Methods for forming delamination resistant glass containers

• US 9,346,707 B2
• Filed: 11/25/2013
• Issued: 05/24/2016
• Est. Priority Date: 11/30/2012
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Danielson, Paul Stephen, Schaut, Robert Anthony, Sick, Sara Jean
• Primary Examiner(s): Herring, Lisa
• Application Number:
  US14/088,556
• Publication Number:
  US 20140150499A1
• Time in Patent Office: 911 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: A61J 1/065 Rigid ampoules, e.g. glass ampoules
• CPC Class Codes: A61J 1/1468 Containers characterised by specific material properties
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B65D 1/0207 characterised by material, e.g. composition, physical features
• CPC Class Codes: B65D 1/0215 multilayered B65D81/3837 takes precedence
• CPC Class Codes: B65D 1/40 Details of walls other container details B65D23/00, B65D25/00
• CPC Class Codes: B65D 23/02 Linings or internal coatings
• CPC Class Codes: B65D 23/0814 characterised by the composition of the material
• CPC Class Codes: B65D 23/0821 consisting mainly of polymeric materials B65D23/0828 takes precedence
• CPC Class Codes: B65D 25/14 Linings or internal coatings of containers made by folding or erecting blanks made of paper B65D5/56 ; linings for domestic water storage heaters F24H1/183
• CPC Class Codes: B65D 25/34 Coverings or external coatings of containers made by folding or erecting blanks made of paper B65D5/62; for bottles or jars B65D23/08; wrappers B65D65/00
• CPC Class Codes: B65D 65/42 Applications of coated or impregnated materials
• CPC Class Codes: C03B 23/04 Re-forming tubes or rods
• CPC Class Codes: C03C 15/02 for making a smooth surface
• CPC Class Codes: C03C 17/005 Coating the outside
• CPC Class Codes: C03C 17/22 with other inorganic material C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C03C 17/30 with silicon-containing compounds
• CPC Class Codes: C03C 17/32 with synthetic or natural resins C03C17/30 takes precedence
• CPC Class Codes: C03C 17/3405 with at least two coatings of organic materials C03C17/36, C03C17/42 take precedence
• CPC Class Codes: C03C 17/42 at least one coating of an organic material and at least one non-metal coating
• CPC Class Codes: C03C 21/002 : to perform ion-exchange between alkali ions C03C21/005 takes precedence
• CPC Class Codes: C03C 2217/78 : Coatings specially designed to be durable, e.g. scratch-resistant
• CPC Class Codes: C03C 2218/111 : by dipping, immersion
• CPC Class Codes: C09D 179/08 : Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/131 : Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/1317 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/315 : Surface modified glass [e.g., tempered, strengthened, etc.]

Abstract

In one embodiment, a method of forming a glass container may include forming a glass container comprising a sidewall at least partially enclosing an interior volume. At least a portion of the interior surface of the sidewall may have an interior surface layer with a persistent layer heterogeneity relative to a midpoint of the sidewall. The interior surface layer of the glass container may be removed from the interior surface of the sidewall such that a modified interior surface of the sidewall has an interior region extending from about 10 nm below the modified interior surface into a thickness of the sidewall. The interior region may have a persistent layer homogeneity relative to the midpoint of the sidewall such that the modified interior surface is resistant to delamination.

Claims

1. A method of forming a glass container, the method comprising:

forming a glass container comprising a sidewall at least partially enclosing an interior volume, at least a portion of an interior surface of the sidewall having an interior surface layer with a persistent layer heterogeneity relative to a midpoint of the sidewall; and

removing the interior surface layer from the interior surface of the sidewall such that a modified interior surface of the sidewall has an interior region extending from about 10 nm below the modified interior surface into a thickness of the sidewall, the interior region having a persistent layer homogeneity relative to the midpoint of the sidewall such that the modified interior surface is resistant to delamination, wherein an extrema in a layer concentration of each constituent component in the interior region is greater than or equal to about 92% and less than or equal to about 108% of a bulk concentration of a same constituent component at a midpoint of the thickness of the sidewall after the interior surface layer has been removed.

2. The method of claim 1, further comprising removing an external surface layer from an external surface of the sidewall.

3. The method of claim 1, wherein the glass container has a delamination factor of less than or equal to 10 after the interior surface layer is removed.

4. The method of claim 1, wherein the interior surface layer is removed from the interior surface of the sidewall with an etchant comprising at least one hydrofluoric acid or at least one mineral acid.

5. The method of claim 1, wherein the interior surface layer has a thickness greater than or equal to 30 nm.

6. The method of claim 1, wherein an extrema in a layer concentration of each constituent component in the interior surface layer is less than about 80% or greater than about 120% of a bulk concentration of a same constituent component at a midpoint of the sidewall when the glass container is in an as-formed condition.

7. The method of claim 1, wherein the glass container is formed from a Type I, Class A or a Type I, Class B glass according to ASTM Standard E438-92.

