Patent Grant
12122709
The present invention relates to a tempered glass and a method of producing the same, and more particularly, to a tempered glass suitable for a cover glass for a cellular phone, a digital camera, a personal digital assistant (PDA), or a touch panel display, and a method of producing the same.
Devices such as a cellular phone (in particular, a smartphone), a digital camera, a PDA, a touch panel display, a large-screen television, and contact-less power transfer show a tendency of further prevalence. In those applications, a tempered glass obtained through ion exchange treatment has been used. In addition, in recent years, the use of the tempered glass in exterior components of a digital signage, a mouse, a smartphone, and the like is increasing.
A tempered glass includes, on its surface, a compressive stress layer formed by ion exchange treatment. Accordingly, the formation and extension of a crack in the surface are suppressed, and hence high strength is obtained. The strength of the tempered glass is considered to be capable of being improved by adjusting the formation mode of such compressive stress layer (e.g., Patent Literature 1).
However, the tempered glass has still room for improvement in terms of the achievement of higher impact resistance.
An object of the present invention is to provide a tempered glass having impact resistance higher than that of the related art.
According to one embodiment of the present invention, which has been devised in order to solve the above-mentioned problem, there is provided a tempered glass having a surface and a thickness T, wherein a stress profile of the tempered glass, which is obtained by measuring a stress in a depth direction from the surface with a compressive stress being represented by a positive number and a tensile stress being represented by a negative number, comprises: a first peak at the surface, at which the compressive stress takes a maximum value; a first bottom at which the stress, which gradually reduces from the first peak in the depth direction, takes a local minimum value; a second peak at which the compressive stress, which gradually increases from the first bottom in the depth direction, takes a local maximum value; and a second bottom at which the tensile stress, which gradually reduces from the second peak in the depth direction, takes a minimum value, wherein the compressive stress at the first peak is 500 MPa or more, wherein the compressive stress at the second peak is from 15 MPa to 250 MPa, and wherein the second peak is present at a depth of from 4% to 20% of the thickness T. The inventors of the present invention have made extensive investigations, and as a result, have recognized that the tempered glass having such stress profile has high impact resistance. In particular, it is important for increasing the impact resistance that the compressive stress at the second peak (local maximum value) and the position thereof in the depth direction be set to fall within the above-mentioned numerical ranges.
In the above-mentioned configuration, it is preferred that the stress profile have a zero stress point at which the stress becomes zero between the second peak and the second bottom, and the zero stress point be present at a depth of from 10% to 35% of the thickness T from the surface. With this configuration, the compressive stress can be generated so as to reach a deep site, and hence the impact resistance can be expected to improve.
In the above-mentioned configuration, it is preferred that the stress at the first bottom be from −50 MPa to +100 MPa. With this configuration, the tensile stress at the second bottom can be relatively reduced to keep balance between the compressive stress and the tensile stress, and hence the impact resistance can be expected to be improved.
In the above-mentioned configuration, it is preferred that the stress at the first bottom be 0 MPa or more and +65 MPa or less. With this configuration, no tensile stress is generated in a surface layer portion of the tempered glass, and hence the occurrence of cracking during the production process of the tempered glass can be suppressed.
In the above-mentioned configuration, it is preferred that the stress at the first bottom be −30 MPa or more and less than 0 MPa. With this configuration, the tensile stress at the second bottom is relatively reduced to keep balance between the compressive stress and the tensile stress, and hence the impact resistance can be expected to be improved.
In the above-mentioned configuration, it is preferred that the first bottom be present at a depth of from 0.5% to 12% of the thickness T from the surface.
In the above-mentioned configuration, it is preferred that a distance from the first bottom to the second peak in the depth direction be 3% or more of the thickness T.
In the above-mentioned configuration, it is preferred that the compressive stress at the first peak be 700 MPa or more, and the second peak be present at a depth of 7.3% or more of the thickness T from the surface.
In the above-mentioned configuration, it is preferred that the thickness T be from 0.3 mm to 0.9 mm, and the tempered glass have the stress profile in each of main surfaces and end surfaces thereof.
In the above-mentioned configuration, it is preferred that the thickness T fall within a range of 0.45 mm or more and 0.85 mm or less, the compressive stress at the first peak fall within a range of 700 MPa or more and 850 MPa or less, the compressive stress at the second peak fall within a range of 20 MPa or more and 80 MPa or less, the second peak be present within a depth range of 7.3% or more and 20% or less of the thickness T from the surface, the stress profile have a zero stress point at which the stress becomes zero between the second peak and the second bottom, the zero stress point be present within a depth range of 17% or more and 25% or less of the thickness T from the surface, and a maximum absolute value of the tensile stress fall within a range of 40 MPa or more and 60 MPa or less.
