Method for Manufacturing Ceramic Member, and Ceramic Member, Gas Sensor Device, Fuel Cell Device, Multi-Layer Piezoelectric Device, Injection Apparatus and Fuel Injection System

Abstract

A ceramic member in which the metal layers with high void ratio are sufficiently sintered to lower a residue of resin is produced. The method for manufacturing a ceramic member which comprises a step of forming a stacked compact from a plurality of metallic paste layers containing a metal component M 1 that are stacked one on another via ceramic green sheets, and a step of firing the stacked compact, wherein at least one of plural metallic paste layers is formed as a second metallic paste layer that has the mass percentage X higher than that of the metallic paste layer that adjoin therewith in the stacking direction, the mass percentage X being the proportion of the metal component M 1 to the total metal content in the metallic paste layer.

1 - 42 . (canceled) 
   
   
       43 . A method for manufacturing a ceramic member comprising:
 a step of forming a stacked compact from a plurality of metallic paste layers containing a metal component M 1  that are stacked one on another via ceramic green sheets,   and   a step of firing the stacked compact,   wherein, when a mass percentage X is a proportion of the metal component M 1  to the total metal content in the metallic paste layer, at least one of said plurality of metallic paste layers is formed as a second metallic paste layer that has the mass percentage X higher than that of a first metallic paste layer which is the metallic paste layer that adjoins the second metallic paste layer in the stacking direction in the step of forming the stacked compact.   
   
   
       44 . The method for manufacturing a ceramic member according to  claim 43 , wherein the mass percentage X of the second metallic paste layer is set higher than those of the first metallic paste layers that adjoin on both side of the second metallic paste layer in the stacking direction. 
   
   
       45 . The method for manufacturing a ceramic member according to  claim 43 , wherein a mass percentage XH which is the mass percentage X of the second metallic paste layer and a mass percentage XL which is the mass percentage X of the first metallic paste layer adjacent to the second metallic paste layer in the stacking direction are set so as to satisfy XL+0.1≦XH≦XL+30. 
   
   
       46 . The method for manufacturing a ceramic member according to  claim 43 , wherein the mass percentages X of said plurality of metallic paste layers are set so as to satisfy 85≦X≦100. 
   
   
       47 . The method for manufacturing a ceramic member according to  claim 43 , wherein a plurality of said second metallic paste layers are disposed in the step of forming a stacked compact. 
   
   
       48 . The method for manufacturing a ceramic member according to  claim 47 , wherein said plurality of second metallic paste layers are disposed so that a plurality of metal layers other than the second metallic paste layers are interposed between the second metallic paste layers. 
   
   
       49 . The method for manufacturing a ceramic member according to  claim 47 , wherein said plurality of second metallic paste layers are disposed in accordance with a predetermined rule in the stacking direction of the stacked compact. 
   
   
       50 . The method for manufacturing a ceramic member according to  claim 47 , wherein the second metallic paste layers and metal layers other than the second metallic paste layers are alternately disposed. 
   
   
       51 . A method for manufacturing a ceramic member comprising:
 a step of forming a stacked compact from a plurality of metallic paste layers containing a metal component M 1  that are stacked one on another via ceramic green sheets,   and   a step of firing the stacked compact,   wherein, when a mass percentage X is a proportion of the metal component M 1  to the total metal content in the metallic paste layer, at least one of said plurality of metallic paste layers is formed as a first metallic paste layer that has the mass percentage X lower than those of a second metallic paste layers which are the metallic paste layers that adjoin on both sides of the first metallic paste layer in the stacking direction.   
   
   
       52 . The method for manufacturing a ceramic member according to  claim 51 , wherein a mass percentage XL which is the mass percentage X of the first metallic paste layer and a mass percentage XH which is the mass percentage X of the second metallic paste layer adjacent to the first metallic paste layer in the stacking direction are set so as to satisfy XH−0.1≦XL≦XH−30. 
   
   
       53 . The method for manufacturing a ceramic member according to  claim 51 , wherein the mass percentages X of said plurality of metallic paste layers are set so as to satisfy 85≦X≦−100. 
   
   
       54 . The method for manufacturing a ceramic member according to  claim 51 , wherein a plurality of said first metallic paste layers are disposed in the step of forming a stacked compact. 
   
   
       55 . The method for manufacturing a ceramic member according to  claim 51 , wherein said plurality of first metallic paste layers are disposed so that a plurality of metallic past layers other than the first metallic paste layers are interposed between the first metallic paste layers. 
   
   
       56 . The method for manufacturing a ceramic member according to  claim 55 , wherein said plurality of first metallic paste layers are disposed in accordance with a predetermined rule in the stacking direction of the stacked compact. 
   
   
       57 . The method for manufacturing a ceramic member according to  claim 55 , wherein the first metallic paste layers and metallic past layers other than the first metallic paste layers are alternately disposed. 
   
