where the center line of the first linear layer and the center line of the second linear layer intersect in a plan view of the grid body, the maximum horizontal length of the cross section of the first linear layer is L.

5. The grid body is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid body, the length of the line segment connecting the two points where the cross-section of the first linear layer and the cross-section of the second linear layer contact is shorter than the maximum horizontal length L of the cross-section of the first linear layer in a cross-section perpendicular to the longitudinal direction of the first linear layer at the point where the center line of the first linear layer and the center line of the second linear layer intersect is shorter than the maximum horizontal length L of the cross-section of the first linear layer.

6. C relative to L ３ The proportion is 0.1% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the first linear layer, the intersection point of the second linear layer with a straight line perpendicular to the horizontal plane passing through one endpoint that makes up the maximum horizontal length of the cross section of the first linear layer is point T. ３ Let point T ３ The vertical thickness of the coating layer in C ３ The lattice body according to claim 5.

7. C １ C ３ The proportion is 10% or more, provided that the grid is placed on a horizontal plane such that the first linear layer is located on the second linear layer, and in a plan view of the grid, at the point where the center line of the first linear layer and the center line of the second linear layer intersect, in a cross section perpendicular to the longitudinal direction of the second linear layer, the intersection point of the second linear layer with a straight line perpendicular to the horizontal plane passing through one endpoint that makes up the maximum horizontal length L of the cross section of the first linear layer is point T. ３ Let point T ３ The vertical thickness of the coating layer in C ３ The lattice body according to claim 5.

8. The lattice body according to claim 1, wherein the first linear portion and the second linear portion are made of ceramics.

9. The lattice body according to claim 1, wherein the coating layer is made of ceramics.

10. The lattice body according to claim 1, wherein the coating layer comprises one or two components selected from the group consisting of alumina, zirconia, yttria, silica, calcia, magnesia, strontia, mullite, and alumina-magnesia spinel composite oxide, calcium zirconate, and barium titanate.

11. A firing jig comprising a grid body according to any one of claims 1 to 10.

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