Method of eliminating voids in ceramic bodies

Claim 1

The method of making a high-density monolithic ceramic body according to claim 1 wherein said metallic coatings are completely surrounded on all sides by said ceramic layers, wherein said sintering and curing step form around said metallic coatings a gastight casing of ceramic material, and then subjecting the same to heat and gas pressure which softens the ceramic particles and squeezes the same by said gas pressure applied around said gastight casing to reduce or eliminate the minute voids in the same.

Claim 5

A method of making high-density monolithic ceramic capacitor bodies, comprising the steps of: depositing upon an air-pervious support wall a first layer comprising a mixture of finely divided raw ceramic particles, a heat-volatile binder and a solvent forming a flowable mixture which cannot pass through air-pervious support wall; drying said first layer to remove the solvent; depositing on one surface of said first dried layer a first plurality of thin metallic coatings in a predetermined pattern to form a capacitor plate for a plurality of capacitor stacks, said metallic coatings being displaced one from the other in at least one direction; removing air from within said first dried layer by suction applied to the opposite side of said support wall while applying over said first layer and said metallic coating a second layer of said mixture of finely divided raw ceramic particles, a heat-volatile binder and a solvent; depositing on the exposed surface of said second layer a second plurality of thin metallic coatings slightly displaced in at least one lateral direction from said predetermined pattern to form another capacitor plate for said plurality of capacitor stacks; forming upon said second metal coated layer additional raw ceramic layers and metallic coatings where desired in the same manner as said second ceramic layer while said suction is applied and said second plurality of thin metallic coatings to form a laminate body where said metallic coatings on each ceramic layer has portions thereof in general registry with portions of corresponding metallic coatings of other ceramic layers to form respective capacitor stacks where the metallic coatings of each capacitor stack are spaced in nonoverlapping relation from the metallic coatings of the adjacent capacitor stacks and wherein certain edge portions of a first group of alternate metallic coatings in each capacitor stack are in registry to form a first common contact region and certain edge portions of a second group of alternate metallic coatings in each capacitor stack are in registry to form a second common contact region; and cutting through only the ceramic material between said capacitor stacks to separate the same into separate capacitor elements where the metallic coatings are completely encased by ceramic material.

Claim 10

A method of making a high-density multilayered ceramic body with one or more metallic coatings therein, comprising the steps of: forming a laminate body of raw ceramic layers and at least one metallic layer completely embedded within the raw ceramic layers and having an edge portion to be ultimately exposed; firing the resultant laminate body to sinter and cure the raw ceramic material and to form around said metallic layer a gastight casing of ceramic material then subjecting said laminate body to gas pressure and a temperature below the firing temperature thereof only to soften the ceramic material and squeeze the same by said gas pressure applied around said gastight casing to reduce minute voids therein; and then exposing said edge portion of each of the one or more metallic layers within the ceramic body.