Zircon-cordierite ceramics with a thermal expansion matching that of silicon

Substrates for polycrystalline silicon thin film solar cells are primarily required to match the thermal expansion of silicon. Ceramics with the same thermal expansion as silicon were synthesized from zircon, which has a higher thermal expansion than silicon, cordierite, which has a lower thermal expansion than silicon, and a glass phase. Zircon, SiO2, Al2O3, MgO and CaO were used as raw materials to synthesize these ceramics. The sintered ceramics had a thermal expansion matching that of silicon and contained no alkali metal oxides. The surface of the sintered bodies was self-glazed using one of the formulations.