CN103764577A

CN103764577A - Ceramic forming devices with a honeycomb structure and methods

Info

Publication number: CN103764577A
Application number: CN201280042068.5A
Authority: CN
Inventors: W·P·安迪葛; I·A·科尔内霍; T·D·凯査姆; J·S·萨瑟兰; C·W·坦纳
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2011-08-31
Filing date: 2012-08-24
Publication date: 2014-04-30
Also published as: KR20140067074A; TW201313629A; WO2013032885A1; JP2014525390A

Abstract

A ceramic forming device for fusion drawing a glass ribbon includes a honeycomb structure. In further examples, a method of fusion drawing a glass ribbon includes the step of providing a ceramic forming device with a honeycomb structure. Methods of making a ceramic forming device for fusion drawing a glass ribbon include the step of extruding a ceramic-forming batch material through a die member to form a green body with a honeycomb structure including a plurality of walls at least partially defining a plurality of channels extending through the green body. Each of the plurality of walls has a thickness defined between a corresponding pair of the channels from about 0.5 mm to about 30 mm. The methods further include the step of firing the green body to form a fired ceramic body with the honeycomb structure. The methods still further include the step of providing the ceramic forming device with a wedge and a trough at least partially defined by a pair of weirs, wherein the honeycomb structure forms at least a portion of the ceramic forming device.

Description

There is the ceramics forming device and method of honeycomb structure

The application is according to 35U.S.C. § 119, requires the right of priority of No. 61/529504th, the U.S. Provisional Application series submitted on August 31st, 2011, herein take this application as basis and it is incorporated herein by reference in full.

Technical field

Relate generally to ceramics forming device of the present invention, relates more specifically to have the ceramics forming device and method of honeycomb structure.

Background of invention

Glass manufacturing equipment is commonly used to form various glassy products, for example LCD flat panel glass.Knownly melten glass is flowed downward by ceramics forming device and from ceramics forming device fusion drawn glass, bring manufacture sheet glass.

Summary of the invention

The simplification that below provides summary of the invention is concluded, to the basic comprehension to the more described illustrative aspects of part are described in detail in detail is provided.

In an illustrative aspects of the present invention, provide the device of the ceramics forming for fusing drawing glassribbons.Described ceramics forming device comprises shaping wedge, and described shaping wedge comprises a pair of downward-sloping profiled surface part of extending between the opposed end of described shaping wedge.Described a pair of downward-sloping profiled surface part is assembled along downstream direction respectively, with the root of forming shaped wedge.Honeycomb structure forms the ceramics forming device of at least a portion, and described honeycomb structure comprises multiple walls, and described multiple walls define multiple passages at least partly.

In an embodiment aspect this, ceramics forming device also comprises groove, and described groove is limited at least partly by a pair of weir, and described a pair of weir comprises the first weir and second weir of the opposite side that defines described groove.

In another embodiment aspect this, described groove be included in described a pair of weir at least one top and described groove compared with the degree of depth between lower part, this degree of depth changes along the axle of ceramics forming device.

In another embodiment aspect this, honeycomb structure forms a pair of weir of at least a portion.

In another embodiment aspect this, honeycomb structure forms the shaping wedge of at least a portion.

In another embodiment aspect this, multiple walls of honeycomb structure comprise respectively the thickness being limited between a pair of corresponding passage, this thickness is that about 0.5mm is to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm.

In other embodiments aspect this, the channel density of honeycomb structure is approximately 1/25 passage/cm ²to approximately 20 passage/cm ², in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².

In another embodiment aspect this, ceramics forming device also comprises the outer refractory being positioned on honeycomb structure outer surface.

In an embodiment aspect this, outer refractory comprises stupalith.

In another embodiment aspect this, outer stupalith comprises closed pore vesicular structure.

In another illustrative aspects of the present invention, a kind of method that fuses drawing glassribbons comprises the following steps: step (I), ceramics forming device is provided, described ceramics forming device comprises groove, described groove is limited at least partly by a pair of weir, and described a pair of weir comprises the first weir and second weir of the opposite side that defines described groove.Described ceramics forming device also comprises shaping wedge, and described shaping wedge comprises a pair of downward-sloping profiled surface part of extending between the opposed end of described shaping wedge.Described a pair of downward-sloping profiled surface part is assembled along downstream direction respectively, with the root of forming shaped wedge.Honeycomb structure forms the ceramics forming device of at least a portion, and described honeycomb structure comprises multiple walls, and described multiple walls define multiple passages at least partly.Described method also comprises step (II), glass melt is introduced in the groove of ceramics forming device.Described method also comprises step (III), and melten glass is overflowed from groove via this top edge to weir, thereby corresponding melten glass plate moves down along intilted profiled surface part respectively.Described method also comprises step (IV), and fusion drawing melten glass plate leaves the root of shaping wedge together as glass ribbon.

In an embodiment aspect this, step (I) provides the honeycomb structure to weir that forms at least a portion.

In another embodiment aspect this, step (I) provides the honeycomb structure that forms the shaping wedge of at least a portion.

In another embodiment aspect this, step (I) provides the honeycomb structure that forms substantially whole shaping wedge.

In another embodiment aspect this, step (I) provides the outer refractory on the outer surface that is positioned at the honeycomb structure that has formed shaping wedge.

In another embodiment aspect this, step (I) provide the outer refractory on the outer surface that is positioned at honeycomb structure.

In another embodiment aspect this, step (I) provides multiple walls of honeycomb structure, multiple walls of described honeycomb structure have respectively the thickness being limited between a pair of corresponding passage, this thickness is that about 0.5mm is to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm.

In another embodiment aspect this, step (I) provide honeycomb structure, and the channel density of described honeycomb structure is approximately 1/25 passage/cm ²to approximately 20 passage/cm ², in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 1 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².

In another illustrative aspects of the present invention, the manufacture method that is used for the ceramics forming device that fuses drawing glassribbons comprises the following steps: step (I), by die component extruded ceramic shaping batch of material, to form the green compact body with honeycomb structure, described honeycomb structure comprises multiple walls, and described multiple walls limit the multiple passages that extend through green compact body at least partly.Described multiple wall has respectively the thickness being limited between a pair of corresponding passage, this thickness is that about 0.5mm is to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm.Described method also comprises step (II), fires green compact body to form the fired ceramic body with honeycomb structure.Described method also comprises step (III), and ceramics forming device is provided, the groove that described ceramics forming device has wedge and limited at least partly by a pair of weir, and wherein, honeycomb structure forms the ceramics forming device of at least a portion.

In an embodiment aspect this, step (III) comprises provides ceramics forming device with mechanical processing process.

In another embodiment aspect this, the mechanical processing process of described step (III) is included in step (II) and before green compact body is carried out to mechanical workout.

In another embodiment aspect this, the mechanical processing process of described step (III) is included in step (II) and afterwards fired ceramic body is carried out to mechanical workout.

In another embodiment aspect this, step (I) has formed honeycomb structure, and the channel density of described honeycomb structure is approximately 1/25 passage/cm ²to approximately 20 passage/cm ², in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 1 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².

In another embodiment aspect this, honeycomb structure forms the wedge of at least a portion of ceramics forming device.

In another embodiment aspect this, ceramic body comprises the vesicular structure of basic closed pore.

