Method for producing cast tape finish on a dry-pressed substrate

A method for producing a smooth-faced ceramic substrate comprising:

• placing a substance comprising powdered ceramic in the cavity of a press;
• forming a smooth carrier by casting on the surface of a film;
• forming a smooth-faced ceramic tape by casting a ceramic slip on one surface of said carrier;
• drying said ceramic tape;
• stripping said film from said carrier;
• punching a portion of said tape in a shape to fit in said cavity;
• placing said shaped tape portion in said cavity with the face opposite said smooth face in contact with said substance;
• dry pressing said tape and said substance to form an integrated smooth-faced green body;
• and
• sintering said green body.

A method for producing a smooth-faced ceramic substrate comprising:

• placing a substance comprising powdered ceramic in the cavity of a die;
• forming a smooth-faced ceramic tape;
• positioning at least a portion of said ceramic tape adjacent to said die;
• positioning a punch adjacent said portion of said ceramic tape;
• cutting said tape portion while moving said punch;
• dry pressing said tape portion and said substance using said punch to form an integrated smooth-faced green body;
• and
• sintering said green body to form a smooth-faced ceramic substrate.

A method of forming a ceramic substrate with a couter-sunk smooth face comprising:

• placing a substance comprising powdered ceramic in the cavity of a press having a first cross sectional area;
• casting a ceramic tape having at least one smooth face and one other face, comprising a ceramic compatible with said powdered ceramic;
• shaping a portion of said tape to fit within said cavity such that the area of one surface of said shaped tape is less than said cross sectional area of said cavity;
• placing said shaped tape portion in said cavity with said other face in contact with said substance;
• and
• dry pressing said tape and said substance to form an integrated ceramic substrate.

A method of forming a ceramic substrate with a pulled-back smooth face comprising:

• placing a substance comprising powdered ceramic in the cavity of a press having a first cross sectional area;
• dry pressing said substance;
• casting a ceramic tape having at least one smooth face and one other face comprising a ceramic compatible with said powdered ceramic;
• shaping a portion of said tape to fit within said cavity such that the area of one surface of said shaped tape is less than said cross sectional area of said cavity;
• placing said shaped tape portion in said cavity with said other face in contact with said substance;
• and
• dry pressing said tape and said substance to form an integrated ceramic substrate.

A method of forming a smooth-faced ceramic substrate with an interior conductor comprising:

• placing a substance comprising powdered ceramic in the cavity of a press;
• casting a ceramic tape having at least one smooth face and one other face comprising a ceramic compatible with said powdered ceramic;
• shaping a portion of said tape to fit in said cavity;
• placing a conductive material in said cavity in contact with said substance;
• placing said shaped tape portion in said cavity with at least a portion of said other face in contact with said conductive material;
• and
• dry pressing said tape, said conductive material, and said substance to form an integrated ceramic body.