CERAMIC GREEN SHEET LAMINATION AID AND CERAMIC GREEN SHEET COMPOSITION

Abstract

(Object) An object is to suppress the peeling and lamination misalignment of ceramic green sheets without deteriorating the sheet strength.

(Solution) A ceramic green sheet lamination aid comprising a compound represented by formula (1).

Z—[O-(AO)n-H]x  (1) (Z represents a residual group of a compound having a number of carbons group of 1 to 22 and having hydroxyl groups of 1 to 6 in which all of said hydroxyl groups are removed; x represents a number of 1 to 6; AO represents an oxyalkylene group having a number of carbons of 2 to 4; n represents a number of 5 to 500; x×n is in a range of 5 to 500; and a weight ratio of oxyethylene group EO contained in the oxyalkylene group AO having the number of carbons of 2 to 4 is 0 to 80 weight %.)

Claims

1. A lamination aid for a ceramic green sheet, said lamination aid comprising a compound represented by a formula (1):
Z—[O-(AO)n-H]x  (1) wherein in the formula (1), Z represents a residual group of a compound having a number of carbons of 1 to 22 and having hydroxyl groups of 1 to 6 in which all of said hydroxyl groups are removed; x represents a number of 1 to 6; AO represents an oxyalkylene group having a number of carbons of 2 to 4; n represents a number of 5 to 500; x×n is in a range of 5 to 500; and a weight ratio of oxyethylene group EO contained in said oxyalkylene group AO having the number of carbons of 2 to 4 is 0 to 80 weight %.

2. The ceramic green sheet composition comprising 0.01 to 5 mass % of a component (A) described below, 1 to 25 mass % of a component (B) described below and 70 to 98 mass % of a component (C) described below: said component (A) said ceramic green sheet of claim 1; said component (B) polyvinyl butyral; and said component (C) ceramic powder.

Description

EXAMPLES

[0042] Although the present invention will be described further in detail below, referring to the examples, the present invention is not limited to the examples in any sense.

[0043] (Lamination Aid)

[0044] As the lamination aids, the lamination aids 1 to 7 and comparative articles 1 and 2 having the compositions shown in table 1 were used. EO and PO in the lamination aids 3 and 4 in table 1 were added in random addition mode and EO and PO in the lamination aids 6 and 7 were added in block addition mode in the order of EO-PO.

[0045] (Molding 1 of Ceramic Green Sheets)

[0046] Media with a particle size of 2 mm and made of YTZ were filled in a 0.5-liter polyethylene pot in 50 vol. %, and the respective materials were charged into the pot in the respective compositions shown in tables 2, 3 and 4. After it was agitated by means of MASUDA UNIVERSAL BALL MILL MODEL UBM-2 at a rotation rate of 60 rpm for 5 hours, the media were filtered to obtain ceramic composition slurry.

[0047] The thus obtained slurry was applied on a PET film by means of a doctor blade coater at a molding speed of 1.5 m/min. At the step, the groove width of the blade was made 140 μm, and the PET film having a thickness of 32 μm was used. Further, the applied slurry was dried at 40° C., 60° C., 75° C. or 85° C. for 10 minutes, respectively, to obtain target ceramic green sheets.

[0048] (Sheet Properties and Adhesiveness)

[0049] The sheet strength, adhesive strength and coefficient of static friction were evaluated according to the following method. The results were shown in tables 2, 3 and 4.

[0050] (Method of Measuring Sheet Strength)

[0051] Test pieces each having a width of 3 cm and length of 10 cm were produced using the respective green sheets described in the tables. The tensile strengths (N/mm.sup.2) of the test pieces were measured by means of MODEL 9502B supplied by AIKOH. The results were evaluated based on the following standard.

[0052] ⊚: 16.0 (N/mm.sup.2) or more

[0053] ◯: 15.0 to 16.0 (N/mm.sup.2)

[0054] X: less than 15.0 (N/mm.sup.2)

[0055] (Method of Measuring Adhesive Strength of the Sheets)

[0056] The respective green sheets described in the table were laminated and then pressure-pressed at 500 kg/cm.sup.2 and 60° C. for 1 minute. The pressure-pressed green sheets were cut in a width of a width of 2.5 cm and length of 25 cm to produce test pieces. Referring to JIS K-6854-1 (Determination of peel strength of bonded assemblies), one surface of each of the test pieces was fixed on a table and the other surface was pulled by means of “MODEL 9502B” supplied by AIKOH at 500 mm/minute to peel the adhesive surface. The force [N] required at the time was divided by the width of the test piece to calculate the adhesive strength (N/m). The results were evaluated based on the following standard.