In another embodiment aspect this, described method also comprises the steps: that the particle with the first mean particle size by mixing the first quantity and the particle with the second mean particle size of the second quantity prepare ceramics forming material, and described the second mean particle size is greater than described the first mean particle size.

In another embodiment aspect this, the particle of the particle of described the first quantity and the second quantity comprises alumina particle.

In another embodiment aspect this, the first mean particle size of the alumina particle of the first quantity is about 0.6 micron, and the second mean particle size of the alumina particle of the second quantity is about 2.7 microns.

In another embodiment aspect this, the weight ratio of the alumina particle of the alumina particle of the first quantity and the second quantity is about 3:1.

In another embodiment aspect this, the particle of the particle of described the first quantity and the second quantity comprises zircon particle.

In another embodiment aspect this, the first mean particle size of the zircon particle of the first quantity is about 1 micron, and the second mean particle size of the zircon particle of the second quantity is about 7 microns.

In another embodiment aspect this, the weight ratio of the zircon particle of the zircon particle of the first quantity and the second quantity is about 1:1.

In another embodiment aspect this, described method also comprises the steps, outer refractory is applied to the outer surface of honeycomb structure.

In another embodiment aspect this, described method also comprises the steps, in the process of step (II), at the oxygen level of firing indoor reduction atmosphere.

In another embodiment aspect this, described method also comprises the steps, in the process of step (II), forces fluid to pass through multiple passages.

In another embodiment aspect this, described method also comprises the steps, in the process of step (II), forces steam to pass through multiple passages.

In another illustrative aspects of the present invention, the manufacture method that is used for the ceramics forming device that fuses drawing glassribbons comprises the following steps: by die component extruded ceramic shaping batch of material, to form the green compact body with honeycomb structure, described honeycomb structure comprises multiple walls, described multiple wall limits the multiple passages that extend through green compact body at least partly, wherein said multiple wall has respectively the thickness being limited between a pair of corresponding passage, this thickness is that about 0.5mm is to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm, and honeycomb structure comprises approximately 1/25 passage/cm ²to approximately 20 passage/cm ²channel density, in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 1 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².Described method also comprises the step of green compact body being carried out to mechanical workout, thus the groove that wedge is provided and is limited at least partly by a pair of weir for green compact building mortion, and wherein, honeycomb structure forms the green compact building mortion of at least a portion.Described method also comprises the step that green compact building mortion is fired, to form the fired ceramics forming device with honeycomb structure.

In another illustrative aspects of the present invention, the manufacture method that is used for the ceramics forming device that fuses drawing glassribbons comprises the following steps: by die component extruded ceramic shaping batch of material, to form the green compact body with honeycomb structure, described honeycomb structure comprises multiple walls, and described multiple walls limit the multiple passages that extend through green compact body at least partly.Described multiple wall has respectively the thickness being limited between a pair of corresponding passage, this thickness is that about 0.5mm is to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm, and honeycomb structure comprises approximately 1/25 passage/cm ²to approximately 20 passage/cm ²channel density, in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 1 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².Described method also comprises the step that green compact body is fired, to form the fired ceramic body with honeycomb structure.Described method also comprises the step of fired ceramic body being carried out to mechanical workout, thus the groove that wedge is provided and is limited at least partly by a pair of weir for ceramics forming device, and wherein, honeycomb structure forms the ceramics forming device of at least a portion.

Accompanying drawing summary

With reference to accompanying drawing, read the following specifically describes and can understand better these and other aspect, wherein:

Fig. 1 is the schematic diagram that comprises the fusion drawing device of ceramics forming device according to certain aspects of the invention;

Fig. 2 is the cross section enlarged perspective of the ceramics forming device of Fig. 1;

Fig. 3 is honeycomb structure and the outer field enlarged view of Fig. 2;

Fig. 4 is the enlarged view of the closed vesicular structure of fired stupalith;

Shown in Fig. 5, be for the schematic diagram with the extrusion of formation green compact body by die component extruded ceramic shaping batch of material;

It shown in Fig. 6, is the exemplary size distribution of the alumina particle of the first quantity and the alumina particle of the second quantity;

Shown in Fig. 7, be the alumina particle of the first quantity and the Computation distribution of alumina particle of the second quantity and the combination of actual distribution of Fig. 6;

Fig. 8 is the local amplification sectional view of a part of die component of Fig. 5;

Fig. 9 is the sectional view of segmentation green compact body along 9-9 line in Fig. 5;

Shown in Figure 10, be to fire green compact body to form the method for fired ceramic body;

Shown in Figure 11, be with what form fired ceramic body, exemplary to fire circulation for firing green compact body;

Figure 12 has schematically shown the process of mechanical workout, and this process provides peripheral shape for honeycomb structure, the peripheral shape of weir, groove and the shaping wedge of the approximate ceramics forming device of this peripheral shape; And

Figure 13 has shown the surperficial outer refractory that is applied to machined honeycomb structure.

detailed Description Of The Invention

At this, more completely describe with reference to the accompanying drawings each embodiment, in accompanying drawing, provided illustrative embodiments.Whenever possible, in institute's drawings attached, with identical Reference numeral, represent same or similar part.But the present invention can implement in many different modes, should not be interpreted to the embodiment being confined in this proposition.

Fig. 1 has shown for fusing the schematic diagram of drawing glassribbons 103 with the follow-up fusion drawing device 101 that is processed into sheet glass.Described fusion drawing device 101 can comprise melt container 105, and this melt container 105 is configured to for receiving batch of material 107 from storage hopper 109.Can introduce described batch of material 107 by the batch of material e Foerderanlage 111 driving with electric motor 113.Optional controller 115 can be configured to for activating electric motor 113, thereby the batch of material of aequum 107 is introduced in melt container 105, as shown in arrow 117.Glass metal probe 119 can be used for measuring the level of the glass melt 121 in vertical tube 123, and by the mode of communication link 125, the information transmission recording is arrived to controller 115.

Fusion drawing device 101 also can comprise such as finer of clarification container 127(), described clarification container 127 is positioned at the downstream of melt container 105, and is connected with described melt container 105 by the mode of the first pipe connecting 129.Such as teeter column of mixing vessel 131() also can be positioned at the downstream of described clarification container 127 and for example alms bowl shape barrel (bowl) of transport box 133() can be positioned at the downstream of described mixing vessel 131.As shown, the second pipe connecting 135 can be connected to described mixing vessel 131 by described clarification container 127, and the 3rd pipe connecting 137 can be connected to transport box 133 by described mixing vessel 131.As further shown, can place overflow pipe 139, glass melt 121 is delivered to the import 141 of ceramics forming device 143 from described transport box 133.As shown, the example in glass melt site has melt container 105, clarification container 127, mixing vessel 131, transport box 133 and ceramics forming device 143, and they can be placed along fusion drawing device 101 with the form of series connection.

Melt container 105 is manufactured by refractory materials conventionally, for example, by the manufacture of fire-resistant (as pottery) brick.Fusion drawing device 101 also comprises common by platinum or the platinum metal parts that for example platinum-rhodium, platinum-iridium and combination thereof are manufactured, but these parts also comprise such as following refractory metal: for example molybdenum, palladium, rhenium, tantalum, titanium, tungsten, ruthenium, osmium, zirconium and alloy thereof and/or zirconium dioxide.Described platinum component can comprise one or more following parts: the first pipe connecting 129, clarification container 127(such as finer), the second pipe connecting 135, vertical tube 123, such as teeter column of mixing vessel 131(), the 3rd pipe connecting 137, for example alms bowl shape barrel (bowl) of transport box 133(), overflow pipe 139 and import 141.Ceramics forming device 143 is manufactured by stupalith, and design is used for forming glass ribbon 103.

