Patent Grant
8389428
The present invention relates to a glass composition having high refractive index, softening property at low temperature and small average thermal expansion coefficient, and a member provided with the composition on a substrate.
Conventionally, a glass composition having (1) high refractive index (refractive index at the d line is from 1.88 to 2.20), (2) low softening temperature (490° C. or lower) and (3) small average thermal expansion coefficient (the average thermal expansion coefficient is (65 to 90)×10−7/K), and a member provided with the glass composition on a substrate (hereinafter referred to as “glass composition and the like) have not been present.
The glass composition and the like simultaneously provided with at most two requirements of the above three requirements are proposed (Patent Documents 1 to 5).
In recent years, environmental pollution becomes serious problem in the melting of a glass containing lead oxide. Therefore, the glass is required to not contain lead oxide.
However, any of Patent Documents 1 to 5 does not disclose or suggest to be simultaneously provided with the above three requirements. It is necessary to be simultaneously provided with the three requirements in order to form a high refractive index film on a soda lime substrate by firing glass frit/glass paste. The glasses of Patent Documents 1 to 3 are developed for use in precision press molding lens. For this reason, the glasses of Patent Documents 1 to 3 do not have the object to fire as a fit, and therefore have the problem that an average thermal expansion coefficient is large.
The glass of Patent Document 4 contains a large amount of bismuth. For this reason, the glass of Patent Document 4 has the problems that coloration is large and an average thermal expansion coefficient is large.
The glass of Patent Document 5 is developed for use in precision press molding lens. For this reason, the glass of Patent Document 5 does not have the object to fire as a frit, and therefore has the problem that a glass transition temperature is high.
The present invention provides a glass composition having high refractive index, softening property at low temperature and small average thermal expansion coefficient, and a member provided with the glass composition on a substrate.
A glass composition the present invention has a refractive index (nd) of from 1.88 to 2.20, a glass transition temperature (Tg) of from 450 to 490° C., and an average thermal expansion coefficient at temperatures from 50° C. to 300° C. (α50-300) of from 60×10−7/K to 90×10−7/K, and comprises Bi2O3 in an amount of from 5 to 25% in terms of mol % on the basis of oxides.
A glass frit of the present invention has a refractive index (nd) of from 1.88 to 2.20, a glass transition temperature (Tg) of from 450 to 490° C., and an average thermal expansion coefficient at temperatures from 50° C. to 300° C. (α50-300) of from 60×10−7/K to 90×10−7/K, and includes Bi2O3 in an amount of from 5 to 25% in terms of mol % on the basis of oxides.
A member of the present invention includes the glass composition or the glass frit having a refractive index (nd) of from 1.88 to 2.20, a glass transition temperature (Tg) of from 450 to 490° C., and an average thermal expansion coefficient at temperatures from 50° C. to 300° C. (α50-300) of from 60×10−7/K to 90×10−7/K, and comprising Bi2O3 in an amount of from 5 to 25% in terms of mol % on the basis of oxides.
According to the present invention, a glass composition having high refractive index, softening property at low temperature and small average thermal expansion coefficient, and a member provided with the composition on a substrate can be provided.
The refractive index (nd) of the glass composition of the present invention is a range of from 1.88 to 2.20. When the refractive index is fallen in this range, the effect of extracting the emitted light is large in the case of using as an organic LED scattering layer.
The refractive index (nd) of the glass composition of the present invention is preferably from 1.95 to 2.10.
The glass transition temperature (Tg) of the glass composition of the present invention is from 450 to 490° C. When the glass transition temperature is fallen in this range, a substrate does not deform by a temperature even though the glass frit of the present invention is fired and softened on a soda lime glass substrate. The glass transition temperature (Tg) is preferably from 450 to 480° C., and more preferably from 450 to 475° C. The glass transition temperature (Tg) used herein is defined by the temperature corresponding to viscosity coefficient η of glass=1014 dPa·S.