In the above-mentioned configuration, it is preferred that the tempered glass comprise as a glass composition, in terms of mass %, 40% to 70% of SiO2, 10% to 30% of Al2O3, 0% to 10% of B2O3, 2% to 11% of Li2O, 5% to 25% of Na2O, 0% to 10% of K2O, 0% to 6% of MgO, 0% to 10% of ZnO, and 0% to 20% of P2O3.
According to one embodiment of the present invention, which has been devised in order to solve the above-mentioned problem, there is provided a method of producing a tempered glass, for obtaining a tempered glass by subjecting a glass to be tempered containing a first alkali metal ion to ion exchange treatment, the method comprising: a first ion exchange step of bringing the glass to be tempered into contact with a first molten salt containing a second alkali metal ion having a larger ionic radius than the first alkali metal ion to introduce the second alkali metal ion into the glass to be tempered; a second ion exchange step of bringing, after the first ion exchange step, the glass to be tempered into contact with a second molten salt containing the first alkali metal ion to desorb at least part of the second alkali metal ion from the glass to be tempered; and a third ion exchange step of bringing, after the second ion exchange step, the glass to be tempered into contact with a third molten salt containing the second alkali metal ion to introduce the second alkali metal ion into the glass to be tempered. The method of producing a tempered glass comprising such steps can provide a tempered glass having high impact resistance.
In the above-mentioned configuration, it is preferred that the first ion exchange step comprise introducing the second alkali metal ion to a depth of 10.5% or more of a thickness T of the glass to be tempered from a surface thereof, the second ion exchange step comprise desorbing at least part of the second alkali metal ion in a region ranging from the surface of the glass to be tempered and being shallower than 10% of the thickness T, and the third ion exchange step comprise introducing the second alkali metal ion to a region ranging from the surface of the glass to be tempered and being shallower than 7% of the thickness T. In this case, it is preferred that, in a region deeper than the above-mentioned depth, no alkali metal ion be introduced or desorbed. With this configuration, the tempered glass having high impact resistance can be more reliably obtained.
In the above-mentioned configuration, it is preferred that the first alkali metal ion be a Na ion, the second alkali metal ion be a K ion, the first molten salt contain KNO3, the second molten salt contain NaNO3, and the third molten salt contain KNO3.
In the above-mentioned configuration, it is preferred that the first alkali metal ion be a Na ion, the second alkali metal ion be a K ion, the first molten salt contain at least KNO3 out of NaNO3 and KNO3, the second molten salt contain at least NaNO3 out of NaNO3 and KNO3, a KNO3 concentration in the first molten salt be higher than a NaNO3 concentration therein, and a NaNO3 concentration in the second molten salt be higher than a KNO3 concentration therein. With this configuration, the first ion exchange step and the second ion exchange step can be efficiently performed.
In this case, it is preferred that the KNO3 concentration in the first molten salt be 50 mass % or more, the NaNO3 concentration in the first molten salt be less than 50 mass %, the NaNO3 concentration in the second molten salt be 60 mass % or more, the KNO3 concentration in the second molten salt be 40 mass % or less, a KNO3 concentration in the third molten salt be higher than the KNO3 concentration in the first molten salt, an ion exchange treatment temperature in the first ion exchange step be from 420° C. to 500° C., an ion exchange treatment temperature in the second ion exchange step be from 420° C. to 500° C., an ion exchange treatment temperature in the third ion exchange step be lower than the ion exchange treatment temperature in the first ion exchange step by 10° C. or more, an ion exchange treatment time in the first ion exchange step be from 2 hours to 40 hours, an ion exchange treatment time in the second ion exchange step be from 2 hours to 40 hours, and an ion exchange treatment time in the third ion exchange step be shorter than the ion exchange treatment time in each of the first ion exchange step and the second ion exchange step.
According to one embodiment of the present invention, which has been devised in order to solve the above-mentioned problem, there is provided a method of producing a tempered glass, for obtaining a tempered glass by subjecting a glass to be tempered containing a first alkali metal ion to ion exchange treatment, the method comprising: a first ion exchange step of bringing the glass to be tempered into contact with a first molten salt containing a second alkali metal ion having a larger ionic radius than the first alkali metal ion to introduce the second alkali metal ion into the glass to be tempered; and a second ion exchange step of bringing, after the first ion exchange step, the glass to be tempered into contact with a second molten salt containing a third alkali metal ion, which has a larger ionic radius than the second alkali metal ion, and the first alkali metal ion to desorb at least part of the second alkali metal ion from the glass to be tempered, and to introduce the third alkali metal ion into the glass to be tempered. The method of producing a tempered glass comprising such steps can provide a tempered glass having high impact resistance.
