Glass sheets with improved mechanical strength

• US 9,434,633 B2
• Filed: 06/28/2011
• Issued: 09/06/2016
• Est. Priority Date: 06/29/2010
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Bookbinder, Dana Craig, House, Keith Leonard, Tandon, Pushkar
• Primary Examiner(s): KHAN, TAHSEEN
• Application Number:
  US13/170,675
• Publication Number:
  US 20110318555A1
• Time in Patent Office: 1,897 Days
• Field of Search: 428/213, 428/220, 428/410, 428/427, 428/428
• US Class Current: 1/1
• 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: C03B 17/068 Means for providing the drawing force, e.g. traction or draw rollers
• CPC Class Codes: C03C 3/083 containing aluminium oxide or an iron compound
• CPC Class Codes: C03C 3/085 containing an oxide of a divalent metal
• CPC Class Codes: C03C 3/087 containing calcium oxide, e.g. common sheet or container glass
• CPC Class Codes: C03C 3/091 containing aluminium
• CPC Class Codes: C03C 3/093 containing zinc or zirconium
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]

Abstract

Transparent glass sheets having increased mechanical strength include an inner layer surrounded by surface compressive layers wherein the difference of the coefficient of thermal expansion of the inner layer and the surface compressive layer is greater than 50×10⁻⁷° C.⁻¹ and wherein the surface compressive layer has a compressive stress of at least about 300 MPa.

Claims

1. A transparent glass sheet comprising a surface compressive layer and an inner layer adjacent to the surface compressive layer,

wherein between 0°

C. and 300°

C. a difference between a coefficient of thermal expansion of the inner layer and a coefficient of thermal expansion of the surface compressive layer is greater than 50×

10<sup>−

7</sup>°

C.<sup>−

1</sup>, and

wherein the surface compressive layer has a compressive stress of at least about 300 MPa and the inner layer has a tensile stress of at least 29 MPa.

2. The transparent glass sheet according to claim 1, wherein between 0°

C. and 300°

C. a ratio of the coefficient of thermal expansion of the inner layer to the coefficient of thermal expansion of the surface compressive layer is greater than 2.5.

3. The transparent glass sheet according to claim 1, wherein the transparent glass sheet has a thickness and the inner layer has a thickness, and a ratio of the thickness of the inner layer to the thickness of the transparent glass sheet is at least about 0.8.

4. The transparent glass sheet according to claim 1, wherein the transparent glass sheet has a thickness ranging from about 0.3 mm to about 3 mm.

5. The transparent glass sheet according to claim 1, wherein the softening point of the surface compressive layer is at least 40°

C. below a softening point of the inner layer.

6. The transparent glass sheet according to claim 1, wherein the ratio of the viscosity of the surface compressive layer to a viscosity of the inner layer in a range of the softening point of the inner layer ±

200°

C. is from about 0.1 to about 0.9.

7. The transparent glass sheet according to claim 1, wherein the inner layer comprises in weight percent on an oxide basis:

(i) 50≦

SiO₂≦

65%;

(ii) 10≦

Al₂O₃≦

20%;

(iii) 0≦

MgO≦

5%;

(iv) 10≦

Na₂O≦

20%;

(iv) 0≦

K₂O≦

5%; and

(v)≧

0 and ≦

1% of at least one of B₂O₃, CaO, ZrO₂ and Fe₂O₃.

8. The transparent glass sheet according to claim 1, wherein the surface compressive layer has a compressive stress of at least about 500 MPa.

9. The transparent glass sheet according to claim 1, wherein no layer of the transparent glass sheet has been subjected to an in situ crystallization process.

10. The transparent glass sheet according to claim 1, wherein less than 10 ppm of any layer in the glass sheet is in a crystalline state.

11. The transparent glass sheet according to claim 1, wherein no layer of the transparent glass sheet has been subjected to an ion exchange process.

12. The transparent glass sheet according to claim 1, wherein between 0°

C. and 300°

C. a ratio of the coefficient of thermal expansion of the inner layer to the coefficient of thermal expansion of the surface compressive layer is greater than 3.

13. The transparent glass sheet according to claim 1, wherein between 0°

C. and 300°

C. the difference of the coefficient of thermal expansion of the inner layer and the coefficient of thermal expansion of the surface compressive layer is greater than 75×

10<sup>−

7</sup>°

C.<sup>−

1</sup>.

14. The transparent glass sheet according to claim 1, wherein the transparent glass sheet has a thickness and the inner layer has a total thickness, and a ratio of the total thickness of the inner layer to the thickness of the transparent glass sheet is at least about 0.9.

15. The transparent glass sheet according to claim 1, wherein between 0°

C. and 300°

C. a ratio of the coefficient of thermal expansion of the inner layer to the coefficient of thermal expansion of the surface compressive layer is greater than 4.

16. The transparent glass sheet according to claim 1, wherein between 0°

C. and 300°

C. the difference between the coefficient of thermal expansion of the inner layer and the coefficient of thermal expansion of the surface compressive layer is greater than 90×

10<sup>−

7</sup>°

C.<sup>−

1</sup>.

17. The transparent glass sheet according to claim 1, wherein the surface compressive layer has a compressive stress of at least about 700 MPa.

18. The transparent glass sheet according to claim 1, wherein the inner layer has a tensile stress of at least about 57 MPa.

19. The transparent glass sheet according to claim 1, wherein the inner layer comprises an alkali aluminosilicate glass.

20. The transparent glass sheet according to claim 1, wherein the surface compressive layer comprises in weight percent on an oxide basis:

(i) 65≦

SiO₂≦

75%;

(ii) 7≦

Al₂O₃≦

13%;

(iii) 5≦

B₂O₃≦

15%;

(iv) 5≦

CaO≦

15%;

(v) 0≦

BaO≦

5%;

(vi) 0≦

MgO≦

3%; and

(vii) 0≦

SrO≦

5%.

21. The transparent glass sheet according to claim 20, wherein the surface compressive layer is essentially free of BaO.

22. The transparent glass sheet according to claim 1, wherein a ratio of a thickness of the inner layer to a thickness of the transparent glass sheet is less than or equal to 0.9.

23. The transparent glass sheet according to claim 1, wherein the inner layer has a tensile stress of at least about 42 MPa.

24. A transparent glass sheet comprising a surface compressive layer and an inner layer adjacent to the surface compressive layer, wherein between 0°

C. and 300°

C. the difference between the coefficient of thermal expansion of the inner layer and the coefficient of thermal expansion of the surface compressive layer is greater than 50×

10<sup>−

7</sup>°

C.<sup>−

1</sup>, the surface compressive layer has a compressive stress of at least about 300 MPa, and a ratio of a thickness of the inner layer to a thickness of the transparent glass sheet is less than or equal to 0.9.