System, process and related sintered article

Patent metadata

Field	Value
Publication number	US-11325837-B2
Application number	US-202117406206-A
Country	US
Kind code	B2
Filing date	Aug 19, 2021
Priority date	Jan 26, 2016
Publication date	May 10, 2022
Grant date	May 10, 2022

Abstract

A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.

First claim

What is claimed is:

1. A process for manufacturing a sintered article, comprising:
conveying a portion of a tape through a furnace, wherein the tape comprises grains of ceramic and/or minerals;
sintering the grains of ceramic and/or minerals of the portion of tape in the furnace; and
tensioning the tape during the sintering,
wherein the tape simultaneously extends into, through, and out of the furnace,
wherein, after the sintering, length of the tape is at least 100 times greater than width of the tape, and wherein the width is at least 10 times greater than thickness of the tape, and wherein the thickness is no more than 500 micrometers.

2. The process of claim 1 , wherein the sintering is at a temperature greater than 800 degrees Celsius.

3. The process of claim 1 , wherein the tensioning comprises 75 kPa of tension.

4. The process of claim 1 , wherein the tensioning flattens the tape, and wherein surfaces of the tape, after the sintering, have a flatness from 0.1 μm to 50 μm over a distance of 1 cm along a length of tape.

5. The process of claim 1 , wherein the tensioning increases translucence of the tape; and wherein the tape, after the sintering, has a total transmittance of at least 30% at wavelengths from 300 nm to 800 nm.

6. The process of claim 5 , wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% at wavelengths from 300 nm to 800 nm.

7. A process for manufacturing sintered article, comprising:
conveying a portion of a tape through a furnace, wherein the tape comprises grains of ceramic and/or minerals;
sintering the grains of ceramic and/or minerals of the portion of tape in the furnace; and
tensioning the tape during the sintering,
wherein the tape is continuously conveyed through the furnace during the sintering,
wherein, after the sintering, length of the tape is at least 100 times greater than width of the tape, and wherein the width is at least 10 times greater than thickness of the tape, and wherein the thickness is no more than 500 micrometers.

8. The process of claim 7 , further comprising unwinding the tape from a reel during the conveying.

9. The process of claim 8 , further comprising collecting the tape on an uptake reel after the sintering.

10. The process of claim 7 , wherein the sintering is at a temperature greater than 800 degrees Celsius, and wherein the tensioning comprises 75 kPa of tension.

11. The process of claim 7 , wherein the tensioning flattens the tape, and wherein surfaces of the tape, after the sintering, have a flatness from 0.1 μm to 50 μm over a distance of 1 cm along a length of tape.

12. The process of claim 7 , wherein the tensioning increases translucence of the tape; and wherein the tape, after the sintering, has a total transmittance of at least 30% at wavelengths from 300 nm to 800 nm; and wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% at wavelengths from 300 nm to 800 nm.

13. A process for manufacturing a sintered article, comprising:
conveying a portion of a tape through a furnace, wherein the tape comprises grains of ceramic and/or minerals;
sintering the grains of ceramic and/or minerals of the portion of tape in the furnace; and
tensioning the tape during the sintering,
wherein, in a processing direction, the tape is longer than the furnace,
wherein, after the sintering, length of the tape is at least 100 times greater than width of the tape, and wherein the width is at least 10 times greater than thickness of the tape, and wherein the thickness is no more than 500 micrometers.

14. The process of claim 13 , wherein the sintering is at a temperature greater than 800 degrees Celsius.

15. The process of claim 13 , wherein the tensioning comprises 75 kPa of tension.

16. The process of claim 13 , wherein the tensioning flattens the tape; and wherein surfaces of the tape, after the sintering, have a flatness from 0.1 μm to 50 μm over a distance of 1 cm along a length of tape.

17. The process of claim 13 , wherein the tensioning increases translucence of the tape; and wherein the tape, after the sintering, has a total transmittance of at least 30% at wavelengths from 300 nm to 800 nm; and wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% at wavelengths from 300 nm to 800 nm.

18. A process for manufacturing sintered article, comprising:
conveying a portion of a tape through a furnace, wherein the tape comprises grains of ceramic and/or minerals;
sintering the grains of ceramic and/or minerals of the portion of tape in the furnace; and
tensioning the tape during the sintering,
wherein the tape is continuously conveyed through the furnace during the sintering,
wherein the tensioning flattens the tape, and wherein surfaces of the tape, after the sintering, have a flatness from 0.1 μm to 50 μm over a distance of 1 cm along a length of tape.

19. The process of claim 18 , wherein the sintering is at a temperature greater than 800 degrees Celsius, and wherein the tensioning comprises 75 kPa of tension.

20. The process of claim 18 , wherein the tape, after the sintering, has a total transmittance of at least 30% at wavelengths from 300 nm to 800 nm.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Bouton William Joseph
• Brackley Douglas Edward
• Kester Lanrik Wayne
• Ketcham Thomas Dale
• Miller Eric Lee
• Tanner Cameron Wayne
• Zimmermann James William

Classifications

• C04B35/638 Primary

  Removal thereof · CPC title

• C04B35/486

  Fine ceramics · CPC title

• C04B35/111

  Fine ceramics · CPC title

• C04B2235/3217

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

• C04B2235/656

  characterised by specific heating conditions during heat treatment · CPC title