Laminated glass articles with phase-separated claddings and methods for forming the same

• US 9,393,760 B2
• Filed: 03/12/2013
• Issued: 07/19/2016
• Est. Priority Date: 02/28/2013
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: He, Mingqian, Mauro, John Christopher, Parysek, Ronald John, Venkataraman, Natesan
• Primary Examiner(s): Sample, David
• Application Number:
  US13/795,925
• Publication Number:
  US 20140242375A1
• Time in Patent Office: 1,225 Days
• Field of Search: None
• US Class Current: 1/1
• 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: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2307/418 Refractive
• CPC Class Codes: B32B 2307/42 Polarizing, birefringent, filtering
• CPC Class Codes: B32B 2307/716 Degradable
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 7/027 Thermal properties
• CPC Class Codes: C03B 17/02 Forming molten glass coated with coloured layers; Forming molten glass of different compositions or layers; Forming molten glass comprising reinforcements or inserts
• CPC Class Codes: C03B 17/064 by the overflow downdraw fusion process; Isopipes therefor
• CPC Class Codes: C03C 1/004 Refining agents refining C03B5/225
• CPC Class Codes: C03C 11/005 obtained by leaching after a phase separation step
• CPC Class Codes: C03C 14/00 Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix devitrified glass ceramics C03C10/00
• CPC Class Codes: C03C 15/00 Surface treatment of glass, not in the form of fibres or filaments, by etching etching or surface-brightening compositions, in general C09K13/00
• CPC Class Codes: C03C 2214/30 Methods of making the composites
• CPC Class Codes: C03C 23/0095 Solution impregnating; Solution doping; Molecular stuffing, e.g. of porous glass in manufacture of preforms C03B37/012
• CPC Class Codes: C03C 3/091 containing aluminium
• CPC Class Codes: C03C 4/005 for opaline glass
• CPC Class Codes: Y10T 428/249969 Of silicon-containing material [e.g., glass, etc.]
• CPC Class Codes: Y10T 428/249994 Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]

Abstract

Laminated glass articles and methods for making the same are disclosed. In one embodiment, a laminated glass article may include a glass core layer and at least one glass cladding layer fused to the glass core layer. The at least one glass cladding layer may be phase separated into a first phase and at least one second phase having different compositions. The first phase of the at least one glass cladding layer may have an interconnected matrix. The at least one second phase of the at least one glass cladding layer may be dispersed throughout the interconnected matrix of the first phase of the at least one glass cladding layer. In some embodiments, the at least one second phase may be selectively removed from the interconnected matrix leaving a porous, interconnected matrix of the first phase.

Claims

1. A laminated glass article comprising:

a glass core layer; and

at least one glass cladding layer fused to the glass core layer, wherein;

the at least one glass cladding layer is phase separated into a first phase and at least one second phase having different compositions;

the first phase comprises an interconnected matrix;

the at least one second phase is dispersed throughout the interconnected matrix; and

the at least one glass cladding layer is free from alkali ions.

2. The laminated glass article of claim 1, wherein the first phase and the at least one second phase have different dissolution rates in water, alkaline solutions, or acidic solutions.

3. The laminated glass article of claim 1, wherein the first phase and the at least one second phase have different moduli of elasticity and loss tangents.

4. The laminated glass article of claim 1, wherein the at least one second phase is interconnected within the interconnected matrix of the first phase.

5. The laminated glass article of claim 1, wherein the at least one glass cladding layer is formed from a glass composition susceptible to spinodal decomposition.

6. The laminated glass article of claim 1, wherein the at least one glass cladding layer is formed from a glass composition comprising:

from about 60 mol. % to about 66 mol. % SiO₂;

from about 7 mol. % to about 10 mol. % Al₂O₃;

from about 14 mol. % to about 18 mol. % B₂O₃;

from about 9 mol. % to about 16 mol. % alkaline earth oxide, wherein the alkaline earth oxide comprises at least CaO and the CaO is present in the glass composition in a concentration from about 3 mol. % to about 12 mol. %.

7. The laminated glass article of claim 1, wherein the glass core layer comprises a non-phase-separable glass composition.

8. The laminated glass article of claim 1, wherein the glass core layer comprises a liquidus viscosity of greater than or equal to about 35 kPoise.

9. The laminated glass article of claim 1, wherein the at least one glass cladding layer comprises a first glass cladding layer fused to a first surface of the glass core layer and a second glass cladding layer fused to a second surface of the glass core layer.

10. The laminated glass article of claim 9, wherein the first glass cladding layer and the second glass cladding layer are formed from a glass composition comprising a lower average coefficient of thermal expansion (CTE) than the glass core layer.

11. The laminated glass article of claim 1, wherein the at least one glass cladding layer is formed from a glass composition comprising an average CTE of less than or equal to about 40×

10<sup>−

7</sup>/°

C. in a range from 20°

C. to 300°

C.

12. The laminated glass article of claim 1, wherein the glass core layer comprises an average CTE of greater than or equal to about 40×

10<sup>−

7</sup>/°

C. in a range from 20°

C. to 300°

C.

13. The laminated glass article of claim 1, wherein the glass core layer comprises about 60 mol. % to about 73 mol. % SiO₂.

14. An electronic substrate comprising the laminated glass article of claim 1.

15. A laminated glass article comprising:

a glass core layer; and

at least one glass cladding layer fused to the glass core layer, wherein;

the at least one glass cladding layer is phase separated into a first phase and at least one second phase having different compositions;

the first phase comprises an interconnected matrix;

the at least one second phase is dispersed throughout the interconnected matrix, and

the at least one glass cladding layer is formed from a glass composition comprising an average CTE of less than or equal to about 40×

10<sup>−

7</sup>/°

C. in a range from 20°

C. to 300°

C.

16. The laminated glass article of claim 15, wherein the glass composition of the at least one glass cladding layer is susceptible to spinodal decomposition.

17. The laminated glass article of claim 15, wherein the at least one glass cladding layer comprises a first glass cladding layer fused to a first surface of the glass core layer and a second glass cladding layer fused to a second surface of the glass core layer.

18. A laminated glass article comprising:

a glass core layer; and

at least one glass cladding layer fused to the glass core layer, wherein;

the at least one glass cladding layer is phase separated into a first phase and at least one second phase having different compositions;

the first phase comprises an interconnected matrix;

the at least one second phase is dispersed throughout the interconnected matrix, and

the at least one glass cladding layer is formed from a glass composition comprising;

from about 60 mol. % to about 66 mol. % SiO₂;

from about 7 mol. % to about 10 mol. % Al₂O₃;

from about 14 mol. % to about 18 mol. % B₂O₃;

from about 9 mol. % to about 16 mol. % alkaline earth oxide, wherein the alkaline earth oxide comprises at least CaO and the CaO is present in the glass composition in a concentration from about 3 mol. % to about 12 mol. %.

19. The laminated glass article of claim 18, wherein the at least one second phase is interconnected within the interconnected matrix of the first phase.

20. The laminated glass article of claim 18, wherein the at least one glass cladding layer is free from alkali ions.