Fig. 2 is the cross-sectional perspective view of fusion drawing device 101 2-2 along the line of Fig. 1.As shown, ceramics forming device 143 can comprise groove 201, and described groove 201 is limited at least partly by a pair of weir, and described a pair of weir comprises the first weir 203 and second weir 205 of the opposite side that defines described groove 201.As further shown, groove also can be limited by diapire 207 at least partly.As shown, the internal surface on weir 203,205 and diapire 207 define the shape of basic U-shaped, and surface is 90 ° of settings mutually substantially.In other examples, the shape of described U-shaped can have fillet.In other examples, groove can have basal surface, and this basal surface is limited by the intersection of the internal surface on weir 203,205.For example, described groove can have the profile of V-arrangement.Although not shown, in other examples, groove can comprise other configurations.

As shown, groove 201 can have the top on weir and described groove 201 compared with the degree of depth between lower part " D ", this degree of depth " D " changes along axle 209, but the degree of depth can be also essentially identical along axle 209.It is consistent that the degree of depth " D " of change groove 201 can contribute to make ribbon thickness on the width of glass ribbon.In a proper example, as shown in Figure 2, the degree of depth " D of the import of close ceramics forming device 143 ₁" can be greater than the degree of depth " D of the groove 201 of the import downstream part that is positioned at groove 201 ₂".As shown in dotted line 210, diapire 207 can extend with the acute angle with respect to axle 209, and so that such degree of depth to be provided, along ceramics forming device 143, the length from entrance end to opposite end is that basic continous reduces to this degree of depth.

Ceramics forming device 143 also comprises shaping wedge 211, and described shaping wedge 211 comprises a pair of downward-sloping profiled surface part 213,215 of extending between the opposed end of described shaping wedge 211.Described a pair of downward-sloping profiled surface part 213,215 is assembled along downstream direction 217 respectively, to form root 219.Draw plane 221 and extend through root 219, wherein can be at downstream direction 217 along described drawing plane 221 drawing glassribbons 103.As shown, drawing plane 221 can split at root 219 places, but described drawing plane 221 also can be extended along other directions with respect to described root 219.

Optionally for ceramics forming device 143 provides one or more edge guide members 223, described one or more edge guide members 223 are crossing with at least one in a pair of downward-sloping profiled surface part 213,215.In other examples, the profiled surface part 213,215 that one or more edge guide members can be downward-sloping with two is all crossing.In other examples, edge guide member can lay respectively at the opposite end of shaping wedge 211, wherein by melten glass, flows out an edge of edge guide member formation glass ribbon 103.For example, as shown in Figure 2, edge guide member 223 can be positioned at first-phase opposite end 225a, and the same edge guide member (not shown) of second-phase can be arranged in second-phase opposite end (referring to the 225b of Fig. 1).It is all crossing that edge guide member can be configured to respectively the profiled surface part downward-sloping with two 213,215.Each edge guide member 223 can be basic mutually identical, but in other examples, edge guide member also can have different characteristics.According to certain aspects of the invention, can use various shaping wedges and edge guide member structure.For example, United States Patent (USP) the 3rd can be used in aspects more of the present invention, 451, No. 798, the 3rd, 537, No. 834, the 7th, 409, the U.S. Provisional Patent Application the 61/155th that No. 839 and/or on February 26th, 2009 submit to, the shaping wedge and the edge guide member structure that disclose in No. 669, it is incorporated into respectively herein by reference of text.

Ceramics forming device 143 can comprise the ceramic composition of wide region, and it has the material character that is applicable to melten glass fusion to be drawn into glass ribbon.Typical material character can comprise high thermal resistance, and can not pollute melten glass, and intensity is avoided ability, wearability and/or other characteristics of creep.In some instances, ceramics forming device is formed by zircon, aluminum oxide, xenotime or other stupaliths.In other examples, ceramic composition can be fired into cordierite bodies.

As shown in Figure 2, the ceramics forming device 143 of at least a portion can comprise honeycomb structure 227, and described honeycomb structure 227 has the multiple walls 229 that define at least partly multiple passages 231.As shown, honeycomb structure 227 can comprise the grid of the cross walls of the cellular network that forms passage.In an example, passage can extend along being included in the axle 209 drawing in plane 221 substantially.As shown, passage 231 can extend along axle 209, and the direction of extension is basically parallel to and draws plane 221, but in other examples, passage 231 also can be along axle 209 helically ground distortions.Again for example, other examples can comprise the passage 231 extending with other directions.For example, passage can be angle with respect to axle 209 and extends.In other examples, passage 231 can be basically perpendicular to drawing plane 221 and extend, but in other examples, passage also can extend with other angles.

For instance, Fig. 3 has shown an example of honeycomb structure 227, and wherein passage 231 is mutually identical substantially, and is mutually evenly spaced apart.In other examples, passage 231 is can be mutually differentially spaced apart and/or be of different sizes and/or shape.As shown, the shape of passage 231 can be basic square, but hole also can comprise other Polygonss (for example, trilateral, rectangle, pentagon, hexagon, heptagon, octagon etc.), circle, oval or other shape structures with three sides or more sides.Although Fig. 3 has shown the passage with sharper angle, also can carry out filler rod to increase the intensity of honeycomb to these angles.

As Fig. 3 further as shown in, honeycomb structure 227 can comprise channel density, this channel density can be considered to perpendicular to axle 209 with draw the average quantity of the passage of the crossing honeycomb structure of the cross section of plane 221.Multiple walls 229 of honeycomb structure can also have thickness " T ", and this thickness " T " is considered to each mean thickness to the passage between corresponding passage 231.As shown, the thickness of wall 229 " T " can be essentially identical with one or more walls, in other examples, can have different thickness.

Can regulate channel density and thickness " T " so that the benefit of wide region to be provided.For example, can regulate channel density with thickness " T " to be reduced in the time that in sintering procedure, firing green bodies is become to ceramic body.In fact, passage can strengthen the interior region to green compact body by heat fast transport.Thereby can promote temperature more quickly and can not set up the thermal gradient that does not conform with hope, otherwise, this can make building mortion cracking in sintering procedure.In addition, as mentioned below, size and channel density that can selector channel, move through passage effectively to realize fluid.Again for example, can regulate channel density and thickness best creep resistant, intensity to be provided, to be easy to mechanical workout and other factors.