In the above-mentioned configuration, it is preferred that the second ion exchange step comprise introducing the third alkali metal ion to a region ranging from the surface of the glass to be tempered and being shallower than 7% of the thickness T. In this case, it is preferred that, in a region deeper than the above-mentioned depth, no alkali metal ion be introduced or desorbed. With this configuration, the tempered glass having high impact resistance can be more reliably obtained.
In the above-mentioned configuration, it is preferred that the glass to be tempered further contain the second alkali metal ion.
In the above-mentioned configuration, it is preferred that the first alkali metal ion be a Li ion, the second alkali metal ion be a Na ion, the third alkali metal ion be a K ion, and a Li ion concentration in the second molten salt be 100 ppm by mass or more.
In the above-mentioned configuration, it is preferred that the first molten salt contain NaNO3, and the second molten salt contain LiNO3 and KNO3.
In the above-mentioned configuration, it is preferred that the first alkali metal ion be a Li ion, the second alkali metal ion be a Na ion, the third alkali metal ion be a K ion, the first molten salt contain at least NaNO3 out of NaNO3 and KNO3, a NaNO3 concentration in the first molten salt be higher than a KNO3 concentration therein, the second molten salt contain LiNO3 and KNO3, and a LiNO3 concentration in the second molten salt be lower than a KNO3 concentration therein. With this configuration, the first ion exchange step and the second ion exchange step can be efficiently performed.
In this case, it is preferred that the NaNO3 concentration in the first molten salt be 50 mass % or more, the KNO3 concentration in the first molten salt be less than 50 mass %, the LiNO3 concentration in the second molten salt be from 0.5 mass % to 5 mass %, the KNO3 concentration in the second molten salt be from 95 mass % to 99.5 mass %, an ion exchange treatment temperature in the first ion exchange step be from 350° C. to 480° C., an ion exchange treatment temperature in the second ion exchange step be from 350° C. to 480° C., an ion exchange treatment time in the first ion exchange step be from 1 hour to 20 hours, and an ion exchange treatment time in the second ion exchange step be shorter than the ion exchange treatment time in the first ion exchange step.
In the above-mentioned configuration, it is preferred that the first ion exchange step comprise introducing the second alkali metal ion to a region ranging from a surface of the glass to be tempered and being deeper than 10% of a thickness T thereof, and the second ion exchange step comprise desorbing at least part of the second alkali metal ion in a region ranging from the surface of the glass to be tempered and being shallower than 10% of the thickness T. In this case, it is preferred that, in a region deeper than the above-mentioned depth, no alkali metal ion be introduced or desorbed.
In the above-mentioned configuration, it is preferred that the first molten salt contain the second alkali metal ion and the third alkali metal ion.
According to the present invention, the tempered glass having impact resistance higher than that of the related art is obtained.
A tempered glass according to an embodiment of the present invention is described below.
As illustrated in
The compressive stress layer 2 is formed in a surface layer portion, which comprises main surfaces 1a and end surfaces 1b, of the tempered glass 1. The tensile stress layer 3 is formed in an inner portion of the tempered glass 1, that is, at a position deeper than that of the compressive stress layer 2.
The stress profile (stress distribution) of the tempered glass 1 is obtained by measuring a stress in a depth direction (direction orthogonal to the main surfaces 1a) from a main surface 1a side with a compressive stress being represented by a positive number and a tensile stress being represented by a negative number. The stress profile of the tempered glass 1 thus obtained is, for example, as shown in
The stress profile of the tempered glass 1 comprises a first peak P1, a first bottom B1, a second peak P2, and a second bottom B2 in the stated order from the main surface 1a side in the depth direction (direction orthogonal to the main surfaces 1a).
The first peak P1 is the maximum value of the compressive stress, and is present at each of the main surfaces 1a. A compressive stress CSmax at the first peak P1 is 500 MPa or more, preferably from 600 MPa to 1,100 MPa, more preferably from 600 MPa to 1,000 MPa, from 700 MPa to 900 MPa, or from 750 MPa to 850 MPa.
