Sintered zircon material for forming block

Patent metadata

Field	Value
Publication number	US-9809500-B2
Application number	US-201514674263-A
Country	US
Kind code	B2
Filing date	Mar 31, 2015
Priority date	Mar 31, 2014
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

A refractory object may include a zircon body that may include at least about 0.1 wt. % and not greater than about 5.5 wt. % of an Al 2 O 3 containing component for a total weight of the zircon body. The zircon body may further include at least about 25 wt. % and not greater than about 35 wt. % of a SiO 2 component for a total weight of the zircon body.

First claim

What is claimed is:

1. A refractory object comprising:
a zircon body, wherein the zircon body comprises:
at least about 1.5 wt. % and not greater than about 3.5 wt. % of Al 2 O 3 for a total weight of the zircon body;
at least about 25 wt. % and not greater than about 35 wt. % of SiO 2 component for a total weight of the zircon body;
at least about 0.1 wt. % of Ta 2 O 5 for a total weight of the zircon body; and
a ratio CB SiO2 /CB AlC of at least about 10, where CB SiO2 represents a content of the SiO 2 component in wt. % for a total weight of the zircon body and CB AlC represents a content of Al 2 O 3 containing component in wt. % for a total weight of the zircon body.

2. The refractory object of claim 1 , wherein the zircon body comprises a content of zircon of at least about 50 wt. % for a total weight of the zircon body.

3. The refractory object of claim 1 , wherein the zircon body comprises at least about 30 wt. % and not greater than about 34 wt. % of SiO 2 component for a total weight of the zircon body.

4. The refractory object of claim 1 , wherein the zircon body comprises not greater than about 3.0 wt. % of Ta 2 O 5 for a total weight of the zircon body.

5. The refractory object claim 1 , wherein the zircon body comprises not greater than about 1.0 wt. % of TiO 2 for a total weight of the zircon body.

6. The refractory object of claim 1 , wherein the zircon body comprises not greater than about 1.0 wt. % of CaO for a total weight of the zircon body.

7. The refractory object of claim 1 , wherein the zircon body comprises a creep deformation rate of not greater than about 1.0 E −4 h −1 as measured using a three point bend test at a temperature of 1350° C. and a stress of 2 MPa.

8. The refractory object of claim 1 , wherein the zircon body comprises a creep deformation rate of not greater than about 4.9 E −5 h −1 as measured using a four point bend test at a temperature of 1350° C. and a stress of 2 MPa.

9. The refractory object of claim 1 , wherein the zircon body has a density of not greater than about 4.5 g/cm 3 .

10. The refractory object of claim 1 , wherein the zircon body comprises an apparent porosity of not greater than about 15 vol. % for a total volume of the zircon body.

11. The refractory object of claim 1 , wherein the zircon body comprises a blistering value of not greater than about 8 bubbles per mm 2 measured after 8 hours at a temperature of 1200° C.

12. The refractory object of claim 1 , wherein the zircon body comprises a blistering value of not greater than about 1 bubble per mm 2 measured after 360 hours at a temperature of 1200° C.

13. A refractory object comprising:
a zircon body comprising a creep deformation rate of not greater than about 5.0 E−5 h −1 as measured using a four point bend test at a temperature of 1350° C. and a stress of 2 MPa, wherein the zircon body comprises at least about 1.5 wt. % and not greater than about 3.5 wt. % of Al 2 O 3 for a total weight of the zircon body, at least about 0.1 wt. % of Ta 2 O 5 for a total weight of the zircon body and a ratio CB SiO2 /CB AlC of at least about 10, where CB SiO2 represents a content of SiO 2 component in wt. % for a total weight of the zircon body and CB AlC represents a content of Al 2 O 3 containing component in wt. % for a total weight of the zircon body.

14. The refractory object of claim 13 , wherein the zircon body comprises a content of zircon of at least about 50 wt. % for a total weight of the zircon body.

15. The refractory object of claim 14 , wherein the zircon body comprises at least about 25 wt. % and not greater than about 35 wt. % of SiO 2 component for a total weight of the zircon body.

16. The refractory object of claim 14 , wherein the zircon body comprises not greater than about 3.0 wt. % of Ta 2 O 5 for a total weight of the zircon body.

Assignees

• Saint-Gobain Ceram & Plastics Inc

Inventors

• Fourcade Julien P
• Lechevalier David J
• Citti Olivier

Classifications

• C04B2235/3463

  Alumino-silicates other than clay, e.g. mullite · CPC title

• C04B35/62685

  characterised by the order of addition of constituents or additives · CPC title

• C04B2235/80

  Phases present in the sintered or melt-cast ceramic products other than the main phase · CPC title

• C04B2235/3251

  Niobium oxides, niobates, tantalum oxides, tantalates, or oxide-forming salts thereof · CPC title

• C04B2235/96

  Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance · CPC title