Zircon Forming Block Composition Reduces Bubble Formation
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Solution Overview
Problem
Current zircon materials used in forming blocks for high strain point alkali-free alumino-silicate glasses suffer from increased bubble formation and creep deformation at high temperatures, making them unsuitable for ultra-high resolution TFT substrate applications.
Innovation Solution
A zircon body with specific compositions, including 0.2-5.5 wt.% Al2O3, 25-35 wt.% SiO2, and a free silica intergranular phase, is developed to reduce blistering and creep deformation, with a blistering value of ≤8 bubbles/mm² and a creep deformation rate of ≤1.1 E-04 h⁻¹ at 1350°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If higher forming temperature (between +30 and 120°C) is used for high strain point alkali free alumino-silicate glasses, then the glass can be processed at high temperature without deformation, but the rate of reaction between the glass and zircon materials increases leading to higher bubble formation
Solution Approach 1:
The patent modifies the chemical composition parameters of the zircon material by adding specific amounts of Al2O3 (0.2-5.5 wt.%) and SiO2 (25-35 wt.%), and controlling the CBSiO2/CBAlC ratio (5-50) to change the material's reactivity characteristics at high temperatures
Solution Approach 2:
The patent creates a composite zircon material system combining zircon grains with a free silica intergranular phase containing Al2O3, where the intergranular phase acts as a buffer to reduce direct reaction between glass and zircon at elevated temperatures
2Temperature
If higher forming temperature (between +30 and 120°C) is used for high strain point alkali free alumino-silicate glasses, then the glass can be processed at high temperature without deformation, but the creep deformation rate of the zircon material increases leading to higher sag of the forming blocks
Solution Approach 1:
The patent changes the physical and chemical parameters of the zircon material through controlled addition of Al2O3 and SiO2, and optimizing their ratio, which modifies the material's thermal stability and creep resistance at high temperatures
Solution Approach 2:
The free silica intergranular phase with Al2O3 creates a composite structure where the intergranular material provides structural support and reduces creep deformation of the zircon grains under high temperature conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new zircon body composition significantly reduces bubble formation and creep deformation, ensuring the stability and integrity of the forming blocks at high temperatures, suitable for high strain point glass formation.
Implementation Method 1
the higher forming temperature activates the creep deformation rate of the zircon material leading to higher sag of the forming blocks
Implementation Method 2
the higher forming temperature can increase the rate of reaction between the glass and the zircon materials leading to higher formation of bubbles in the glass
Data Source
AI summary
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.