Philips Ceramics Uden
Ceramic Materials, Processing and Applications
Arno Brus
Arno.Brus@Philips.com
Botlek Studie Groep
April 9th 2015
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Introduction
• Founded 1891 in Eindhoven, Headquarter in Amsterdam
• Conglomerate of Businesses in Healthcare, Lighting and
Consumer lifestyle
• Turnover of EUR 21,391 million Euro and 113.678
employees (2014)
• Globally present in 100 countries with factories and
sales offices
• An R&D force with expenditures of EUR 1,635 million
(2014)
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Philips Ceramics Uden (PCU)
• PCU is the global competence center for ceramics for Philips
and non-Philips customers
– Product innovation
– Process innovation
– Production
– Commercial and consultancy services
• World leader in translucent ceramics
• Locations : Uden (NL)
Pila (Poland)
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New Product Introductions
(Injection Molding, Extrusion)
Traditional products
Philips Lighting PCA (Poly Crystalline Alumina)
Main stream application area
Shop Lighting/Interior Lighting
Outdoor Lighting
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New Markets for Philips Ceramics Uden
Ceramic membranes and substrate
materials
Replacement Technical Ceramics
Sensor components and housing
Service activities
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Mainly Project based
Product Development
Material Development
Firing/sintering services
Why Ceramics?
By Injection molding or Extrusion
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Why Ceramics?
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Design freedom due to manufacturing process
Shaping
Pressure
Polycrystalline
1. Al2O3 powder
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2. Shaping
3. Sintering (1900°C)
Complex shapes possible via Injection Molding Technology
Efficient manufacturing processes, no additional machining required
Sintering in hydrogen environment -> fully dense 99,99%, no pores
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Design freedom due to manufacturing process
Shaping by Injection Molding or Extrusion
• Feedstock made out of
Alumina and plastic binders
• Alumina isn’t moldable;
plastic is
• Ceramic particles encapsuled
by plastic
• Filling of mold by high
pressure
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Design freedom due to manufacturing process
Shaping by Injection Molding or Extrusion
• Feedstock made out of
Alumina and plastic binders
• Alumina isn’t moldable;
plastic is
• Ceramic particles encapsuled
by plastic
• Filling of mold by high
pressure
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Hardness of PCA (Al2O3)
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Temperature and Inertness
High Intensity Discharge lamp
PCA
5000K
1500K
T-Wall inner side
PCA:
 Poly Crystalline Alumina
 Al2O3
 In Dutch DGA; Doorschijnend Gasdicht
Aluminiumoxide
PCA
Light
40 Bar
Molten salts like Re,
Tl, Na - Iodides
Life time 32000 hrs
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Characteristics:
 High operating temperature (>1500 °C)
 High thermal shock resistant
 High corrosive resistance for aggressive
salts inside
 Mechanically very strong
 Very long life time
What makes Philips Ceramics Uden
special?
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Unique position in the market……
Ceramic injection
molding
8 folded molds
Hot runner systems
Furnace processing Unique HT furnaces, Philips
Optimal cost price
Mass production
Very high accuracy
Capacity.
technology.
Feedstock
development
Knowledge, link feedstock processing
and injection molding/extrusion
Translucent
ceramics
Build up knowledge over last
decades. Link quality alumina
versus translucency
Sapphire like quality
Mass production
extrusion
Unique (fast) drying technology
Capacity
Freedom of design/co developing
Complex problems
solved
R&D capacity
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Limited amount of
manufacturers of high
end feedstock
Highly automated Lines
Ceramic Injection Molding
Philips Ceramics Uden pictures of Ceramic
Injection Molding lines
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Superb chemical inertness due to full density
Firing Process in hydrogen atmosphere
Grains are ‘melting’ together and grow, pores are disappearing
1200°C
1600°C
1850°C
Fully dense ceramics have sapphire like properties with respect to
chemical inertness and hardness
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Joining Technology
Assembly via unique joining technology
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Ceramic parts can be assembled and sintered
to a monolithic structure
Properties of ‘join’ identical to main body material
Fully gastight connection
Body part 1
Body part 1
Join
Body part 2
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Body part 2
Mechanical Strength joined parts
Bursting Pressure measurement
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Water pressure applied from inside
Wall thickness 2mm, outer diameter <20mm, bursting pressure
>600bar)
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Outer diameter 20mm, wall thickness 1mm
Probability Plot (Outer Diameter 20mm)
Normal - 95% CI
99.9
Mean
StDev
N
AD
P-Value
99
95
Percent
90
What influences strength?
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60
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40
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1
0.1
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271.6
13.07
225
2.698
<0.005
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Bursting 330W
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320
• Local density variation
by applied raw materials
• Influenced
Grain size distribution
processing conditions
• Typeand
of porosity
• Chemical impurities
• Local defects
Feedthrough / Metal-Ceramic connection
Technology
Feedthrough Technology
• Gastight connection
• Co-sintering process for
sintering metal to ceramic
• Feedthrough material and
type depending on application
• Types; Mo/Al2O3 cermet, Nb
feedthrough, Mo coil, Ir cosintered
Nb feedthrough and sealing glass
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Gastight co-sintered feedthrough
Philips Ceramics Uden (PCU)
Characteristics;
• Production volume
• Employees
– Total
– Innovation
• Turn over 26 Mio
>30 Mio pieces/yr
155 FTE
21 FTE
• Shaping technologies: Ceramic Injection Molding , Extrusion
• High volumes, large capacity
• Highly mechanized
– robotics
– automatic in line inspection, vision systems
• Eco friendly materials, ROHS compliant
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Material & Product Characteristics
Material & Product
• Highly inert
• Translucent (optional)
• Fully gas tight material
• Gastight ceramic to metal
feedthroughs
• Sapphire like properties
Product & Manufacturing
• High accuracy in product details
• Joining Technology (monolithic seals)
• Freedom in shape by Injection
Molding
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Example applications for our
Ceramics
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Ceramic membrane applications
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Carrier tubes/systems for pervaporation
Porous tubes for Ultra and Micro filtration
Connectors for gas separation module
Metal/ ceramic or ceramic/ceramic interfaces/ connections
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(micro) reactor component
• Chemical and Pharmaceutical industry
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Enabling high temperature and high pressure processes
Superb resistance against corrosion
Gastight
Metal / ceramic connections
Possibility for inline measurements (Infrared wavelengths)
Milling, grinding, piercing
• F.e Pharmaceutical and Food industry
• Fully inert material
• Heat conductive
• Extreme lifetime due to
hardness
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Sensors
• Sensor housing, component, carriers, capacitors
• Design freedom by applying Injection Molding
• Withstands extreme conditions
(temperature, pressure, corrosive substances/gases)
• Metal/ ceramic or ceramic/ceramic interfaces/ connections
• Electrical insulator
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Arno Brus
Innovation Manager Ceramics
Arno.Brus@philips.com
www.philips.com/ceramics
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