At the first bottom B1, with the stress gradually reducing from the first peak P1 in the depth direction, the stress takes a local minimum value. A case in which a stress CSb at the first bottom B1 is a compressive stress (positive value) is shown as an example in
At the second peak P2, with the stress gradually increasing from the first bottom B1 in the depth direction, the stress takes a local maximum value. A stress CSp at the second peak P2 is a compressive stress. The compressive stress CSp at the second peak P2 is from 15 MPa to 250 MPa, preferably from 15 MPa to 240 MPa, from 15 MPa to 230 MPa, from 15 MPa to 220 MPa, from 15 MPa to 210 MPa, from 15 MPa to 200 MPa, from 15 MPa to 190 MPa, from 15 MPa to 180 MPa, from 15 MPa to 175 MPa, from 15 MPa to 170 MPa, from 15 MPa to 165 MPa, from 15 MPa to 160 MPa, or from 18 MPa to 100 MPa, more preferably from 20 MPa to 80 MPa. A depth DOLp of the second peak P2 is from 4% to 20% of the thickness T, preferably from 4% to 19%, from 4% to 18.5%, from 4% to 18%, from 4% to 17.5%, or from 4% to 17%, more preferably from 4.5% to 17%, from 5% to 17%, from 6% to 17%, from 7.3% to 17%, or from 8% to 15% of the thickness T.
A distance from the first bottom B1 to the second peak P2 in the depth direction, that is, DOLp-DOLb is 3% or more of the thickness T, preferably 4% or more of the thickness T, more preferably from 5% to 13% of the thickness T.
At the second bottom B2, the stress, which gradually reduces from the second peak P2 in the depth direction, takes the minimum value of the tensile stress (maximum value in terms of absolute value). The absolute value of the tensile stress CTmax at the second bottom B2 is 70 MPa or less, preferably 65 MPa or less, or 60 MPa or less, more preferably from 40 MPa to 55 MPa.
The product of the tensile stress CTmax at the second bottom B2 and the thickness T is preferably −70 MPa·mm or more, more preferably −65 MPa·mm or more, −60 MPa·mm or more, or −55 MPa mm or more. In addition, the product of the tensile stress CTmax at the second bottom B2 and the thickness T is preferably −5 MPa·mm or less, −10 MPa·mm or less, −15 MPa·mm or less, −20 MPa·mm or less, −25 MPa·mm or less, or −30 MPa·mm or less.
Between the second peak P2 and the second bottom B2, there is a zero stress point Z at which the stress becomes zero. In general, it is difficult for a depth DOLzero of the zero stress point Z to exceed 20% of the thickness T, and its physical limit is about 22%. However, in this embodiment, a DOLzero exceeding the limit value can be obtained. As the depth DOLzero of the zero stress point Z increases, strength against penetration by a protruding object becomes higher, and the depth DOLzero is preferably 10% or more, 10.5% or more, 11% or more, 11.5% or more, 12% or more, 12.5% or more, 13% or more, 13.5% or more, 14% or more, 14.5% or more, 15% or more, 15.5% or more, 16% or more, 16.5% or more, 17% or more, 17.5% or more, or 18% or more, more preferably 18.5% or more, 19% or more, 19.5% or more, 20% or more, 20.5% or more, 21% or more, 21.5% or more, 22.0% or more, 22.5% or more, 23% or more, or 23.5% or more, most preferably 24% or more of the thickness T. However, when the depth DOLzero of the zero stress point Z is excessively large, an excessive tensile stress may be generated at the first bottom B1 or the second bottom B2. Thus, the depth DOLzero of the zero stress point Z is preferably 35% or less, 34.5% or less, 34% or less, 33.5% or less, 33% or less, 32.5% or less, 32% or less, 31.5% or less, 31% or less, 30.5% or less, 30% or less, 29.5% or less, 29% or less, 28.5% or less, or 28% or less, more preferably 27% or less of the thickness T.
In this embodiment, the tempered glass 1 has a similar stress profile in each of the end surfaces 1b as well. That is, the stress profile of the tempered glass 1 includes: a first peak at each of the end surfaces 1b, at which the compressive stress takes a maximum value; a first bottom at which the stress, which gradually reduces from the first peak in the depth direction, takes a local minimum value; a second peak at which the compressive stress, which gradually increases from the first bottom in the depth direction, takes a local maximum value; and a second bottom at which the tensile stress, which gradually reduces from the second peak in the depth direction, takes a minimum value, wherein the compressive stress at the first peak is 500 MPa or more, wherein the compressive stress at the second peak is from 15 MPa to 250 MPa, and wherein the second peak is present at a depth of from 4% to 20% of the thickness T. In addition, the preferred ranges of the stress profile for each of the main surfaces 1a may be similarly applied to the preferred ranges of the stress profile for each of the end surfaces 1b.
Values obtained by measurement and synthesis with, for example, FSM-6000LE and SLP-1000 manufactured by Orihara Manufacturing Co., Ltd. may be used as the stress of the tempered glass 1 and its distribution.
