JP2019019053A - Ceramic lattice body - Google Patents

Abstract

To provide a ceramic lattice body having high strength and excellent in spalling resistance.SOLUTION: A ceramic lattice body 1 comprises a plurality of first rod parts 10 and a plurality of second rod parts 20. The first rod part 10 is of a cross section having a shape constituted of a straight line part 10A and a convex curve part 10B with its two end parts each constituting either end part of the straight line part 10A respectively, at any portion thereof other than the intersection parts 2. The second rod part 20 is of a cross section having a circular or elliptical shape at any portion thereof other than the intersection parts 2. The projection image in plane view of the second rod part 20 is of a curved shape outwardly swelling in the width direction at each of the intersection parts 2, and thereby the width of the projected image at each of the intersection parts 2 is made greater than that of the projection image at any portion thereof other than the intersection parts 2.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a ceramic lattice.

  When firing ceramic electronic parts or glass, firing is generally performed by placing an object to be fired on a setter called a shelf board or a floor board. In order to shorten the degreasing and firing time of the material to be fired and increase the number of products manufactured per unit time, it is necessary to rapidly heat and cool the firing process. When heated and / or rapidly cooled, defects such as cracks are likely to occur. Moreover, it becomes easy to produce defects, such as a crack, by repeated use. In addition, it has been pointed out that when a metal setter is used, it cannot be used in an oxidizing atmosphere, and when it is repeatedly used in a high temperature region of 1200 ° C. or more, it is greatly deformed.

  As a conventional technology related to ceramic setters, for example, a heat setter setter made of a perforated plate made of ceramics mainly composed of aluminum nitride and having a large number of holes penetrating the front and back is known (Patent Literature). 1). According to this document, by using aluminum nitride as ceramics, the maximum usable temperature is higher than that of oxide ceramics typified by alumina and magnesia, and the thermal conductivity is large. The resistance to heat shock is said to increase.

  Patent Document 2 describes a ceramic firing kiln tool plate that is provided with at least uneven shapes on the front surface side and back surface side on which the object to be fired is placed, and in which an opening is formed. According to this document, according to this kiln tool plate, the heat capacity can be reduced and the cost can be reduced, and the contact area with the fired product is reduced, so that the escape of gas is improved and the atmosphere is uniform. It describes that a to-be-fired body can be manufactured uniformly by conversion.

JP-A-6-207785 No. 2009/110400

  However, even when the techniques described in the above patent documents are used, it is easy to prevent the setter from cracking or the like to a satisfactory level when rapidly heating and cooling the object to be fired. Not.

  Therefore, the subject of this invention is providing the ceramic lattice body which can eliminate the various fault which the prior art mentioned above has.

The present invention includes a plurality of first filaments made of ceramics extending in one direction, and a plurality of second filaments made of ceramics extending in a direction intersecting with the first filaments. A ceramic lattice body having
The intersection of the first filament part and the second filament part has the second filament part arranged on the first filament part in any of the intersection parts,
The first striated portion has a shape in which a cross section thereof is configured by a straight portion and a convex curved portion having both ends of the straight portion as ends in a portion other than the intersecting portion. And
The second linear portion has a circular or oval shape in cross section in a portion other than the intersecting portion,
The projected image in the plan view of the second linear portion has a shape that is curved and bulged outward in the width direction at the intersecting portion, whereby the width of the projected image at the intersecting portion is reduced. Further, the present invention provides a ceramic lattice body that is larger than the width of the projected image at a portion other than the intersection.

  The ceramic lattice of the present invention has high strength and excellent spalling resistance.

Fig.1 (a) is a perspective view which shows one Embodiment of the ceramic lattice body of this invention, FIG.1 (b) is the perspective view which looked at the ceramic lattice body shown to Fig.1 (a) from the other side. is there. 2 is a cross-sectional view taken along line II-II in FIG. 3 is a cross-sectional view taken along line III-III in FIG. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 5 is a cross-sectional view taken along line VV in FIG. FIG. 6 is a projection view of the vicinity of the intersecting portion of the ceramic lattice body shown in FIG. 1 viewed from the second filament portion side. FIG. 7 is a projection view of the vicinity of the intersecting portion as seen from the first filament portion side in the ceramic lattice shown in FIG. FIG. 8 is a schematic diagram showing the shape of the through hole in the ceramic lattice shown in FIG. 9 (a) and 9 (b) are schematic views showing another embodiment of the ceramic lattice body of the present invention.

  The present invention will be described below based on preferred embodiments with reference to the drawings. 1 (a) and 1 (b) show an embodiment of the ceramic lattice body of the present invention. A ceramic lattice body (hereinafter also simply referred to as “lattice body”) 1 shown in these drawings has a plurality of first filament portions 10 made of ceramics extending in one direction X. Each 1st filament part 10 is carrying out the straight line, and is mutually extended in parallel. The ceramic lattice body 1 has a plurality of ceramic second linear portions 20 extending in the Y direction, which is a direction different from the X direction. Each of the second linear portions 20 is straight and extends in parallel with each other. Since the X direction and the Y direction are different directions, the first linear portion 10 and the second linear portion 20 intersect each other. The crossing angle between the two line sections 10 and 20 can be set according to the specific application of the ceramic lattice body 10. For example, the crossing angle of the second linear portion 20 with respect to the first linear portion 10 can be 90 degrees. Or the crossing angle of the 2nd filament part 20 with respect to the 1st filament part 10 can also be changed in the range of 90 degree +/- 10 degree. The grid body 1 is formed by the plurality of first linear portions 10 and the plurality of second linear portions 20 intersecting each other.

  The ceramic lattice body 1 forms a lattice when the first linear portion 10 and the second linear portion 20 intersect, and has a plate-like shape having a plurality of through holes 3 defined by the lattice. doing. The ceramic lattice body 1 has a first surface 1a and a second surface 1b opposite to the first surface 1a.

