Manufacturing line, process, and sintered article

Patent metadata

Field	Value
Publication number	US-12429281-B2
Application number	US-202519085613-A
Country	US
Kind code	B2
Filing date	Mar 20, 2025
Priority date	Jun 29, 2015
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.

First claim

What is claimed is:

1. A sintered polycrystalline ceramic ribbon, comprising:
ceramic grains fused to one another;
a length of at least 10 m,
a thickness of at least 20 nm and no more than 100 μm,
a width at least 10 times the thickness, and wherein the length is at least 100 times greater than the width, and
wherein the ribbon has fewer than 10 pin holes having a cross-sectional area of at least a square micrometer per square millimeter of surface on average over full surfaces thereof.

2. The ribbon of claim 1 , wherein the thickness is less than 50 micrometers.

3. The ribbon of claim 1 ,
wherein the width is at least 5 mm and no greater than 20 cm.

4. The ribbon of claim 3 , wherein the thickness is at least 10 μm and less than 50 μm.

5. The ribbon of claim 4 , wherein the ribbon has fewer than 1 pin hole having a cross-sectional area of at least a square micrometer per square millimeter of surface on average over full surfaces thereof.

6. The ribbon of claim 3 , wherein porosity of the ribbon is less than 1%.

7. The ribbon of claim 3 , wherein the ceramic grains are lithium garnet.

8. The ribbon of claim 7 , wherein the ribbon has a surface area exceeding 1000 cm 2 .

9. The ribbon of claim 7 , wherein the ribbon is flexible enough to be wound on a mandrel of 0.7 m diameter.

10. The ribbon of claim 7 , wherein surfaces thereof have a roughness in a range of 10 nanometers to 1000 nanometers across a distance of 10 millimeters along the length of the ribbon.

11. The ribbon of claim 7 , wherein the ribbon has flatness in a range of 0.1 μm to 50 μm over a distance of 1 cm along a single axis.

12. The ribbon of claim 3 , wherein the ribbon can support 20 megapascals of tension without failure.

13. The ribbon of claim 1 ,
wherein the ribbon has fewer than 1 pin holes having a cross-sectional area of at least a square micrometer per square millimeter of surface on average over full surfaces thereof.

14. The ribbon of claim 13 , wherein the thickness is less than 50 micrometers.

15. The ribbon of claim 13 , further comprising:
a first surface, a second surface, and a body extending therebetween, wherein the body comprises the ceramic grains fused to one another;
wherein the first and second surfaces each have a granular profile, wherein the granular profile includes grains with a height in a range from twenty-five nanometers to one-hundred-and-fifty micrometers relative to recessed portions of the first and second surfaces at boundaries between the respective grains; and
wherein the ribbon has high surface quality such that the first and second surfaces both have at least a square centimeter of area having fewer than ten surface defects from adhesion or abrasion with a dimension greater than five micrometers.

16. The ribbon of claim 15 , wherein the ribbon has high surface quality such that the first and second surfaces both have at least a square centimeter of area having fewer than 10 surface defects from adhesion or abrasion with a dimension greater than 5 micrometers.

17. The ribbon of claim 15 , wherein the ribbon has high surface quality such that the first and second surfaces both have at least a square centimeter of area having fewer than 10 surface defects from adhesion or abrasion with a dimension greater than 5 micrometers.

18. A sintered polycrystalline ceramic ribbon, comprising:
ceramic grains fused to one another;
a length of at least 10 m,
a thickness of at least 10 μm and less than 100 μm,
a width at least 10 times the thickness, and wherein the length is at least 100 times greater than the width,
wherein the ribbon has fewer than 10 pin holes having a cross-sectional area of at least a square micrometer per square millimeter of surface on average over full surfaces thereof; and
wherein porosity of the ribbon is less than 1%.

19. A sintered polycrystalline ceramic ribbon, comprising:
ceramic grains fused to one another;
a length of at least 10 m,
a thickness of at least 10 μm and less than 100 μm,
a width at least 10 times the thickness, and wherein the length is at least 100 times greater than the width,
wherein the ribbon has fewer than 10 pin holes having a cross-sectional area of at least a square micrometer per square millimeter of surface on average over full surfaces thereof, and
wherein the ceramic grains are lithium garnet.

20. The ribbon of claim 19 , wherein the width is at least 5 mm and no greater than 20 cm.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Bouton William Joseph
• Brown Jacqueline Leslie
• Curry Timothy Joseph
• Hurny Roman E
• Kester Lanrik Wayne
• Ketcham Thomas Dale
• Olenick John Albert
• Olenick Kathleen Ritter
• Paananen Jeremy
• Silverblatt Thomas
• St Julien Dell Joseph
• Venkateswaran Viswanathan
• Zink Nathan Michael

Classifications

• B28B11/243

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• C04B2235/95

  Products characterised by their size, e.g. microceramics · CPC title

• F26B13/10

  Arrangements for feeding, heating or supporting materials; Controlling movement, tension or position of materials (heating processes F26B3/00) · CPC title

• F27B13/10

  Arrangements of linings · CPC title

• F27B9/28

  for treating continuous lengths of work · CPC title