Ceramic liner and method of forming

Patent metadata

Field	Value
Publication number	US-10295260-B2
Application number	US-201715787573-A
Country	US
Kind code	B2
Filing date	Oct 18, 2017
Priority date	Oct 18, 2016
Publication date	May 21, 2019
Grant date	May 21, 2019

Abstract

A ceramic liner can include a monolithic body having a surface portion and a bulk portion. The surface portion can have a thickness less than the total thickness of the monolithic body. The monolithic body can include an amorphous phase. The amorphous phase can be discontinuous. At least one member of the discontinuous phase can be embedded in the surface portion. The bulk portion can be substantially free of the amorphous phase. A method of forming a ceramic liner can include providing a furnace with a coating and a bulk material of the ceramic liner and heating the bulk material and the coating. In an embodiment, a coated lining form can be used to provide the coating. In a particular embodiment, the coating can be transferred to the bulk material from the coated lining form.

First claim

What is claimed is:

1. A method of forming a ceramic liner, comprising;
placing a form having a coating in a furnace;
providing the furnace with the coating and a bulk material of the ceramic liner, wherein the bulk material is between a wall of the furnace and the form having the coating;
heating the bulk material and the coating to form the ceramic liner having a monolithic body, wherein heating the bulk material and the coating comprises heating the bulk material and the coating at a first temperature, wherein the first temperature is at least 500° C. to at most 1200° C. and sufficient to transfer at least a portion of the coating to the bulk material; and
removing the form from the furnace after heating the bulk material and the coating at the first temperature,
wherein the monolithic body comprises a surface portion and a bulk portion, the surface portion including an inner surface of the monolithic body and having a thickness less than a total thickness of the monolithic body; and
wherein the surface portion comprises an amorphous phase embedded within the surface portion and the bulk portion is substantially free of an amorphous phase.

2. The method of claim 1 , wherein heating the bulk material and the coating further comprises heating the bulk material and the coating at a second temperature after removing the form, wherein the second temperature is sufficient to sinter the bulk material.

3. The method of claim 2 , wherein the second temperature is at least 1200° C. to at most 1650° C.

4. The method of claim 1 , wherein the first temperature is sufficient to sinter a portion of the bulk material to form the surface portion of the monolithic body.

5. The method of claim 4 , wherein the bulk portion is not sintered after heating the bulk material and the coating at the first temperature.

6. The method of claim 1 , wherein heating at the first temperature is performed for at least 20 minutes to at most 6 hours.

7. The method of claim 1 , further comprising spraying the coating onto the form, wherein spraying is performed with a dual-component solution.

8. The method of claim 7 , wherein the dual-component solution comprises a silicate solution.

9. The method of claim 7 , wherein the dual-component solution comprises a solution including aluminum phosphate, aluminum fluoride, or a combination thereof.

10. The method of claim 7 , wherein the dual-component solution comprises an acidic solution including boric acid, citric acid, or a combination thereof.

11. The method of claim 1 , wherein the ceramic liner comprises an alumina, a magnesia, or a combination thereof.

12. The method of claim 1 , wherein the amorphous phase comprises silica, one or more elements selected from a group consisting of Group I and Group II elements, an alumina, a cryolite, or a combination thereof.

13. The method of claim 1 , wherein the amorphous phase is discontinuous, wherein a discrete amorphous member of the amorphous phase is embedded within the surface portion and is spaced apart from the inner surface of the monolithic body.

Assignees

• Saint Gobain Ceramics

Inventors

• Walsh Iii John Carl
• Schnelzer Michael P
• Cortellini Edmund A

Classifications

• F27D1/10 Primary

  Monolithic linings; Supports therefor · CPC title

• C04B2235/365

  Borosilicate glass · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title

• C04B2235/3201

  Alkali metal oxides or oxide-forming salts thereof · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title