Patent Application
20160200629
The present invention relates to a method for manufacturing a glass sheet.
Recently, in flat panel display devices of mobile phones or personal digital assistances (PDAs), personal computers, televisions, car-mounted navigation display devices and the like, a thin sheet-shaped cover glass is arranged on the front side of displays so as to cover a wider region than the image display area thereof, for the purpose of protecting the displays and improving the beauty thereof.
Such flat panel display devices are required to be lighterweight and thinner, and therefore the cover glass to be used for display protection is also required to be thinned.
However, if the thickness of the cover glass is reduced, the strength thereof lowers and the cover glass itself may be broken owing to dropping or the like during use or carrying. Thus, there arises a problem that its primary role of protecting the display devices cannot be fulfilled.
Consequently, in already-existing cover glass, a glass produced by a float process (hereinafter sometimes referred to as float glass) is chemically strengthened to form a compressive stress layer on the surface thereof, thereby enhancing the scratch resistance of the cover glass.
It has been reported that a float glass is warped after chemical strengthening to impair flatness (Patent Documents 1 to 3). It is said that the warpage may be caused by the heterogeneity between the glass surface not in contact with a molten metal such as molten tin during float forming (hereinafter also referred to as top surface) and the glass surface in contact with the molten metal (hereinafter also referred to as bottom surface), thereby providing a difference in the degree of chemical strengthening between the two surfaces.
The warpage of the float glass becomes large with increasing the degree of chemical strengthening. Accordingly, in the case where surface compressive stress is set to be higher than before, especially 600 MPa or more, for responding to the requirement for high scratch resistance, the problem of warpage becomes more obvious.
Patent Document 1 discloses a glass strengthening method of conducting chemical strengthening after formation of an SiO2 film on a glass surface, to thereby control the amount of the ions entering the glass during the chemically strengthening Patent Documents 2 and 3 disclose a method of reducing the warpage after chemical strengthening by controlling the surface compression stress on the top surface side so as to fall within a specific range.
Heretofore, for reducing the problem of warpage, there have been taken a coping method of reducing the strengthening stress caused by chemical strengthening or performing chemical strengthening after removing a surface heterogeneous layer by grinding treatment, polishing treatment, or the like of at least one surface of glass.
Patent Document 1: US-A-2011/0293928
Patent Document 2: WO 2007/004634
Patent Document 3: JP-A-S62-191449
However, in the method described in Patent Document 1 in which chemical strengthening is performed after formation of an SiO2 film on a glass surface, the preheating conditions during the chemical strengthening are restricted and further, there is a possibility that film quality of the SiO2 film would change depending on the conditions to give influence on the warpage. In addition, the method as described in Patent Documents 2 and 3 in which the surface compressive stress on the top surface side is controlled so as to fall within a specific range is problematic from the viewpoint of strength of the glass.
The method of performing grinding treatment, polishing treatment or the like on at least one surface of glass before chemical strengthening is problematic from the viewpoint of improving the productivity, and therefore it is preferable to omit the grinding treatment, polishing treatment or the like.
In the case where warpage may occur in a certain degree or more after chemical strengthening, the gap between the glass and a stage would be too large at the time of printing a black frame of a cover glass and therefore the glass may not be suctioned on the stage. Moreover, in the case of being used as a cover glass integrated with a touch panel, a film of ITO (Indium Tin Oxide) or the like may be formed thereon in the state of a large sheet in a later step. At that time, there may occur such transport failure that the glass would be brought into contact with an air knife in a chemical liquid processing tank or in a washing tank, or there may arise such trouble that the warpage may increase during the formation of ITO film and thus the ITO film formation condition in the substrate peripheral part may not be suitable and would peel away. Furthermore, in the case of a type where there exists a space between an LCD (Liquid Crystal Display) and the cover glass having a touch panel attached thereto, if the cover glass has warpage in a certain degree or more, there may occur luminance unevenness or Newton rings.
Accordingly, an object of the present invention is to provide a method for manufacturing a glass sheet in which warpage after chemical strengthening can be effectively suppressed and polishing treatment or the like before chemical strengthening can be omitted or simplified.
The present inventors focused on an amount of fluorine contained in a glass after the glass surface is subjected to fluorine treatment (total incorporated fluorine amount) and have found that the warpage after chemical strengthening can be reduced by controlling the amount of fluorine contained in the glass within a certain range. Based on the findings, they have accomplished the present invention.
That is, the present invention is as follows.
1. A method for manufacturing a float glass containing a step of melting a glass raw material, a step of forming the glass melted by the preceding step into a glass ribbon while floating the glass on a molten metal, and a step of annealing the glass ribbon,
In which, in the forming step, a fluid containing a molecule having a fluorine atom is sprayed onto an upper surface of the glass ribbon to allow the fluorine atom to penetrate up to a depth of 0.5 μm or more in a thickness direction from the upper surface,
subsequently, before the step of annealing or in the step of annealing, the fluorine atom that has penetrated is allowed to penetrate up to a depth of 1 μm or more in the thickness direction from the upper surface to control a fluorine amount in the depth of up to 30 μm in the thickness direction from the upper surface of the glass ribbon to more than 0.23 mol %·μm, and
thereafter, the glass ribbon is conveyed from the step of annealing.
2. The method for manufacturing a float glass according to the above 1, in which the fluorine amount in the depth of up to 30 μm in the thickness direction from the upper surface of the glass ribbon is controlled to more than 0.23 mol %·μm and 21 mol %·μm or less.
3. The method for manufacturing a float glass according to the above 1 or 2, in which temperature of the upper surface of the glass ribbon at the time of spraying the fluid is 600° C. or higher.
4. The method for manufacturing a float glass according to any one of the above 1 to 3, in which the fluid has a fluorine atom concentration of from 0.1% by volume to 15% by volume.
5. The method for manufacturing a float glass according to any one of the above 1 to 4, in which the float glass has a glass transition temperature Tg of 550° C. or higher, and temperature of the upper surface of the glass ribbon at the time of spraying the fluid is from (Tg+50)° C. to (Tg+460)° C.
6. The method for manufacturing a float glass according to the above 5, in which the float glass has the Tg of higher than 600° C.