[0057] ⊚: 15.0 [N/m] or larger

[0058] ◯: 10.0 to 15.0 [N/m]

[0059] X: smaller than 10.0 [N/m]

[0060] (Method of Measuring Friction Coefficient Between the Sheets)

[0061] The coefficients of static friction and dynamic friction between the sheets of the respective green sheets described in the tables were measured. The coefficients were measured by means of a friction tester (Model: TL201Tt, supplied by Trinity Labo corporation) and the green sheets were adhered at a region (a square of 1 cm×1 cm) where a contact pad contacts the sample, so that the friction coefficients between the sheets were measured. The measurement was made under conditions of a temperature of 25° C., a moving velocity of the contact pad of 5 mm/second and a load of 25 g/cm.sup.2. The results were evaluated based on the following standard.

[0062] ⊚: 10.0 or more

[0063] ◯: 5.0 to 10.0

[0064] X: less than 5.0

TABLE-US-00001 TABLE 1 Alkylene oxide molar number added Weight ratio (mol) of EO in AO Molecular Z EO PO (weight %) n x x × n weight lamination aid 1 n-butyl alcohol 0 50 0 50 1 50 3,000 lamination aid 2 n-butyl alcohol 0 85 0 85 1 85 5,000 lamination aid 3 n-butyl alcohol 45 50 40 95 1 95 5,000 lamination aid 4 ethylene glycol 315 80 75 198 2 395 18,500 lamination aid 5 glycerin 0 84 0 28 3 84 5,000 lamination aid 6 3,5,5,-trimethyl hexanol 8 3 65 11 1 11 670 lamination aid 7 3,5,5,-trimethyl hexanol 3 10 20 13 1 13 860 Comparative article 1 ethylene glycol 10 0 100 5 2 10 400 Comparative article 2 ethylene glycol 450 0 100 225 2 450 20,000

TABLE-US-00002 TABLE 2 Inventive Inventive Inventive Inventive Inventive Inventive Test example Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Component (A) lamination aid 1 0.4 0.4 lamination aid 2 0.4 lamination aid 3 0.4 lamination aid 4 0.2 lamination aid 5 0.6 lamination aid 6 lamination aid 7 Component (A)′ Comparative article 1 Comparative article 2 Component (B) Polyvinyl butyral supplied by Sekisui 6.9 6.9 6.9 6.9 6.9 6.9 Chemical Co. Ltd. “BH-3” (Weight average molecular weight = 110,000) Component (C) barium titanate powder 92.7 92.7 92.7 92.9 92.5 92.7 (Average particle size 200 μm) total amount Total of (A) + (B) + (C); mass % 100 100 100 100 100 100 The other components Unit: mass parts with respect to 100 mass parts of (A) + (B) + (C) Plasticzer dibutyl phthalate 0 0 0 0 0 1.5 Dispersant Maliulim SC-0505K 1.0 Solvent Toluene/Ethanol = 50 wt/50 wt 120    Evaluation Sheet strength [N/mm.sup.2] 16.8 17.0 16.7 16.4 16.9 16.8 ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ Adhesive strength [N/m] 13.1 13.7 14.1 14.5 13.8 17.0 ◯ ◯ ◯ ◯ ◯ ⊚ Static friction coefficient 7.9 10.2 8.2 9.6 10.3 8.1 ◯ ⊚ ◯ ◯ ⊚ ◯