The average thermal expansion coefficient of the glass composition of the present invention is from 60×10−7/K to 90×10−7/K in a temperature range of from 50 to 300° C. When the average thermal expansion coefficient is satisfied with this requirement, even though the glass frit of the present invention is fired and softened on the soda lime glass substrate, the glass frit does not break and the substrate does not greatly warp. The average thermal expansion coefficient at temperatures from 50 to 300° C. is preferably from 65×10−7/K to 85×10−7/K, and particularly preferably from 70×10−7/K to 75×10−7/K. The average thermal expansion coefficient is a numerical value measured with a thermo-mechanical analyzer (TMA).
The glass composition of the present invention contains P2O5, Bi2O3, Nb2O5 and ZnO as essential components, and can contain B2O3, Li2O, Na2O, K2O, TiO2, WO3, TeO2, GeO2, Sb2O3 and alkaline earth metal oxides as optional components.
The range of each component content is, in terms of mol %, 15 to 30% of P2O5, 5 to 25% of Bi2O3, 5 to 27% of Nb2O5, 4 to 35% of ZnO, 0 to 17% of B2O3, 0 to 14% of Li2O, 0 to 7% of Na2O, 0 to 7% of K2O, 0 to 13% of TiO2, 0 to 20% of WO3, 0 to 7% of TeO2, 0 to 7% of GeO2, 0 to 2% of Sb2O3 and 0 to 10% of alkaline earth metal oxides, in which the total content of alkali metal oxides is 14% or less.
In the components of the glass composition of the present invention, P2O5 is an essential component which forms a network structure becoming a skeleton of a glass, and imparts stability to a glass. In the case where P2O5 is less than 15 mol %, the glass is easily devitrified. In the case where P2O5 exceeds 30 mol %, it becomes difficult to obtain high refractive index required in the present invention. The preferred range thereof is 19 to 28 mol %, and further preferred range is 20 to 26 mol %.
Bi2O3 is an essential component which imparts high refractive index and increases stability of a glass, and in the case where the content thereof is less than 5%, its effect becomes insufficient. At the same time, Bi2O3 increases the average thermal expansion coefficient and additionally increases coloration. Therefore, the content is 25 mol % or less. The preferred range thereof is 10 to 23 mol %, and further preferred range of 13 to 20 mol %.
Nb2O5 is an essential component which imparts high refractive index and additionally lowers the average thermal expansion coefficient, and in the case where the content is less than 5 mol %, its effect becomes insufficient. At the same time, Nb2O5 increases the glass transition temperature. Therefore, the content is 27 mol % or less. In the case where Nb2O5 exceeds 27 mol %, the glass transition temperature becomes too high, and the glass is easily devitrified. The preferred range thereof is 7 to 20 mol %, and further preferred range is 10 to 18 mol %.
ZnO is an essential component which greatly decreases the glass transition temperature while suppressing excess increase in the average thermal expansion coefficient, and additionally has the effect to impart high refractive index. In the case where the content is less than 4 mol %, its effect becomes insufficient. On the other hand, in the case where ZnO exceeds 35 mol %, devitrification tendency of a glass is increased. The content of ZnO is 4 to 35 mol %, preferably 16 to 35 mol % (7 to 17% in mass % indication), more preferably 21 to 35 mol % (9 to 17% in mass % indication), and particularly preferably more than 23 mol % and more than 10 mass %, and up to 35 mol %. However, in the case of containing ZnO in an amount of 21 mol % or more, it is preferred that TiO2 is not substantially contained in order to avoid devitrification.
B2O3 is not an essential component, but has the effect of improving meltability of a glass. In the case where the content exceeds 17 mol %, devitrification and phase separation easily occur, and additionally it becomes difficult to obtain high refractive index required in the present invention.