In other examples, can regulate channel density and thickness " T " to reduce the weight of ceramics forming device 143.The decline of weight can contribute to the transportation of ceramics forming device 143, reduces ceramics forming device is transported to expending of position, site and resource, and simplify the operation that makes ceramics forming device 143 enter the position in fusion drawing device 101.Again for example, the weight that reduces ceramics forming device 143 can contribute to reduce moment of flexure, and this may cause ceramics forming device 143 distortion in use.Again for example, the decline of weight can contribute to ceramics forming device 143 to tolerate not conform with the thermal distortion (for example, thermal creep) of hope.Again for example, can selector channel density and thickness " T ", thus provide enough intensity with the distortion in avoiding using for ceramics forming device 143.For example, the grid of cross walls can contribute to prepare enough intensity for ceramics forming device 143, has the firing time of reduction, the weight decline of honeycomb structure 227 and the benefit of other useful features simultaneously.Also can wish to make passage wall thickness " T " is inhomogeneous on honeycomb cross section.For example, making passage wall thickness " T " can be important to increase skin intensity and thermal conductivity greatly near circumference place.Or, can wish to make vertical thicker towards the conduit wall of wall than level towards the conduit wall of wall.The method can be used for reducing moment of flexure (this moment of flexure can cause the distortion in use of ceramics forming device), makes the gross weight of device minimize simultaneously.Identical method is also used in that the transmission of heat in hot procedure enters or the preferred orientations of separating device.For example, in binder burnout process, can cause the base material corner of shrinkage cracking to set up two and three dimensions thermal gradient close.By setting up the preferred orientations of the heat transmission in base material, can in binder burnout process, in base material, along single shaft, set up thermal gradient, make substrate material shrink and can not ftracture along direction of principal axis.In this binder burnout process, around base material, also can need outside refractory thermal insulating material, to maintain one dimension thermal gradient.

In some instances, hole density can be approximately 1/25 passage/cm ²to approximately 20 passage/cm ², in some embodiments, be at least 1/20 passage/cm ², in some embodiments, be at least 1/15 passage/cm ², in some embodiments, be at least 1/10 passage/cm ², in some embodiments, be at least 1/5 passage/cm ², in some embodiments, be at least 1/2 passage/cm ², in some embodiments, be at least 1 passage/cm ², in some embodiments, be at least 2 passage/cm ², in some embodiments, be at least 5 passage/cm ², in some embodiments, be at least 10 passage/cm ², in some embodiments, be at least 15 passage/cm ².For instance, Fig. 3 has shown an example of the square area of the honeycomb porous structure 227 that side length is " L ".In an example, length " L " can be 1cm, but in other examples, also can adopt other length.As shown, in 1 square centimeter, there are 16 passages.Like this, if shown square area represents the whole region of honeycomb structure 227, the hole density shown in is 16 passage/cm ².In other examples, channel density can be greater than 1 passage/cm ²or be less than 20 passage/cm ², for example, be less than 19 passage/cm ², this depends on application.In addition or as an alternative, thickness " T " can be that about 0.5mm(is, approximately 0.02 inch) to about 30mm, in some embodiments, mostly be most 25mm, in some other embodiment, mostly be most 20mm, in some other embodiment, mostly be most 15mm, in some other embodiment, mostly be most 10mm, in some other embodiment, mostly be most 8mm, in some other embodiment, mostly be most 5mm, in some other embodiment, mostly be most 3mm, in some other embodiment, mostly be most 2mm, in some other embodiment, mostly be most 1mm, but in other examples, also can use other thickness.

In other examples, cross section along the honeycomb structure 227 of the planar interception perpendicular to passage can present such honeycomb structure, it overall channel area (" C ") that has comprised honeycomb structure is with respect to total floor space (" F ") C/F ratio of (that is, having comprised total cross-sectional area of wall and passage).In this type of example, C/F ratio can be about 0.25-0.80, but in other examples, also can adopt other ratios.

As shown in Figures 2 and 3, ceramics forming device 143 also can comprise optional outer 233.Referring to Fig. 3, if can apply outer 233(, provide), so that smooth surface 301 to be provided, this smooth surface is arranged so that melten glass can flow incessantly.Like this, skin 233 can be applied in machined periphery 303, to be applied on the machined outward flange 305 that the wall 229 exposing can occur in mechanical processing process and/or in part passage 307.In an example, can be with forming outer 233 with the same or analogous material of honeycomb structure 227.In addition, or as an alternative, can select for outer 233 with the material of honeycomb structure 227 to there is similar or identical thermal expansivity.

Fig. 4 has shown the exemplary signal internal structure of of fired stupalith 401, and it can be considered to present the material of wall 229 and/or outer 233.As described in, fired stupalith 401 comprises the porous material with closed pore 403.Like this, stupalith comprises the vesicular structure of basic closed pore.The closed hole of fired stupalith 401 can contribute to make the displacement of undesirable melten glass to enter ceramics forming device to minimize.Can regulate the batch of material composition of machined parameters and/or ceramics forming material, the mean pore sizes that makes hole is to be for example less than approximately 100 microns, is less than approximately 50 microns, or is less than approximately 25 microns.

Honeycomb structure 227 can be used for forming shaping wedge 211 and/or the weir 203,205 of at least a portion.For example, honeycomb structure can form the shaping wedge 211 of at least a portion.In addition or as an alternative, honeycomb structure 227 can form the weir 203,205 of at least a portion.Like this, honeycomb structure can be used for the only ceramics forming device 143 of forming section.In other examples, as shown, honeycomb structure 227 can form substantially whole ceramics forming device 143, but in other examples, honeycomb structure 227 can form whole ceramics forming devices 143.In fact, as shown, honeycomb structure has formed whole shaping wedge 211 and weir 203,205 substantially.

Initial reference Fig. 1 sets forth the method for manufacturing glass ribbon with fusion drawing device 101 below.First, can introduce batch of material 107 from storage hopper 109.Controller 115 activates electric motor 113, thereby batch of material 107 is delivered into melt container 105, as shown in arrow 117.Then batch of material is melt into glass melt 121 in melt container 105.Then make glass melt 121 enter clarification container 127 by the first pipe connecting 129, wherein can be from glass melt 121 place to go bubble.Then glass melt enters mixing vessel 131 by the second pipe connecting 135.Operation mixing vessel 131 carrys out hybrid glass melt 121, so that uniform mixture to be provided.Then make glass melt by the 3rd pipe connecting 137 and enter transport box 133, by the mode of overflow pipe 139, transmitting the import 141 that enters ceramics forming device 143 afterwards.

Referring to Fig. 2, glass melt 121 transmission enter groove 201, then from the top on weir 203,205, overflow.Then corresponding melten glass plate is moved down into respectively the intilted profiled surface 213,215 of shaping wedge 211, makes when melten glass plate moves to the root 219 of shaping wedge 211, and the edge of melten glass plate finally flows through edge guide member 223.Then two blocks of melten glass plates fuse together at root 219, and draw and leave root 219 as glass ribbon 103.

The honeycomb structure 227 relevant to ceramics forming device 143 can reduce the gross weight of building mortion 143 significantly.Meanwhile, the wall 229 of honeycomb structure 227 can be designed to the structure support that provides required, and this structure support is for melten glass being bearing in groove 201 and making it be downward through downward-sloping profiled surface the 213, the 215th, essential.The weight decline causing due to honeycomb structure 227 can contribute to prevent that ceramics forming device 143 from not conforming with the bending of hope, and described bending may occur due to High Operating Temperature.In fact, can hang ceramics forming device 143 by two

opposite end

225a, 225b, wherein may be due to the bending of the middle portion of the weight generation ceramics forming device 143 of building mortion 143.Honeycomb structure 227 can provide enough power to tolerate this bending, and the decline of weight simultaneously has further reduced the trend that ceramics forming device 143 bends under himself weight.In addition, the weight reducing of the building mortion 143 providing due to honeycomb structure 227 and enough bearing characteristicses, can avoid the creep of building mortion 143 under the condition of high temperature.

