1. A structural alignment member for use in operably receiving a plurality of structural support members in a customizable arrangement, said structural alignment member comprising:
(a) a single-piece main body having an elongated base portion with an upper surface and an opposed lower surface, and first and second substantially opposed sides extending along a length of said base portion;
(b) first and second end flanges extending upwardly from said upper surface of said base portion at said first and second sides, and further extending along said length of said base portion;
(c) said main body being partially separated into a plurality of support member receptor portions; and
(d) one or more preformed creases in at least one of said base portion and said first end flange, and being interposed between and integrally connecting respective adjacent said support member receptor portions,
such that said support member receptor portions are operably repositionable with respect to one another along a plurality of distinct planes, wherein said creases are formed prior to repositioning of said support member receptor portions.
2. A structural alignment member as in claim 1 wherein said first and second end flanges extend perpendicularly upwardly from said base portion.
3. A structural alignment member as in claim 1 wherein adjacent ones of said support member receptor portions are partially separated by respective cut-out portions disposed in said base portion and extending partially transversely thereacross, said cut-out portions each defining an open gap in said base portion, and respective cuts extending through said second end flange.
4. A structural alignment member as in claim 3 wherein said cut-out portions extend across at least about fifty percent of a width dimension of said base portion.
5. A structural alignment member as in claim 3 wherein said cut-out portions are spaced apart along the length of said base portion at predetermined intervals.
6. A structural alignment member as in claim 5 wherein said predetermined intervals are each four inches.
7. A structural alignment member as in claim 3, including a fastener aperture disposed in said second end flange adjacent to each of the cuts, such that a fastener may locatably couple respective adjacent overlapped portions of said second end flange to one another.
8. A structural alignment member as in claim 1, including one or more overlay tabs longitudinally extending from the base portions of respective support member receptor portions to thereby operably overlap adjacent support member receptor portions.
9. A structural alignment member as in claim 8 wherein each of said overlay tabs include a fastener aperture therein.
10. A structural alignment member as in claim 1 wherein said preformed creases are disposed in both said base portion and said first end flange.
11. A structural alignment member as in claim 10 wherein respective pairs of said preformed creases interconnecting respective adjacent said support member receptor portions coextensively meet at a merge point.
12. A structural alignment member for use in operably receiving a structural support member, said structural alignment member comprising:
a main body being partially separated into a plurality of support member receptor portions, said main body having:
(a) a base portion;
(b) a first end flange extending substantially perpendicularly from a first side of the base portion and further extending substantially along a length of said base portion;
(c) a first crease in said first end flange, said first crease including a first apex that is spaced from a plane of a portion of said first end flange adjacent to said first crease; and
(d) a second crease in said base portion, said second crease including a second apex that is spaced from a plane of a portion of said base portion adjacent to said second crease,
wherein said first and second creases integrally connect respective adjacent support member receptor portions to permit said support member receptor portions to be repositioned with respect to one another along a plurality of distinct planes.
13. A structural alignment member as in claim 12 including a second end flange extending substantially perpendicularly from a second side of said base portion and further extending substantially along said length of said base portion.
14. A structural alignment member as in claim 12 wherein first and second creases coextensively meet at a merge point.
15. A structural alignment member as in claim 12 wherein said first and second creases are formed prior to repositioning of said support member receptor portions.
16. A structural alignment member for use in operably receiving a structural support member, said structural alignment member comprising:
a single-piece main body being partially separated into a plurality of support member receptor portions, said main body having:
(a) a base partially separated into a series of base portions each associated with a support member receptor portion\u2032
(b) a first end flange extending substantially perpendicularly from a first side of the base portion and further extending substantially alogn a length of said base portion;
(c) a first crease in said first end flange, said first crease including a first apex that is spaced from a plane of a portion of said first end flange adjacent to said first crease, and said first crease integrally connecting respective adjacent support member receptor portions to permit said support member receptor portions to be repositioned with respect to one another along a plurality of distinct planes; and
(d) a second end flange extending substantially perpendicularly from a second side of said base portion and further extending substantially along said length of said base portion, said second end flange being separated into a series of separated and overlapping end flange portions each associated with a respective support member receptor portion.
17. A structural alignment member as in claim 16, including a second crease in said base portion, said second crease including a second apex that is spaced from a plane of a portion of said base portion adjacent to said second crease.
18. A structural alignment member as in claim 17 wherein said first and second creases coextensively meet at a merge point.