Li2O has the effect of imparting devitrification resistance to a glass and additionally decreasing the glass transition temperature, but at the same time, increases the average thermal expansion coefficient. In the case where Li2O is excessively contained, the average thermal expansion coefficient becomes too large. Therefore, the content of Li2O is preferably 0 to 14 mol %, and more preferably 2 to 7 mol %.
Na2O has the effect of imparting devitrification resistance of a glass, but depending of its content, the average thermal expansion coefficient is extremely increased. Na2O can be contained in a range of 0 to 7 mol % (0 to 2.5% in mass % indication), but it is more preferred that Na2O is not substantially contained.
K2O has the effect of imparting devitrification resistance to a glass, but depending of its content, the average thermal expansion coefficient is extremely increased. K2O can be contained in a range of 0 to 7 mol %, but it is more preferred that K2O is not substantially contained.
TiO2 has the effect of imparting high refractive index, but depending on its content, the glass transition temperature is increased and additionally, a glass is easily devitrified. TiO2 can be contained in a range of 0 to 13 mol %. It is preferred that the content is 0 to 9 mol %, and it is more preferred that TiO2 is not substantially contained.
WO3 has the effect of imparting high refractive index without greatly changing the average thermal expansion coefficient and the glass transition temperature. However, when the content exceeds 20 mol %, coloration is increased, and additionally, a glass is easily devitrified.
TeO2 has the effect of decreasing the glass transition temperature while suppressing excess increase in the average thermal expansion coefficient. However, TeO2 is expensive and may corrode a platinum crucible. Therefore, the content thereof is 7 mol % or less.
GeO2 has the effect of imparting high refractive index, but is expensive. Therefore, it is not preferred that the content exceeds 7 mol %.
Sb2O3 is effective as a refining agent, and further has the effect of suppressing coloration. Sb2O3 can be added in a range of 0 to 2 mol %.
The alkaline earth metal oxides (at least one kind of MgO, CaO, SrO and BaO) improve the stability of a glass. However, in the case where those are contained exceeding 10 mol %, the refractive index is decreased, and additionally the average thermal expansion coefficient and the glass transition temperature are increased.
The alkaline metal oxides have the effects of imparting devitrification resistance to a glass and decreasing the glass transition temperature. Therefore, the total content thereof is preferably 14 mol % or less, and more preferably 2 to 7 mol %.
Na2O and K2O particularly increase the thermal expansion coefficient, as compared with Li2O. Therefore, it is preferred that Na2O and K2O are not substantially contained and only Li2O is used.
The glass composition of the present invention can contain SiO2, Al2O3, La2O3, Y2O3, Gd2O3, ZrO2, Ta2O3, Cs2O, transition metal oxides and the like in a range that the effect of the invention is not impaired. The total content thereof is preferably less than 5%, and more preferably less than 3 mol %, and it is further preferred that those are not substantially contained (the content is substantially zero).
The glass of the present invention does not substantially contain lead oxide (the content is substantially zero). Therefore, the possibility of causing environmental pollution is low.
The term “does not substantially contain” used herein means that the components are not positively contained, and includes the case that the components are incorporated as impurities derived from other components.
The glass composition of the present invention can be obtained by using raw materials such as oxides, phosphates, metaphosphates, carbonates, nitrates and hydroxides, weighing those so as to achieve a desired composition, mixing those, melting the mixture at a temperature of 950 to 1,500° C. using a crucible of platinum or the like, casting the melt or pouring the melt in a space of a twin-roll, and rapidly cooling the melt. The melt may be slowly cooled to remove strain.
The glass frit of the present invention is obtained by grinding the glass composition obtained by the above method with a mortar, a ball mill, a jet mill or the like, and as necessary, classifying the resulting powder. The mass-standard average particle size of the glass frit is typically 0.5 to 10 μm. The surface of the frit glass may be modified with a surfactant or a silane coupling agent. The mass-standard average particle size is a particle diameter measured with a laser diffraction type particle size distribution measurement method.