The glass sheet obtained by the manufacturing method according to the present invention has an amount of fluorine contained in the glass on a depth-direction profile by SIMS falling within a certain range. Accordingly, the warpage of the glass after chemical strengthening can be reduced and excellent flatness can be obtained while the stress value by chemical strengthening of the glass is controlled to a desired value and even in the case where polishing treatment or the like before the chemical strengthening is simplified or omitted.
(a) of
(a) to (d) of
(a) to (d) of
(a) to (c) of
The method of manufacturing a glass sheet according to the present invention includes a step of melting a glass raw material, a step of forming the glass melted by the preceding step into a glass ribbon while floating the glass on a molten metal, and a step of annealing the glass ribbon. Among these steps, in the step of forming (hereinafter referred to as forming step), a fluid containing a molecule having a fluorine atom in the structure thereof (hereinafter referred to as fluorine-containing fluid) is sprayed onto the upper surface of the glass ribbon to allow the fluorine atom to penetrate up to a depth of 0.5 μm or more in a thickness direction from the upper surface of the glass ribbon. Subsequently, before the step of annealing or in the step of annealing, the fluorine atom that has penetrated through spraying the fluorine-containing fluid in the forming step is allowed to penetrate up to a depth of 1 μm or more in the thickness direction from the upper surface of the glass ribbon to control the amount of fluorine contained in the glass ribbon in the depth of up to 30 μm in the thickness direction to more than 0.23 mol %·μm. Thereafter, the glass ribbon into which the fluorine atom has penetrated is conveyed from the step of annealing.
That is, in the forming step, when the fluorine-containing fluid is sprayed onto a glass ribbon, the sprayed fluorine penetrates from the upper surface of the glass ribbon up to a depth of 0.5 μm or more in the thickness direction during the forming step. Thereafter, as the glass ribbon moves to a lower stream of a float bath, the fluorine that has penetrated into the glass ribbon further penetrates deeper in the thickness direction. In this case, in the case where temperature of the upper surface of the glass ribbon is preferably a temperature of (Tg+60)° C. or higher at the time of spraying the fluorine-containing fluid, fluorine can be allowed to penetrate up to a predetermined depth in the forming step and fluorine can be further allowed to penetrate in the thickness direction of the glass ribbon after spraying. Accordingly, by lowering the temperature of the glass ribbon while transferring the glass ribbon from the forming step to the annealing step, deep penetration of fluorine in the thickness direction is gradually promoted and, before the annealing step or in the annealing step, the fluorine atom that has penetrated through spraying of the fluorine-containing fluid in the forming step is allowed to penetrate up to a depth of 1 μm or more in the thickness direction of the glass ribbon.
As the glass in the present invention, specifically, for example, a soda lime silicate glass, an aluminosilicate glass, a borate glass, a lithium aluminosilicate glass, and a borosilicate glass, and the other various types of glass are typically mentioned.
Of these, glass having a composition containing Al is preferable. If alkali coexists, Al is tetracoordinated, and similarly to Si, participates in forming a network that becomes a skeleton of glass. If tetracoordinated Al increases, the movement of alkali ions is facilitated, and ion exchange easily proceeds during chemical strengthening treatment.
The thickness of the glass sheet is not particularly limited, and for example, there may be mentioned 2 mm, 0.8 mm, 0.73 mm, 0.7 mm, 0.56 mm, and 0.4 mm. In order to effectively perform chemical strengthening treatment to be described below, the thickness is usually preferably 5 mm or less, more preferably 3 mm or less, further preferably 1.5 mm or less, and particularly preferably 0.8 mm or less.
Usually, the warpage amount of a glass sheet having a thickness of 0.7 mm after chemical strengthening is required to be 40 μm or less. In the case of a 90 mm square glass sheet having CS of 750 MPa and DOL of 40 μm, the warpage amount after chemical strengthening is about 130 μm. On the other hand, since the warpage amount of a glass sheet after chemical strengthening is inversely proportional to the square of sheet thickness, the warpage amount in a glass sheet having a thickness of 2.0 mm becomes about 16 μm, and warpage will not substantially become a problem. Accordingly, there is a possibility that the problem of warpage after chemical strengthening is likely to occur in a glass sheet having a thickness of less than 2 mm, and typically 1.5 mm or less.
As the composition of a glass of the present invention, there may be mentioned glass containing, as a composition in terms of mol %, from 50 to 80% of SiO2, from 0.1 to 25% of Al2O3, from 3 to 30% of Li2O+Na2O+K2O, from 0 to 25% of MgO, from 0 to 25% of CaO, and from 0 to 5% of ZrO2, but is not particularly limited. More specifically, the following glass compositions are mentioned. For example, the description of “containing from 0 to 25% of MgO” means that MgO is not essential and may be contained up to 25%. The glass (i) is included in soda lime silicate glass and the glass (ii) or (iii) is included in aliminosilicate glass.
(i) Glass containing, as a composition in terms of mol %, from 63 to 73% of SiO2, from 0.1 to 5.2% of Al2O3, from 10 to 16% of Na2O, from 0 to 1.5% of K2O, from 5 to 13% of MgO, and from 4 to 10% of CaO.
(ii) Glass containing, as a composition in terms of mol %, from 50 to 74% of SiO2, from 1 to 10% of Al2O3, from 6 to 14% of Na2O, from 3 to 11% of K2O, from 2 to 15% of MgO, from 0 to 6% of CaO, and from 0 to 5% of ZrO2, in which a total content of SiO2 and Al2O3 is 75% or less, a total content of Na2O and K2O is from 12 to 25%, and a total content of MgO and CaO is from 7 to 15%.
(iii) Glass containing, as a composition in terms of mol %, from 68 to 80% of SiO2, from 4 to 10% of Al2O3, from 5 to 15% of Na2O, from 0 to 1% of K2O, from 4 to 15% of MgO, and from 0 to 1% of ZrO2.
(iv) Glass containing, as a composition in terms of mol %, from 67 to 75% of SiO2, from 0 to 4% of Al2O3, from 7 to 15% of Na2O, from 1 to 9% of K2O, from 6 to 14% of MgO, and from 0 to 1.5% of ZrO2, in which a total content of SiO2 and Al2O3 is from 71 to 75%, a total content of Na2O and K2O is from 12 to 20%, and in the case where CaO is contained, the content thereof is less than 1%.