Use description to the manufacture method of the ceramics forming device 143 that fuses drawing glassribbons 103 below.Described method can comprise the step of preparing ceramics forming batch of material, in Fig. 5, by step 501, represents.In various examples, can use various ceramics forming batch of materials and/or composition.In an example, batch composition can comprise zircon or alumina particle.In an example, can provide the particle with different mean particle sizes with different quantity, to obtain required particle, load.For example, the preparing the batch method of preparing ceramics forming batch of material can comprise mixes the alumina particle with the first mean particle size of the first quantity and the alumina particle with the second mean particle size of the second quantity, and described the second mean particle size is greater than described the first mean particle size.In this type of example, can realize better filling, make being filled in the gap producing between larger particles intermeshing of lesser amt compared with small-particle of larger amt.

In an example, alumina particle can be used as ceramics forming batch of material.Aluminum oxide may conform with hope, for example, because this material is compatible with much glass, when during fusion pulling process, when glass melt is during by ceramics forming device 143, can not pollute glass melt.Aluminum oxide provides firmer ceramics forming device 143, and it can operate the time extending and creep strain can not occur at 1200 ℃.Alumina particle can be purchased from many suppliers, and they are more cheap, thereby have reduced manufacturing cost.

Can be fired into extruding before ceramics forming device 143 based on ceramics forming material, alumina particle is selected, thereby provide gratifying performance for ceramics forming device 143.Can alumina particle be distributed and be controlled, to produce microstructure, hole be wherein closed, thereby glass cannot easily permeate main body and reduce creep resistant.Like this, can control the size of sintering particle afterwards, make to have minimized tiny crack (if any) to make intensity optimization, or there is controlled tiny crack to make toughness optimization.

Fig. 6 has only shown the exemplary particle contrast of between the size distribution 601 of alumina particle " A " of the first quantity and the size distribution 603 of the alumina particle " B " of the second quantity.The transverse axis of Fig. 6 represents the size (unit: micron) of particle, and the longitudinal axis represents the volume percent of particle.Size distribution 601,603 shown in obtaining by the measurement of light scattering particle size analyser.The alumina particle " A " of the first quantity shown in determining has first mean particle size of approximately 0.6 micron, and the alumina particle " B " of the second quantity shown in determining has second mean particle size of approximately 2.7 microns.

Use funk (Funk) and enlightening outstanding person (Dinger) (D.R.Dinger, outstanding ceramic consulting service (the Dinger Ceramic Consulting Services of Clemson city, South Carolina state enlightening, Clemson, SC)) particle that calculates of described method loads and determines that the particle " A " of the first quantity and the best proportioning of the particle " B " of the second quantity can cause combination the best size distribution 701 as shown in Figure 7.The transverse axis of Fig. 7 represents the size (unit: micron) of particle, and the longitudinal axis represents the volume percent of particle.The particle " A " of the first quantity mixes with the ratio of 3:1 with the particle " B " of the second quantity.Measure the actual combination size distribution 703 obtaining.As shown in Figure 7, the actual combination size distribution 703 of 3:1 ratio is closely mated the best size distribution 701 of loading.

Then prepare batch composition, fire afterwards after sintering, to produce substantially pure aluminum oxide building mortion, it is believed that described substantially pure aluminum oxide building mortion dissolves and has (resilient) ability of highly recovering for glass, good creep resistant at 1200 ℃, and there is the high static fatigue life-span.As shown in the batch of material composition in following table 1, in batch of material, do not contain inorganic sintered auxiliary agent.Be also noted that the particle " A " of the first quantity and the particle " B " of the second quantity, they sieved with 100 eye mesh screens before extruding, to remove large impurity arbitrarily.

table 1-exemplary alumina batch of material composition

In other examples, can use zircon to replace aluminum oxide.In this type of example, find that the median particle diameter of 50 % by weight is that the median particle diameter of the zircon particle of 7 microns and 50 % by weight is that the mixture of the zircon particle of 1 micron has sintered very DB well into, without extra sintering aid.

Fig. 5 shows the schematic diagram that is configured to the forcing machine equipment 503 of extruding green compact body 505.Wish that extrusion produces the green compact body of potential indefinite length, thereby can form very large ceramics forming device, this very large ceramics forming device can be proved to be and be difficult to produce with other routine techniquess.Shown forcing machine has shown the twin screw extruder that comprises

twin screw

507a, 507b, thereby described

twin screw

507a, 507b are configured to be rotated when the batch of material of ceramics forming material moves through die component 511 along direction 509 batch of material of described ceramics forming material is mixed and compressed by electric motor.Can also adopt series connection extruding technology to form the green compact body with larger cross-section size.

Fig. 8 is the amplification sectional view that can be used for the exemplary die element 511 of aspects more of the present invention.As shown, die component 511 comprises feed port 801, and described feed port 801 is configured to, with direction 803, batch of material is fed to multiple core rods (die pin) 805.Core rod is spaced from each other to limit seam 807, and described seam 807 is designed to form the wall 229 of honeycomb structure 227 when batch of material is drawn into green compact body 505.Core rod 805 described in Fig. 8 can have square shape to limit the passage 231 of square shape, but depends on required channels configuration, also can select other core rod structures.In addition, in some instances, the angle of core rod can be round, to produce fillet in passage 231.Fillet can contribute to be reduced in fires contingent cracking in green compact body process.

Like this, as shown in Figure 5, can be used as the continuous element of many different lengthss by die component 511 extruded ceramic shaping batch of materials.Like this, depend on concrete application, extruding technology can be used for producing the ceramics forming device 143 of various different lengthss.Once realized required length, can be with direction 515 movable cutting machines 513 to cut off in off-position 517 the green compact body 505 of extruding, so that segmentation green compact body 519 to be provided.As shown in Figure 9, segmentation green compact body 519 can comprise the honeycomb structure 227 with multiple walls 229, and described multiple walls 229 define the multiple passages 231 that extend through green compact body at least partly.

In an example, described method can comprise the steps: green compact body 519 to be dried, and then described green compact body 519 is fired, to form the fired ceramic body with honeycomb structure 227.Can use, for example radio-frequency seasoning device (" RF moisture eliminator ") or other drying plants are realized described dry.Figure 10 and 11 has only shown an example that the green ceramic bodies of drying is fired into fired ceramic body.As shown, the green compact body 519 of drying can be placed on and there is the firing in chamber 1001 of heating mechanism 1003.Optionally with level towards placing the green compact body of drying, to make passage 231 are levels towards.In an example, the green compact body 519 of drying can be placed on the fireproof lining 1005 with aluminum oxide sand 1007 or alumina bead, make in sintering procedure, when waiting indent to shrink, it can move freely.

Then can fire green compact body 519, to form the fired ceramic body with honeycomb structure.An example firing circulation sees the following form 2, its also as shown in figure 11, wherein the transverse axis of Figure 11 is firing time (unit: hour), the longitudinal axis is temperature (unit be degree Celsius).

table 2-aluminum oxide green compact body exemplary fired circulation

As shown in figure 11, fire circulation and comprise four-stage.Stage 1113 is binder burnout stages, is about 20-600 ℃.During the stage 1113, from the green compact body tackiness agent that burnouts.Stage 1115 is temperature rise periods, is about 600-1300 ℃.During the temperature rise period, by the temperature increase of green compact body to sintering temperature.Stage 1117 is sintering stages, is about 1300-1700 ℃.During the sintering stage, sinter green compact body into fired ceramic body.Stage 1119 is cooling stagess, is about 1700-20 ℃.At cooling stages, make fired ceramic body return room temperature.Once complete sintering process, fired ceramic body can comprise closed pore alumina walls structure, as Fig. 4 is schematically shown.