The member of the present invention is a member having a glass layer having a given composition formed on a glass or ceramic substrate, as shown in
The member of the present invention can contain scattering materials in the glass fit fired layer as shown in
In the member of the present invention, as shown in
Composition of the glass in terms of mol %, refractive index (nd), glass transition temperature (Tg), and average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C., in each Example are shown in Tables 1 to 3. Composition in terms of mass % calculated based on the composition in terms of mol % is also shown therein. In each glass composition, when the glass transition temperature was 490° C. or lower and the average thermal expansion coefficient was from 60×10−7/K to 85×10−7/K, the glass composition was evaluated as “Good”. Particularly, when the glass transition temperature was 475° C. or lower and the average thermal expansion coefficient was from 70×10−7/K to 75×10−7/K, the glass composition was evaluated as “Excellent”. Each glass composition was obtained as follows. Oxides, phosphates, metaphosphates and carbonates were used as raw materials of each component. The raw materials were weighted so as to achieve the composition shown in Table 1 after vitrification, and sufficiently mixed. The mixture was melted in an electric furnace at a temperature range of 950 to 1,350° C. using a platinum crucible. The melt was cast in a carbon-made mold, and the resulting glass cast was cooled to the transition temperature, immediately placed in an annealing furnace, and slowly cooled to a room temperature.
The refractive index (nd), the glass transition temperature (Tg), and the average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C., of the glass compositions obtained were measured as follows.
(1) Refractive Index (nd)
After polishing a glass, its refractive index was measured with a precision refractometer KPR-2000, a product of Kalnew, by a V block method.
(2) Grass Transition Temperature (Tg)
A glass was processed into a rod having a diameter of 5 mm and a length of 200 mm, and its glass transition temperature was measured with a thermomechanical analyzer (TMA) TD5000SA, a product of Bruker AXS in a temperature rising rate of 5° C./min.
(3) Average Thermal Expansion Coefficient (α50-300) at Temperatures from 50° C. to 300° C.
A glass was processed into a rod having a diameter of 5 mm and a length of 200 mm, and its average thermal expansion coefficient was measured with a thermomechanical analyzer (TMA) TD5000SA, a product of Bruker AXS in a temperature rising rate of 5° C./min. When the length of the glass rod at 50° C. is L50 and the length of the glass rod at 300° C. is L300, the average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C. is obtained by α50-300={(L300/L50)−1}/(300-50).
The flake-like glass having each composition shown in Examples 1, 2, 4 and 5 was weighed, mixed and melted in the manners as in Examples 1 to 27, and its melt was poured in a space of a twin-roll and then rapidly cooled to prepare a flake. Each flake was dry ground with an alumina-made ball mill for 1 hour to obtain each glass frit. The mass mean size of each frit glass was about 3 μm. 75 g of each glass frit obtained was kneaded with 25 g of an organic vehicle (obtained by dissolving 10 mass % of ethyl cellulose in α-terpineol) to prepare a glass paste. The glass paste was uniformly printed in a size of 9 cm square on the center of a soda lime glass substrate having a size of 10 cm square and a thickness of 0.55 mm, having a silica film coated on the surface thereof such that the film thickness after firing becomes 30 μm, and then dried at 150° C. for 30 minutes. The temperature was once returned to room temperature, and increased to 450° C. over 30 minutes, followed by maintaining the temperature (450° C.) for 30 minutes. Thereafter, the temperature was increased to 550° C. over 12 minutes, followed by maintaining the temperature (550° C.) for 30 minutes. Thereafter, the temperature was decreased to room temperature over 3 hours. Thus, a glass frit fired layer was formed on the soda lime glass substrate. Each substrate thus obtained was observed as to whether breakage occurs in the fired layer and the substrate. Furthermore, an average value of warpage of the substrate at four corners of the fired layer was measured, and it was judged as to whether or not the warpage can be allowable. When the average value of warpage exceeds 1.00 mm, it was judged that the warpage is not allowable. The results are shown in Table 4. The average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C. of the soda lime glass used is 83×10−7/K.