In the method of manufacturing a glass sheet according to the present invention, a fluorine-containing fluid is sprayed onto the upper surface of the glass ribbon. Incidentally, the upper surface of a glass ribbon in the present specification means a surface opposite to the molten metal on which the glass ribbon is floated. One surface and the other surface of a glass sheet means one surface and the other surface, the surfaces being opposite to each other in the thickness direction. Both surfaces of a glass sheet means both surfaces being opposite to each other in the thickness direction.
The upper surface temperature of a glass ribbon onto which the fluid is sprayed is preferably 600° C. or higher, more preferably higher than 650° C., and particularly preferably 700° C. or higher or 750° C. or higher. By controlling the temperature to higher than 650° C., the spraying treatment with a fluorine-containing fluid can be easily performed in a sufficient total fluorine contact amount to reduce the warpage amount of the glass after chemical strengthening, while maintaining good surface smoothness of the obtained glass. Hereinafter, the term “glass sheet” may be used as a generic term indicating a glass ribbon.
Examples of the fluorine-containing fluid include hydrogen fluoride (HF), freon (e.g., chlorofluorocarbon, fluorocarbon, hydrochlorofluorocarbon, hydrofluorocarbon, and halon), hydrofluoric acid, fluorine simple substance, trifluoroacetic acid, carbon tetrafluoride, silicon tetrafluoride, phosphorus pentafluoride, phosphorus trifluoride, boron trifluoride, nitrogen trifluoride, chlorine trifluoride, and the like but the fluid is not limited to these fluids.
Of these, hydrogen fluoride, freon, or hydrofluoric acid is preferred from the viewpoint of high reactivity with the glass sheet surface. Of these gases, two or more kinds thereof may be used as a mixture. Furthermore, in the case of spraying the fluorine-containing fluid onto the glass ribbon at the time of manufacturing the glass by a float process, it is preferable that fluorine simple substance is not used since oxidation power thereof is too strong in a float bath.
In the case where a liquid is used as the fluorine-containing fluid, for example, the liquid may be sprayed onto a glass sheet upper surface by spray coating as the liquid form or the liquid may be vaporized and then sprayed onto the glass sheet upper surface. The fluid may be diluted with other fluid as necessary.
The fluorine-containing fluid may contain a fluid other than the fluid thereof, which is preferably a fluid which does not react, at ordinary temperature, with the molecule having a fluorine atom.
Examples of the fluid include N2, air, H2, O2, Ne, Xe, CO2, Ar, He, Kr, and the like, and the fluid is not limited thereto. Of these gases, two or more kinds thereof may be used as a mixture.
As a carrier gas of the gas containing a molecule having a fluorine atom in the structure thereof, an inert gas such as N2 or argon is preferably used. The gas containing a molecule having a fluorine atom in the structure thereof may further contain SO2. SO2 is used at the time of successively producing a glass sheet by a float process or the like, and prevents the occurrence of a flaw in the glass caused by a contact of a conveying roller with the glass sheet in an annealing zone. Furthermore, a gas which is decomposed at a high temperature may be included.
Furthermore, the fluorine-containing fluid may contain water vapor or water. Water vapor may be taken out by bubbling heated water with an inert gas such as nitrogen, helium, argon or carbon dioxide. In the case where a large amount of water vapor is required, it is also possible to adopt a method in which water is supplied to a vaporizer and is directly vaporized.
By spraying the fluorine-containing fluid onto a glass ribbon, fluorine is allowed to penetrate from the glass surface and thus a glass containing fluorine can be obtained.
On this occasion, it is necessary to adjust conditions for spraying the fluorine-containing fluid so that the amount of fluorine contained in the depth of up to 30 μm in the thickness direction from the upper surface of the resulting glass is more than 0.23 mol %·μm. The upper limit of the amount of fluorine is preferably 21 mol %·μm or less.
For example, in the case where fluorine is allowed to penetrate into a glass ribbon by spraying the fluorine-containing fluid in a float process, fluorine atom concentration in the fluorine-containing fluid is preferably from 0.1% by volume to 15% by volume from the viewpoint of reduction of load on the facilities and is more preferably from 0.1% by volume to 10% by volume. Furthermore, the surface temperature of the glass ribbon is preferably 600° C. or higher from the viewpoint of the penetration of fluorine up to a deeper region of the glass.
With respect to the surface temperature of a glass ribbon, the surface temperature of a glass sheet is preferably from (Tg+50)° C. to (Tg+460)° C., particularly preferably from (Tg+60)° C. to (Tg+460)° C., more preferably from (Tg+150)° C. to (Tg+460)° C., and further preferably from (Tg+230)° C. to (Tg+460)° C., where the glass transition temperature of the glass sheet is indicated as Tg.
In the case where the fluorine-containing fluid is sprayed onto a glass ribbon, fluorine is allowed to penetrate into the glass by spraying the fluorine-containing fluid but, during the glass ribbon is annealed to manufacture a float glass sheet, a part of the penetrating fluorine may escape from the inside of the glass.
However, since the escaping amount of fluorine is minute, the amount of fluorine contained in the glass ribbon in the forming step or in the annealing step is regarded as the same as the amount of fluorine contained in the float glass after the annealing step. Even if the amounts are not regarded as the same, in the case where the amount of fluorine contained in the depth of up to 30 μm in the thickness direction from the upper surface in the resulting float glass is more than 0.23 mol %·μm, it is meant that the amount of fluorine contained in the depth of up to 30 μm in the thickness direction from the upper surface of the glass ribbon, the fluorine being allowed to penetrate into the glass ribbon in the forming and annealing step of the glass ribbon, is more than 0.23 mol %·μm.
In the float process in the present invention, a glass sheet is manufactured by using a glass manufacturing apparatus including a melting furnace (including a clarifying tank) in which raw materials of the glass are melted, a float bath in which the molten glass is floated on a molten metal (tin, etc.) to form a glass ribbon, and an annealing furnace in which the glass ribbon is annealed. At the time when glass is formed on a molten metal (tin) bath, the fluorine-containing fluid may be supplied to the glass sheet being conveyed on the molten metal bath from the side (top surface) not in contact with the metal surface, thereby treating the glass sheet surface. In the annealing zone subsequent to the molten metal (tin) bath, the glass sheet is conveyed by a roller. Here, the annealing zone includes not only the inside of the annealing furnace but also a portion where the glass sheet is conveyed from the molten metal (tin) bath into the annealing furnace in the float bath. In the annealing zone, the gas may be supplied from the side not in contact with the molten metal (tin).
