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US 7,497,093 B2Granted
Method of making ceramic articles
Assignee3M Innovative Properties Company
InventorAnatoly Z. Rosenflanz
Life of this patent
Estimating the term…
Abstract
Method of making an article, the method comprising coalescing a plurality of the glass particles. Examples of articles include kitchenware (e.g., plates), dental brackets, and reinforcing fibers, cutting tool inserts, abrasives, and structural components of gas engines, (e.g., valves and bearings).
Claims77
A method of making an article, the method comprising:
- providing a substrate having an outer surface;
- providing at least a glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the first glass comprising one of a REO-Al2O3—ZrO2, Y2O3—Al2O3—ZrO2, REO-Al2O3—ZrO2—SiO2, Y2O3—Al2O3—ZrO2—SiO2, REO-Al2O3, or Y2O3—Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- heating the glass above the Tg such that at least a portion of the glass wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of the glass.
A method of making an article, the method comprising:
- providing a substrate having an outer surface;
- providing at least a plurality of particles comprising glass, the particles comprising glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass comprising REO-Al2O3—ZrO2, Y2O3—Al2O3—ZrO2, REO-Al2O3—Zr2—SiO2, Y2O3—Al2O3—ZrO2—SiO2, REO-Al2O3, or Y2O3—Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- heating the glass above the Tg such that at least a portion of the glass of the plurality of particles wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass.
A method of making an article, the method comprising:
- providing at least a first glass and second glass each having an outer surface, wherein the first glass comprises at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass comprising one of a REO-Al2O3—ZrO2, Y2O3—Al2O3—ZrO2, REO-Al2O3—Zr2—SiO2, Y2O3—Al2O3—ZrO2—SiO2, REO-Al2O3, or Y2O3—Al2O3 composition, and the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- heating the first and second glasses above at least Tg1 and at least the first glass coalescing with the second glass to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses.
A method of making an article, the method comprising:
- providing at least a first glass and second glass each having an outer surface, wherein the first glass comprises at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass comprising one of a REO-Al2O3—ZrO2, Y2O3—Al2O3—ZrO2, REO-Al2O3—Zr2—SiO2, Y2O3—Al2O3—ZrO2—SiO2, REO-Al2O3, or Y2O3—Al2O3 composition, and the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5, and wherein the second glass comprises at least two different metal oxides, wherein the second glass has a Tg2 and Tx2, and wherein the difference between the Tg2 and the Tx2 is at least 5K, the second glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- heating at least the first and second glasses above the higher of Tg1 or Tg2 and coalescing the first and second glasses to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses.
A method of making an article, the method comprising:
- providing at least a first plurality of particles comprising glass, the particles comprising glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass comprising one of a REO-Al2O3—ZrO2, Y2O3—Al2O3—ZrO2, REO-Al2O3—Zr2—SiO2, Y2O3—Al2O3—ZrO2—SiO2, REO-Al2O3, or Y2O3—Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- heating the glass above the Tg and coalescing at least a portion of the first plurality of particles to provide the article, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass.
A method of making an article, the method comprising:
- identifying a glass comprising at least two different metal oxides, wherein the class has a Tg and Tx, and wherein the difference between the Tg and the Tx of the class is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- providing at least the glass, wherein the glass has an outer surface:
- providing a substrate having an outer surface;
- and
- heating the glass above the Tg such that at least a portion of the glass wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of the glass.
2 more elements
A method of making an article, the method comprising:
- identifying a glass comprising at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- providing at least a plurality of particles comprising the glass, the particles comprising the glass having an outer surface;
- providing a substrate having an outer surface;
- and
- heating the glass above the Tg such that at least a portion of the glass of the plurality of particles wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass.
2 more elements
A method of making an article, the method comprising:
- identifying a first glass comprising at least two different metal oxides, wherein the first glass has as a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- providing at least the first glass and a second glass each having an outer surface;
- and
- heating the first and second glasses above at least Tg1 and at least the first glass coalescing with the second glass to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glasses as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses.
1 more element
A method of making an article, the method comprising:
- identifying a first glass comprising at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass containing less than 20% by weight SiO2, less than 20% weight B2O3, and less than 40% by weight P2O5, and wherein the second glass comprises at least two different metal oxides, wherein the second glass has a Tg2 and Tx2, and wherein the difference between the Tg2 and the Tx2 is at least 5K, the second glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- providing at least the first glass and a second glass each having an outer surface;
- and
- heating at least the first and second glasses above the higher of Tg1 or Tg2 and coalescing the first and second glasses to provide the article, wherein the heating of at least the first and second classes is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glasses as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses.
1 more element
A method of making an article, the method comprising:
- identifying a class comprising at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5;
- providing at least a first plurality of particles comprising the glass, the particles comprising the class having an outer surface;
- and
- heating the glass above the Tg and coalescing at least a portion of the first plurality of particles to provide the article, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass.
1 more element
Dependencies are inferred from the claim text.