Hybrid Sol-Gel Coated Glass Containers

• US 20120217181A1
• Filed: 02/24/2011
• Published: 08/30/2012
• Est. Priority Date: 02/24/2011
• Status: Active Grant

• Current Assignee: Owens-Brockway Glass Container Incorporated (O-I Glass, Inc.)
• Original Assignee: Owens-Brockway Glass Container Incorporated (O-I Glass, Inc.)
• Inventors: Sharma, Pramod K., Click, Carol A.
• Granted Patent: US 10,450,221 B2
• Time in Patent Office: Days
• US Class Current: 206/524.6
• CPC Class Codes: C03C 1/008 for the production of films or coatings
• CPC Class Codes: C03C 17/005 Coating the outside
• CPC Class Codes: C03C 17/009 Mixtures of organic and inorganic materials, e.g. ormosils and ormocers
• CPC Class Codes: C03C 2218/113 by sol-gel processes
• CPC Class Codes: C03C 2218/114 by brushing, pouring or doctorblading
• CPC Class Codes: Y10T 428/1317 Multilayer [continuous layer]

Abstract

A glass container and related methods of manufacturing and coating glass containers. The glass container includes a hybrid sol-gel cross-linked on at least a portion of an exterior glass surface of the glass container.

Claims

1. A method of coating an exterior surface of a glass container that includes the steps of:

(a) providing a heated hybrid sol-gel having a composition including at least one silane and at least one solvent;

(b) coating the exterior glass surface of the glass container with said heated hybrid sol-gel; and

(c) heating said coated exterior glass surface of the glass container to cross-link said hybrid sol-gel and result in a coating on said exterior glass surface of the glass container having greater than 90% silicate-based material by weight.

2. The method set forth in claim 1 wherein said composition in step (a) includes between 50% and 60% by weight of at least one silane and between 40% and 50% by weight of at least one solvent, said hybrid sol-gel is heated to a temperature between 70 degrees Celsius and 130 degrees Celsius in step (a), said temperature in step (b) is between 90 degrees Celsius and 130 degrees Celsius, and said heating step (c) is carried out at a temperature of between 130 degrees Celsius and 170 degrees Celsius and for a time between ten minutes and ten hours.

3. The method set forth in claim 1 wherein said composition in step (a) includes between 52% and 58% by weight of at least one silane and between 42% and 46% by weight of at least one solvent, said temperature in step (a) is between 90 degrees Celsius and 110 degrees Celsius, said temperature in step (b) is between 95 degrees Celsius and 125 degrees Celsius, and said heating step (c) is carried out at a temperature of between 140 degrees Celsius and 160 degrees Celsius.

4. The method set forth in claim 1 wherein said composition in step (a) includes about 56% by weight of at least one silane and about 44% by weight of at least one solvent, said temperature in step (a) is about 100 degrees Celsius, said temperature in step (b) is about 110 degrees Celsius, and said heating step (c) is carried out at a temperature of about 150 degrees Celsius.

5. The method set forth in claim 1 wherein said at least one silane in step (a) includes at least one of methyltriethoxysilane, dimethyldiethoxysilane, phenyltriethoxysilane, diphenyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, 3-glycidoxypropyltrimethoxisilane, 3-glycidoxypropyldimethoxyethoxysilane, aminopropylmethyldimethosilane, aminopropyltrimethoxysilane, gamma mercaptopropyltrimethoxysilane, or vinyltrimethoxysilane, and wherein said at least one solvent in step (a) includes at least one of denatured ethanol, anhydrous ethanol, methanol, normal propanol, isopropanol, butanol, diethylene glycol, acetones, methylethylketons, tryethyleneglycols, vinylpyrrolidones, toluene, glycerine, phenol, benzyl alcohol, or dioxane.

6. The method set forth in claim 1 wherein said at least one silane in step (a) includes methyltriethoxysilane and dimethyldiethoxysilane, and wherein said at least one solvent includes at least one of denatured ethanol or anhydrous ethanol.

7. The method set forth in claim 1 wherein said at least one silane in step (a) includes phenyltriethoxysilane and diphenyldiethoxysilane, and wherein said at least one solvent includes anhydrous ethanol.

8. The method set forth in claim 1 wherein said at least one silane in step (a) includes phenyltrimethoxysilane and diphenyldimethoxysilane, and wherein said at least one solvent includes methanol.

9. The method set forth in claim 1 wherein said composition in step (a) includes a silane to solvent weight ratio of between 1.5:

1 and 1;

1.

10. The method set forth in claim 1 wherein said composition in step (a) includes a silane to solvent weight ratio of about 1.3:

1.

11. The method set forth in claim 1 wherein said hybrid sol-gel is doped with an ultraviolet blocking material, wherein ultraviolet blocking material is not applied in a separate step.

12. The method set forth in claim 11 wherein said ultraviolet blocking material is at least one of cerium oxide, titanium oxide, zinc oxide, bismuth oxide, or barium titanate.

13. The method set forth in claim 1 wherein said hybrid sol-gel is doped with at least one metal alkoxide that is not applied in a separate step.

14. The method set forth in claim 13 wherein said at least one metal alkoxide is at least one of cerium alkoxide or titanium dialkoxide.