(a) of
In the float bath in which molten glass is floated on a molten metal (tin, etc.) to form a glass ribbon 101, the fluorine-containing gas is sprayed onto the glass ribbon 101 by a beam 102 inserted into the float bath. As illustrated in (a) of
In the case where the float glass has a glass transition point of 550° C. or higher, the position where the fluorine-containing fluid is sprayed onto the glass ribbon 101 with the beam 102 is preferably a position where the temperature of the glass ribbon 101 is from (Tg+50)° C. to (Tg+460)° C., particularly preferably a position of from (Tg+60)° C. to (Tg+460)° C., more preferably a position of from (Tg+150)° C. to (Tg+460)° C., and still more preferably a position of from (Tg+230)° C. to (Tg+460)° C. Preferable temperature of the glass ribbon also varies depending on the kind of the fluid to be sprayed but, in principle, the amount of fluorine contained in the resulting glass can be increased by spraying the fluid having a higher concentration and/or a larger amount of the fluid at higher temperature.
The position of the beam 102 may be on the upstream side or the downstream side of a radiation gate 103. It is preferable that the amount of the fluorine-containing fluid to be sprayed onto the glass ribbon 101 is from 1×10−6 to 5×10−3 mol/1 cm2 of the glass ribbon in the case of HF.
Incidentally, in the case where a predetermined amount of fluorine is allowed to penetrate up to a deep position of a glass, as mentioned before, the purpose can be achieved by spraying a fluorine-containing fluid of higher concentration and/or a larger amount at higher temperature. However, in the case of spraying at a high temperature, fluorine that reacts with the glass raw material increases to increase foreign matter and thus defects are formed in the glass.
On the other hand, the defects can be reduced by spraying the fluorine-containing fluid at a low temperature but, at low temperature, fluorine cannot be allowed to penetrate up to a deep position of the glass.
As above, it is said that the penetration depth of fluorine and the occurrence of the defects depending on a level of the temperature at which a fluorine-containing fluid is sprayed are in a trade-off relation.
Consequently, it is preferable to spray a fluorine-containing fluid in two or more zones having high temperature and low temperature with respective appropriate amounts. Thereby, it is possible to obtain glass in which the penetration depth of fluorine is deep, that is, the amount of fluorine that has penetrated is large and also the defects are reduced.
(b) of
The warpage amount of the glass sheet after chemical strengthening may vary depending on the position of the glass ribbon 101 in the width direction, and in such a case, it is preferable to adjust the amount of the fluorine-containing fluid. That is, it is preferable that the amount of the fluorine-containing fluid to be sprayed is increased at a position where the warpage amount is large, and the amount of the fluorine-containing fluid to be sprayed is decreased at a position where the warpage amount is small.
In the case where the warpage amount of the glass sheet after chemical strengthening varies depending on the position of the glass ribbon 101, the structure of the beam 102 may be made such that the amount of the fluorine-containing fluid can be adjusted in the width direction of the glass ribbon 101, and thereby, the warpage amount may be controlled in the width direction of the glass ribbon 101.
As a specific example thereof, (a) of
Arrows in (a) of
As a method of spraying the fluorine-containing fluid to the glass ribbon upper surface of a glass sheet, for example, a method of using an injector, a method of using an introduction tube, and the like are mentioned.
The fluorine-containing fluid is injected toward a glass sheet 20 from a center slit 1 and an outer slit 2, flows through a channel 4 on the glass sheet 20, and is discharged from a discharge slit 5. The symbol 21 in
In the case where the fluorine-containing fluid to be supplied from the injector is a gas, it is preferable that the distance between a gas injection port of the injector and a glass sheet is 50 mm or less.
By controlling the distance to 50 mm or less, it is possible to suppress the diffusion of the gas into the air and to allow a sufficient amount of the gas to reach the glass sheet with respect to a desired amount of the gas. Conversely, in the case where the distance from a glass sheet is too short, at the time when the treatment of a glass sheet to be produced by a float process is performed on-line, there is a concern that the glass sheet and the injector come into contact with each other due to fluctuation of the glass ribbon.
In the case where the fluorine-containing fluid to be supplied from the injector is a liquid, the distance between the liquid injection port of the injector and a glass sheet is not particularly limited, and an arrangement may be made such that the glass sheet can be treated uniformly.
Any type of injector, such as a double-flow type or a single-flow type, may be used, and two or more injectors may be arranged in series in the flow direction of a glass sheet to treat the glass sheet surface. As illustrated in
The double-flow type injector is common and is also known as one to be used for manufacturing low reflection glass. For example, the injector may be used such that a mixed gas of 1.12 SLM (liter per minute in terms of a gas in a standard state) of HF gas and 9 SLM of nitrogen (N2) gas is heated to 150° C. and sprayed at a flow rate of 64 cm/s from the center slit 1 and 45.5 SLM of N2 gas is sprayed from the outer slit 2 onto soda lime silicate glass re-heated to 600° C., which is manufactured by Asahi Glass Co., Ltd (glass transition point: 560° C.) and has a thickness of 1.8 mm. Surface roughness (arithmetic average roughness) Ra of the glass surface onto which HF gas has been sprayed in such a manner is 30.6 nm and the value of x mentioned above is 2.5 μm.
As illustrated in
Also, it is preferable that a supply port of the fluorine-containing fluid is present on the same side of the surface of the glass sheet with a discharge port of unreacted fluorine-containing fluid and a gas which is formed by a reaction with the glass sheet or a gas which is formed by a reaction of two or more kinds of gases in the fluorine-containing fluid.
