Novel structure of ceramic tape for multilayer devices

To reduce the content of binders surrounding ceramic powders in a ceramic tape and the residual pore after burnout to a minimum, a ceramic tape with double layers was manufactured. One layer was comprised of only organic binder, which imparted sufficient strength and strong adhesive property to the green tape. The other one was a ceramic layer with a very small amount of binder. The binder content of the slurry for ceramic layer was less than 2 wt%, which could lower the viscosity, make the slurry well dispersed and considerably increase solid loading in the slurry. This higher solid loading led to higher green tape density, higher fired density of the product. The two-layer ceramic tape showed much better qualities than a common (or conventional) green tape especially in microstructure, laminatablilty, and tape density. In the multilayer structure made of the two-layer ceramic tape, the binder layer completely disappeared after binder-burnout and no defects from the two-layer structure were observed.