Method of making multilayer structures using tapes on non-densifying substrates
AssigneeFerro Corporation
InventorsChandrashekhar S. Khadilkar, Srinivasan Sridharan, Aziz S. Shaikh
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Abstract
A method of applying a ceramic coating to a substrate comprises laminating one or more layers of a green ceramic tape to a rigid substrate using a tackifying resin to adhere the tape to the substrate. Upon firing, the tackifying resin ensures near zero shrinkage of the tape in the XY plane without usage of elevated pressures or temperatures during lamination of green tape to the substrate. The thermal degradation completion temperature of the tackifying resin is lower than that of the resin binder used in the green tape.
Claims27
A method for applying a ceramic coating to a substrate comprising:
- a. applying a tackifying resin to at least one of a green ceramic tape and a rigid substrate,
- i. wherein the green ceramic tape comprises a solids portion and an organics portion,
- ii. wherein the solids portion comprises a glass component,
- iii. wherein the organics portion comprises a polymer resin,
- iv. wherein the tackifying resin is selected from the group consisting of rosin resins, terpene resins, hydrocarbon resins and combinations thereof, and
- v. wherein the thermal degradation initiation temperature of the tackifying resin is lower than the thermal degradation initiation temperature of the polymer resin,
- vi. wherein the thermal degradation completion temperature of the tackifying resin is no greater than that of the resin used in the green ceramic tape,
- b. laminating together at a lamination pressure of less than about 100 psi, the green ceramic tape and the substrate to form a monolith, and
- c. firing the monolith at a temperature and a time sufficient to flow and densify the glass component,
- d. wherein the green ceramic tape exhibits less than 5% area shrinkage during firing.
A method for applying a porcelain enamel coating to a substrate comprising:
- a. applying a tackifying resin to at least one of a green ceramic tape and a rigid substrate,
- i. wherein the tackifying resin is selected from the group consisting of dehydroabietyl alcohol and a substance having chemical abstracts service registry number 65997-05-9, and
- ii. wherein the green ceramic tape is made from a slurry comprising
- 1. about 50 to about 70 wt % of a glass composition,
- 2. about 0.1 to about 10 wt % of a dispersant,
- 3. about 20 to about 40 wt % of an organic solvent,
- 4. about 0.1 to about 10 wt % of a polymer resin
- 5. about 0.1 to about 10 wt % of a plasticizer,
- b. laminating together at a lamination pressure of less than about 100 psi, the green ceramic tape and the substrate to form a monolith, and
- c. firing the monolith at a temperature of about 500° C. to about 1050° C. for about 1 to about 60 minutes,
- d. wherein the green ceramic tape exhibits less than 5% area shrinkage during firing.
Dependencies are inferred from the claim text.