15. The method set forth in claim 1 wherein said at least one silane includes at least one of methyltriethoxysilane, dimethyldiethoxysilane, phenyltriethoxysilane, diphenyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, 3-glycidoxypropyltrimethoxisilane, 3-glycidoxypropyldimethoxyethoxysilane, aminopropylmethyldimethosilane, aminopropyltrimethoxysilane, gamma mercaptopropyltrimethoxysilane, or vinyltrimethoxysilane.

16. The method set forth in claim 1 wherein said at least one solvent includes at least one of denatured ethanol, anhydrous ethanol, methanol, normal propanol, isopropanol, butanol, diethylene glycol, acetones, methylethylketones, tryethyleneglycols, vinylpyrrolidones, toluene, glycerine, phenol, benzyl alcohol, or dioxane.

17. A glass container made by the method set form in claim 1.

18. A glass container that includes:

an axially closed base at an axial end of the glass container;

a body extending axially from said base and being circumferentially closed;

an axially open mouth at another end of the glass container opposite of said base;

an exterior glass surface; and

a cross-linked hybrid sol-gel on at least a portion of said exterior glass surface.

19. The glass container set forth in claim 18 wherein said cross-linked hybrid sol-gel has greater than 90% silicate-based material by weight for increasing strength of the glass container and for increasing fragment-retention.

20. The glass container set forth in claim 19, wherein said cross-linked hybrid sol-gel includes at least one silane.

21. The glass container set forth in claim 20, wherein said at least one silane includes a first silane and a multiple of said first silane.

22. The glass container set forth in claim 21, wherein said first silane includes at least one ofmethyltriethoxysilane, phenyltriethoxysilane, or phenyltrimethoxysilane, and said multiple of said first silane includes at least one of dimethyldiethoxysilane, diphenyldiethoxysilane, diphenyldimethoxysilane, 3-glycidoxypropyltrimethoxisilane, 3-glycidoxypropyldimethoxyethoxysilane, aminopropylmethyldimethosilane, aminopropyltrimethoxysilane, gamma mercaptopropyltrimethoxysilane, or vinyltrimethoxysilane.

23. The glass container set forth in claim 20, wherein said hybrid sol-gel includes an ultraviolet blocking material including at least one of cerium oxide, titanium oxide, zinc oxide, bismuth oxide, or barium titanate.

24. A glass container that includes:

an axially closed base at an axial end of the glass container;

a body extending axially from said base and being circumferentially closed;

an axially open mouth at another end of the glass container opposite of said base;

an exterior glass surface; and

a coating of hybrid sol-gel on at least a portion of said exterior glass surface, wherein said hybrid sol-gel includes at least one silane and at least one solvent.

25. The method set forth in claim 24 wherein said composition in step (a) includes a silane to solvent weight ratio of between 1.5:

1 and 1;

1.

26. The method set forth in claim 24 wherein said composition in step (a) includes a silane to solvent weight ratio of about 1.3:

1.

27. The glass container set forth in claim 24, wherein said at least one silane includes a first silane and a multiple of said first silane.

28. The glass container set forth in claim 24, wherein said first silane includes at least one of methyltriethoxysilane, phenyltriethoxysilane, or phenyltrimethoxysilane, and said multiple of said first silane includes at least one of dimethyldiethoxysilane, diphenyldiethoxysilane, diphenyldimethoxysilane, 3-glycidoxypropyltrimethoxisilane, 3-glycidoxypropyldimethoxyethoxysilane, aminopropylmethyldimethosilane, aminopropyltrimethoxysilane, gamma mercaptopropyltrimethoxysilane, or vinyltrimethoxysilane.

29. The glass container set forth in claim 24, wherein said at least one solvent includes at least one of denatured ethanol, anhydrous ethanol, methanol, normal propanol, isopropanol, butanol, diethylene glycol, acetones, methylethylketones, tryethyleneglycols, vinylpyrrolidones, toluene, glycerine, phenol, benzyl alcohol, or dioxane.

30. The glass container set forth in claim 24, wherein said hybrid sol-gel also includes an ultraviolet blocking material including at least one of cerium oxide, titanium oxide, zinc oxide, bismuth oxide, or barium titanate.

31. A method of manufacturing that includes the steps of:

(a) forming a glass container;

(b) applying a hot end coating to an exterior glass surface of said glass container;

(c) annealing said glass container;

(d) heating a hybrid sol-gel to a temperature of between 70 degrees Celsius and 130 degrees Celsius, wherein a composition of said hybrid sol-gel includes 50% to 60% by weight of at least one silane, 40% to 50% by weight of at least one solvent, and optionally also including at least one dopant, wherein said heated hybrid sol-gel has a viscosity of between 0.001 Pa-s and 100 Pa-s;

(e) coating said exterior glass surface of the glass container with said heated hybrid sol-gel, at a temperature between 80 degrees Celsius and 140 degrees Celsius;

(f) heating said coated exterior glass surface of the glass container at a temperature between 140 degrees Celsius and 160 degrees Celsius for a time between ten minutes and ten hours to cross-link said hybrid sol-gel and result in a coating on said exterior glass surface of the glass container having greater than 90% silicate-based material by weight to increase at least one of strength or fragment retention of the glass container; and

thereafter

(g) applying a cold end coating to said exterior glass surface of said glass container.

32. The method set forth in claim 31 wherein said step (d) is carried out after step (c) begins but before step (c) ends.