Articles comprising ceramics and method of making the same

Patent metadata

Field	Value
Publication number	US-2021078908-A1
Application number	US-201816611906-A
Country	US
Kind code	A1
Filing date	May 10, 2018
Priority date	May 12, 2017
Publication date	Mar 18, 2021
Grant date	—

Abstract

Ceramic comprising at least one polycrystalline metal oxide and amorphous phase, wherein the metal oxide comprises crystals with grain boundaries and triple points, wherein the amorphous phase is present at the grain boundaries and triple points. Exemplary articles made by a method described herein include electronics enclosure (e.g., a watch case, cellular phone case, or a tablet case).

First claim

1 - 6 . (canceled)

7 . A ceramic comprising polycrystalline zirconia, a first polycrystalline rare earth aluminate, a second, different polycrystalline rare earth aluminate, and an amorphous phase comprising, on a theoretical oxides basis, SiO 2 , Al 2 O 3 , and rare earth oxide, wherein the polycrystalline zirconia and the first and second polycrystalline rare earth aluminate comprise crystals with grain boundaries, wherein the crystals of the first crystalline rare earth aluminate are acicular, and wherein the amorphous phase is present at the grain boundaries.

8 . The ceramic of claim 7 , wherein the ceramic is in the form of a three-dimensional ceramic article, wherein the article has at least one portion having a bend radius of at 1 mm, wherein the article has a thickness of at least 0.3 mm.

9 . The ceramic of claim 7 , wherein the first rare earth aluminate is at least one of LaAlO 3 , CeAlO 3 , Er 3 Al 5 O 12 , GdAlO 3 , or Dy 3 Al 5 O 12 , and wherein the second rare earth aluminate is at least one of LaAl 11 O 18 or CeAl 11 O 18 .

10 . The ceramic of claim 7 passing the Flow Property Test.

11 . The ceramic of claim 7 , wherein the article is an electronics enclosure.

12 . A method of forming a ceramic article of claim 7 , the method comprising:
providing a ceramic preform having a volume, a first shape, the ceramic preform comprising polycrystalline zirconia, a first polycrystalline rare earth aluminate, a second, different polycrystalline rare earth aluminate, and an amorphous phase comprising, on a theoretical oxides basis, SiO 2 , Al 2 O 3 , and rare earth oxide; providing a major surface; placing at least a portion of the preform in contact with the major surface; and heating the preform at sufficient temperature and sufficient pressure to form the article having a second, different shape.

13 . A ceramic comprising polycrystalline zirconia, polycrystalline alumina, polycrystalline yttrium aluminate, and an amorphous phase comprising, on a theoretical oxides basis, SiO 2 , Al 2 O 3 , and yttrium oxide, wherein the polycrystalline zirconia, the polycrystalline alumina, and the polycrystalline yttrium aluminate comprise crystals with grain boundaries, and wherein the amorphous phase is present at the grain boundaries.

14 . The ceramic of claim 13 , wherein the ceramic is in the form of a three-dimensional ceramic article, wherein the article has at least one portion having a bend radius of at 1 mm, wherein the article has a thickness of at least 0.3 mm.

15 . The ceramic of claim 13 passing the Flow Property Test.

16 . The ceramic of claim 13 , wherein the article is an electronics enclosure.

17 . A method of forming a ceramic article of claim 13 , the method comprising:
providing a ceramic preform having a volume, a first shape, the ceramic preform comprising polycrystalline zirconia, polycrystalline alumina, polycrystalline yttrium aluminate, and an amorphous phase comprising, on a theoretical oxides basis, SiO 2 , Al 2 O 3 , and yttrium oxide; providing a major surface; placing at least a portion of the preform in contact with the major surface; and heating the preform at sufficient temperature and sufficient pressure to form the article having a second, different shape.

Assignees

• 3M Innovative Properties Co

Inventors

• Rosenflanz Anatoly Zhanovich
• Anderson Jason D
• Shanti Noah O
• Stolzenburg Fabian
• Tangeman Jean A

Classifications

• C04B35/50 Primary

  based on rare-earth compounds {(non-oxide rare earth compounds C04B35/5156)} · CPC title

• C04B35/111 Primary

  Fine ceramics · CPC title

• C04B35/01

  based on oxide ceramics · CPC title

• C04B2235/3222

  Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4) · CPC title

• C04B2235/3227

  Lanthanum oxide or oxide-forming salts thereof · CPC title