  The ceramic lattice body 1 has the intersection part 2 in the site | part where each 1st filament part 10 and each 2nd filament part 20 intersect. The intersecting portion 2 is a portion where the first linear portion 10 and the second linear portion 20 overlap in the projected image of the ceramic lattice 1 in plan view.

  The first linear portion 10 has a constant width W1 (see FIG. 2) in a plan view at a position other than the intersecting portion 2 between the two linear portions 10 and 20. As shown in FIGS. 2 and 3, the first linear portion 10 has a cross-sectional shape along the thickness direction in a direction orthogonal to the longitudinal direction, and is located on the first surface 1 a side of the ceramic lattice body 1. The first surface 10a and the second surface 10b located on the second surface 1b side of the ceramic lattice body 1 are defined. Specifically, the first linear portion 10 has a straight portion 10A and both end portions of the straight portion 10A in a portion other than the intersecting portion 2 in a cross section along the thickness direction in a direction orthogonal to the longitudinal direction. And a curved portion 10B having a convex shape with the end portion as the end portion. As a result, the first surface 10 a of the first linear portion 10 has a flat cross section in the thickness direction of the linear portion 10. The flat surface is substantially parallel to the in-plane direction of the ceramic lattice body 1. On the other hand, the second surface 10b of the first linear portion 10 has a convex curved surface shape in which the cross section in the thickness direction of the linear portion 10 is directed from the first surface 1a to the second surface 1b of the ceramic lattice body 1. I am doing.

  Similar to the first filament part 10, the second filament part 20 also has a certain width W2 (see FIG. 5) in plan view at a position other than the intersecting part 2 of the two filament parts 10, 20. Have. The width W2 may be the same as or different from the width W1 of the first linear portion 10. As shown in FIGS. 4 and 5, the second linear portion 20 has a cross-sectional shape along the thickness direction in a direction orthogonal to the longitudinal direction thereof, which is located on the first surface 1 a side of the ceramic lattice body 1. The first surface 20a and the second surface 20b located on the second surface 1b side of the ceramic lattice 1 are defined. The first surface 20a of the second linear portion 20 has a convex curved shape from the second surface 1b of the ceramic lattice body 1 toward the first surface 1a. On the other hand, the second surface 20b of the second linear portion 20 has a convex curved surface shape in which the cross section in the thickness direction of the linear portion 20 is directed from the first surface 1a to the second surface 1b of the ceramic lattice 1. I am doing. The curved surface shape may be the same as or different from the curved surface shape in the first linear portion 10. In the present embodiment, the first surface 20a and the second surface 20b of the second linear portion 20 are symmetrical, and as a result, the second linear portion 20 is orthogonal to the longitudinal direction. The cross-sectional shape along the thickness direction in the direction is circular or elliptical.

  As shown in FIGS. 3 and 4, when the linear portion 10 </ b> A in the first linear portion 10, i.e., the first surface 10 a is placed on the plane P as a placement surface, all the first surfaces 10 a are all on the plane P. Located in. Since the first surface 10a forms the first surface 1a of the ceramic lattice body 1, the fact that each of the first surfaces 10a is all on the plane P means that the first surface 1a of the lattice body 1 is a flat surface. Means that Therefore, when the ceramic lattice body 1 is placed such that the first surface 1a is in contact with the flat placement surface, the entire area of the first surface 1a is in contact with the placement surface.

  As shown in FIG. 3, when the linear portion 10 </ b> A in the first linear portion 10, i.e., the first surface 10 a is placed on the plane P as the placement surface, the second linear portion 20 includes two adjacent linear portions 20. The crossing portions 2 are separated from the plane P. Therefore, a space S is formed between the second linear portion 20 and the plane P between two adjacent intersecting portions 2.

  On the other hand, since the 2nd surface 1b in the ceramic lattice body 1 is comprised from the 2nd surface 20b of the 2nd linear part 20 which is a convex curved surface shape, it becomes an uneven surface instead of a flat surface. Yes.

  In the intersecting portion 2 between the first linear portion 10 and the second linear portion 20 in the ceramic lattice body 1, both the linear portions 10 and 20 are integrated. “Integrated” means that, when the cross section of the intersecting portion 2 is observed, the space between the two linear portions 10 and 20 is a continuous structure as ceramics. The through-holes 3 formed in the ceramic lattice 1 by the intersection of both the line portions 10 and 20 have the same dimensions and the same shape. Each through-hole 3 has a substantially rectangular shape. The through holes 3 are regularly arranged.

  As shown in FIG. 1, FIG. 3, and FIG. 4, the intersection 2 between the first filament 10 and the second filament 20 is on the first filament 10 in any intersection 2. The 2nd filament part 20 is distribute | arranged to. That is, at the intersection 2 between the first linear portion 10 and the second linear portion 20, the first surface side 1a of the two surfaces 1a, 1b of the lattice 1 is relatively positioned. On the 1 line part 10, the 2nd line part 20 located relatively on the 2nd surface 1b side is distribute | arranged. And the thickness in the intersection part 2 is larger than any of the thickness of the 1st filament part in the site | parts other than this intersection part, and the thickness of the 2nd filament part. That is, the thickness of the first filament 10 at a position other than the intersection 2 of the two filaments 10 and 20 is T1 (see FIG. 2), and the position of the both filaments 10 and 20 at a position other than the intersection 2. When the thickness of the second linear portion 20 is T2 (see FIG. 5) and the thickness at the intersecting portion is Tc (see FIGS. 3 and 4), Tc> T1 and Tc> T2. Therefore, on the second surface 1 b of the ceramic lattice body 1, the position of the intersecting portion between the two filament portions 10 and 20 is the highest.

  As shown in FIG. 4, the first line portion 10 has the highest position of the second surface 10 b in the first line portion 10, that is, the position of the top portion in the portion other than the intersecting portion 2. It is the same along the direction in which the strip 10 extends. With respect to the second striated portion 20, as shown in FIG. 3, the highest position of the second surface 20b in the second striated portion 20 is the position of the intersecting portion 2 and the position other than the intersecting portion 2, They are in the same position along the direction in which the first linear portion 10 extends. The lowest position of the first surface 20 a in the second linear portion 20 is the same position along the direction in which the second linear portion 20 extends in a portion other than the intersecting portion 2.