In order to obtain an improvement effect of warpage after chemical strengthening while maintaining good surface smoothness on the glass ribbon upper surface, as mentioned above, the temperature of the upper surface of the glass ribbon 101 at the time of spraying a fluorine-containing fluid is preferably from (Tg+50)° C. to (Tg+460)° C., particularly preferably from (Tg+60)° C. to (Tg+460)° C., more preferably from (Tg+150)° C. to (Tg+460)° C., and further preferably from (Tg+230)° C. to (Tg+460)° C. In the present specification, the surface smoothness can be evaluated, for example, by surface roughness Ra and the presence or absence of concave portions, obtained by observation through Atomic Force Microscope (AFM) or Scanning Electron Microscope (SEM). The concave portion is a minute hole generated on the surface of a glass sheet. The concave portion can be visually recognized by SEM. In the case where the concave portion is generated on a glass sheet, strength of the glass sheet decreases. In the present invention, as one suitable for practical use, the generation of the concave portion is suppressed. Glass having Tg of 550° C. or higher is preferably used and Tg is more preferably higher than 600° C.
Typically, the concave portion has a shape that decreases its diameter from the surface along the depth direction and extends into a nearly spherical bag shape. The diameter of such the concave portion indicates a diameter of the neck between the diameter-reduced part and the bag-shaped part and can be observed by SEM or the like. The depth of the concave portion indicates a depth from the glass surface to the deepest part of the bag-shaped part and can be measured by cross-section SEM observation or the like.
The concave portion in the present invention is one having a size or diameter of 10 nm or more and usually of 20 nm or more. The diameter of the concave portion is typically 40 nm or less. The depth of the concave portion is measured by, for example, cross-section SEM observation and the depth is usually 10 nm or more and typically 150 nm or less.
In the case where the concave portions are present in a density of more than 7 spots/μm2 on the glass surface, there is a concern that the strength of the chemically strengthened glass sheet decreases. Therefore, even in the case where there are concave portions, the density thereof is preferably 6 spots/μm2 or less, more preferably 4 spots/μm2 or less, and most preferably 0 spots/μm2. Incidentally, the average distance between concave portions in the case where the concave portion density is 6 spots/μm2 is 460 nm.
With regard to the concave portion, a case where an aluminosilicate glass is subjected to fluorine treatment by using HF gas as the fluorine-containing fluid will be described as an example. If the presence or absence of the concave portion is plotted with respect to an HF total contact amount (mol/cm2) and HF treating temperature (° C.), a correlation is indicated as the graph shown in
Here, it is considered that the concave portion is not generated by HF treatment in the case where the HF total contact amount and the HF treating temperature satisfy the following Formula (a). That is, the concave portion is more likely to generate in the case where (1) treating temperature is low (vaporization rate of fluorides is low) and (2) the HF total contact amount is large (formation rate of fluorides is high).
Y>81 ln X+1500 Formula (a)
In Formula (a), Y represents HF treating temperature (° C.) and X represents an HF total contact amount (mol/cm2), and X is determined according to the following Formula (b).
[HF total contact amount (mol/cm2)]=[HF gas concentration (% by volume)]×[gas flow rate (mol/s/cm2)]×[Treating time (s)] Formula (b)
(a) to (d) of
The pressure of the glass sheet surface when spraying the fluorine-containing fluid to the glass sheet surface is preferably in an atmosphere within a pressure range of from (atmospheric pressure-100 Pa) to (atmospheric pressure+100 Pa), and more preferably, in an atmosphere within a pressure range of from (atmospheric pressure-50 Pa) to (atmospheric pressure+50 Pa).
With regard to the gas flow rate, the case where HF gas is used as the fluorine-containing fluid will be described as a representative example. In the case where a glass sheet is treated with HF gas, the higher the HF gas flow rate is, the greater the warpage improvement effect during chemical strengthening treatment is, so that the case is preferable. In the case where the total gas flow rate is equal, the higher the HF concentration is, the greater the warpage improvement effect during chemical strengthening treatment is.
In the case where the total gas flow rate and the HF gas flow rate are constant, the longer the time for treating a glass sheet is, the greater the warpage improvement effect during chemical strengthening treatment is. For example, in the case where a glass sheet is heated and the glass sheet surface is then treated by using HF gas, the warpage after chemical strengthening is improved as the conveying speed of the glass sheet decreases. Even with an equipment where the total gas flow rate or the HF gas flow rate cannot be well controlled, the warpage after chemical strengthening can be improved by appropriately controlling the conveying speed of a glass sheet.
The glass sheet obtained by the manufacturing method according to the present invention has an amount of fluorine contained in the glass of more than 0.23 mol %·μm on a depth-direction profile by secondary ion mass spectrometry (SIMS) in which the horizontal axis expresses depth and the vertical axis expresses fluorine concentration (mol %).
Warpage of the glass sheet after chemical strengthening occurs due to a difference in the degree of chemical strengthening on one surface and the other surface of the glass sheet. Specifically, for example, in the case of a float glass, the warpage after chemical strengthening occurs due to the difference in the degree of chemical strengthening between a glass surface (top surface) which is not in contact with a molten metal such as a molten tin during float forming and a glass surface (bottom surface) which is in contact with the molten metal (usually tin).
According to the manufacturing method of the present invention, the upper surface of a glass ribbon is subjected to fluorine treatment by spraying a fluorine-containing fluid onto the glass ribbon upper surface to control the amount of fluorine contained in the glass (total incorporated fluorine amount) so as to fall within a predetermined range, and thereby, diffusion rates of ions in one surface and the other surface of the glass sheet can be adjusted and thus the degrees of chemical strengthening in one surface and the other surface can be balanced. For this reason, in the glass sheet of the present invention, it is possible to reduce the warpage of the glass sheet after chemical strengthening without controlling strengthening stress or without conducting such a treatment as grinding or polishing before chemical strengthening treatment.
As the mechanism for achieving the reduction of the warpage after chemical strengthening by subjecting the upper surface of a glass ribbon to a fluorine treatment, it is considered that the following phenomena take place.
(1) Relaxation is promoted by fluorine incorporated into the glass surface to lower CS (compressive stress, surface compressive stress) of the surface subjected to the fluorine treatment.
(2) Ion exchange is inhibited by the fluorine incorporated into the glass surface to lower DOL (depth of layer, depth of compressive stress) of the surface subjected to the fluorine treatment.
(3) Dealkalization of the glass is caused by the fluorine treatment.
(4) The main component in the glass surface is changed by the fluorine treatment and Si in the glass is reduced from the glass surface as SiF4 or H2SiF6 and, so that the degree of the stress is changed.
