Patent ID: 11858850
Assignee: LEATEC FINE CERAMICS CO., LTD.
Field: Materials, metallurgy (Chemistry)
Classification: CPC C  H | IPC C  H

Claim 0:
1. A method for manufacturing a zirconia-alumina composite ceramic substrate, comprising the following steps:
a ball milling step of mixing alumina, zirconia, and a sintering additive respectively by ball milling using organic solvents as a mixing medium at room temperature;
a slurry preparing step of preparing an alumina-based slurry mix in combination with the alumina, the zirconia, and the sintering additive according to a predetermined mass ratio;
a degassing step of degassing and defoaming said slurry mix until the viscosity of the slurry mix reaches a pre-set range value;
a green tape roll forming step of obtaining a green tape of a predetermined thickness by tape casting the slurry mix;
a calculation step of calculating a size of green sheets based on a pre-tested sintering shrinkage rate;
a punching step of punching the green tape roll into said green sheets of said calculated size;
a sintering step of sintering said green sheets of said calculated size into a zirconia-alumina composite ceramic substrate in a furnace,
wherein the sintering additive is a pre-calcined synthetic sintering additive composed of calcium oxide, silicon dioxide and magnesium oxide in a ratio of calcium oxide 0.8 to 8.8 wt. %, silicon dioxide 56.7 to 61.7 wt. %, and magnesium oxide 32.5 to 37.5 wt. %,
wherein the sintering additive is produced by mixing the calcium oxide, silicon dioxide and magnesium oxide by a bead mill to obtain a silicon-magnesium-calcium mixture; drying the silicon-magnesium-calcium mixture, and after the silicon-magnesium-calcium mixture is dried, calcining the silicon-magnesium-calcium mixture to produce a silicon-magnesium-calcium compound.