The tempered glass 1 having the configuration as described above may be produced by, for example, the following procedure. First, as a preparation step, a sheet-shaped glass that contains an alkali metal oxide as a composition and is to be subjected to tempering treatment (hereinafter referred to as “glass to be tempered”) is prepared. Next, a first ion exchange step (first tempering step) of bringing a surface of the glass to be tempered into contact with a first molten salt, a second ion exchange step (relaxing step) of bringing the surface of the glass to be tempered into contact with a second molten salt, and a third ion exchange step (second tempering step) of bringing the surface of the glass to be tempered into contact with a third molten salt are performed in the stated order. In each of the ion exchange steps, the glass to be tempered is preferably immersed in the molten salt.
It is preferred that the glass to be tempered to be prepared in the preparation step comprise, for example, as a glass composition, in terms of mass %, 40% to 70% of SiO2, 10% to 30% of Al2O3, 0% to 3% of B2O3, 5% to 25% of Na2O, 0% to 5.5% of K2O, 0% to 10% of Li2O, 0% to 5.5% of MgO, and 2% to 10% of P2O3.
Described below are reasons why the composition as described above is preferred. In the description of the content range of each component, the expression “%” means “mass %” unless otherwise specified.
SiO2 is a component that forms a glass network. When the content of SiO2 is too small, vitrification does not occur easily, and acid resistance is liable to lower. Thus, a suitable lower limit range of the content of SiO2 is 40% or more, 40.5% or more, 41% or more, 41.5% or more, 42% or more, 42.5% or more, 43% or more, 44% or more, 45% or more, 46% or more, 47% or more, 48% or more, or 49% or more, particularly 50% or more. Meanwhile, when the content of SiO2 is too large, meltability and formability are liable to lower, and a thermal expansion coefficient becomes too low, with the result that it becomes difficult to match the thermal expansion coefficient with those of peripheral materials. Thus, a suitable upper limit range of the content of SiO2 is 70% or less, 68% or less, 65% or less, 62% or less, 60% or less, 58% or less, 57% or less, 56% or less, or 55% or less, particularly 54% or less.
Al2O3 is a component that increases an ion exchange rate, and is also a component that increases a Young's modulus to increase a Vickers hardness. Further, Al2O3 is a component that increases a viscosity at which phase separation occurs. The content of Al2O3 is from 10% to 30%. When the content of Al2O3 is too small, the ion exchange rate and the Young's modulus are liable to lower. Thus, a suitable lower limit range of the content of Al2O3 is 10% or more, 11% or more, 12% or more, 13% or more, 14% or more, 14.5% or more, 15% or more, 15.5% or more, 16% or more, 16.5% or more, 17% or more, 17.5% or more, 18% or more, 18.5% or more, or 19% or more, particularly 19.5% or more. Meanwhile, when the content of Al2O3 is too large, devitrified crystals are liable to be deposited in the glass, and it becomes difficult to form a sheet shape by an overflow down-draw method or the like. In particular, when the sheet shape is formed by the overflow down-draw method through use of an alumina refractory as a forming body refractory, a devitrified crystal of spinel is liable to be deposited at an interface between the glass and the alumina refractory. In addition, the acid resistance reduces and hence it becomes difficult to apply the glass to an acid treatment step. In addition, viscosity at high temperature increases, which is liable to lower the meltability. Thus, a suitable upper limit range of the content of Al2O3 is 30% or less, 28% or less, 26% or less, 25% or less, 24% or less, 23.5% or less, 23% or less, 22.5% or less, 22% or less, or 21.5% or less, particularly 21% or less.
B2O3 is a component that lowers the viscosity at high temperature and a density, and increases devitrification resistance. However, when the content of B2O3 is too large, the ion exchange rate (in particular, depth of layer) is liable to lower. In addition, coloring on the surface of the glass called weathering may occur through ion exchange, and acid resistance and water resistance are liable to lower. Thus, a suitable range of the content of B2O3 is from 0% to 3%, from 0% to 2.5%, from 0% to 2%, from 0% to 1.9%, from 0% to 1.8%, from 0% to 1.7%, from 0% to 1.6%, from 0% to 1.5%, or from 0% to 1.3%, particularly from 0% to less than 1%.
