Locally-sintered porous soot parts and methods of forming

Patent metadata

Field	Value
Publication number	US-9452946-B2
Application number	US-201314057329-A
Country	US
Kind code	B2
Filing date	Oct 18, 2013
Priority date	Oct 18, 2013
Publication date	Sep 27, 2016
Grant date	Sep 27, 2016

Abstract

A porous soot sheet is formed using a roll-to-roll glass soot deposition and sintering process. The soot sheet formation involves depositing glass soot particles on a deposition surface to form a supported soot layer, removing the soot layer from the deposition surface to form a soot sheet, and heating a portion of the soot sheet to locally-sinter the glass soot particles and form a porous soot part having a sintered peripheral edge.

First claim

We claim:

1. A partially-sintered soot part of at least 50 mole percent silica glass comprising:
a porous soot body, and
a peripheral sintered glass edge of sintered soot surrounding the porous soot body, wherein the glass edge width ranges from 0.5 to 5 mm, and wherein density of the sintered soot across the glass edge decreases proximate to the porous soot body.

2. The partially-sintered soot part of claim 1 , wherein the porous soot body density ranges from 0.2 to 1.76 g/cm 3 and the glass edge density ranges from 1.76 to 2.2 g/cm 3 .

3. The partially-sintered soot part of claim 1 , wherein the porous soot body is from 10 to 80% dense and the glass edge is at least 80% dense.

4. The partially-sintered soot part of claim 1 , wherein the glass edge is at least 80% dense.

5. The partially-sintered soot part of claim 1 , wherein the glass edge is at least 95% dense.

6. The partially-sintered soot part of claim 1 , wherein the porous soot body thickness ranges from 50 microns to 5 mm.

7. The partially-sintered soot part of claim 1 , wherein the porous soot body composition and the glass edge of sintered soot composition are the same as one another.

8. The partially-sintered soot part of claim 1 , wherein the porous soot body comprises a composite of at least two soot layers.

9. The partially-sintered soot part of claim 1 , further comprising a sintered glass region formed within the porous soot body.

10. The partially-sintered soot part of claim 1 , further comprising an inner sintered glass edge.

11. The partially-sintered soot part of claim 1 , where the peripheral sintered glass edge of sintered soot is semi-rigid.

Assignees

• Corning Inc

Inventors

• Hawtof Daniel Warren
• Mozdy Eric John

Classifications

• C03B19/1492 Primary

  Deposition substrates, e.g. targets · CPC title

• C03B19/06 Primary

  by sintering, {e.g. by cold isostatic pressing of powders and subsequent sintering, by hot pressing of powders, by sintering slurries or dispersions not undergoing a liquid phase reaction} · CPC title

• Y10T428/24777

  Edge feature · CPC title

• C03B19/1453

  Thermal after-treatment of the shaped article, e.g. dehydrating, consolidating, sintering · CPC title

• C03C23/0025

  by a laser beam · CPC title