Described method also can comprise the step that reduces the oxygen level of firing the atmosphere in chamber 1001.For example, as shown in figure 10, can with rare gas element tank 1008, replace oxygen firing in chamber 1001.The oxygen level that the atmosphere in chamber is fired in reduction can contribute to control temperature fluctuation, for example, when burnouting tackiness agent.

In addition, or as an alternative,, during described method also can be included in and fire step, force the fluid 1011(atmosphere that for example oxygen declines) by the step of multiple passages.In an example, oxygen level is reduced to lower than normal atmospheric level, in other examples, be reduced to the trouble-free burning lower than green compact body assembly.In an example, oxygen level can be less than or equal to 6%.

As shown in figure 10, device 1009 can be used for guiding, for example, force fluid 1011 by passage 231, as shown in direction arrow 1013.In some instances, fluid can comprise air, N ₂, air aerating kiln products of combustion, H ₂o etc., or other fluids.As the water droplet in Figure 10 is schematically shown, fluid 1011 can comprise steam, but in other examples, described fluid 1011 also can comprise substantially moisture free gas.For example, than the sintering time for air calcination (4-6 days), use steam can contribute to reduce sintering time (for example 48 hours) as fluid.In addition, find that the contraction of the ceramics forming device of steam sintering can be less than the ceramics forming device of air calcination.

Passage 231 self and guiding step (if providing), for example, force fluid can contribute to heat to transfer to more quickly the total quality of ceramics forming material by passage 231.In fact, square proportional for gentle bulk diffusion time of heat and body thickness.Passage in body is more, and the gentle bulk diffusion distance of net heat is thinner.Like this, than the method for firing channel-less building mortion, the wall of the thickness with reduction between passage (and optionally guiding fluid to pass through passage) and passage together, can reduce and fire cycling time.Passage also can cause more uniform firing condition, thereby even provides more uniform performance in larger ceramics forming device.

The method of manufacturing ceramics forming device also comprises the honeycomb structure that forms at least a portion ceramics forming device 143.The technology of wide region can provide honeycomb structure as the ceramics forming device that forms at least a portion.For example, the body itself (without obvious mechanical workout) of extruding can be used for manufacturing ceramics forming device 143.For example, the body of extruding can be used as the core of ceramics forming device 143 and extrudes.In this type of example, the internal portion of ceramics forming device 143 can be formed by honeycomb structure 227, and the periphery of ceramics forming device is structured in core honeycomb structure 227 around.Like this, can avoid the honeycomb self to extruding further to process, the part using structure as ceramics forming device 143 is carried out combination simultaneously.

In other examples, described method can adopt mechanical processing process so that ceramics forming device to be provided.For example, mechanical processing process can be used at least rough go out the general shape of a part of ceramics forming device.As mentioned above, honeycomb structure can be used for the various piece of ceramics forming device 143, the shaping wedge 211 of for example at least a portion and/or part weir 203,205.

Can each the selectable time during the process of manufacturing ceramics forming device carry out mechanical processing process (if employed).For example, described method can be carried out mechanical processing process before firing green compact body.For example, can carry out cutting process to remove part honeycomb structure 227, to obtain required style characteristic.In an example, honeycomb structure can be cut into and has periphery, described periphery is similar to or substantially meets the outer shape of the ceramics forming device 143 of at least a portion cursorily.In a proper example, can cut honeycomb structure to form wedge-type shape, described wedge-type shape is approximate, for example, substantially meet the periphery of shaping wedge 211.In addition or as an alternative, can cut honeycomb structure to form at least one or two in weir 203,205, thereby be similar to, for example, substantially meet the periphery on weir 203,205.

Again for example, before can firing, the green compact body of drying is carried out to mechanical workout with mechanical processing process (if employed) after green compact body is dried and to green compact body.In this type of example, can be to green compact body but not fired ceramic body carries out mechanical processing process.In addition or as an alternative, can, after firing green bodies is become to the process of ceramic body, to fired ceramic body, carry out mechanical processing process (if employed).For example, can carry out process of lapping to remove part honeycomb structure 227, to obtain required style characteristic.In an example, process of lapping can be used for removing part honeycomb structure, and to have periphery, described periphery is similar to or substantially meets the outer shape of the ceramics forming device 143 of at least a portion cursorily.In a proper example, process of lapping can process to form wedge-type shape to honeycomb structure, and described wedge-type shape is approximate, for example, substantially meet the periphery of shaping wedge 211.In addition, or as an alternative, process of lapping can be processed honeycomb structure, to form at least one or two in weir 203,205, thereby is similar to, for example, substantially meet the periphery on weir 203,205.

Figure 12 has schematically shown the process of mechanical workout, and this process provides peripheral shape for honeycomb structure 227, the weir 203,205 of the approximate ceramics forming device 143 of this peripheral shape, the peripheral shape of groove 201 and shaping wedge 211.As shown, machinery processing apparatus 1201, for example cutter, emery wheel, broacher, milling apparatus or other machinery processing apparatus can be used for removing the external portion of honeycomb structure, so that required shape configurations to be provided.The arrangement of the internal passages in also can change structure, to simplify or to eliminate the exterior mechanical course of processing.For example, can be in the trilateral wedge area of the rectangular area of structure (towards weir) and structure, passage is arranged with the row of the outside surface that is parallel to structure.In needs, also the passage in this region can be made to trilateral.A kind of channel configurations from rectangular area to trilateral wedge area be transformed into other configurations can be sudden change or gradual change among multiple passages rows.

As shown in figure 13, described method also can comprise the step that applies outer 233, in reference described in Fig. 2.In an example, can apply refractory materials, then fire the surrounded surface of honeycomb structure.Can before being become to ceramic body, firing green bodies apply refractory materials.In this type of example, skin can be applied to machined green compact body, then in single burning techniques process, they are fired together.In another example, can carry out mechanical workout to green compact body and then be fired into ceramic body.Then skin can be applied to machined ceramic body, and again fire with sintering skin 233.In another example, firing green bodies can be become to ceramic body.After ceramic body is carried out to mechanical workout, skin 233 can be applied in machined surrounding, and again fire.Predictably, in some embodiments, when the honeycomb structure of green compact body or fired body be through mechanical workout time, through the outmost surface of the body of mechanical workout, can comprise many partial bores.Then on partial bores surface, apply cladding material.The interface of embodiment as shown in figure 13 between outer and substantially unfilled honeycomb structure has partial bores.Can manufacture relatively easily this class formation, and still can be provided for enough physical strengths of intended application.But, in some embodiments, highly wish the interface of these partial bores between skin and honeycomb inner structure, described honeycomb inner structure is configured described outer field stupalith and fills partially or completely.Although rear a kind of structure (not shown) that this partial bores is filled substantially is completely than the embodiment complexity shown in Figure 13, due to better adhesion outer and honeycomb inner structure, it can provide more excellent outer intensity.Because partial bores is filled, cause the less stress concentration in partial bores place, Deng indent honeycomb, can there is higher intensity, at the Kong Zhonghui near surperficial, can not there is geometry deformation, at surface/partial bores network infall, can not ftracture, and in use can not bore a hole, this can make glass penetrate in the hole of honeycomb.