(5) Dehydration from the glass surface is suppressed or water enters due to the fluorine treatment and thereby the warpage is reduced.
It is sufficient that the glass sheet obtained by the present invention has an amount of fluorine contained in the glass of more than 0.23 mol %·μm on a depth-direction profile by secondary ion mass spectrometry (SIMS) in which the horizontal axis expresses depth asn the glass surface being zero and the vertical axis expresses fluorine concentration (mol %), and the amount of fluorine is preferably more than 0.23 mol %·μm and 21 mol %·μm or less and more preferably 0.7 mol %·μm or more and 9 mol %·μm or less.
The amount of fluorine contained in a glass can be determined, as shown in
The amount of fluorine contained in a glass is accurately an amount of fluorine atoms contained in the whole glass sheet. However, it is considered that there is a limit in a depth to which fluorine can penetrate into the glass by fluorine treatment. Therefore, actually, the amount of fluorine contained in a glass can be regarded to be the same as the integrated value when the depth-direction profile is measured in a depth of from 0 to 30 μm from the glass surface.
It is considered that the amount (mol %·μm) of fluorine contained in a glass is in a linearly proportional relationship with the warpage improvement amount after the glass is chemically strengthened (
In the case where the amount of fluorine contained in a glass falls within the above range, the warpage due to chemical strengthening can be improved regardless of the type of the glass. Especially, glass produced by a float process is preferred because an effect of improvement in warpage is much observed.
Even with respect to the glass sheet after chemical strengthening, the glass sheet obtained by the manufacturing method of the present invention has an amount of fluorine contained in the glass of more than 0.23 mol %·μm on the depth-direction profile by secondary ion mass spectrometry (SIMS) in which the horizontal axis expresses depth (μm) and the vertical axis expresses fluorine concentration (mol %).
The following will describe a method of determining the fluorine concentration (mol %) in secondary ion mass spectrometry (SIMS).
Secondary ion intensity IM1 of an isotope M1 of an element M in secondary ion mass spectrometry is proportional to primary ion intensity Ip, sputtering rate Y of a matrix, concentration CM (ratio relative to total concentration) of the element M, existence probability α1 of the isotope M1, secondary ionization rate PM of the element M, and permeation efficiency η (including detection efficiency of a detector) of a mass spectrometer.
I
M1
=A·I
p
·Y·C
M·α1·βM·η (Formula 1)
Here, A is a ratio of the detection area of a secondary ion relative to the scanning range of a primary ion beam. In general, since it is difficult to determine η of the apparatus, an absolute value of βM cannot be determined. Therefore, η is deleted by using a main component element or the like in the same sample as a reference element and taking a ratio to (Formula 1).
Here, in the case where the reference element is expressed as R and an isotope thereof is expressed as (Formula 2) is obtained.
I
M1
/I
Rj=(CM·α1·βM)/(CR·αj·βR)=CM/K (Formula 2)
Here, K is a relative sensitivity factor of the element M to the element R.
K=(CR·αj·βR)/(α1·βM) (Formula 3)
In this case, the concentration of the element M is determined from (Formula 4).
C
M
=K·I
M1
/I
Rj (Formula 4)
In the present invention, F corresponds to M1 and Si corresponds to R1. Therefore, from (Formula 2), the intensity ratio (F/Si) of the both is equal to one obtained by dividing the fluorine concentration CM by K. That is, F/Si is a direct index of the fluorine concentration.
The average fluorine concentration is calculated from the results of the measurement of the fluorine concentration profile in a glass on an SIMS apparatus mentioned above through the following procedures (a1) to (a3). (a) to (c) of
(a1) A fluorine concentration profile of standard samples each having a known concentration and a target sample to be measured is measured by SIMS ((a) of
(a2) A calibration curve is prepared based on the measurement results of the standard samples and a coefficient for converting 19F/30Si into fluorine concentration (mol %) is calculated ((b) of
(a3) The fluorine concentration (mol %) of the target sample to be measured is determined based on the coefficient calculated in the step (a2). For example, the average fluorine concentration (mol %) by SIMS in the depth of 0 to 30 μm is a value obtained by integrating the fluorine concentration in the depth of 0 to 30 μm and dividing the resulting value by 30 μm that is the depth ((c) of
An integrated value where the fluorine concentration (mol %) is on the vertical axis and the depth (μm) is on the horizontal axis is defined as the amount (mol %·μm) of fluorine contained in a glass.
As analytical conditions for the secondary ion mass spectrometry (Secondary Ion Mass Spectrometry; SIMS analysis), for example, the following conditions may be mentioned. Incidentally, the analytical conditions shown in the following are examples, and are to be appropriately modified depending on a measuring apparatus, samples and the like. The depth on horizontal axis of the depth-direction profile by SIMS analysis can be determined by measuring the depth of analysis crater with a stylus type film thickness meter (e.g., Dektak 150 manufactured by Veeco Corp.).
Primary ion species: Cs+
Primary ion incidence angle: 60°
Primary acceleration voltage: 5 kV
As more specific analytical conditions, for example, the following conditions may be mentioned.
Measurement apparatus: a secondary ion mass spectrometry apparatus having a quadrupole mass spectrometer
Primary ion species: Cs+
Primary acceleration voltage: 5.0 kV
Primary ion current: 1 μA
Primary ion incident angle (angle from vertical direction of sample surface): 60°
Raster size: 200×200 μm2
Detection area: 40×40 μm2
Secondary ion polarity: minus
Use of electron gun for neutralization: yes
As the secondary ion mass spectrometry apparatus having a quadrupole mass spectrometer, for example, ADEPT 1010 manufactured by ULVAC-PHI Inc. may be mentioned.
The thickness of the glass sheet is not particularly limited, and for example, there may be mentioned 2 mm, 0.8 mm, 0.73 mm, 0.7 mm, 0.56 mm, and 0.4 mm. In order to effectively perform chemical strengthening treatment to be described below, the thickness is usually preferably 5 mm or less, more preferably 3 mm or less, further preferably 1.5 mm or less, and particularly preferably 0.8 mm or less.
