TWI531553B - 焊接鋯石塊之材料及方法 - Google Patents

焊接鋯石塊之材料及方法 Download PDF

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TWI531553B
TWI531553B TW098114708A TW98114708A TWI531553B TW I531553 B TWI531553 B TW I531553B TW 098114708 A TW098114708 A TW 098114708A TW 98114708 A TW98114708 A TW 98114708A TW I531553 B TWI531553 B TW I531553B
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威廉比特 亞迪哥
克力多服 顧魯司
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康寧公司
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Description

焊接鋯石塊之材料及方法
本發明是關於形成鋯石塊的材料和方法。特別地，本發明是關於將鋯石塊銲接來形成較大尺寸之鋯石塊的材料和方法。本發明可以用來，例如製造生產玻璃薄片之熔融下拉法中所使用的大-尺寸等管。
等管是熔融法中所使用的耐火鋯石塊用來載運，塑形，和拉製熔融玻璃使成為液晶顯示器(LCD)裝置中的玻璃薄片。為了製造等管，將鋯石等靜壓壓製成較大塊體，然後在高溫例如超過1550℃下燃燒。如果寬度符合的話，然後可以把此塊體切割成製造LCD薄片玻璃所需要之預定長度等管的形狀和尺寸。如果需要更寬的平板顯示器，那麽就需要較大的等靜壓壓製來製造夠寬的鋯石塊以生產在考量收縮和研磨之後所需要之寬度的完工等管。然而，較大等靜壓壓製的大資本投資可能過高。此外，處理大很多且重很多的塊體會引起相當困難的技術問題，例如較高的破裂可能性，晶粒分佈的不均勻性，較低的素坯和燒結密度，和較低的強度，以及其他由於物品尺寸的增加，可能會拖延更久的問題。
對於這個問題的潛在方案是發展一個方法，將幾個較小的等靜壓壓製素坯鋯石塊接合在一起，並且在燃燒期間將它們銲接在一起。將此較大的燒成鋯石塊形成最終形狀和尺寸。本發明描述一種方式，將鋯石接合在一起，使用鋯石-二氧化鈦-類熔塊將這些素坯鋯石塊"銲接"在一起。此外，<1600℃的燃燒鋯石塊或已燒成鋯石塊也可以考慮被熔接，而燒結成較大塊體。
本發明一項為用來銲接鋯石塊的銲接材料。該銲接材料包含：鋯石顆粒；二氧化鈦顆粒；以及選擇性的燒結輔助劑例如SiO2,Y2O3，和Fe2O3。
本發明另一項為製造鋯石塊的方法。該製造鋯石塊方法包含底下步驟：(i)提供多個欲接合的鋯石組件，含有欲接合的表面；(ii)塗覆鋯石塊的銲接材料到欲接合之多個鋯石組件的表面；以及(iii)將此介面加熱到至少1500℃的溫度。
除非有特別指示，否則在此規格和聲明中所使用的所有數字，例如成分的重量百分比，尺寸，和某個物理特性的數值，在所有情況中都應該視為有"大約"一詞的修飾。同時要瞭解的是，在說明書和申請專利範圍中所使用的精準數值，形成本發明額外的實施例。我們盡最大努力來確定在例子中所提出之數值的準確度。然而，任何測量數值都可能由於各別測量技術的標準差，因而固有地包含某些誤差。
如這裡所使用的，在描述和主張本發明時，使用不定冠詞"一個"，意指"至少一個"，不應該被限定為"只有一個"，除非有明顯的指示。因此，例如當提及"一個燒結輔助劑"時，包括含有兩個或更多個燒結輔助劑的實施例，除非上下文中很清楚地有不同的指示。這裡所使用之成分的"%重量比"除非特別說明，否則是根據包含此成分之組成或物品的總重量而言。這裡所使用的所有百分比都是以重量為準，除非有特別的指示。
將非常細的鋯石跟均勻-分散之二氧化鈦和/或其他燒結輔助劑的混合物，混合成糊漿(陶瓷銲接糊漿)。將等靜壓壓製的鋯石製品不管是燒成或未燒成形成含有互鎖接頭，用來承擔重量，並抵抗機械應力。讓這些接頭溢滿銲接糊漿(考量到燃燒時的收縮)，然後壓縮並燃燒到溫度>1500℃，將兩個鋯石部分(素坯或預-燒結)接合在一起。壓縮可以藉由某個適合的耐火材將重量加到接合部分上來施加。在冷卻之後，將此部分成形，並加工成最終的等管尺寸和形狀。
本發明排除為了較大的LCD玻璃薄片，而投資較大等靜壓壓製法的需求，延長了目前壓製法的使用。可以製造比傳統的等靜壓壓製法還寬很多的塊體。
上面的圖1顯示使用榫頭榫孔接頭，將兩個鋯石棒接合。其他的接合設計和其他材料的組合，也可以考慮。將接頭壓縮可以幫忙確定良好的接觸，和鋯石晶體從糊漿生長到鋯石棒的表面，以及鋯石晶體從棒生長到接頭，達到兩個棒的銲接。本發明在燃燒期間，運用了鋯石和二氧化鈦之間的燒結生長機制，和奧斯特瓦德熱化。細鋯石(來自糊漿)解離，然後再-結晶到較大的鋯石晶粒和棒的表面上。鋯石晶體離開鋯石表面往相對面生長形成兩個鋯石棒之間的銲接。
在特定實施例中，將鋯石粉末細微地研磨到中位尺寸<2微米，在特定實施例中<1微米。將鋯石跟二氧化鈦粉末(金紅石或銳鈦礦)乾混合，或是跟膠體分散二氧化鈦溶膠混合，其中顆粒尺寸<<1微米，或溶膠<10微米，使得二氧化鈦>0.1重量%；在特定實施例中>0.5重量%。讓此混合物充分均勻分佈以確保二氧化鈦有高的分散和均勻性。此材料可以配製成泥漿，剪切混合，並噴霧-乾燥；其他燒結輔助劑也可以一起混合，包括氧化釔和氧化鐵。之後，將鋯石/二氧化鈦粉末配製成水溶性漿體，可以選擇性地使用有機黏接劑，例如丙烯酸乳膠或黏著劑，這個就作為鋯石製品的陶瓷銲接糊漿。將等靜壓壓製的鋯石製品，不管是燒成或未燒成形成含有互鎖接頭用來承擔重量，並抵抗機械應力。將接頭表面塗覆糊漿，而讓接頭溢滿銲接糊漿(考量到燃燒時的收縮)。壓縮並燃燒到溫度>1500℃，將兩個鋯石部分接合在一起。壓縮可以藉由某個適合的耐火材將重量加到接合部分上來施加。在冷卻之後將此部分切割，並加工成最終的等管尺寸和形狀。此外，燒結輔助劑例如二氧化鈦也可以單獨作為銲接糊漿。同時，鋯石先驅物例如氧化鋯鹽和膠質矽石也可以跟細鋯石銲接糊漿一起使用以促進接合和晶體生長。
熟知此技術者瞭解本發明能夠作許多變化及改變而並不會脫離本發明之精神及範圍。預期本發明含蓋本發明各種變化及改變，其屬於下列申請專利範圍以及同等物範圍內。
101．．．榫頭榫孔接頭
103．．．壓力
圖1顯示使用榫頭榫孔接合，將兩個鋯石棒接合。
圖2顯示出鋯石晶體由糊狀物成長至鋯石棒之表面以及成為銲接接頭。
101．．．榫頭榫孔接頭
103．．．壓力

