Polycrystalline silicon articles containing boron by sintering

Claim 2

A process for producing a polycrystalline sintered body of silicon which comprises forming a particulate mixture of silicon powder and boron, said silicon powder and boron having an average particle size less than 3 microns, said boron being present in an amount ranging from 0.1% by weight to 5% by weight of said silicon powder, shaping said mixture into a green body having a density of at least 30% of the theoretical density of silicon, and sintering the green body at a temperature ranging from 1250° C. to a temperature below the melting point of silicon in an atmosphere which has no significant deteriorating effect on the green body or the resulting sintered body to produce a sintered body having a density of at least 60% of the theoretical density of silicon, and sintering densifying said green body in an amount of at least 2%.

Claim 3

A process for producing a polycrystalline sintered body of silicon according to claim 1 wherein said boron is present in an amount ranging from 0.1% by weight to about 0.46% by weight of said silicon powder and said sintering temperature ranges from 1300° C. to a temperature below 1390° C.

Claim 4

A process for producing a polycrystalline sintered body of silicon according to claim 1 wherein said silicon powder has an average particle size ranging from about 1 micron to less than 3 microns, and said boron being present in a minimum amount of 0.3% by weight of said silicon, said sintering temperature ranges from the temperature at which boron forms a liquid eutectic with silicon which is about 1390° C. to a temperature below the melting point of silicon.

Claim 5

A process for producing a polycrystalline sintered body of silicon which comprises forming a particulate mixture of silicon powder having an average particle size less than 0.2 micron and boron, said boron having an average particle size less than 1 micron and being present in an amount ranging from 0.1% by weight to 5% by weight of said silicon powder, shaping said mixture into a green body having a density of at least 40% of the theoretical density of silicon, and sintering the green body at a temperature ranging from 1300° C. to 1380° C. in an atmosphere which has no significant deteriorating effect on the green body or the resulting sintered body to produce a sintered body having a density of at least 60% of the theoretical density of silicon, said sintering densifying said green body in an amount of at least 2%.

Claim 6

A process for producing a polycrystalline sintered body of silicon which comprises forming a particulate mixture of silicon powder having an average particle size less than 0.2 micron and boron, said boron having an average particle size less than 1 micron and being present in an amount ranging from 0.1% by weight to 5% by weight of said silicon powder, shaping said mixture into a green body having a density of at least 40% of the theoretical density of silicon, and sintering the green body at a temperature ranging from 1300° C. to 1380° C. in an atmosphere which has no significant deteriorating effect on the green body or the resulting sintered body to produce a sintered body having a density of at least 60% of the theoretical density of silicon, said sintering densifying said green body in an amount of at least 2%.

Claim 7

A process for producing a polycrystalline sintered body of silicon according to claim 4 wherein said boron is present in an amount ranging from 0.1% by weight to about 0.46% by weight of said silicon powder.

Claim 8

A polycrystalline sintered body consisting essentially of silicon and boron in solid solution with said silicon, or consisting essentially of silicon and boron in solid solution with said silicon and an SiB 4 phase, said boron in solid solution ranging from 0.1% by weight to 0.46% by weight of said silicon, said SiB 4 phase being present in an amount ranging up to 7.5% by volume of the total solid phase of said sintered body, said SiB 4 phase being distributed at least significantly uniformly throughout said sintered body and being of a size which is substantially the same or finer than the average size of said silicon grains, said sintered body having a density of at least 60% of the theoretical density of silicon, said sintered body having an average grain size ranging up to about 8 microns and an average pore size ranging up to about 10 microns, said silicon grains being at least substantially equiaxed and of a significantly uniform size.

Claim 9

A polycrystalline sintered body consisting essentially of silicon and boron in solid solution with said silicon, or consisting essentially of silicon and boron in solid solution with said silicon and an SiB 4 phase, said boron in solid solution ranging from 0.1% by weight to 0.46% by weight of said silicon, said SiB 4 phase being present in an amount ranging up to 7.5% by volume of the total solid phase of said sintered body, said SiB 4 phase being distributed at least significantly uniformly throughout said sintered body and being of a size which is substantially the same or finer than the average size of said silicon grains, said sintered body having a density of at least 60% of the theoretical density of silicon, said sintered body having an average grain size ranging up to about 8 microns and an average pore size ranging up to about 10 microns, said silicon grains being at least substantially equiaxed and of a significantly uniform size.

Claim 10

A polycrystalline sintered body of silicon according to claim 6 wherein said density ranges from 60% to about 75% of the theoretical density of silicon and wherein at least a major portion of the pores are interconnecting and open to the surface of said body.

Claim 11

A polycrystalline sintered body of silicon according to claim 6 wherein the density is at least 92% of the theoretical density of silicon and wherein all or substantially all of the residual pores are closed pores.

Claim 12

A polycrystalline sintered body consisting essentially of silicon and boron in solid solution with said silicon, or consisting essentially of boron in solid solution with said silicon and an SiB 4 phase, said boron in solid solution ranging from 0.1% by weight to 0.46% by weight of said silicon, said SiB 4 phase being present in an amount ranging up to 7.5% by volume of the total solid phase of said sintered body, said SiB 4 phase being distributed at least significantly uniformly throughout said sintered body and being of a size which is substantially the same or finer than the average size of said silicon grains, said sintered body having a density of at least 92% of the theoretical density of silicon, said sintered body having an average grain size and an average pore size of 1 micron or less, said grains and pores being of significantly uniform size and being distributed significantly uniformly throughout said body.

Claim 13

A polycrystalline sintered body consisting essentially of silicon and boron in solid solution with said silicon, or consisting essentially of boron in solid solution with said silicon and an SiB 4 phase, said boron in solid solution ranging from 0.1% by weight to 0.46% by weight of said silicon, said SiB 4 phase being present in an amount ranging up to 7.5% by volume of the total solid phase of said sintered body, said SiB 4 phase being distributed at least significantly uniformly throughout said sintered body and being of a size which is substantially the same or finer than the average size of said silicon grains, said sintered body having a density of at least 92% of the theoretical density of silicon, said sintered body having an average grain size and an average pore size of 1 micron or less, said grains and pores being of significantly uniform size and being distributed significantly uniformly throughout said body.