Zircon Forming Block Composition for High-Temperature Stability
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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, which are unacceptable 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 ≤1.1E-04 h⁻¹ at 1350°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional zircon materials are used in forming blocks for high strain point alkali-free alumino-silicate glasses, then the forming block can operate at high temperatures, but increased bubble formation and creep deformation occur which are unacceptable for ultra-high resolution TFT substrate applications
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the zircon material, specifically limiting Al2O3 to 0.2-5.5 wt.% and SiO2 to 25-35 wt.%, and controlling the crystal phase composition with 90-99 wt.% zircon and 1-10 wt.% baddeleyite. These parameter adjustments resolve the contradiction by minimizing harmful reactions and creep deformation while maintaining high temperature stability.
Solution Approach 2:
The patent employs composite materials by creating a multi-phase zircon-based refractory material containing zircon (ZrSiO4), baddeleyite (monoclinic ZrO2), and controlled amounts of Al2O3 and SiO2. This composite structure combines the high temperature stability of zircon with the creep resistance of baddeleyite, resolving the contradiction between thermal stability and resistance to deformation.
2Temperature
If higher forming temperature is used for high strain point alkali-free alumino-silicate glasses, then the glass can be formed with desired properties, but the rate of reaction between glass and zircon materials increases leading to higher bubble formation
Solution Approach 1:
The patent resolves this contradiction by changing the chemical composition parameters of the zircon material to be less reactive at high temperatures. By limiting Al2O3 to 0.2-5.5 wt.% and SiO2 to 25-35 wt.%, and controlling the crystal phases, the material maintains stability at high forming temperatures while minimizing harmful reactions that cause bubble formation.
3Temperature
If higher forming temperature is used for high strain point alkali-free alumino-silicate glasses, then the glass can be formed with desired properties, but the creep deformation rate of the zircon material increases leading to higher sag of the forming blocks
Solution Approach 1:
The patent resolves this contradiction by creating a composite refractory material where baddeleyite (monoclinic ZrO2) serves as a key component. Baddeleyite has superior creep resistance compared to pure zircon, allowing the forming block to maintain dimensional stability at high forming temperatures while still enabling glass formation with desired properties.
Solution Approach 2:
The patent applies parameter changes by controlling the baddeleyite content at 1-10 wt.% and the Al2O3/SiO2 ratios, which optimizes the creep resistance and dimensional stability of the zircon-based material at high temperatures, preventing excessive sag of the forming blocks.
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 solution effectively minimizes bubble formation and creep deformation, ensuring the stability and integrity of zircon forming blocks at high temperatures, suitable for forming high strain point glasses.
Implementation Method 1
Zircon forming blocks that come in contact with alkali free alumino-boro-silicate glasses offer good corrosion resistance and mechanical properties at the forming temperature of glass
Implementation Method 2
the higher forming temperature activates the creep deformation rate of the zircon material leading to higher sag of the forming blocks
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.