Patent ID: 7955461
Filing Date: 2011-06-07
Classification: B32B,C04B

Abstract:
1. A method for forming a three-dimensional forming portion comprising: a mold preparation step of preparing a mold having a concave portion which has a predetermined shape in a front view; a slurry preparation step of preparing a slurry including particles of a main raw material, a solvent for said particles, and an organic material; a substrate preparation step of preparing a porous substrate through which gases can pass, said porous substrate being at least one of a ceramic green sheet, a porous ceramic substrate, a porous film and a paper; a pre-dried three dimensional forming portion forming step of placing said slurry in said mold and positioning said mold on one surface side of said porous substrate in such a manner that a pre-dried three dimensional forming portion of said slurry which has a shape following said predetermined mold shape is formed on said one surface side of the porous substrate by means of said concave portion of said mold; and a post-dried three dimensional forming portion forming step of having said solvent included in said slurry permeate into fine pores of said porous substrate while said mold is kept on said one surface side of the porous substrate to dry said pre-dried three dimensional forming portion so as to form a post-dried three dimensional forming portion including: placing said porous substrate on a porous sintered support, wherein said porous substrate contacts said porous sintered support only on a porous substrate surface side that is opposite to said one porous substrate surface side contacting said slurry, and wherein an inside pressure within said porous substrate is reduced to a pressure lower than atmospheric pressure, via a suction force applied through said porous sintered support and said directly opposite porous substrate side, whereby said solvent permeates into said fine pores of said porous substrate.