  As shown in FIG. 1A and FIG. 6, the second linear portion 20 has a shape in which the projected image in plan view is curved and bulged outward in the width direction X at the intersecting portion 2. It has become. As a result, the width W2a of the projected image at the intersection 2 is larger than the width W2b of the projection image at a portion other than the intersection 2. More specifically, the second linear portion 20 has curved contours 21, 21 whose contours along the longitudinal direction of the projected image in plan view are gently convex outward in the width direction X at the intersection 2. I'm drawing. The contour along the longitudinal direction of the projected image in plan view of the second linear portion 20 has a maximum width portion having a width W2a, and the width gradually decreases gradually as the distance from the maximum width portion increases. The width is W2b at the position between the intersections 2. The width W2b is the same as the width W2 described above.

  On the other hand, as shown in FIGS. 1B and 7, the projected image in the plan view of the first linear portion 10 bulges outward in the width direction Y at the intersecting portion 2. It has a shape. Thereby, the width W1a of the projection image at the intersection 2 is larger than the width W1b of the projection image at a portion other than the intersection 2. More specifically, the first linear portion 10 has gently convex curves 11 and 11 whose contours along the longitudinal direction of the projected image in plan view are gradually outward in the width direction Y at the intersection 2. I'm drawing. The outline along the longitudinal direction of the projected image of the first linear portion 10 in plan view has a maximum width portion having a width W1a, and the width gradually decreases gradually as the distance from the maximum width portion increases. The width is W1b at the position between the intersections 2. The width W1b is the same as the width W1 described above.

  FIG. 8 shows a plan view of the ceramic lattice body 1. As shown in the figure, the grid body 1 has a plurality of first line sections 10 and a plurality of second line sections 20 substantially orthogonal to each other, so that the grid body has a substantially rectangular shape in plan view. A plurality of through holes 3 are formed. The substantially rectangular through-hole 3 has first sides 3a and 3a that are a pair of opposing sides. At the same time, the through-hole 3 has second sides 3b and 3b which are another set of sides facing each other. The first sides 3 a and 3 a are sides corresponding to both side edges of the first linear portion 10. On the other hand, the second sides 3 b and 3 b are sides corresponding to both side edges of the second linear portion 20. The through hole 3 is defined by these four sides. The opposing first sides 3a, 3a are straight and extend parallel to each other. Similarly, the opposing second sides 3b, 3b are straight and extend parallel to each other. And when the 1st filament part 10 and the 2nd filament part 20 have the curve bulging shape mentioned above in those crossing parts 2, the 1st filament part 10 and the 2nd filament part The through-hole 3 formed by being substantially orthogonal to 20 has a corner portion 30 that is not a rectangle with a right angle, but a corner portion 30 that is slightly rounded as shown in the schematic diagram of FIG.

  When the ceramic lattice body 1 having the above configuration is used as, for example, a setter for firing a body to be fired, the corner 30 of the rectangular through hole 3 is rounded, resulting in strength and strength. Improved spalling resistance. This is because the portion of the ceramic lattice 1 where defects such as cracks are most likely to occur is the corner 30 of the through-hole 3, and the corner 30 is rounded. This is because cracks and the like are hardly generated in the corner 30. In contrast to this, for example, in the kiln tool plate having the opening described in Patent Document 2 described above, the corners of the opening are at right angles, so that cracks and the like are likely to occur.

  The above-described improvement in strength and spalling resistance is obtained by projecting at least the second linear portion 20 in a plan view at the intersection 2 between the first linear portion 10 and the second linear portion 20. If the above-mentioned convex curve 21 is included in the contour along the longitudinal direction, the above-mentioned is achieved sufficiently. In particular, when both the first linear portion 10 and the second linear portion 20 have the convex curves 11 and 21 on the contour along the longitudinal direction of the projected image in plan view, Strength and spalling resistance are further improved.

  When the ceramic lattice body 1 having the above configuration is used as, for example, a setter for firing a body to be fired, the first surface is formed by placing the body to be fired on the first surface 1a of the lattice body 1. Since 1a is a flat surface, it becomes suitable for mounting the to-be-fired body for which flatness is required. As a to-be-fired body from which flatness is calculated | required, small chip-shaped electronic components, such as a multilayer ceramic capacitor, etc. are mentioned, for example. Since these small electronic components are required not to be caught by the setter in the firing process, it is advantageous that the first surface 1a of the lattice body 1 is flat. Moreover, since the to-be-fired body contacts only the 1st filament part 10 which is the member which comprises the 1st surface 1a, the contact area of the grid | lattice body 1 and a to-be-fired body reduces significantly, and, thereby, to-be-fired It becomes easy to perform rapid heating and cooling of the body. Further, since the lattice body 1 is formed by the intersection of the first and second linear portions 10 and 20 and the plurality of through holes 3 are formed, the heat capacity is small. Easy heating and cooling. Furthermore, since the lattice body 1 has good air permeability due to the presence of the plurality of through holes 3, this also facilitates rapid cooling of the fired body. Good air permeability becomes more remarkable by the fact that the second linear portion 20 floats between the adjacent intersecting portions 2. Moreover, in the lattice body 1, the first and second linear portions 10 and 20 are integrated at the intersecting portion 2, so that the lattice body 1 has sufficient strength.

  On the other hand, it is advantageous to place an object to be fired in the order of mm on the second surface 1b of the lattice body 1. The second surface 1b is an uneven surface caused by the curved surface of the second linear portion 20, and the electronic component of this order size has an uneven surface on which it is placed. This is because it is advantageous from the viewpoint of enhancing the performance.

  As described above, the lattice body 1 of the present embodiment has one surface that is flat and the other surface is an uneven surface, so that the mounting surface can be properly used according to the type of the body to be fired. This is advantageous.