Usually, the warpage amount of a glass sheet having a thickness of 0.7 mm after chemical strengthening is required to be 40 μm or less. In the case of a 90 mm square glass sheet having CS of 750 MPa and DOL of 40 μm, the warpage amount after chemical strengthening is about 130 μm. On the other hand, since the warpage amount of a glass sheet after chemical strengthening is inversely proportional to the square of sheet thickness, the warpage amount in a glass sheet having a thickness of 2.0 mm becomes about 16 μm, and warpage will not substantially become a problem. Accordingly, there is a possibility that the problem of warpage after chemical strengthening is likely to occur in a glass sheet having a thickness of less than 2 mm, and typically 1.5 mm or less.
Chemical strengthening is treatment in which alkali metal ions (typically, Li ions or Na ions) having a smaller ion radius in a glass surface are exchanged with alkali metal ions (typically, K ions) having a larger ion radius by ion exchange at a temperature equal to or lower than a glass transition point to thereby form a compressive stress layer in the glass surface. The chemical strengthening treatment may be performed by a conventionally known method.
In the present invention, a glass sheet having improved warpage after chemical strengthening can be obtained by chemically strengthening a fluorine-introduced glass sheet. The change amount of warpage (warpage change amount) of a glass sheet after chemical strengthening with respect to the glass sheet before the chemical strengthening can be measured by a three-dimensional shape measurement instrument (e.g., manufactured by Mitaka Kohki Co., Ltd.) or a surface roughness/outline shape measurement instrument (e.g., manufactured by Tokyo Seimitsu Co., Ltd.).
In the present invention, the improvement of warpage after chemical strengthening is evaluated by a warpage displacement amount determined by the following formula in an experiment under the same conditions only except that surface treatment is performed by the fluorine-containing fluid.
Warpage Displacement Amount=ΔX−ΔY
ΔX: warpage change amount of untreated glass sheet caused by chemical strengthening
ΔY: warpage change amount of treated glass sheet caused by chemical strengthening
Here, the warpage change amount is a value obtained by subtracting the warpage amount of a glass sheet before chemical strengthening from the warpage amount of the glass sheet after the chemical strengthening. The warpage change amount is as follows: ΔX>0. As for ΔY, ΔY>0 in the case where the warpage occurs in the same direction as that in the case of ΔX and ΔY<0 in the case where the warpage occurs in the direction reverse to that in the case of ΔX.
The warpage change amount of an untreated glass sheet caused by chemical strengthening depends on various conditions and widely varies. The fact that the warpage displace amount is larger than a predetermined value means that the warpage can be controlled regardless of the above variation. Therefore, a glass sheet exhibiting a warpage displacement amount of a predetermined value, specifically 10 μm or more, can reduce the problem of warpage.
CS (surface compressive stress) and DOL (depth of compressive stress layer) of a glass sheet can be measured by a surface stress meter. The surface compressive stress of a chemically strengthened glass is preferably 600 MPa or more, and the depth of the compressive stress layer is preferably 15 μm or more. By controlling the surface compressive stress and the depth of the compressive stress layer of a chemically strengthened glass within the ranges, excellent strength and scratch resistance are obtained.
Hereinafter described is an example where the glass sheet of the present invention is chemically strengthened and the chemically strengthened glass is then used as a cover glass for a flat panel display device.
As illustrated in
The cover glass 30 is primarily provided for the purpose of improving beauty and strength of the display device 40 or preventing damage caused by impact, and is formed of one sheet of sheet-shaped glass having an entire shape of a substantially planar shape. The cover glass 30 may be arranged so as to be separated from the display side (front side) of the display panel 45 (to have an air layer) as illustrated in
A functional film 41 is provided on the front surface of the cover glass 30 on which light from the display panel 45 is emitted, and a functional film 42 is provided on the rear surface, on which light from the display panel 45 is incident, at a position corresponding to the display panel 45. Although the functional films 41 and 42 are provided on both surfaces in
The functional films 41 and 42 have functions of, for example, preventing reflection of ambient light, preventing damage caused by impact, shielding electromagnetic waves, shielding near infrared rays, correcting color tone, and/or improving scratch resistance, and the thickness, shape and the like thereof are appropriately selected depending on use applications. For example, the functional films 41 and 42 are formed by attaching a resin-made film to the cover glass 30. Alternatively, they may be formed by a thin film-forming method such as a vapor deposition method, a sputtering method, or a CVD method.
Reference numeral 44 indicates a black layer, and for example, is a coating film formed by applying ink containing pigment particles onto the cover glass 30 and performing ultraviolet irradiation or heating and burning, followed by cooling. Thus, the display panel or the like is not viewed from the outside of the housing 15, and the aesthetics of the appearance is improved.
In the case where the glass sheet of the present invention is used as a cover glass of a display device as above, surface roughness (arithmetic average roughness) Ra is preferably 2.5 nm or less and further preferably 1.5 nm or less. As a result, it can be prevented the cover glass from impairing clearness of displayed images on the display device. The surface roughness Ra of a glass sheet can be measured as follows in accordance with JIS B0601 (2001). By using AFM (Atomic Force Microscope), for example, XE-HDM manufactured by Park System as a measuring apparatus, the roughness is measured at three points in a scan size of 1 μm×1 μm and an average value of the values at three points is taken as the Ra value of the glass sheet.
Hereinafter, Examples of the present invention will be specifically described. However, the present invention is not limited thereto.
In the present Examples, glass sheets of glass materials A to D having the following compositions were used.
(Glass material A) Glass containing, in terms of mol %, 72.0% of SiO2, 1.1% of Al2O3, 12.6% of Na2O, 0.2% of K2O, 5.5% of MgO, and 8.6% of CaO (glass transition temperature: 566° C.).
(Glass material B) Glass containing, in terms of mol %, 64.3% of SiO2, 8.0% of Al2O3, 12.5% of Na2O, 4.0% of K2O, 10.5% of MgO, 0.1% of CaO, 0.1% of SrO, 0.1% of BaO, and 0.5% of ZrO2 (glass transition temperature: 604° C.).
(Glass material C) Glass containing, in terms of mol %, 68.0% of SiO2, 10.0% of Al2O3, 14.0% of Na2O, and 8.0% of MgO (glass transition temperature: 662° C.).
(Glass material D) Glass containing, in terms of mol %, 68.8% of SiO2, 3.0% of Al2O3, 14.2% of Na2O, 7.8% of CaO, 6.2% of MgO, and 0.2% of K2O (glass transition temperature: 552° C.).
