# US 10,308,556 B2 · Sintered zircon material for forming block

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- Number: US 10,308,556 B2
- Document ID: US10308556B2
- Status: Granted
- Kind: B2
- Application number: 15/726,886
- Filed: 2017-10-06
- Published: 2018-04-05
- Granted: 2019-06-04
- Earliest claimed: 2014-03-31
- Assignees: Saint-Gobain Ceramics & Plastics, Inc.
- Applicants: Saint-Gobain Ceramics & Plastics, Inc.
- Inventors: Julien P. Fourcade; David J. Lechevalier; Olivier Citti
- Web page: https://patentgrep.com/patent/US10308556B2

## CPC

- C04B 35/481: {containing silicon, e.g. zircon}
- C03B 17/064: {by the overflow downdraw fusion process; Isopipes therefor}
- C04B 35/62685: {characterised by the order of addition of constituents or additives}
- C04B 35/64: Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F})
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3222: Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
- C04B 2235/3224: Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3248: Zirconates or hafnates, e.g. zircon
- C04B 2235/3251: Niobium oxides, niobates, tantalum oxides, tantalates, or oxide-forming salts thereof
- C04B 2235/3287: Germanium oxides, germanates or oxide forming salts thereof, e.g. copper germanate
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3463: Alumino-silicates other than clay, e.g. mullite
- C04B 2235/604: Pressing at temperatures other than sintering temperatures
- C04B 2235/6567: Treatment time
- C04B 2235/72: Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
- C04B 2235/77: Density
- C04B 2235/786: Micrometer sized grains, i.e. from 1 to 100 micron
- C04B 2235/80: Phases present in the sintered or melt-cast ceramic products other than the main phase
- C04B 2235/85: Intergranular or grain boundary phases
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B 2235/9692: Acid, alkali or halogen resistance
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C03B: MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES

## 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 Al2O3 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 SiO2 component for a total weight of the zircon body.

## Claims

### Claim 1

A refractory object comprising:
a zircon body, wherein the zircon body comprises:
at least 25 wt. % and not greater than 35 wt. % of SiO2 component for a total weight of the zircon body;
a Al2O3 component not greater than 4.5 wt. % for a total weight of the zircon body; and
Yb2O3 at a content of at least 0.1 wt % for a total weight of the zircon body.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

The refractory object of claim 1, wherein the zircon body comprises not greater than about 5.0 wt. % of Yb2O3 for a total weight of the zircon body.

### Claim 4 (depends on 1)

The refractory object of claim 1, wherein the zircon body comprises a creep deformation rate of not greater than about 4.0 E−5 h−1 as measured using a three point bend test at a temperature of 1300° C. and a stress of 2 MPa.

### Claim 5 (depends on 1)

The refractory object of claim 1, wherein the zircon body comprises a creep deformation rate of not greater than about 2.6 E−5 h−1 as measured using a four point bend test at a temperature of 1325° C. and a stress of 2 MPa.

### Claim 6 (depends on 1)

The refractory object of claim 1, wherein the zircon body has a density of not greater than about 4.5 g/cm3.

### Claim 7 (depends on 1)

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.

### Claim 8

A refractory object comprising:
a zircon body, wherein the zircon body comprises:
at least 25 wt. % and not greater than 35 wt. % of SiO2 component for a total weight of the zircon body;
a Yb2O3 at a content of at least 0.1 wt % for a total weight of the zircon body; and
a ratio CBYb2O3/CBSiO2 of at least about 0.005, where CBYb2O3 represents a content of the Yb2O3 component in wt. % for a total weight of the zircon body and CBSiO2 represents a content of SiO2 containing component in wt. % for a total weight of the zircon body.

### Claim 9 (depends on 8)

The refractory object of claim 8, wherein the zircon body comprises a content of zircon of at least about 50 wt. % for a total weight of the zircon body.

### Claim 10 (depends on 8)

The refractory object of claim 8, wherein the ratio CBYb2O3/CBSiO2 is not greater than 0.5.

### Claim 11 (depends on 8)

The refractory object of claim 8, wherein the zircon body comprises a creep deformation rate of not greater than about 4.0 E−5 h−1 as measured using a three point bend test at a temperature of 1300° C. and a stress of 2 MPa.

### Claim 12 (depends on 8)

The refractory object of claim 8, wherein the zircon body comprises a creep deformation rate of not greater than about 2.6 E−5 h−1 as measured using a four point bend test at a temperature of 1325° C. and a stress of 2 MPa.

### Claim 13 (depends on 8)

The refractory object of claim 8, wherein the zircon body has a density of not greater than about 4.5 g/cm3.

### Claim 14 (depends on 8)

The refractory object of claim 8, wherein the zircon body comprises an apparent porosity of not greater than about 15 vol. % for a total volume of the zircon body.