  From the viewpoint of making the various advantageous effects described above more remarkable, the value of T1 is preferably 50 μm or more and 5 mm or less, and more preferably 200 μm or more and 2 mm or less. On the other hand, the value of T2 is preferably 50 μm or more and 5 mm or less, and more preferably 200 μm or more and 2 mm or less. The magnitude relationship between the values of T1 and T2 is not particularly limited, and may be T1> T2, conversely, T1 <T2, or T1 = T2.

  From the same viewpoint, the thickness Tc at the intersection 2 is preferably 0.1 mm or more and 2 mm or less, and more preferably 0.3 mm or more and 1.5 mm or less. Note that the thickness Tc at the intersection 2 is smaller than T1 + T2, which is the sum of T1 and T2.

  Moreover, when the cross-sectional shape (refer FIG. 5) in the thickness direction of the 2nd filament part 20 is an ellipse, an elliptical short axis corresponds to the thickness direction of the grid | lattice body 1, and an elliptical long axis Is preferably coincident with the planar direction of the lattice body 1 from the viewpoint of successfully placing the object to be fired. In this case, the ratio of the major axis / minor axis is preferably 1 or more and 5 or less, and more preferably 1 or more and 3 or less. In addition, the fact that the cross-sectional shape in the thickness direction of the second linear portion 20 is an ellipse or a circle contributes to an improvement in the strength of the lattice 1.

The through hole 3 formed in the ceramic lattice body 1 has an area of 100 μm ² or more and 100 mm ² or less, particularly 2500 μm ² or more and 1 mm ² or less, which reduces the heat capacity of the lattice body 1 and improves air permeability. This is preferable from the viewpoint of maintaining the strength of the grid body 1. The ratio of the total area of the through holes 3 to the apparent area of the ceramic lattice body 1 in plan view (this value) is preferably 1% to 80%, and preferably 3% to 70%. More preferably, it is 10% or more and 70% or less. This ratio is obtained by cutting the ceramic lattice body 1 into a rectangular shape in plan view, calculating the sum of the areas of the through holes 3 included in the rectangle, and dividing the sum by the rectangular area. Calculated by multiplying by Moreover, the area of each through-hole 3 can be measured by image analysis of the microscope observation image of the lattice 1.

  In relation to the area of the through-hole 3, the width W1 of the first linear portion 10 is preferably 50 μm or more and 10 mm or less, and more preferably 75 μm or more and 1 mm or less. On the other hand, the width W2 of the second linear portion 20 is preferably 50 μm or more and 10 mm or less, and more preferably 75 μm or more and 1 mm or less. There is no particular limitation on the magnitude relationship between the values of W1 and W2, W1> W2 may be satisfied, W1 <W2 may be conversely, or W1 = W2.

  In relation to the widths W1 and W2 of the first and second linear portions 10 and 20, the pitch P1 between the adjacent first linear portions 10 is preferably 100 μm or more and 10 mm or less, and 150 μm or more and 5 mm. More preferably, it is as follows. On the other hand, the pitch P2 between the adjacent second linear portions 20 is preferably 100 μm or more and 10 mm or less, and more preferably 150 μm or more and 5 mm or less.

  As for the 1st filament part 10, it is preferable that the 1st surface 10a is smooth among the surfaces. Since the first surface 10a of the linear portion 10 is smooth, there is an advantage that when the object to be fired is placed on the ceramic lattice body 1, the object to be fired is hardly damaged. In addition, there is an advantage that the fired body obtained by firing the body to be fired is not easily caught by the ceramic lattice body 1 and the take-out property is improved. Furthermore, if the body to be fired is a thin tape molded body such as a substrate, the surface state of the first surface 10a is transferred to the bottom surface of the body to be fired, so that the bottom surface of the body to be fired can be finished more smoothly. is there. On the other hand, when the surface roughness is large, there is an advantage that the degreasing easily proceeds smoothly because the gas flow under the fired body is improved when the fired body is placed. From these viewpoints, the surface roughness Ra of the first surface 10a of the first filament portion 10 is preferably 0.01 μm or more and 20 μm or less, and more preferably 0.01 μm or more and 10 μm or less. On the other hand, the surface roughness Ra of the second surface 20b of the second linear portion 10 is preferably 10 μm or more and 300 μm or less, and more preferably 20 μm or more and 100 μm or less. Specifically, the surface roughness Ra is measured by the following method. Using a color 3D laser microscope (manufactured by Keyence Co., Ltd., VK-8710), the measurement magnification was 200 times. For the first surface 10a of the first filament 10, the surface roughness was measured along the middle line of the first surface 10a, and an average value was calculated from the 20 measured values, which was Ra. On the other hand, on the second surface 20b of the second striated portion 20, the surface roughness was measured along the middle line of the striated portion 10b, and an average value was calculated from the 20 measured values to be Ra.

  In order to reduce the value of the surface roughness Ra of the linear portions 10a and 20a, for example, a substrate having a small surface roughness is used as a substrate on which the paste used for forming the linear portions is applied, or the paste A low-viscosity material may be used. On the other hand, in order to increase the value of the surface roughness Ra of the linear portions 10b and 20b, for example, a high-viscosity paste may be used, or the nozzle diameter to be discharged may be increased. In some cases, the first surface 1a and / or the second surface 1b of the ceramic lattice body 1 may be polished and processed to have a predetermined surface roughness.