Claims (10)

  1. 一種藉由接合多個鋯石組件來製造鋯石塊的方法，包含下列步驟：(i)提供多個欲接合的鋯石組件，含有欲接合的表面；(i)(a)提供鋯石顆粒及一二氧化鈦溶膠，該些鋯石顆粒具有一中間值尺寸為小於2微米；(ii)配製該些鋯石顆粒和該二氧化鈦溶膠的一混合物；(ii)(a)配製一焊接材料成為該混合物的一水溶性漿體；(iii)塗覆該焊接材料到欲接合之該多個鋯石組件的表面；以及(iv)將介於該些鋯石組件的該介面加熱到至少1500℃的溫度以影響在該介面的一焊接。
  2. 依據申請專利範圍第1項之製造鋯石塊的方法，其中在步驟(i)中所提供之該些鋯石組件的該些表面具有互鎖接頭。
  3. 依據申請專利範圍第2項之製造鋯石塊的方法，其中該焊接材料在步驟(iv)之前預先塗覆至該些接頭之該表面上。
  4. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中在步驟(i)中所提供之至少該些欲接合鋯石組件中的一者並未在溫度高於1500℃下進行處理，或所有該些組件並未在溫度高於1500℃下進行處理。
  5. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中在步驟(i)中所提供至少該些欲接合之鋯石組件中的一者在步驟(iii)之前在 溫度高於1500℃下已預先加以燒結，或所有該些組件在步驟(iii)之前在溫度高於1500℃下已預先加以燒結。
  6. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中在至少步驟(iii)部份的過程中，該些鋯石組件施以壓縮。
  7. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中該焊接材料在該焊接界面處為溢滿的。
  8. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中該焊接材料進一步包含一燒結輔助劑。
  9. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中在該混合物中的該二氧化鈦之總重量%高於0.1%。
  10. 依據申請專利範圍第1至3項中任何一項之製造鋯石塊的方法，其中在該混合物中的該二氧化鈦之總重量%高於0.5%。
TW098114708A 2008-05-02 2009-05-02 焊接鋯石塊之材料及方法 TWI531553B (zh)

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US7988804B2 (en) 2011-08-02
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