In a proper example, fire with mechanical workout after, alumina clinker and/or alumina powder and the composition that is less than 25 volume % can be had to full-bodied glass and be applied to the machined surface of ceramic honeycomb structure 227.Then the combination of honeycomb structure 227 can be reheated to 1300-1750 ℃, continue 1/2 to 96 hour, and can obtain the alumina-ceramic building mortion 143 with the skin based on closed hole aluminum oxide 233.

In another example, can extrude cellular alumina body, be then machined into desired shape.Before sintering, can use the inside of watery fusion polymkeric substance or wax filling channel 231.Then, can with one deck aluminum oxide batch of material, cover by for example isobaric compacting the outside of honeycomb structure.Then can carry out mechanical workout to realize the desired shape of ceramics forming device 143.Then can remove polymkeric substance or wax, afterwards building mortion is fired into ceramics forming device 143.

prediction embodiment and model result

Manufacture is about the large indent base substrate that waits of the square-section of the long 300cm of the high 100cmx of wide 50cmx.If be that 3.8g/cc(is assumed to 95% theoretical density Deng the density of indent material, shown in theoretical density be 4.0gcm ^-3), the quality of base substrate is 5700kg.Open positive region (OFA) be 25%(, 25% open channel space) the quality of honeycomb such as indent such as grade be 4275kg; The quality that waits indent honeycomb that open positive region is 50% is 2850kg; The quality that waits indent honeycomb that open positive region is 75% is 1425kg.When root wedge being placed on etc. on indent, if wedge from root 1/3 highly, for 0%, 25%, 50% and 75% the positive region of opening, quality is respectively 4750,3562.5,2375 and 1187.5kg.If root wedge is placed on etc. on indent, wherein wedge from root 1/2 highly,, for 0%, 25%, 50% and 75% the positive region of opening, quality can be respectively 4,275,3,206.3,2,137.5 and 1,068.8kg.This is that obvious quality is saved.

Use simple helix (screw rod) forcing machine and macropore die head to extrude sample.Honeycomb is square hole design.Aluminum oxide grain size distribution, aqueous level and methylcellulose gum content described in example before batch ceramic comprises.Between 1000-3000psi, extrude the indents such as honeycomb.The indent such as horizontal sintering under the top temperature of 1550-1750 ℃, keeps time of 4-48 hour in this top temperature.Net thickness through sintering changes at 0.5-3.0cm, and open positive region changes at 25%-75%.

Hole dimension and hole density are as shown in the table.The combination in 3.0cm net thickness and 50% the positive region of opening makes to be only less than 3 holes through waiting indent, and the positive region of 75% opening and 3.0 or the net of 2.6cm make only～2.23 and 2.58 holes pass the width of the indents such as 50cm.Making to be less than 3 holes is (the mark underscore) that does not conform with hope through the net thickness of width and the combination in open positive region that wait indent.

table 3: the various predictions based on honeycomb structure wait greatly indent

Depend on minimum block size, for example, for the thermal cycling of the block monoblock type refractory body of the sintering large-sized solid indent that waits of through hole (without), may need several weeks.In order to set forth the advantage of honeycomb with respect to indents such as solid blocks, let us considers to fire stress.We can adopt simple dull and stereotyped stress model to set forth this advantage.

Adopt fourier series method can solve the stress causing due to transient heat gradient in the flat board of endless and infinite height.The Young's modulus of supposing squeeze-up be complete DB Young's modulus 1/10, and thermal diffusivity be also complete DB thermal diffusivity 1/10, can estimate the dull and stereotyped relative firing time/heating rate of various thickness.Can infer that the indent sizes such as pore wall thickness and minimum monoblock type can be to control thickness.For compact aluminum oxide, Young's modulus is～55x10 ⁶psi, thermal diffusivity is about 12x10 ^-6m ²/ second.Can be by these numerical value be similar to body of powder (when comparing the identical thickness of extruding powder divided by 10, in fact ratio for the heating rate of given applied stress level does not rely on specific Young's modulus and thermal diffusivity, because they are all identical in calculating, and finding ratio).

Raleigh equation can be write fourier series, as follows:

σ (x) : = 4 α \cdot \frac{E \cdot (R - T)}{π (1 - v)} \cdot [Σ_{n = 1}^{12} [\frac{1}{(2 n - 1)} \cdot [e^{- κ \cdot t \cdot [{(2 n - 1)}^{2} \cdot \frac{1}{h^{2}} \cdot π^{2}]} \cdot [\frac{2}{π \cdot (2 n - 1)} - {(- 1)}^{n + 1} \cdot \cos [[(2 n - 1) \cdot \frac{π \cdot x}{2 \cdot h}]]]]]]

Wherein, σ is stress, and α is thermal expansivity, and x is the position in flat board, and E is Young's modulus, and R-T is that the step of the temperature in model changes (in this calculating, being 1 ℃), and ν is Poisson's ratio, and κ is thermal diffusivity, and t is the time, and h is a dull and stereotyped half thickness.

Because diffusion equation has all identical constants, and only variable is time and thickness, so in the body that is 1/10 at thickness, the time of realizing identical stress and the identical temperature difference is 1/100.

Except low-temperature heat speed/diffusivity is considered, at the temperature promoting, can because usually controlling sintering, circulate by sintering shrinkage speed and other, and not carry out diffusivity analysis.But, conservatively, when manufacturing the indents such as the netted honeycomb of 5cm or thinner netted honeycomb but not the solid monoblock type that thickness is 50cm is block while waiting indent, can be by slowly heating, the firing time in diffusion-controlled region is reduced to 1/5-1/10.Thereby, according to the present invention, can be in one week the indent base substrate such as honeycomb of the long 3000mm of the sintering high 100cm x of wide 50cm x, and under comparing, for solid body, need many weeks.

To those skilled in the art, obviously can carry out various modifications and changes to the present invention, and not depart from scope and spirit of the present invention.

Claims

1. for fusing a ceramics forming device for drawing glassribbons, it comprises:

Shaping wedge, described shaping wedge is included in a pair of downward-sloping profiled surface part of extending between the opposite end of described shaping wedge, described a pair of downward-sloping profiled surface part is assembled along downstream direction respectively, with the root of forming shaped wedge, wherein, honeycomb structure forms the described ceramics forming device of at least a portion, and described honeycomb structure comprises multiple walls, and described multiple walls limit multiple passages at least partly.

2. ceramics forming device as claimed in claim 1, described ceramics forming device also comprises groove, and described groove is limited at least partly by a pair of weir, and described a pair of weir comprises the first weir and second weir of the opposite side that defines described groove.

3. ceramics forming device as claimed in claim 2, is characterized in that, described groove be included in described a pair of weir at least one top and described groove compared with the degree of depth between lower part, this degree of depth changes along the axle of ceramics forming device.

4. ceramics forming device as claimed in claim 2, is characterized in that, described honeycomb structure forms at least a portion on described a pair of weir.

5. ceramics forming device as claimed in claim 4, is characterized in that, described honeycomb structure forms the shaping wedge of at least a portion.

6. ceramics forming device as claimed in claim 1, is characterized in that, described honeycomb structure forms the shaping wedge of at least a portion.