  Various materials can be used as the ceramic material constituting the ceramic lattice body 1. Examples thereof include alumina, silicon carbide, silicon nitride, zirconia, mullite, zircon, cordierite, aluminum titanate, magnesium titanate, magnesia, titanium diboride, boron nitride and the like. These ceramic materials can be used singly or in combination of two or more. In particular, it is preferably made of a ceramic containing alumina, mullite, cordierite, zirconia or silicon carbide. In the case of using ceramics containing zirconia, zirconia that is completely stabilized by addition of yttria can be used in order to make the lattice body 1 more suitable for use in high-temperature firing. When the ceramic lattice body 1 is subjected to rapid heating and cooling, it is particularly preferable to use silicon carbide as the ceramic material. In addition, since silicon carbide has a concern about a reaction with a to-be-fired body, when using silicon carbide as a ceramic material, it is preferable to coat the surface with a low-reactivity ceramic material such as zirconia. As the raw material powder of the ceramic material constituting the lattice body 1, it is preferable to use a powder having a particle diameter of 0.1 μm or more and 200 μm or less in consideration of viscosity and ease of sintering when the paste is made. The ceramic material constituting the first filament part 10 and the ceramic material constituting the second filament part 20 may be the same or different. From the viewpoint of increasing the integrity of the first and second linear portions 10 and 20 at the intersecting portion 2, it is preferable that the ceramic materials constituting both the linear portions 10 and 20 are the same.

  Next, the suitable manufacturing method of the ceramic lattice body 1 of this embodiment is demonstrated. In this manufacturing method, first, raw material powder of a ceramic material is prepared, and the raw material powder is mixed with a medium such as water and a binder to prepare a paste for manufacturing a filament portion.

  As the binder, those similar to those conventionally used for this type of paste can be used. Examples include polyvinyl alcohol, polyethylene glycol, polyethylene oxide, dextrin, sodium lignin sulfonate and ammonium, carboxymethylcellulose, ethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, hydroxyethylcellulose, hydroxyethylmethylcellulose, sodium and ammonium alginate, epoxy resin, phenol 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 Etc., and the like. Two or more of these may be mixed and used.

  The viscosity of the paste is preferably high at the temperature at the time of application from the viewpoint that the lattice body 1 having the structure of this embodiment can be successfully manufactured. Specifically, the viscosity of the paste is preferably 1.5 MPa · s or more and 5.0 MPa · s or less, preferably 1.7 MPa · s or more and 3.0 MPa · s or less, at the temperature at the time of application. preferable. As the viscosity of the paste, a measured value at 4 minutes after the start of measurement was used at a rotation speed of 0.3 pm using a cone plate type rotary viscometer or a rheometer.

  A paste having a relatively low viscosity can also be used. In the case of using a low-viscosity paste, after producing the lattice precursor described later, before subjecting the lattice precursor to the firing step, the lattice precursor is dried to remove the liquid component, It is preferable to perform firing after increasing the shape retention of the lattice precursor. When using a paste having a relatively low viscosity, the viscosity is preferably 10 kPa · s or more and 1.5 MPa · s or less, and 0.5 MPa · s or more and 1.3 MPa · s or less at the temperature during application. More preferably.

  Whether the paste has a high viscosity or a relatively low viscosity, the ratio of the raw material powder of the ceramic material in the paste is 20% by mass or more and 85% by mass or less. It is preferably 35% by mass or more and 75% by mass or less. The ratio of the medium in the paste is preferably 15% by mass to 60% by mass, and more preferably 20% by mass to 55% by mass. The proportion of the binder in the paste is preferably 1% by mass or more and 40% by mass or less, and more preferably 5% by mass or more and 25% by mass or less.

  The paste may contain a thickener, a flocculant, a thixotropic agent, etc. as a viscosity modifier. Examples of the thickener include polyethylene glycol fatty acid ester, alkylallyl sulfonic acid, alkyl ammonium salt, ethyl vinyl ether / maleic anhydride copolymer, fumed silica, albumin and other proteins. In many cases, the binder may be classified as a thickener because it has a thickening effect. However, if more precise viscosity adjustment is required, a thickener that is not classified separately as a binder. An agent can be used. Examples of the flocculant include polyacrylamide, polyacrylic acid ester, aluminum sulfate, and polyaluminum chloride. Examples of thixotropic agents include fatty acid amides, oxidized polyolefins, polyether ester type surfactants, and the like. As a solvent for preparing the paste, in addition to water, alcohol, acetone, ethyl acetate, and the like are used, and two or more of these may be mixed. In order to stabilize the discharge amount, a plasticizer, a lubricant, a dispersant, a sedimentation inhibitor, a pH adjuster, or the like may be added. Examples of the plasticizer include glycols such as trimethylene glycol and tetramethylene glycol, glycerin, butanediol, phthalic acid, adipic acid, and phosphoric acid. Examples of the lubricant include hydrocarbons such as liquid paraffin, micro wax, and synthetic paraffin, higher fatty acids, fatty acid amides, and the like. Examples of the dispersant include sodium polycarboxylate or ammonium salt, acrylic acid type, polyethyleneimine, and phosphoric acid type. Examples of the precipitation inhibitor include polyamide amine salts, bentonite, and aluminum stearate. Examples of the pH adjusting agent include sodium hydroxide, aqueous ammonia, oxalic acid, acetic acid, hydrochloric acid and the like.

  Using the obtained paste, a plurality of linear first coated bodies are formed in parallel and linearly on a flat substrate. The filament first coating body corresponds to the first filament portion 10 in the target lattice body 1. Various coating apparatuses can be used for forming the first filament coated body. For example, a dispenser can be used. When the paste has a relatively low viscosity, the screw type is preferable from the viewpoint of discharge accuracy, and when the paste is relatively high, the uniaxial eccentric screw pump type is preferable from the viewpoint of discharge stability. The diameter of the nozzle in the dispenser can be, for example, 0.2 mm or more and 5.0 mm or less.

  When the filament first coated body is formed, a plurality of filament second coated bodies are then formed in parallel and in a straight line so as to intersect the filament first coated body. The filament second coated body corresponds to the second filament portion 20 in the target lattice body 1. For the formation of the second filament coated body, a coating device similar to the first filament coated body can be used. Thus, the grid body 1 in which the 2nd filament part 20 is located on the 1st filament part 10 is succeeded by forming a filament 1st coating body and a filament 2nd coating body sequentially. Well obtained. In this case, by using a high-viscosity paste, the filament second coated body is appropriately applied to the filament first coating at the intersection of the filament first coated body and the filament second coated body. It sinks into the work body, whereby the side edges of these coated bodies bulge out toward the outside in the width direction. Further, between the adjacent intersections, the second filament coated body is in a bridging state (that is, in a floating state).

