System, process and related sintered article

Patent metadata

Field	Value
Publication number	US-11505468-B2
Application number	US-202217718484-A
Country	US
Kind code	B2
Filing date	Apr 12, 2022
Priority date	Jan 26, 2016
Publication date	Nov 22, 2022
Grant date	Nov 22, 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:
sintering a tape comprising grains of ceramic and/or minerals; and
tensioning the tape during the sintering, wherein the tensioning comprises 75 kPa of tension,
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 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.

4. 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.

5. The process of claim 4 , wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% at wavelengths from 300 nm to 800 nm.

6. The process of claim 1 , wherein the grains of ceramic and/or minerals comprise alumina, zirconia, lithium garnet, and/or spinel.

7. The process of claim 6 , wherein the length is greater than 70 cm.

8. The process of claim 7 , wherein the width is greater than 20 cm.

9. The process of claim 8 , wherein the thickness is less than 100 micrometers.

10. A process for manufacturing a sintered article, comprising:
sintering a tape comprising grains of ceramic and/or minerals, wherein the grains of ceramic and/or minerals comprise alumina, zirconia, lithium garnet, and/or spinel; and
tensioning the tape during the sintering, wherein the tensioning comprises 75 kPa of tension, wherein the tensioning flattens the tape,
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, wherein the length is greater than 70 cm, wherein the width is greater than 20 cm, and wherein the thickness is less than 100 micrometers;
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.

11. The process of claim 10 , wherein the sintering is at a temperature greater than 800 degrees Celsius.

12. The process of claim 10 , 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.

13. The process of claim 12 , wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% at wavelengths from 300 nm to 800 nm.

14. A process for manufacturing a sintered article, comprising:
sintering a tape comprising grains of ceramic and/or minerals, wherein the grains of ceramic and/or minerals comprise alumina, zirconia, lithium garnet, and/or spinel; and
tensioning the tape during the sintering, wherein the tensioning comprises 75 kPa of tension, wherein the tensioning increases translucence of the tape;
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, wherein the length is greater than 70 cm, wherein the width is greater than 20 cm, and wherein the thickness is less than 100 micrometers;
wherein the tape, after the sintering, has a total transmittance of at least 30% at wavelengths from 300 nm to 800 nm.

15. The process of claim 14 , wherein diffuse transmission through tape, after the sintering, is in a range from 10% to 60% 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

• C04B2235/3244

  Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof · CPC title

• C04B35/632

  Organic additives · CPC title

• C03C2205/00

  Compositions applicable for the manufacture of vitreous enamels or glazes · CPC title

• C01F7/441 Primary

  by calcination · CPC title

• C04B2235/6586

  Processes characterised by the flow of gas · CPC title