JP5852663B2 - 大寸ゼノタイムセラミックブロック及びその作製のための乾式プロセス - Google Patents
大寸ゼノタイムセラミックブロック及びその作製のための乾式プロセス Download PDFInfo
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Description
(I)Y2O3の乾燥粉末及びP2O5の乾燥粉末を提供する工程、
(II)均一な粉末混合物を得るためにY2O3粉末とP2O5粉末を混合する工程、
(III)工程(II)で得られた粉末混合物を(Y2O3)x・P2O5組成を有する前駆体セラミック材料を得るために第1の炉内で焼結する工程、
(IV)工程(III)で得られた前駆体セラミック材料を複数の粒子を得るために粉砕する工程、
(V)工程(IV)で得られた複数の粒子を有機結合剤とともに均一に混合することによりセラミックブロックの、VVより大きな体積を有する、第1の生地体を形成する工程、
(VI)工程(V)で得られた第1の生地体を、標準状態下のY2O3・P2O5の理論最大密度の少なくとも60%の標準状態における密度を有する第2の生地体を得るため、少なくとも500MPaの圧力において等方プレス(isopress)する工程、及び
(VII)第2の生地体を第2の炉内で少なくとも1500℃の温度に加熱する工程、
を含む方法に関する。
(VIII)セラミックブロックの表面から1.0cm以内の材料を取り除く工程、
を含む。
(VII.1)炉の温度を200℃から1500℃まで、50℃/時間以下、いくつかの実施形態において40℃/時間以下、いくつかの実施形態において30℃/時間以下、いくつかの実施形態において20℃/時間以下、いくつかの実施形態では10℃/時間以下の、平均昇温速度で高める工程、及び
(VII.2)炉の温度を1500℃以上に、少なくとも100時間、いくつかの実施形態において少なくとも200時間、いくつかの実施形態において少なくとも300時間、いくつかの実施形態において少なくとも400時間、いくつかの実施形態において少なくとも500時間、維持する工程を含む。
(V−1)以下の個々の成分の複数の粒子を以下のそれぞれの量、
(p1)45μm以下の粒径及び約2μmの中央粒径値を有する粒子を15%から35%、
(p2)45μm以下の粒径及び約5μmの中央粒径値を有する粒子を15%から35%、及び
(p3)45μmから100μmの粒径を有する粒子を45%から65%、
で提供する工程、
(V−2)混和物を形成するために3つの成分(p1)、(p2)及び(p3)を結合剤とともに均一に混合する工程、及び
(V−3)工程(V−2)で得られた混和物から第1の生地体を形成する工程、
を含む。
(IV−1)工程(III)で得られた前駆体セラミックを圧して大径粒子にする工程、
(IV−2)工程(IV−1)で得られた大径粒子の少なくとも一部を粉砕して微細粒子にする工程、及び
(IV−3)金属粒子を取り除くため、工程(IV−2)で得られた微細粒子に磁気分離機を通過させる工程、
を含む。
(p1)15%から35%の、45μm以下の粒径及び約2μmの粒径中央値を有する粒子、
(p2)15%から35%の、45μm以下の粒径及び約5μmの粒径中央値を有する粒子、及び
(p3)45%から65%の、45μmから100μmの粒径を有する粒子、
の成分を含むことができる。
(VII.1)炉の温度を200℃から1500℃まで、50℃/時間以下、いくつかの実施形態において40℃/時間以下、いくつかの実施形態において30℃/時間以下、いくつかの実施形態において20℃/時間以下、いくつかの実施形態では10℃/時間以下の、平均昇温速度で高める工程、及び
(VII.2)炉の温度を1500℃以上に、少なくとも100時間、いくつかの実施形態において少なくとも200時間、いくつかの実施形態において少なくとも300時間、いくつかの実施形態において少なくとも400時間、いくつかの実施形態において少なくとも500時間、維持する工程、
を含む。
実施例
複数本のYPO4ベースロッドを作製し、特性を明らかにした。全ての実施例は、化学量論的バッチ材料から作製し、化学量論的YPO4と同じかまたは近い化学組成を有すると考えられる。実施例7及び8は、前駆体セラミック材料を合成するための原材料として無水P2O5及び無水Y2O3を用いる乾式プロセスで作製した。実施例1,2,3,4,5,6,9及び10は湿式プロセスを用いる、すなわち前駆体セラミック材料を合成するための原材料としてY2O3及びH3PO4を用いることで作製した。
101 取入管
103 アイソパイプ
105 エンドキャップ
107 溶融ガラスリボン
109 ルート
111 ガラスリボン
Claims (15)
- セラミックブロックにおいて、実質的に均質な(Y2O3)x・P2O5から実質的になり、ここで0.95≦x≦1.05であり、長さLL,幅WW及び高さHHを有し、少なくとも8×10−3m3の体積VVを有し、前記体積の全体にわたり実質的にクラックがなく、標準状態下のY2O3・P2O5の理論最大密度の少なくとも85%の密度を有し、1250℃及び6.89MPaにおいてCRのクリープ速度を有し、ここでCR≦8.0×10−6/時間であることを特徴とするセラミックブロック。
- LL≧20cm,WW≧20cm及びHH≧20cmであることを特徴とする請求項1に記載のセラミックブロック。
- カルシウムを重量で[Ca]の濃度で含有し、ここで[Ca]≦100ppmであることを特徴とする請求項1または2に記載のセラミックブロック。
- ジルコニウムを重量で[Zr]の濃度で含有し、ここで[Zr]≦50ppmであることを特徴とする請求項1から3のいずれかに記載のセラミックブロック。
- アルミニウムを重量で[Al]の濃度で含有し、ここで[Al]≦60ppmであることを特徴とする請求項1から4のいずれかに記載のセラミックブロック。
- アルカリ金属を実質的に含有していないことを特徴とする請求項1から5のいずれかに記載のセラミックブロック。
- バリウムを重量で[Ba]の濃度で含有し、ここで[Ba]≦100ppmであることを特徴とする請求項1から6のいずれかに記載のセラミックブロック。
- 炭素を実質的に含有していないことを特徴とする請求項1から7のいずれかに記載のセラミックブロック。
- 実質的に均質な(Y2O3)x・P2O5から実質的になり、ここで0.95≦x≦1.05であり、長さLL,幅WW及び高さHHを有し、少なくとも8×10−3m3の体積VVを有し、前記体積の全体にわたり実質的にクラックがなく、標準状態下のY2O3・P2O5の理論最大密度の少なくとも85%の密度を有し、1250℃及び6.89MPaにおいてCRのクリープ速度を有し、ここでCR≦8.0×10−6/時間である、セラミックブロックを作製するための方法において、
(I)Y2O3の乾燥粉末及びP2O5の乾燥粉末を提供する工程、
(II)均一な粉末混合物を得るために、前記Y2O3粉末と前記P2O5粉末を混合する工程、
(III)工程(II)で得られた前記粉末混合物を、(Y2O3)x・P2O5の組成を有する前駆体セラミック材料を得るために第1の炉内で焼結する工程、
