Patent ID: 7556755
Filing Date: 2009-07-07
Classification: C04B

Abstract:
1. A process for producing a ceramic molding having a three-dimensional network structure with a plurality of spherical cells and a plurality of through holes present in dividing walls between adjacent spherical cells, the process comprising: a step of dry mixing an aggregate of spherical synthetic resin particles and an aggregate of ceramic particles having a diameter smaller than that of the spherical synthetic resin particles so as to obtain an aggregate of coated particles free of liquid and in which a plurality of the ceramic particles are attached to the surface of the spherical synthetic resin particles; a step of placing the aggregate of coated particles in a mold and performing a vacuum filtration process to arrange the coated particles in closest packed form; a step of filling gaps in the aggregate of coated particles with a ceramic so as to give a shaped product; a step of releasing the shaped product from the mold; a step of thermally decomposing the spherical synthetic resin particles of the shaped product so as to form the spherical cells and form the plurality of through holes in dividing wall-forming sections that are present between adjacent spherical cells and that are formed from the plurality of ceramic particles and the ceramic; and a step of sintering the plurality of ceramic particles and the ceramic so as to form the dividing walls.