Na2O is an ion exchange component, and is also a component that lowers the viscosity at high temperature to increase the meltability and the formability. In addition, Na2O is also a component that improves the devitrification resistance, including resistance to devitrification through a reaction with a forming body refractory, in particular, an alumina refractory. When the content of Na2O is too small, the meltability lowers, the thermal expansion coefficient lowers excessively, and the ion exchange rate is liable to lower. Thus, a suitable lower limit range of the content of Na2O is 5% or more, 7% or more, 8% or more, 8.5% or more, 9% or more, 9.5% or more, 10% or more, 11% or more, or 12% or more, particularly 12.5% or more. Meanwhile, when the content of Na2O is too large, the viscosity at which phase separation occurs is liable to lower. In addition, the acid resistance lowers, and the glass composition loses its component balance, with the result that the devitrification resistance lowers contrarily in some cases. Thus, a suitable upper limit range of the content of Na2O is 22% or less, 20% or less, 19.5% or less, 19% or less, 18% or less, 17% or less, 16.5% or less, 16% or less, or 15.5% or less, particularly 15% or less.
K2O is a component that lowers the viscosity at high temperature to increase the meltability and the formability. Further, K2O is also a component that improves the devitrification resistance, and increases the Vickers hardness. However, when the content of K2O is too large, the viscosity at which phase separation occurs is liable to lower. In addition, there is a tendency that the acid resistance lowers, and the glass composition loses its component balance, with the result that the devitrification resistance lowers contrarily. Thus, a suitable lower limit range of the content of K2O is 0% or more, 0.01% or more, 0.02% or more, 0.1% or more, 0.5% or more, 1% or more, 1.5% or more, 2% or more, 2.5% or more, or 3% or more, particularly 3.5% or more, and a suitable upper limit range thereof is 5.5% or less, or 5% or less, particularly less than 4.5%.
Li2O is an ion exchange component, and is also a component that lowers the viscosity at high temperature to increase the meltability and the formability. Further, Li2O is a component that increases the Young's modulus. A suitable lower limit range of the content of Li2O is 0% or more, 0.0001% or more, 0.01% or more, 1% or more, 2% or more, 2.5% or more, or 2.8% or more, and a suitable upper limit range of the content of Li2O is 10% or less, 5% or less, 4.5% or less, 2% or less, 1% or less, less than 1%, 0.5% or less, 0.3% or less, 0.1% or less, or 0.05% or less.
MgO is a component that lowers the viscosity at high temperature to increase the meltability and the formability. In addition, MgO is also a component that increases the Young's modulus to increase the Vickers hardness, and increases the acid resistance. Thus, a suitable lower limit range of the content of MgO is 0% or more, 0.1% or more, 0.5% or more, 1% or more, 1.5% or more, particularly 2% or more. However, when the content of MgO is too large, there is a tendency that the ion exchange rate is liable to lower, and the glass is liable to devitrify. In particular, when a sheet shape is formed by an overflow down-draw method through use of an alumina refractory as a forming body refractory, a devitrified crystal of spinel is liable to be deposited at an interface between the glass and the alumina refractory. Thus, a suitable upper limit range of the content of MgO is 5.5% or less, 4.5% or less, 4% or less, 3.5% or less, or 3% or less, particularly 2.5% or less.
P2O5 is a component that increases the ion exchange rate while maintaining a compressive stress value. Thus, a suitable lower limit range of the content of P2O5 is 2% or more, 2.1% or more, 2.5% or more, 3% or more, or 4% or more, particularly 4.5% or more. However, when the content of P2O5 is too large, white turbidity resulting from phase separation occurs in the glass, and the water resistance is liable to lower. Thus, a suitable upper limit range of the content of P2O5 is 10% or less, 8.5% or less, 8% or less, 7.5% or less, 7% or less, 6.5% or less, 6.3% or less, 6% or less, 5.9% or less, 5.7% or less, 5.5% or less, 5.3% or less, or 5.1% or less, particularly 5% or less.
As a fining agent, one kind or two or more kinds selected from the group consisting of Cl, SO3, and CeO2 (preferably the group consisting of Cl and SO3) may be added at from 0% to 3%.
SnO2 has an effect of enhancing the ion exchange performance. Thus, the content of SnO2 is preferably from 0% to 3%, from 0.01% to 3%, from 0.05% to 3%, particularly from 0.1% to 3%, particularly preferably from 0.2% to 3%.
The content of Fe2O3 is preferably less than 1,000 ppm (less than 0.10), less than 800 ppm, less than 600 ppm, or less than 400 ppm, particularly preferably less than 300 ppm. With this configuration, the transmittance (400 nm to 770 nm) of glass having a thickness of 1 mm is easily improved.
A rare earth oxide, such as Nb2O5 or La2O3, is a component that enhances the Young's modulus. However, the cost of the raw material itself is high, and when the rare earth oxide is added in a large amount, the devitrification resistance is liable to lower. Thus, the content of the rare earth oxide is preferably 3% or less, 2% or less, 1% or less, or 0.5% or less, particularly preferably 0.1% or less.