  In this way, a lattice-shaped precursor formed by two types of linear coated bodies is obtained. When the viscosity of the paste used for producing the lattice precursor is relatively low, it is preferable to dry the lattice precursor to develop shape retention. Thereby, the second coated body of the filaments is prevented from excessively sinking into the first coated body of the filaments, and the side edges of these coated bodies are appropriately curved and expanded toward the outside in the width direction. Put out. Moreover, it is prevented that a filament 2nd coating body bends downward with dead weight between adjacent intersections, and the bridging state of a filament 2nd coating body is maintained. Drying is performed, for example, by heating the lattice precursor at a temperature of 40 ° C. or higher and 80 ° C. or lower in the atmosphere. The heating time can be, for example, 0.5 hours or more and 12 hours or less. When the viscosity of the paste is high, it is often unnecessary to dry the lattice precursor, and in that case, the lattice precursor can be directly subjected to the firing step described below.

  The dried lattice-like precursor is peeled off from the substrate and placed in a firing furnace to be fired. The target ceramic lattice 1 is obtained by this firing. Baking can generally be performed in air. The firing temperature may be selected appropriately depending on the type of raw material powder of the ceramic material. The same applies to the firing time.

  The target ceramic lattice 1 is obtained by the above method. This ceramic lattice body 1 can be suitably used as a setter for degreasing or firing ceramic products such as shelf boards and floorboards, and can also be used as a kiln tool other than a setter, such as a firewood or beam. Furthermore, it can also be used as various jigs and various structural materials such as filters and catalyst carriers other than kiln tools. In this case, although it is common to place a to-be-fired body on the 2nd surface 1b which is an uneven surface in the lattice body 1, depending on the kind of to-be-fired body, on the 1st surface 1a which is a flat surface You may mount a to-be-fired body. For example, when performing a firing step in the manufacturing process of the multilayer ceramic capacitor (MLCC), it is preferable to place the body to be fired on the first surface 1a which is a flat surface.

  As mentioned above, although this invention was demonstrated based on the preferable embodiment, this invention is not restrict | limited to the said embodiment. For example, in the ceramic lattice body 1 of the above embodiment, the first linear portion 10 and the second linear portion 20 intersect so as to be substantially orthogonal, but the intersecting angle of both the linear portions 10, 20 is It is not limited to 90 degrees.

  Moreover, although the ceramic lattice body 1 of the said embodiment used two types of linear parts, the 1st linear part 10 and the 2nd linear part 20, in addition to this, a 3rd linear part ( You may use 3 or more types of filament parts, such as a 4th, 5th filament part (not shown), and also the 4th, 5th filament part (not shown). In the case of using three or more types of linear portions, the linear portions subsequent to the third linear portion are the first and second linear portions as described above with respect to the thickness T1, the width W1, and the pitch P1, respectively. It is desirable to have the same configuration as Also, the configuration of the intersection formed by the linear portions after the third linear portion may have the same configuration as the intersection formed by the first and second linear portions as described above. desirable.

  Further, the ceramic lattice body 1 of the above embodiment has a single-layer structure, but instead of this, a plurality of the lattice bodies 1 are used, for example, as shown in FIGS. 9 (a) and 9 (b). Multiple layers may be used. In the embodiment shown in FIG. 9 (a), a first lattice body 1 ′ composed of a first linear portion 10 ′ and a second linear portion 20 ′, a first linear portion 10 ″ and a second linear portion 10 ′. Are laminated to form a lattice body 1. The first linear portion 10 'in the first lattice body 1' and the second lattice body 1 are laminated. Are arranged so as to have the same pitch. Similarly, the second linear portion 20 ′ in the first grid 1 ′ and the second grid 1 ” It arrange | positions so that it may become the same pitch also as 2nd filament part 20 ".

  On the other hand, in the embodiment shown in FIG. 9A, the first filament 10 ′ in the first grid 1 ′ and the first filament 10 ″ in the second grid 1 ″ are half pitch. It is arranged so as to be displaced. Similarly, the second filament 20 'in the first grid 1' and the second filament 20 "in the second grid 1" are arranged so as to be shifted by a half pitch.

  Further, for the purpose of improving the strength of the ceramic lattice body 1 of the embodiment, an outer frame may be provided on the outer periphery of the lattice body 1. The outer frame may be integrally formed from the same material as that of the grid body 1 or may be manufactured separately from the grid body 1 and bonded by a predetermined bonding means. In addition, for the purpose of improving the spalling resistance, a slit is made inward in the width direction in a part of the side along the longitudinal direction of the first linear portion 10 and / or the second linear portion 20. May be.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such examples. Unless otherwise specified, “part” means “part by mass”.

[Example 1]
(1) Preparation of a paste for forming a linear coated body 65.3 parts of 8 mol% yttria-added fully stabilized zirconia powder having an average particle diameter of 0.8 μm, and hydroxypropyl methylcellulose (average polymerization degree: 30) as an aqueous binder 10 g / mol) 5.0 parts, 2.5 parts of glycerin as a plasticizer, 1.1 parts of a polycarboxylic acid-based dispersant (molecular weight 12000) and 26.1 parts of water are mixed and defoamed. A paste was prepared. The viscosity of the paste was 2.3 MPa · s at 25 ° C.
(2) Formation of a linear coated body Using the above paste as a raw material, a linear first coated body is formed on a resin substrate using a dispenser having a nozzle having a diameter of 0.4 mm, and then the linear strip intersects with it. A second coated body was formed. The crossing angle between the two filament coated bodies was 90 degrees. Thus, a lattice precursor was obtained.
(3) Firing step After the dried lattice precursor was peeled from the resin substrate, it was placed in an atmospheric firing furnace. Degreasing and firing were performed in this firing furnace to obtain a ceramic lattice body having the shape shown in FIGS. The firing temperature was 1450 ° C., and the firing time was 3 hours. The specifications of the obtained lattice are shown in Table 1 below. In the obtained lattice body, as shown in FIG. 8, the corners of the rectangular through holes were rounded.