(IV)工程(III)で得られた前記前駆体セラミック材料を、複数の粒子を得るために粉砕する工程、
(V)工程(IV)で得られた前記複数の粒子を有機結合剤とともに均一に混合することによって前記セラミックブロックの、VVより大きな体積を有する、第1の生地体を形成する工程、
(VI)工程(V)で得られた前記第1の生地体を、標準状態下のY2O3・P2O5の理論最大密度の少なくとも60%の標準状態における密度を有する第2の生地体を得るため、少なくとも50MPaの圧力において等方プレス(isopress)する工程、及び
(VII)前記第2の生地体を第2の炉内で少なくとも1500℃の温度に加熱する工程、
を含むことを特徴とする方法。 - 工程(IV)において、前記第2の生地体が標準状態下のY2O3・P2O5の理論最大密度の少なくとも65%の密度を有することを特徴とする請求項9に記載の方法。
- 工程(VII)後に、
(VIII)前記セラミックブロックの表面から1.0cm以内の材料を取り除く工程、
をさらに含むことを特徴とする請求項9または10に記載の方法。 - 工程(VII)が、
(VII.1)前記炉の温度を200℃から1500℃まで、50℃/時間以下の平均昇温速度で高める工程、及び
(VII.2)前記炉の温度を1500℃以上に少なくとも100時間維持する工程、
を含むことを特徴とする請求項9から11のいずれかに記載の方法。 - 前記第2の生地体の重力ベクトルに垂直な方向における線収縮速度が5%/時間以下に制御されることを特徴とする請求項12に記載の方法。
- 工程(III)及び(VII)において、前記第1および第2の炉内が酸化性であり、アルカリ金属を実質的に含んでいないことを特徴とする請求項9から13のいずれかに記載の方法。
- 工程(I),(II)及び(V)において、Al,Ba,Ca及びZrによる汚染が避けられることを特徴とする請求項9から14のいずれかに記載の方法。
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US61/408,071 | 2010-10-29 | ||
PCT/US2011/057621 WO2012058194A1 (en) | 2010-10-29 | 2011-10-25 | Large xenotime ceramic block and dry process for making the same |
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JP (1) | JP5852663B2 (ja) |
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KR102377994B1 (ko) | 2014-09-30 | 2022-03-23 | 코닝 인코포레이티드 | 유리 리본을 형성하는, 압축 말단에서 커브를 갖는 아이소파이프 및 방법 |
US11565962B2 (en) * | 2015-05-01 | 2023-01-31 | Corning Incorporated | Method and apparatus for controlling thickness of glass sheet |
WO2017066361A1 (en) * | 2015-10-13 | 2017-04-20 | Corning Incorporated | Rare earth phosphate ceramic article and process for making same |
CN107814564B (zh) * | 2016-09-13 | 2019-12-17 | 上海硅酸盐研究所中试基地 | 一种低成本碳包覆的磷酸钛化合物批量制备的方法 |
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JP2022097010A (ja) * | 2020-12-18 | 2022-06-30 | 日本電気硝子株式会社 | ガラス物品の製造方法 |
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WO2003014032A1 (en) | 2001-08-08 | 2003-02-20 | Richard Pitbladdo | Sheet glass forming apparatus |
US7690221B2 (en) | 2004-02-23 | 2010-04-06 | Corning Incorporated | Sheet width control for overflow downdraw sheet glass forming apparatus |
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US7958748B2 (en) * | 2007-02-23 | 2011-06-14 | Corning Incorporated | Isopipe design feature to reduce sag |
CN101468918B (zh) | 2007-12-28 | 2012-06-20 | 北京有色金属研究总院 | 高纯硼化锆/硼化铪粉体及其超高温陶瓷靶材的制备方法 |
US8796168B2 (en) * | 2008-02-27 | 2014-08-05 | Corning Incorporated | Modified synthetic xenotime material, article comprising same and method for making the articles |
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US20100210444A1 (en) * | 2009-02-19 | 2010-08-19 | Rhoads Randy L | Large refractory article and method for making |
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EP2632873B1 (en) | 2017-07-12 |
KR20140057470A (ko) | 2014-05-13 |
CN103476732A (zh) | 2013-12-25 |
KR101815725B1 (ko) | 2018-01-05 |
JP2013542166A (ja) | 2013-11-21 |
US9266782B2 (en) | 2016-02-23 |
CN103476732B (zh) | 2016-08-31 |
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US20130224465A1 (en) | 2013-08-29 |
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