8. The method of claim 1, wherein the glass container is formed from a borosilicate glass.

9. The method of claim 1, wherein the interior surface layer is silica-poor.

10. The method of claim 1, wherein the modified interior surface of the sidewall comprises a surface region extending over the modified interior surface of the glass container to a depth from about 10 nm to about 50 nm from the interior surface of the glass container;

and

for a discrete point on the modified interior surface of the glass container, an extrema of a surface concentration of each constituent component of the glass in the surface region at the discrete point is greater than or equal to about 70% and less than or equal to about 130% of a same constituent component in the surface region at any second discrete point on the modified interior surface of the glass container after the persistent layer heterogeneity has been removed.

11. The method of claim 1, wherein the modified interior surface of the glass container is substantially free from topographical variations.

12. A method for forming a glass container, the method comprising:

forming a glass container comprising a sidewall at least partially enclosing an interior volume, at least a portion of an interior surface of the sidewall having an interior surface layer with a persistent layer heterogeneity relative to a midpoint of the sidewall; and

etching the interior surface of the sidewall with an etchant to remove the interior surface layer such that a modified interior surface of the sidewall has an interior region extending from about 10 nm below the modified interior surface into a thickness of the sidewall, the interior region having a persistent layer homogeneity relative to the midpoint of the sidewall such that the modified interior surface is resistant to delamination, wherein an extrema in a layer concentration of each constituent component in the interior region is greater than or equal to about 92% and less than or equal to about 108% of a bulk concentration of a same constituent component at a midpoint of the thickness of the sidewall after the interior surface layer has been removed.

13. The method of claim 12, further comprising etching an exterior surface of the sidewall.

14. The method of claim 13, wherein the exterior surface is etched to a depth greater than a depth of surface flaws present in the exterior surface of the sidewall.

15. The method of claim 12, wherein the glass container has a delamination factor of less than or equal to 10 after the interior surface layer is removed.

16. The method of claim 12, wherein the etchant comprises hydrofluoric acid.

17. The method of claim 12, wherein the etchant comprises hydrochloric acid.

18. The method of claim 12, wherein the etchant comprises at least one mineral acid.

19. The method of claim 12, wherein the interior surface layer has a thickness greater than or equal to 10 nm.

20. The method of claim 12, wherein the glass container is formed from a Type I, Class A or a Type I, Class B glass according to ASTM Standard E438-92.

21. The method of claim 12, wherein the interior surface layer comprises a sodium borate rich glass material.

22. The method of claim 12, wherein an extrema in a layer concentration of each constituent component in the interior surface layer is less than about 80% or greater than about 120% of a bulk concentration of a same constituent component at a midpoint of the sidewall when the glass container is in an as-formed condition.

23. The method of claim 12, wherein the modified interior surface of the sidewall comprises a surface region extending over the modified interior surface of the glass container to a depth from about 10 nm to about 50 nm from the interior surface of the glass container;

and

for a discrete point on the modified interior surface of the glass container, an extrema of a surface concentration of each constituent component of the glass in the surface region at the discrete point is greater than or equal to about 70% and less than or equal to about 130% of a same constituent component in the surface region at any second discrete point on the modified interior surface of the glass container after the persistent layer heterogeneity has been removed.

24. The method of claim 12, wherein an average peak-to-valley roughness per 10,000 μ

m² of surface area of the modified interior surface is less than 1 μ

m.

25. A method of forming a glass container, the method comprising:

forming a glass container comprising a sidewall at least partially enclosing an interior volume such that at least a portion of an interior surface of the sidewall has an interior surface layer wherein an extrema in a layer concentration of each constituent component in the interior surface layer is less than about 80% or greater than about 120% of a bulk concentration of a same constituent component at a midpoint of the sidewall when the glass container is in an as-formed condition; and

removing the interior surface layer from the interior surface of the sidewall such that a modified interior surface of the sidewall has an interior region extending into a thickness of the sidewall wherein an extrema in a layer concentration of each constituent component in the interior region is greater than or equal to about 92% and less than or equal to about 108% of a bulk concentration of a same constituent component at a midpoint of the thickness of the sidewall after the interior surface layer has been removed.

26. The method of claim 25, wherein at least the modified interior surface of the glass container has a delamination factor of less than or equal to 10 after the interior surface layer is removed.

27. The method of claim 25, wherein the glass container is formed from a Type I, Class A or a Type I, Class B glass according to ASTM Standard E438-92.

28. The method of claim 25, wherein an average peak-to-valley roughness per 10,000 μ

m² of surface area of the modified interior surface is less than 1 μ

m.

29. The method of claim 25, wherein the modified interior surface of the sidewall comprises a surface region extending over the modified interior surface of the glass container to a depth from about 10 nm to about 50 nm from the interior surface of the glass container;

and

for a discrete point on the modified interior surface of the glass container, an extrema of a surface concentration of each constituent component of the glass in the surface region at the discrete point is greater than or equal to about 70% and less than or equal to about 130% of a same constituent component in the surface region at any second discrete point on the modified interior surface of the glass container after the interior surface layer has been removed.