TABLE-US-00003 TABLE 3 Inventive Inventive Inventive Inventive Inventive Test examples Example 7 Example 8 Example 9 Example 10 Example 11 Component (A) lamination aid 1 lamination aid 2 0.4 lamination aid 3 0.4 lamination aid 4 lamination aid 5 lamination aid 6 1.5 lamination aid 7 1.5 0.7 Component (A)′ Comparative article 1 Comparative article 2 Component (B) Polyvinyl butyral supplied by Sekisui 6.9 6.9 6.9 6.9 6.9 Chemical Co. Ltd. “BH-3” (Weight average molecular weight = 110,000) Component (C) barium titanate powder 92.7 92.7 91.6 91.6 92.4 (Average particle size 200 μm) Total amount Total of (A) + (B) + (C); mass % 100 100 100 100 100 The other components Unit: mass parts with respect to 100 mass parts of (A) + (B) + (C) Plasticzer dibutyl phthalate 1.5 1.5 0 0 0.7 Dispersant Maliulim SC-0505K 1.0 Solvent Toluene/Ethanol = 50 wt/50 wt 120    Evaluation Sheet strength [N/mm.sup.2] 16.9 16.5 16.1 16.3 16.4 ⊚ ⊚ ⊚ ⊚ ⊚ Adhesive strength [N/m] 17.7 18.2 14.3 13.5 13.8 ⊚ ⊚ ◯ ◯ ◯ Static friction coefficient 10.7 8.9 8.5 9.5 9.7 ⊚ ◯ ◯ ◯ ◯

TABLE-US-00004 TABLE 4 Comparative Comparative Comparative Comparative Test examples Example 1 Example 2 Example 3 Example 4   (A) lamination aid 1 lamination aid 2 lamination aid 3 lamination aid 4 lamination aid 5 lamination aid 6 lamination aid 7 Component (A)′ Comparative article 1 0.4 Comparative article 2 0.4 Component (B) Polyvinyl butyral supplied by Sekisui 6.9 6.9 7.0 6.9 Chemical Co. Ltd. “BH-3” (Weight average molecular weight = 110,000) Component (C) barium titanate powder 92.7 92.7 93.0 93.1 (Average particle size 200 μm) Total amount Total of (A) + (B) + (C); mass % 100 100 100 100 The other components Unit: mass parts with respect to 100 mass parts of (A) + (B) + (C) Plasticzer dibutyl phthalate 0 0 0 1.5 Dispersant Maliulim SC-0505K 1.0 Solvent Toluene/Ethanol = 50 wt/50 wt 120    Evaluation Sheet strength [N/mm.sup.2] 14.1 16.3 16.6 16.3 X ⊚ ⊚ ⊚ Adhesive strength [N/m] 7.5 5.1 5.2 7.2 X X X X Static friction coefficient 0.9 0.8 0.8 0.9 X X X X

[0065] (Molding 2 of Ceramic Green Sheet)

[0066] The sheet properties and adhesive properties were evaluated as the molding 1 except that barium titanate powder used in the molding 1 of the ceramic green sheet was changed to alumina powder. The results were shown in table 5.

TABLE-US-00005 TABLE 5 Inventive Inventive Comparative Test examples Example 12 Example 13 Example 5 Component (A) lamination aid 1 lamination aid 2 0.4 lamination aid 3 lamination aid 4 lamination aid 5 lamination aid 6 0.7 lamination aid 7 Component (A)′ Comparative article 1 0.4 Comparative article 2 Component (B) Polyvinyl butyral supplied by Sekisui 6.9 6.9 6.9 Chemical Co. Ltd. “BH-3” (Weight average molecular weight = 110,000) Component (C) Alumina powder 92.7 92.4 92.7 (Average grain size 170 μm) Total amount Total of (A) + (B) + (C); mass % 100 100 100 The other components Unit: mass parts with respect to 100 mass parts of (A) + (B) + (C) Plasticzer dibutyl phthalate 0 0.7 0 Dispersant Maliulim SC-0505K 1.0 Solvent Toluene/Ethanol = 50 wt/50 wt 120    Evaluation Sheet strength [N/mm.sup.2] 16.8 16.1 13.5 ⊚ ⊚ X Adhesive strength [N/m] 13.5 14.5 7.5 ◯ ◯ X Static friction coefficient 10.3 9.9 1.3 ⊚ ◯ X

[0067] As can be seen from the results shown in tables 2, 3, 4 and 5, according to the inventive examples 1 to 13, good results were obtained in the sheet strength, adhesive strength and static friction coefficient.

[0068] On the other hand, according to the comparative examples 1 and 5, as the weight ratio of EO contained in AO is out of the range of the present invention, sufficient static friction coefficient were not be obtained and sheet strength is lowered.

[0069] According to the comparative example 2, the weight ratio of EO contained in AO is out of the range of the present invention, sufficient adhesive strength and static friction coefficient were not obtained.

[0070] According to the comparative examples 3 and 4, as the lamination aid was not contained, the adhesion strength and static friction coefficient were insufficient.