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US 12,623,968 B2Granted
Functionally graded firing setters and process for manufacturing these setters
OwnerLucian Garrett Fergusoninventor
Life of this patent
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Abstract
A functionally graded firing setter that includes a substrate layer of cubic oxide; a top layer of unstabilized zirconium dioxide/hafnium dioxide; and a continuous transitional gradient layer disposed between the substrate layer and the top layer. The continuous transitional gradient layer includes cubic oxide stabilized zirconium dioxide/hafnium dioxide. The cubic oxide can be calcium oxide (CaO) or magnesium oxide (MgO).
Claims9
A functionally graded firing setter comprising:
- a substrate layer consisting essentially of cubic oxide selected from a group consisting of calcium oxide (CaO), magnesium oxide (MgO), yttrium oxide (Y2O3), and cerium dioxide (CeO2);
- a top layer consisting essentially of unstabilized zirconium dioxide, unstabilized hafnium dioxide, or a combination thereof;
- and
- a continuous transitional gradient layer disposed between the substrate layer and the top layer, wherein the continuous transitional gradient layer comprises cubic oxide stabilized zirconium dioxide, cubic oxide stabilized hafnium dioxide, or a combination thereof, wherein the functionally graded firing setter are chemically non-reactive and peel resistant at temperatures of about 1650° C. in air atmospheres,
- wherein a surface of the firing setter consists of unstabilized zirconium dioxide, unstabilized hafnium dioxide, or a combination thereof, and is essentially free of alumina, stabilized zirconia, magnesia, and silicates.
2 more elements
A functionally graded firing setter prepared by a method comprising:
- preparing a first slurry consisting essentially of a cubic oxide selected from a group consisting of calcium oxide (CaO), magnesium oxide (MgO), yttrium oxide (Y2O3), and cerium dioxide (CeO2);
- preparing a second slurry consisting essentially of unstabilized zirconium dioxide, unstabilized hafnium dioxide, or a combination thereof;
- depositing the first slurry over a planar carrier;
- maintaining the first slurry deposited over the planar carrier for a predetermined duration;
- after the predetermined duration, depositing the second slurry over the maintained first slurry;
- upon depositing the second slurry, drying the deposited second slurry and the maintained first slurry;
- and
- upon drying, sintering the dried second slurry and the first slurry at a predetermined temperature range to obtain the functionally graded firing setter,
- wherein a surface of the firing setter consists of unstabilized zirconium dioxide, unstabilized hafnium dioxide, or a combination thereof, and is essentially free of alumina, stabilized zirconia, magnesia, and silicates.
6 more elements
Dependencies are inferred from the claim text.