   
       58 . A method for manufacturing a ceramic member comprising:
 a step of forming a stacked compact from a plurality of metallic paste layers containing a metal component M 1  that are stacked one on another via ceramic green sheets,   and   a step of firing the stacked compact,   wherein, when a mass percentage X is a proportion of the metal component M 1  to the total metal content in the metallic paste layer, the mass percentage X of a portion of at least one of said plurality of metallic paste layers is set higher than that of the metallic paste layer that adjoins said at least one of the first metallic paste layers in the stacking direction.   
   
   
       59 . The method for manufacturing a ceramic member according to  claim 58 , wherein the mass percentage X of the portion is set higher than those of the metallic paste layers that adjoin on both sides of said at least one of the first metallic paste layers in the stacking direction. 
   
   
       60 . The method for manufacturing a ceramic member according to  claim 58 , wherein the mass percentage X of a region other than said portion is set same as that of the metallic paste layer that adjoin said at least one of the first metallic paste layers in the stacking direction. 
   
   
       61 . The method for manufacturing a ceramic member according to  claim 43 , wherein a group 11 element is used as the metal component M 1  and a group 10 element is contained as an other metal component. 
   
   
       62 . The method for manufacturing a ceramic member according to  claim 61 , wherein silver is used as the metal component M 1  and palladium is used as the other metal component. 
   
   
       63 . The method for manufacturing a ceramic member according to  claim 62 , wherein platinum is contained in the metallic paste layer. 
   
   
       64 . A ceramic member having a three-layer structure comprising a first metal layer containing the metal component M 1 , a second metal layer that include more voids than the first metal layer and a ceramic layer sandwiched by the first and second metal layers. 
   
   
       65 . The ceramic member according to  claim 64 , comprising at least two said three-layer structures. 
   
   
       66 . The ceramic member according to  claim 65 , comprising a five-layer structure composed of two said three-layer structures which share the first metal layer. 
   
   
       67 . The ceramic member according to  claim 65 , comprising a five-layer structure composed of two said three-layer structures which share the second metal layer. 
   
   
       68 . The ceramic member according to  claim 64 , wherein, when a mass percentage Y is a proportion of the metal component M 1  to the total metal content in the metal layer, the second metal layer has a mass percentage Y higher than that of the first metal layer. 
   
   
       69 . The ceramic member according to  claim 64 , wherein the second metal layer has a void ratio higher than that of the metal layer. 
   
   
       70 . The ceramic member according to  claim 64 , wherein the second metal layer is composed of a plurality of metal lumps dispersed on the ceramic layer that adjoin the second metal layer in the stacking direction while being separated from each other by the voids. 
   
   
       71 . The ceramic member according to  claim 64 , wherein
 the mass percentage Y has a peak in the second metal layer and gradually decreases away from the second metal layer over both at least two metal layers.   
   
   
       72 . The ceramic member according to  claim 64 , wherein the second metal layer has a thickness smaller than that of the first metal layer. 
   
   
       73 . The ceramic member according to  claim 64 , wherein the second metal layer has an electric resistance higher than that of the first metal layer. 
   
   
       74 . The ceramic member according to  claim 64 , wherein a plurality of the second metal layers are disposed in accordance with a predetermined rule. 
   
   
       75 . The ceramic member according to  claim 74 , wherein a plurality of the second metal layers are disposed so as to sandwich a plurality of metal layers other than the second metal layers. 
   
   
       76 . The ceramic member according to  claim 74 , wherein the second metal layers and the first metal layers are alternately disposed. 
   
   
       77 . The ceramic member according to  claim 74 , wherein the second metal layers are disposed at both ends of said plurality of metal layers respectively. 
   
   
       78 . The ceramic member according to  claim 64 , further comprising a pair of external electrodes electrically connected to said plurality of metal layers, wherein the second metal layers are connected with positive external electrode. 
   
   
       79 . The ceramic member according to  claim 64 , comprising a pair of external electrodes connected with said plurality of the metal layers, wherein the two first metal layers that adjoin the second metal layer on both sides thereof in the stacking direction are connected to the external electrodes of different polarities. 
   
   
       80 . A multi-layer piezoelectric device comprising the ceramic member according to  claim 64 . 
   
   
       81 . A gas sensor comprising the ceramic member according to  claim 64 . 
   
   
       82 . A fuel cell device comprising the ceramic member according to  claim 64 . 
   
   
       83 . An injection apparatus comprising:
 a container having an injection hole;   the multi-layer piezoelectric device according to  claim 80 ;   wherein a liquid that fills in the container is discharged through the injection hole by the operation of the multi-layer piezoelectric component.   
   
   
       84 . A fuel injection system comprising:
 a common rail that stores a high-pressure fuel;   the injection apparatuses according to  claim 83  to eject the fuel stored in the common rail;   a pressure pump that supplies the high-pressure fuel to the common rail; and   an injection control unit that sends a drive signal to the injection apparatus.