CERAMIC LAMINATE SHEET WITH FLEXIBILITY AND PREPARATION METHOD THEREOF

• US 20140017486A1
• Filed: 07/11/2013
• Published: 01/16/2014
• Est. Priority Date: 07/12/2012
• Status: Active Grant

• Current Assignee: SKC Company Limited
• Original Assignee: SKC Company Limited
• Inventors: LEE, Dong Gyu, YOO, Il Hwan, KIM, Jin Cheol, KIM, Tae Kyoung, LEE, Yu Jin
• Granted Patent: US 9,640,304 B2
• Time in Patent Office: Days
• US Class Current: 428/325
• CPC Class Codes: B29C 67/0011 for shaping plates or sheets
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2038/0024 Crushing
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2315/02 Ceramics
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/005 comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/045 of synthetic resin
• CPC Class Codes: C04B 2235/6025 Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 2235/6562 Heating rate
• CPC Class Codes: C04B 2235/668 Pressureless sintering
• CPC Class Codes: C04B 2237/34 Oxidic
• CPC Class Codes: C04B 2237/62 Forming laminates or joined articles comprising holes, channels or other types of openings
• CPC Class Codes: C04B 2237/704 : of one or more of the ceramic layers or articles
• CPC Class Codes: C04B 2237/708 : of one or more of the interlayers
• CPC Class Codes: C04B 35/265 : Compositions containing one or more ferrites of the group comprising manganese or zinc and one or more ferrites of the group comprising nickel, copper or cobalt
• CPC Class Codes: C04B 37/008 : by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• CPC Class Codes: H01B 17/60 : Composite insulating bodies
• CPC Class Codes: H01F 1/375 : Flexible bodies
• CPC Class Codes: H01Q 1/38 : formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 7/06 : with core of ferromagnetic material H01Q7/02 takes precedence
• CPC Class Codes: H05K 9/0075 : Magnetic shielding materials
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 428/252 : Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]

Abstract

Disclosed is a ceramic laminate sheet comprising a ceramic sheet having a plurality of cracks and a polymer resin layer disposed on one side or both sides of the ceramic sheet, wherein the plurality of cracks pass through the ceramic sheet from one side to the other side thereof, the cracks divide the ceramic sheet into a plurality of pieces, grooves for formation of the cracks are not provided in one side and the other side of the ceramic sheet.

Claims

1. A ceramic laminate sheet comprising a ceramic sheet having a plurality of cracks and a polymer resin layer disposed on one side or both sides of the ceramic sheet, wherein the plurality of cracks pass through the ceramic sheet from one side to the other side thereof, the cracks divide the ceramic sheet into a plurality of pieces, grooves for formation of the cracks are not provided in one side and the other side of the ceramic sheet, and the number of the plurality of pieces is 100 or more per unit area (cm²) of the ceramic sheet.

2. The ceramic laminate sheet of claim 1, wherein the number of the plurality of pieces formed is in the range of from 100 to 1,200 per unit area (cm²).

3. The ceramic laminate sheet of claim 1, wherein the number of the plurality of pieces formed is in the range of 350 to 950 per unit area (cm²).

4. The ceramic laminate sheet of claim 1, wherein the plurality of cracks formed in the ceramic sheet include cracks disposed in at least two directions crossing each other.

5. The ceramic laminate sheet of claim 1, wherein the plurality of cracks formed in the ceramic sheet include cracks disposed in at least four directions crossing one another.

6. A ceramic laminate sheet comprising a ceramic sheet having a plurality of cracks and a polymer resin layer disposed on one side or both sides of the ceramic sheet, wherein the plurality of cracks pass through the ceramic sheet from one side to the other side thereof, the cracks divide the ceramic sheet into a plurality of pieces, grooves for the formation of the cracks are not provided in one side and the other side of the ceramic sheet, and an average space between parallel cracks among the plurality of cracks is 800 μ

m or less.

7. The ceramic laminate sheet of claim 6, wherein the average space between parallel cracks of the plurality of cracks is in the range of 200 μ

m to 800 μ

m.

8. The ceramic laminate sheet of claim 6, wherein the average space between parallel cracks of the plurality of cracks is in the range of 300 μ

m to 600 μ

m.

9. A method for preparing a ceramic laminate sheet comprising the steps of:

(a) forming a polymer resin layer on one side or both sides of a sintered ceramic sheet to obtain a laminate sheet; and

(b) forming a plurality of cracks in the ceramic sheet by pressurizing the laminate sheet to dividing the ceramic sheet into a plurality of pieces,

wherein the number of the plurality of pieces formed is 100 or more per unit area (cm²) of the ceramic sheet.

10. The method of claim 9, wherein the pressurizing is performed by allowing the laminate sheet to pass under a pressure roller in step (b).

11. The method of claim 9, wherein the pressurizing is performed by allowing the laminate sheet to pass between the pressure roller and the elastic roller in step (b).

12. The method of claim 9, wherein the pressurizing is performed by allowing the laminate sheet to pass between the pressure roller and an elastic support plate in step (b).

13. The method of claim 9, wherein the step (a) of forming the polymer resin layer and the step (b) of forming the cracks are performed simultaneously through a roll lamination process.

14. The method of claim 13, wherein the roll lamination process is performed to form the laminate sheet simultaneously with forming the plurality of cracks by passing the laminate sheet under a pressure roller in the processing direction X, and thereafter step (b) of forming the cracks is performed three times by primarily passing the laminate sheet under the pressure roller in the direction Y perpendicular to the processing direction X, by secondarily passing the laminate sheet under the pressure roller in the direction XY diagonal to the processing direction X, and by tertiarily passing the laminate sheet under the pressure roller in another direction X-Y diagonal to the processing direction X.

15. The method of claim 9, wherein the step (a) of forming the polymer resin layer is performed first, and then step (b) of forming the cracks is performed four times in total by primarily passing the laminate sheet under the pressure roller in the processing direction X, by secondarily passing the laminate sheet under the pressure roller in the direction Y perpendicular to the processing direction X, by tertiarily passing the laminate sheet under the pressure roller in the direction XY diagonal to the processing direction X, and by quaternarily passing the laminate sheet under the pressure roller in another direction X-Y diagonal to the processing direction X.