Composition of the glass in terms of mol %, refractive index (nd), glass transition temperature (Tg), and average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C., in each Comparative Example are shown in Table 5. Composition in terms mass % calculated based on the composition in terms of mol % is also shown in Table 6. In each glass, when the glass transition temperature is not 490° C. or lower and the average thermal expansion coefficient is not from 60×10−7/K to 85×10−7/K, the glass was evaluated as “Poor”. Each physical value of the glasses prepared in the same manners as in Examples 1 to 27 was measured in the same manner as in Examples 1 to 27. The refractive index (nd) of Comparative Example 9 could not be measured due to large coloration. Comparative Examples 1 and 2 correspond to Examples 5 and 12 of the above-described Patent Document 3 (JP-A-2006-111499), respectively, Comparative Example 3 corresponds to Example 3 of the above-described Patent Document 1 (JP-A-2003-300751), Comparative Examples 4 and 5 correspond to Examples 1 and 2 of the above-described Patent Document 2 (JP-A-2003-160355), respectively, Comparative Examples 6, 7 and 8 correspond to Examples 1, 10 and 13 of the above-described Patent Document 5 (JP-A-2007-51060), respectively, and Comparative Example 9 corresponds to Example 3 of the above-described Patent Document 4 (JP-A-2002-201039).
Glass fits having each composition shown in Comparative Examples 1 and 10 were prepared in the same manner as in Examples 28 to 31, and fired on the same soda lime substrates in the same manner. Each substrate thus obtained was observed as to whether breakage occurs in the fired layer and the substrate. Furthermore, an average value of warpage of the substrate at four corners of the fired layer was measured, and it was judged as to whether or not the warpage can be allowable. When the average value of warpage exceeds 1.00 mm, it was judged that the warpage is not allowable. The results are shown in Table 7. The average thermal expansion coefficient (α50-300) at temperatures from 50° C. to 300° C. of the soda lime glass used is 83×10−7/K.
This application is based on Japanese Patent Application No. 2009-014331 filed on Jan. 26, 2009, the disclosures of which are incorporated herein by reference.
The present invention makes it possible to produce a high efficient scattering light extraction member for particularly organic LED uses by applying a glass composition having high refractive index, softening property at low temperature and small average thermal expansion coefficient to an optical member. Especially, according to the present invention, a glass frit suitable for a scattering layer which enables an organic LED light extraction to improve can be provided. Furthermore, the glass frit of the present invention does not give deformation and unallowable warpage to the substrate after firing and softening on the soda line substrate, and does not cause breakage. For this reason, the glass frit of the present invention can use a soda lime substrate as a substrate of an organic LED scattering layer, and can reduce the production cost.
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| Number | Date | Country |
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| 2 178 343 | Apr 2010 | EP |
| 2 383 235 | Nov 2011 | EP |
| 2001-058845 | Mar 2001 | JP |
| 2002-201039 | Jul 2002 | JP |
| 2003-160355 | Jun 2003 | JP |
| 2003-300751 | Oct 2003 | JP |
| 2005-154248 | Jun 2005 | JP |
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| 2005-247659 | Sep 2005 | JP |
| 2006-111499 | Apr 2006 | JP |
| 2007-015904 | Jan 2007 | JP |
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| WO 2008-065937 | Jun 2008 | WO |
| Entry |
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| International Search Report dated Mar. 30, 2010, PCT/JP2010/050731. |
| Communication Pursuant to Rule 114(2)—Third Party Observation for Application No. EP 20100733532 dated Nov. 26, 2012. |
| Number | Date | Country | |
|---|---|---|---|
| 20110287264 A1 | Nov 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2010/050731 | Jan 2010 | US |
| Child | 13137165 | US |