In addition, it is preferred that the glass to be tempered be substantially free of As2O3, Sb2O3, and PbO as a glass composition from the standpoint of environmental considerations. In addition, it is also preferred that the glass to be tempered be substantially free of Bi2O3 and F from the standpoint of environmental considerations.
It is more preferred that the glass to be tempered comprise as a glass composition, in terms of mass %, 40% to 70% of SiO2, 10% to 30% of Al2O3, 0.1% to 3% of B2O3, 5% to 25% of Na2O, 1% to 5.5% of K2O, 0.01% to 10% of Li2O, 0.1% to 5.5% of MgO, 2% to 10% of P2O3, and 0.01% to 3% of SnO2.
The composition of the glass to be tempered described above is an example, and a glass to be tempered having a known composition may be used as long as the glass can be chemically tempered by ion exchange. In addition, the composition of the tempered glass to be obtained by subjecting the above-mentioned glass to be tempered to ion exchange treatment is similar to the composition of the glass to be tempered before the ion exchange treatment.
The glass to be tempered may be produced as described below.
First, glass raw materials, which have been blended so as to have the above-mentioned glass composition, are loaded in a continuous melting furnace, are melted by heating at from 1,500° C. to 1,600° C., and are fined. After that, the resultant is fed to a forming apparatus, is formed into, for example, a sheet shape, and is annealed. Thus, the glass to be tempered can be produced.
An overflow down-draw method is preferably adopted as a method of forming the glass sheet. The overflow down-draw method is a method by which a high-quality glass sheet can be produced in a large amount, and by which even a large-size glass sheet can be easily produced. In addition, the method allows scratches on the surface of the glass sheet to be reduced to the extent possible. In the overflow down-draw method, alumina or dense zircon is used as a forming body. The glass to be tempered according to the present invention has satisfactory compatibility with alumina or dense zircon, in particular, alumina (hardly produces bubbles, stones, and the like through a reaction with the forming body).
Various forming methods other than the overflow down-draw method may also be adopted. For example, forming methods such as a float method, a down draw method (such as a slot down method or a re-draw method), a roll out method, and a press method may be adopted.
Bending processing may be performed as required after the forming of the glass to be tempered, or simultaneously with the forming. In addition, processing such as cutting processing, boring processing, surface polishing processing, chamfering processing, end surface polishing processing, or etching processing may be performed as required.
The dimensions of the glass to be tempered may be arbitrarily set, but the thickness T is preferably 2.0 mm or less, more preferably 1.0 mm or less, still more preferably from 0.3 mm to 0.9 mm.
The glass to be tempered obtained as described above is subjected to the ion exchange treatment a plurality of times. In this embodiment, description is given by taking a case in which the ion exchange treatment is performed three times as an example. Specifically, in a method of producing the tempered glass according to this embodiment, as illustrated in
In the first ion exchange step S1, the ion exchange treatment of the surface of the glass to be tempered is performed by: immersing the glass to be tempered in a treatment tank filled with a first molten salt containing a second alkali metal ion a2 having a larger ionic radius than a first alkali metal ion a1 contained in the glass to be tempered; and holding the glass to be tempered at a predetermined temperature for a predetermined time. Thus, the first alkali metal ion a1 contained in the glass to be tempered and the second alkali metal ion a2 contained in the first molten salt m1 are subjected to ion exchange to introduce the second alkali metal ion a2 to a depth of 10.5% or more of the thickness T from the surface (in this embodiment, main surfaces and end surfaces) of the glass to be tempered. As a result, a compressive stress layer is formed in a surface layer portion of the glass to be tempered, and thus the glass to be tempered is tempered.
In the first ion exchange step S1, the first alkali metal ion a1 is a desorbed ion to be desorbed from the glass to be tempered, and the second alkali metal ion a2 is an introduced ion to be introduced into the glass to be tempered.
In the first ion exchange step S1, a region in which the second alkali metal ion a2 is introduced into the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 12% or more of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 13.5% or more and 30% or less of the thickness T.
The first molten salt m1 comprises, as a main component, a mixed salt of: the nitrate of a first alkali metal ion a1 that is incorporated in advance into the composition of the glass to be tempered, and that is desorbed in the ion exchange; and the nitrate of a second alkali metal ion a2 introduced into the glass to be tempered by the ion exchange. In this embodiment, a case in which the first alkali metal ion a1 is a Na ion and the second alkali metal ion a2 is a K ion is described. That is, in this embodiment, the first molten salt m1 is a mixed salt comprising NaNO3 and KNO3 as main components. The first molten salt m1 is not limited thereto, and may be, for example, a molten salt formed only of KNO3.