The warpage amount was measured by SURFCOM surface roughness/outline shape measurement instrument (for example, manufactured by Tokyo Seimitsu Co., Ltd.) before chemical strengthening, and then, each glass was subjected to chemical strengthening, and the warpage amount after chemical strengthening was measured in the same manner, and warpage displacement amount was calculated based on the aforementioned procedures.
Analytical conditions of the secondary ion mass spectrometry were as follows.
Measurement apparatus: ADEPT 1010 manufactured by ULVAC-PHI Inc.
Primary ion species: Cs+
Primary acceleration voltage: 5.0 kV
Primary ion current: 1 μA
Primary ion incident angle (angle from vertical direction of sample surface): 60°
Raster size: 200×200 μm2
Detection area: 40×40 μm2
Secondary ion polarity: minus
Use of electron gun for neutralization: yes
In addition, the depth on the horizontal axis of the depth-direction profile obtained by SIMS analysis was determined by measuring the depth of analysis crater with a stylus type thickness meter (Dcktak 150 manufactured by Veeco Corp.).
CS and DOL in the obtained glass sheet after chemical strengthening were measured by using a surface stress meter (FSM-6000LE) manufactured by Orihara Industrial Co., Ltd.
In a float bath in which a glass ribbon made of the glass material B flowed, fluorine treatment (hereinafter referred to as HF treatment) was conducted by using HF gas as a fluorine-containing fluid. Table 1 shows HF concentration (% by volume) of the gas brought into contact and the time (second) thereof, and HF contact amount per 1 cm2 of a glass ribbon (HF total contact amount (mol/cm2)) calculated therefrom, and the surface temperature (° C.) of the glass ribbon at the time of bringing the gas containing HF into contact.
Incidentally, as a reference, a float glass was prepared in the case where N2 gas was brought into contact with the surface of the glass ribbon instead of the fluorine-containing fluid (Comparative Example 1-1).
The glass sheets subjected to HF treatment and, as a reference, the glass sheet in which fluorine was not allowed to penetrate were chemically strengthened with potassium nitrate molten salt at 450° C. for 2 hours and the warpage displacement amount (μm) was measured from ΔWarpage amount before and after the chemical strengthening. Table 1 shows the evaluation results on the amount of fluorine contained in the glass and the warpage displacement amount (μm).
As shown in Table 1, it was found that warpage of a glass sheet after chemical strengthening was improved by performing the chemical strengthening after the surface was subjected to HF treatment to increase the fluorine concentration in the glass. In addition, from the results of Table 1, a relationship between the amount of fluorine contained in the glass and the warpage displacement amount was summarized in
HF treatment and chemical strengthening treatment of a glass ribbon were performed in the same manner as in Example 1 except that the glass material B was changed to the glass material A. A warpage improvement amount (urn) was measured from ΔWarpage amount before and after chemical strengthening treatment. Table 2 shows conditions for the HF treatment, the amount of fluorine contained in the glass, and the warpage displacement amount. Furthermore, Comparative Example 2-1 was the same as Comparative Example 1-1 except that the glass material B was changed to the glass material A, and was used as a reference.
As shown in Table 2, it was found that warpage of a glass sheet after chemical strengthening was improved by performing the chemical strengthening after the surface was subjected to HF treatment to increase the fluorine concentration in the glass. In addition, from the results of Table 2, a relationship between the amount of fluorine contained in the glass and the warpage displacement amount was summarized in
HF treatment and chemical strengthening treatment of a glass ribbon were performed in the same manner as in Example 1-1 except that the glass material B was changed to the glass material C and the time for the chemical strengthening treatment was 1.5 hours, and a warpage displacement amount (μm) was measured from ΔWarpage amount before and after the chemical strengthening treatment. Table 3 shows conditions for the HF treatment, the amount of fluorine contained in the glass, and the warpage displacement amount (μm). Furthermore, Comparative Examples 3-1 and 3-2 were the same as Comparative Example 1-1 except that the time for chemical strengthening treatment was 1.5 hours, and were used as references. Incidentally, in Examples 3-1 to 3-6, the surface temperature (° C.) of the glass ribbon at the time of bringing the gas containing HF into contact is set high, as compared with Examples 1-1 to 1-12.
As shown in Table 3, it was found that warpage of a glass sheet after chemical strengthening was improved by performing the chemical strengthening after the surface was subjected to HF treatment to increase the fluorine concentration in the glass. Also, it was found that the warpage displacement amount became 10 μm or more and the warpage after chemical strengthening could be effectively improved by controlling the amount of fluorine contained in the glass to more than 0.23 mol %·μm.
HF treatment and chemical strengthening treatment of a glass ribbon were performed in the same manner as in Example 2-1 except that the glass material A was changed to the glass material D, and a warpage displacement amount (μm) was measured from ΔWarpage amount before and after the chemical strengthening. Table 4 shows conditions for the HF treatment, the amount of fluorine contained in the glass, and the warpage displacement amount (urn). Furthermore, Comparative Example 4-1 was the same as Comparative Example 2-1 and was used as a reference. Incidentally, in Examples 4-1 to 4-4, the surface temperature (° C.) of the glass ribbon at the time of bringing the gas containing HF into contact is set high, as compared with Examples 2-1 to 2-9.
As shown in Table 4, it was found that warpage of a glass sheet after chemical strengthening was improved by performing the chemical strengthening after the surface was subjected to HF treatment to increase the fluorine concentration in the glass. Also, it was found that the warpage displacement amount became 10 μm or more and the warpage after chemical strengthening could be effectively improved by controlling the amount of fluorine contained in the glass to 0.7 mol %·μm or more.
The present application is based on Japanese Patent Application No. 2013-198478 filed on Sep. 25, 2013, Japanese Patent Application No. 2013-258466 filed on Dec. 13, 2013, and Japanese Patent Application No. 2013-258467 filed on Dec. 13, 2013 and the contents thereof are incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-198478 | Sep 2013 | JP | national |
| 2013-258466 | Dec 2013 | JP | national |
| 2013-258467 | Dec 2013 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2014/075017 | Sep 2014 | US |
| Child | 15079516 | US |