7. ceramics forming device as claimed in claim 1, is characterized in that, multiple walls of described honeycomb structure have respectively the thickness being limited between a pair of corresponding passage, and this thickness is that about 0.5mm is to about 30mm.

8. ceramics forming device as claimed in claim 1, is characterized in that, the channel density of described honeycomb structure is about 1/25 passage/cm ²to approximately 20 passage/cm ².

9. ceramics forming device as claimed in claim 1, described ceramics forming device also comprises the outer refractory being positioned on honeycomb structure outer surface.

10. ceramics forming device as claimed in claim 9, is characterized in that, described outer refractory comprises stupalith.

11. ceramics forming devices as claimed in claim 10, is characterized in that, outer stupalith comprises closed pore vesicular structure.

12. 1 kinds fuse the method drawing, said method comprising the steps of to glass ribbon:

(I) provide ceramics forming device, described ceramics forming device comprises groove, described groove is limited at least partly by a pair of weir, described a pair of weir comprises the first weir and second weir of the opposite side that defines described groove, described ceramics forming device also comprises shaping wedge, described shaping wedge is included in a pair of downward-sloping profiled surface part of extending between the opposed end of described shaping wedge, described a pair of downward-sloping profiled surface part is assembled along downstream direction respectively, with the root of forming shaped wedge, wherein honeycomb structure forms the described ceramics forming device of at least a portion, described honeycomb structure comprises multiple walls, described multiple wall defines multiple passages at least partly,

(II) glass melt is introduced in the groove of described ceramics forming device;

(III) melten glass is overflowed from groove via the top edge on a pair of weir, thereby corresponding melten glass plate move down respectively along intilted profiled surface part; And

(IV) fusion drawing melten glass plate leaves the root of shaping wedge together as glass ribbon.

13. methods as claimed in claim 12, is characterized in that, step (I) provides the honeycomb structure of at least a portion that forms described a pair of weir.

14. methods as claimed in claim 12, is characterized in that, step (I) provides the honeycomb structure that forms the shaping wedge of at least a portion.

15. methods as claimed in claim 12, is characterized in that, step (I) provides the honeycomb structure that forms substantially whole shaping wedge.

16. methods as claimed in claim 15, is characterized in that, step (I) provides the outer refractory on the outer surface that is positioned at the honeycomb structure that has formed shaping wedge.

17. methods as claimed in claim 12, is characterized in that, step (I) provide the outer refractory on the outer surface that is positioned at honeycomb structure.

18. methods as claimed in claim 12, is characterized in that, multiple walls that step (I) is described honeycomb structure provide respectively the thickness being limited between a pair of corresponding passage, and this thickness is that about 0.5mm is to about 30mm.

19. methods as claimed in claim 12, is characterized in that, described step (I) is about 1/25 passage/cm for honeycomb structure provides ²to approximately 20 passage/cm ²channel density.

20. 1 kinds of manufactures are used for the method for the ceramics forming device that fuses drawing glassribbons, said method comprising the steps of:

(I) by die component extruded ceramic shaping batch of material, to form the green compact body with honeycomb structure, described honeycomb structure comprises multiple walls, described multiple wall limits the multiple passages that extend through green compact body at least partly, wherein said multiple wall has respectively the thickness being limited between a pair of corresponding passage, and this thickness is that about 0.5mm is to about 30mm;

(II) fire green compact body to form the fired ceramic body with honeycomb structure; And

(III) provide ceramics forming device, the groove that described ceramics forming device has wedge and limited at least partly by a pair of weir, wherein, honeycomb structure forms the ceramics forming device of at least a portion.

21. methods as claimed in claim 20, is characterized in that, step (III) comprises provides ceramics forming device with mechanical processing process.

22. methods as claimed in claim 21, is characterized in that, the mechanical processing process of described step (III) is included in step (II) and before green compact body is carried out to mechanical workout.

23. methods as claimed in claim 21, is characterized in that, the mechanical processing process of described step (III) is included in step (II) and afterwards fired ceramic body is carried out to mechanical workout.

24. methods as claimed in claim 20, is characterized in that, described step (I) forms honeycomb structure, and described honeycomb structure has and is about 1/25 passage/cm ²to approximately 20 passage/cm ²channel density.

25. methods as claimed in claim 20, is characterized in that, described honeycomb structure forms the wedge of at least a portion of ceramics forming device.

26. methods as claimed in claim 20, is characterized in that, described ceramic body comprises the vesicular structure of basic closed pore.

27. methods as claimed in claim 20, described method also comprises the steps: that the particle with the first mean particle size by mixing the first quantity and the particle with the second mean particle size of the second quantity prepare ceramics forming material, and described the second mean particle size is greater than described the first mean particle size.

28. methods as claimed in claim 27, is characterized in that, the particle of the particle of described the first quantity and the second quantity comprises alumina particle.

29. methods as claimed in claim 28, is characterized in that, the first mean particle size of the alumina particle of the first quantity is about 0.6 micron, and the second mean particle size of the alumina particle of the second quantity is about 2.7 microns.

30. methods as claimed in claim 28, is characterized in that, the weight ratio of the alumina particle of the alumina particle of the first quantity and the second quantity is about 3:1.

31. methods as claimed in claim 27, is characterized in that, the particle of the particle of described the first quantity and the second quantity comprises zircon particle.

32. methods as claimed in claim 31, is characterized in that, the first mean particle size of the zircon particle of the first quantity is about 1 micron, and the second mean particle size of the zircon particle of the second quantity is about 7 microns.

33. methods as claimed in claim 31, is characterized in that, the weight ratio of the zircon particle of the zircon particle of the first quantity and the second quantity is about 1:1.

34. methods as claimed in claim 20, described method also comprises the step that applies outer refractory to the outer surface of honeycomb structure.

35. methods as claimed in claim 20, described method also comprises the step that reduces the oxygen level of firing the atmosphere in chamber in step (II) process.

36. methods as claimed in claim 20, described method is also included in the process of step (II), forces fluid by the step of multiple passages.

37. methods as claimed in claim 20, described method is also included in the process of step (II), forces steam by the step of multiple passages.

38. 1 kinds of manufactures are used for the method for the ceramics forming device that fuses drawing glassribbons, said method comprising the steps of:

(I) by die component extruded ceramic shaping batch of material, to form the green compact body with honeycomb structure, described honeycomb structure comprises multiple walls, described multiple wall limits the multiple passages that extend through green compact body at least partly, wherein said multiple wall has respectively the thickness being limited between a pair of corresponding passage, this thickness is extremely about 30mm of about 0.5mm, and described honeycomb structure comprises approximately 1/25 passage/cm ²to approximately 20 passage/cm ²channel density;

(II) green compact body is carried out to mechanical workout, thus the groove that wedge is provided and is limited at least partly by a pair of weir for green compact building mortion, and wherein, honeycomb structure forms the green compact building mortion of at least a portion; And

(III) fire green compact building mortion to form the fired ceramics forming device with honeycomb structure.

39. 1 kinds of manufactures are used for the method for the ceramics forming device that fuses drawing glassribbons, said method comprising the steps of:

(III) fired ceramic body is carried out to mechanical workout, thus the groove that wedge is provided and is limited at least partly by a pair of weir for ceramics forming device, and wherein, honeycomb structure forms the ceramics forming device of at least a portion.