[Example 2]
A ceramic lattice was obtained in the same manner as in Example 1 except that the nozzle diameter was 0.8 mm. In the obtained lattice body, as shown in FIG. 8, the corners of the rectangular through holes were rounded.

Example 3
83.6% yttria-added fully stabilized zirconia powder having an average particle size of 0.8 μm, hydroxypropyl methylcellulose (average polymerization degree: 300,000 g / mol) as an aqueous binder, 4.1 parts, and plasticizer Then, 2.0 parts of glycerin, a polycarboxylic acid-based dispersant (molecular weight 12000), and 39.4 parts of water were mixed and defoamed to prepare a paste. The viscosity of the paste was 1.15 million Pa · s at 25 ° C. Using this paste, a lattice precursor was obtained by the same operation as in Example 1. However, the nozzle diameter was 0.4 mm. A coated body was formed with a dispenser while drying the lattice-shaped precursor with a dryer. Further, after the coated body was formed, the coated body was dried with a dryer at 60 ° C. for 12 hours. A ceramic lattice was obtained in the same manner as in Example 1 except for this. In the obtained lattice body, as shown in FIG. 8, the corners of the rectangular through holes were rounded.

Example 4
In Example 3, the nozzle diameter was 0.8 mm. A ceramic lattice was obtained in the same manner as in Example 3 except for this. In the obtained lattice body, as shown in FIG. 8, the corners of the rectangular through holes were rounded.

Example 5
In Example 1, the line part was made into four types. The four types of line sections were stacked in the order of the first line section, the second line section, the third line section, and the fourth line section. The strips adjacent to each other at the top and bottom intersect at 90 degrees. The position of the intersection produced by the intersection of the first filament and the second filament is the position of the filament produced by the intersection of the second filament and the third filament, and in plan view. I tried to be the same. The same applies to the intersection of the second and third filaments and the intersection of the third and fourth filaments. A ceramic lattice was obtained in the same manner as in Example 1 except for this. In Table 1 showing the specifications, the thickness and width of the third linear portion and the pitch between the linear portions are shown as T3, W3 and P3, respectively. Further, the thickness and width of the fourth linear portion and the pitch between the linear portions are indicated as T4, W4 and P4, respectively. In Table 1, the first surface of the ceramic lattice body is the outer surface of the first striated portion, and the second surface is the surface of the fourth striated portion. In the obtained lattice body, as shown in FIG. 8, the corners of the rectangular through holes were rounded.

[Comparative Example 1]
This comparative example is an example using a nickel net as a lattice. This nickel mesh is obtained by applying a zirconia spray coating to 32 mesh formed by plain weaving of a nickel wire having a thickness of 315 μm, and has a thickness of 0.6 mm.

[Comparative Example 2]
In this comparative example, a solution obtained by dissolving gelatin in hot water (the concentration of gelatin is 3% with respect to water) is prepared, and this solution is mixed with a yttria fully stabilized zirconia slurry prepared in advance. did. The mixing was performed so that the volume ratio of yttria fully stabilized zirconia to water in the mixed solution was 10:90. This mixed solution was allowed to stand in a refrigerator to be gelled. The gel was frozen with an ethanol freezer. After the frozen gel was dried (lyophilized), the obtained dried product was degreased and baked at 1600 ° C. for 3 hours. The lattice body thus obtained had a porosity of 79%, a pore diameter of 95 μm, and a structure in which pores were oriented in the thickness direction.

[Evaluation]
About the lattice body obtained by the Example and the comparative example, the spalling evaluation was performed with the following method. The results are shown in Table 2 below.

[Evaluation of spalling resistance]
A sample having a length of 150 mm, a width of 150 mm, and a thickness of 0.8 to 1.5 mm was prepared. A rack-shaped kiln tool with mullite foot (external dimension is 165 mm x 165 mm, cross-shaped width in the center is 15 mm, and there are four hollow structures of 60 mm x 60 mm between the outer frame and the cross) Place the sample on the base plate, set the sample on the rack, heat at high temperature in an atmospheric firing furnace and keep it at a desired temperature for 1 hour or more, then remove it from the electric furnace and expose it to room temperature. The presence or absence was evaluated. The set temperature was changed from 200 ° C. to 950 ° C. while increasing the temperature by 50 ° C., and the upper limit of the temperature at which no cracks occurred was defined as “spoling resistance”.

[Evaluation of shape change by repeated firing]
Prepare each sample 150mm long x 150mm wide, heat up in a carbon crucible at 400 ° C / hr in an argon atmosphere, keep at 1300 ° C for 5 minutes, and cool at 400 ° C / hr 65 times firing pattern Repeatedly, the difference in the sample shape after the initial firing after repeated firing was evaluated from the appearance.

  As is clear from the results shown in Table 2, it can be seen that the lattice bodies obtained in each example have higher spalling resistance than each comparative example.

DESCRIPTION OF SYMBOLS 1 Ceramic lattice body 1a 1st surface 1b 2nd surface 2 Crossing part 3 Through-hole 10 1st filament part 10a 1st surface 10b 2nd surface 20 2nd filament part 20a 1st surface 20b 2nd surface

The present invention will be described below based on preferred embodiments with reference to the drawings. 1 (a) and 1 (b) show an embodiment of the ceramic lattice body of the present invention. A ceramic lattice body (hereinafter also simply referred to as “lattice body”) 1 shown in these drawings has a plurality of first filament portions 10 made of ceramics extending in one direction X. Each 1st filament part 10 is carrying out the straight line, and is mutually extended in parallel. The ceramic lattice body 1 has a plurality of ceramic second linear portions 20 extending in the Y direction, which is a direction different from the X direction. Each of the second linear portions 20 is straight and extends in parallel with each other. Since the X direction and the Y direction are different directions, the first linear portion 10 and the second linear portion 20 intersect each other. The intersecting angle between the two filaments 10 and 20 can be set according to the specific application of the ceramic lattice 1 . For example, the crossing angle of the second linear portion 20 with respect to the first linear portion 10 can be 90 degrees. Or the crossing angle of the 2nd filament part 20 with respect to the 1st filament part 10 can also be changed in the range of 90 degree +/- 10 degree. The grid body 1 is formed by the plurality of first linear portions 10 and the plurality of second linear portions 20 intersecting each other.

