Ceramic assembly and method of forming the same

Patent metadata

Field	Value
Publication number	US-11795116-B2
Application number	US-202017080906-A
Country	US
Kind code	B2
Filing date	Oct 27, 2020
Priority date	Dec 21, 2016
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

Ceramic assembly can comprise a ceramic article comprising a thickness defined between a first major surface and a second major surface. The thickness can be about 100 micrometers or less. The ceramic assembly can comprise a polymer coating deposited over at least an outer peripheral portion of the first major surface of the ceramic article. The polymer coating can comprise a thickness of about 30 micrometers or less. An edge strength of the ceramic assembly can be greater than an edge strength of the ceramic article by about 50 MegaPascals or more. Methods of forming a ceramic assembly can comprise depositing a polymer coating on an outer peripheral portion of a first major surface of a ceramic article. Methods can further comprise curing the polymer coating.

First claim

What is claimed is:

1. A ceramic assembly, comprising:
a body comprising ceramic grains sintered to one another, wherein a thickness of the body, between first and second major surfaces thereof, is in a range from 3 μm to 1 mm, and the first and second major surfaces of the body have an unpolished granular profile such that the unpolished granular profile includes grains protruding outward from a respective major surface with a height of at least 25 nm and no more than 150 μm relative to recessed portions of the respective major surface at boundaries between respective grains;
a coating overlaying the unpolished granular profile of the first major surface, wherein an outward facing surface of the coating is less rough than the unpolished granular profile of the first major surface, the coating is disposed over a portion of an edge portion, and the edge portion comprises an outer peripheral edge circumscribing the body; and
an adhesion promoter is positioned between the body and the coating.

2. The ceramic assembly of claim 1 , wherein the unpolished granular profile includes grains with a height of at least 150 nanometers relative to recessed portions of the respective major surface at boundaries between the respective grains.

3. The ceramic assembly of claim 2 , wherein the height of the grains is no more than 80 micrometers relative to recessed portions of the respective major surface at boundaries between the respective grains.

4. The ceramic assembly of claim 3 , wherein the coating fills in crevasses between grains of the unpolished granular profile.

5. The ceramic assembly of claim 1 , wherein the body is thicker than the coating.

6. The ceramic assembly of claim 5 , wherein thickness of the coating is less than 30 micrometers.

7. The ceramic assembly of claim 1 , wherein the grains sintered to one another have an average grain size of 5 μm or less, and wherein over a distance of 1 cm along a single axis, a surface roughness (Ra) of the coating is less than half that of the unpolished granular profile.

8. The ceramic assembly of claim 7 , wherein the surface roughness (Ra) of the coating is less than a third that of the unpolished granular profile.

9. The ceramic assembly of claim 1 , wherein a surface roughness (Ra) of the coating is less than 15 nm over a distance of 1 cm along a single axis.

10. The ceramic assembly of claim 1 , wherein a surface roughness (Rq) of the coating is less than 15 nm over a distance of 1 cm along a single axis.

11. The ceramic assembly of claim 1 , wherein the coating is amorphous.

12. The ceramic assembly of claim 1 , wherein the coating comprises a material with melting temperature above 500° C.

13. The ceramic assembly of claim 1 , wherein the body comprises an oxide.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Behan Francis Martin
• Cho Seo-Yeong
• Johnson Benedict Yorke
• Ketcham Thomas Dale
• Manley Robert George
• Seok Seongho
• Zhelev Nikolay Zhelev
• Zhuang cheng-gang

Classifications

• C04B41/009 Primary

  characterised by the material treated · CPC title

• B05D3/007

  After-treatment · CPC title

• C04B41/488

  Other macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds · CPC title

• C04B41/4823

  Phenol-formaldehyde condensation products · CPC title

• C04B41/4846

  Perfluoro-compounds · CPC title