Methods and Appartus for Casting Ceramic Sheets

摘要

A method for making a thin, free-standing ceramic sheet may include drawing a carrier film proximate a casting head and across a casting bed of a tape caster at a rate from about 2 cm/min to about 500 cm/min. Depositing a thin film of ceramic slip less than about 150μm on the carrier film with the casting head. The ceramic slip may comprises a ceramic powder with an ultimate crystallite size of less than about 10μm dispersed in a fluid vehicle such that the ceramic slip has a ceramic solids fraction of greater than about 20% by volume. The deposited ceramic slip may be dried on the carrier film thereby forming a green ceramic sheet on the carrier film. After the green ceramic sheet is dried, the green ceramic sheet may be sintered.