As shown in FIG. 1, FIG. 3, and FIG. 4, the intersection 2 between the first filament 10 and the second filament 20 is on the first filament 10 in any intersection 2. The 2nd filament part 20 is distribute | arranged to. That is, in the intersection part 2 of the 1st filament part 10 and the 2nd filament part 20, among the two surfaces 1a and 1b of the grid | lattice body 1, it is relatively located in the 1st surface 1a side . On the 1 line part 10, the 2nd line part 20 located relatively on the 2nd surface 1b side is distribute | arranged. And the thickness in the intersection part 2 is larger than any of the thickness of the 1st filament part in the site | parts other than this intersection part, and the thickness of the 2nd filament part. That is, the thickness of the first filament 10 at a position other than the intersection 2 of the two filaments 10 and 20 is T1 (see FIG. 2), and the position of the both filaments 10 and 20 at a position other than the intersection 2. When the thickness of the second linear portion 20 is T2 (see FIG. 5) and the thickness at the intersecting portion is Tc (see FIGS. 3 and 4), Tc> T1 and Tc> T2. Therefore, on the second surface 1 b of the ceramic lattice body 1, the position of the intersecting portion between the two filament portions 10 and 20 is the highest.

As for the 1st filament part 10, it is preferable that the 1st surface 10a is smooth among the surfaces. Since the first surface 10a of the first filament 10 is smooth, there is an advantage that when the object to be fired is placed on the ceramic lattice body 1, the object to be fired is hardly damaged. In addition, there is an advantage that the fired body obtained by firing the body to be fired is not easily caught by the ceramic lattice body 1 and the take-out property is improved. Furthermore, if the body to be fired is a thin tape molded body such as a substrate, the surface state of the first surface 10a is transferred to the bottom surface of the body to be fired, so that the bottom surface of the body to be fired can be finished more smoothly. is there. On the other hand, when the surface roughness is large, there is an advantage that the degreasing easily proceeds smoothly because the gas flow under the fired body is improved when the fired body is placed. From these viewpoints, the surface roughness Ra of the first surface 10a of the first filament portion 10 is preferably 0.01 μm or more and 20 μm or less, and more preferably 0.01 μm or more and 10 μm or less. On the other hand, the surface roughness Ra of the second linear portions 2 0 of the second surface 20b is preferably 10μm or more 300μm or less, and more preferably 20μm or more 100μm or less. Specifically, the surface roughness Ra is measured by the following method. Using a color 3D laser microscope (manufactured by Keyence Co., Ltd., VK-8710), the measurement magnification was 200 times. For the first surface 10a of the first filament 10, the surface roughness was measured along the middle line of the first surface 10a, and an average value was calculated from the 20 measured values, which was Ra. On the other hand, the second surface 20b of the second linear portions 20, along the second surface 2 0b midline measuring the surface roughness, the average value of twenty measurements was Ra.

In order to reduce the value of the surface roughness Ra of the first surfaces 10a and 20a, for example, a substrate having a small surface roughness is used as a substrate on which a paste used for forming the linear portion is applied, or the paste A low-viscosity material may be used. On the other hand, in order to increase the value of the surface roughness Ra of the second surfaces 10b and 20b, for example, a high-viscosity paste may be used, or the nozzle diameter to be discharged may be increased. In some cases, the first surface 1a and / or the second surface 1b of the ceramic lattice body 1 may be polished and processed to have a predetermined surface roughness.

On the other hand, in the embodiment shown in FIG. 9 ( b ), the first filament 10 'in the first grid 1' and the first filament 10 "in the second grid 1" are half pitch. It is arranged so as to be displaced. Similarly, the second linear portion 20 ′ in the first lattice body 1 ′ and the second linear portion 20 ″ in the second lattice body 1 ″ are arranged so as to be shifted by a half pitch.

Claims (6)

A ceramic lattice body having a plurality of first filaments made of ceramics extending in one direction and a plurality of second filaments made of ceramics extending in a direction intersecting the first filaments Because
The intersection of the first filament part and the second filament part has the second filament part arranged on the first filament part in any of the intersection parts,
The first striated portion has a shape in which a cross section thereof is configured by a straight portion and a convex curved portion having both ends of the straight portion as ends in a portion other than the intersecting portion. And
The second linear portion has a circular or oval shape in cross section in a portion other than the intersecting portion,
The projected image in the plan view of the second linear portion has a shape that is curved and bulged outward in the width direction at the intersecting portion, whereby the width of the projected image at the intersecting portion is reduced. A ceramic lattice body that is larger than the width of the projected image at a portion other than the intersection.   When the linear portion of the first linear portion is placed on a plane as a placement surface, the second linear portion has a shape that is separated from the plane between two adjacent intersections. The ceramic lattice body according to claim 1.   The first linear portion has a shape in which a projection image in a plan view is curved and bulged outward in the width direction at the intersecting portion, whereby the width of the projected image at the intersecting portion is increased. The ceramic lattice body according to claim 1, wherein the ceramic lattice body is larger than a width of a projected image at a portion other than the intersection.   The ceramic lattice body according to any one of claims 1 to 3, comprising a ceramic containing alumina, mullite, cordierite, zirconia, silicon nitride, or silicon carbide.   The ceramic lattice body according to claim 4, wherein the surface is coated with zirconia.   The ceramic lattice body as described in any one of Claims 1 thru | or 5 used as a setter for baking of ceramic products.

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