19. A structural alignment member as in claim 16, including a fastener aperture disposed in each of said end flange portions.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A plasma resistant member, comprising:
a base material made of alumina; and
a thermal spray layer made of Y2O3 or YAG formed on a surface of the base material,
wherein at least a part of the surface of the base material on which the thermal spray layer is formed has a surface roughness Ra ranging from 5 \u03bcm to 15 \u03bcm.
2. A plasma resistant member, comprising:
a base material made of alumina; and
a thermal spray layer made of Y2O3or YAG formed on a surface layer of the base material,
wherein at least a part of the surface layer of the base material is a porous layer having a porosity of 20% or more and 60% or less with a depth thereof being 10 \u03bcm or more and 100 \u03bcm or less.
3. The plasma resistant member as set forth in claim 2, wherein at least the part of the surface layer on which the thermal spray layer is formed has a surface roughness Ra ranging from 2 \u03bcm to 10 \u03bcm.
4. The plasma resistant member as set forth in claim 1, wherein the thermal spray layer comprises Y2O3 including Si ranging from 100 ppm to 1000 ppm.
5. The plasma resistant member as set forth in claim 2, wherein the thermal spray layer comprises Y2O3 including Si ranging from 100 ppm to 1000 ppm.
6. The plasma resistant member as set forth in claim 1, wherein at least a surface layer of the base material on which the thermal spray layer is formed has an aspect ratio ranging from 0.3 to 1.0.
7. The plasma resistant member as set forth in claim 2, wherein at least the surface layer of the base material on which the thermal spray layer is formed has an aspect ratio ranging from 0.3 to 1.0.
8. A method for manufacturing a plasma resistant member, comprising steps of:
performing a chemical etching on a surface of a base material made of alumina, and performing thermal spray Y2O3 or YAG onto the surface of the base material to form a plasma resistant layer.
9. The method for manufacturing the plasma resistant member as set forth in claim 8, wherein the chemical etching is performed with an acid etching solution at a temperature ranging from 160\xb0 C. to 240\xb0 C. in a pressure ranging from 0.6 MPa to 3.3 MPa for 3 hours or more and 10 hours or less.
10. The method for manufacturing the plasma resistant member as set forth in claim 8, wherein the chemical etching is performed with an acid etching solution at a temperature ranging from 180\xb0 C. to 240\xb0 C. in a pressure ranging from 1.0 MPa to 3.3 MPa for 3 hours or more and 10 hours or less.
11. The method for manufacturing the plasma resistant member as set forth in claim 9, further comprising a step of:
annealing the base material at a temperature ranging from 1,500\xb0 C. to 1,800\xb0 C. in an atmosphere for 4 hours or more and 8 hours or less after performing the chemical etching.
12. The method for manufacturing the plasma resistant member as set forth in claim 11, wherein at least a surface layer of the base material on which the thermal spray is performed has an aspect ratio ranging from 0.3 to 1.0 after annealing.
13. The method for manufacturing the plasma resistant member as set forth in claim 8, wherein the plasma resistant layer is made of the Y2O3, the Y2O3 contains Si in an amount of 100 ppm or more and 1000 ppm or less.
14. The method for manufacturing the plasma resistant member as set forth in claim 8, wherein the surface of the base material has a surface roughness Ra ranging from 5 \u03bcm to 15 \u03bcm after performing the chemical etching.
15. The method for manufacturing the plasma resistant member as set forth in claim 6, wherein a surface layer of the base material is a porous layer having a porosity ratio of 20% or more and 60% or less, and
a depth of the porous layer is 10 \u03bcm or more and 100 \u03bcm or less.
16. A method for forming a thermal spray coat, comprising steps of:
chemically roughening a surface of a brittle material; and
forming the thermal spray coat by performing thermal spray on the surface of the brittle material,
wherein the roughened surface of the brittle material has a surface roughness Ra of 1 \u03bcm or more and 10 or less.
17. The method for forming the thermal spray layer as set forth in claim 16, wherein the brittle material is a sintered ceramic material containing crystals having a grain size of 2 \u03bcm or more and 70 \u03bcm or less, and
the chemical roughening is performed with an acid etching solution.
18. The method for forming the thermal spray layer as set forth in claim 16, wherein the brittle material is quartz, and
the chemical roughening is performed by chemical frosting treatment.
19. A method for manufacturing a composite material comprising a brittle material and a protective coat formed on a surface of the brittle material, comprises steps of;
chemically roughening the surface of the brittle material to obtain a surface roughness thereof ranging from 1 \u03bcm to 10 \u03bcm; and
performing thermal spray on the surface of the brittle material to form the protective coat.