A KNO3 concentration in the first molten salt m1 is preferably higher than a NaNO3 concentration in the first molten salt m1. Specifically, the NaNO3 concentration is preferably less than 50 mass %, more preferably from 5 mass % to 40 mass %. The KNO3 concentration is preferably 50 mass % or more, more preferably from 60 mass % to 95 mass %.
In the second ion exchange step S2, the ion exchange treatment of the surface of the glass to be tempered is performed by: immersing the glass to be tempered that has been subjected to the first ion exchange step S1 in a treatment tank filled with a second molten salt m2 containing the first alkali metal ion a1; and holding the glass to be tempered at a predetermined temperature for a predetermined time. Thus, the second alkali metal ion a2 contained in the glass to be tempered and the first alkali metal ion a1 contained in the second molten salt m2 are subjected to ion exchange to desorb, from the glass to be tempered, at least part the second alkali metal ion a2 in a region ranging from the surface (in this embodiment, main surfaces and end surfaces) of the glass to be tempered and being shallower than 10% of the thickness T. As a result, the compressive stress of the compressive stress layer formed in the glass to be tempered is reduced. Meanwhile, a region in which the compressive stress layer is formed expands to a deep site in the glass to be tempered.
In the second ion exchange step S2, the second alkali metal ion a2 is a desorbed ion to be desorbed from the glass to be tempered, and the first alkali metal ion a1 is an introduced ion to be introduced into the glass to be tempered.
In the second ion exchange step S2, a region in which the second alkali metal ion a1 is desorbed from the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 9% or less of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 4% or more and 8% or less of the thickness T.
The second molten salt m2 comprises, as a main component, a mixed salt of: the nitrate of a second alkali metal ion a2 that is incorporated in advance into the composition of the glass to be tempered, and that is desorbed in the ion exchange; and the nitrate of a first alkali metal ion a1 introduced into the glass to be tempered by the ion exchange. That is, in this embodiment, the second molten salt m2 is a mixed salt comprising NaNO3 and KNO3 as main components. The second molten salt m2 is not limited thereto, and may be, for example, a molten salt formed only of NaNO3.
A NaNO3 concentration in the second molten salt m2 is preferably higher than a KNO3 concentration in the second molten salt m2. Specifically, the NaNO3 concentration is preferably 60 mass % or more, more preferably from 70 mass % to 95 mass %. The KNO3 concentration is preferably 40 mass % or less, more preferably from 5 mass % to 30 mass %.
In the third ion exchange step S3, the ion exchange treatment of the surface of the glass to be tempered is performed by: immersing the glass to be tempered that has been subjected to the second ion exchange step S2 in a treatment tank filled with a third molten salt m3 containing the second alkali metal ion a2; and holding the glass to be tempered at a predetermined temperature for a predetermined time. Thus, the first alkali metal ion a1 contained in the glass to be tempered and the second alkali metal ion a2 contained in the first molten salt m1 are subjected to ion exchange to introduce the second alkali metal ion a2 to a region ranging from the surface (in this embodiment, main surfaces and end surfaces) of the glass to be tempered and being shallower than 7% of the thickness T. As a result, the glass to be tempered is tempered again, and the compressive stress layer 2 having a high compressive stress can be formed in the vicinity of the surface in the surface layer portion. At this time, the compressive stress layer 2 is maintained in a state of expanding to some degree of depth.
In the third ion exchange step S3, the first alkali metal ion a1 is a desorbed ion to be desorbed from the glass to be tempered, and the second alkali metal ion a2 is an introduced ion to be introduced into the glass to be tempered.
In the third ion exchange step S3, a region in which the second alkali metal ion a2 is introduced into the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 6% or less of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 1% or more and 5% or less of the thickness T.
A KNO3 concentration in the third molten salt m3 is preferably higher than a NaNO3 concentration in the third molten salt m3.
The NaNO3 concentration in the third molten salt m3 is preferably lower than the NaNO3 concentration in the first molten salt m1. Specifically, the NaNO3 concentration in the third molten salt m3 is preferably 10 mass % or less, more preferably from 0 mass % to 5 mass %, still more preferably from 0.1 mass % to 5 mass %.
The KNO3 concentration in the third molten salt m3 is preferably higher than the KNO3 concentration in the first molten salt m1. Specifically, the KNO3 concentration in the third molten salt m3 is preferably 90 mass % or more, more preferably from 95 mass % to 100 mass %, still more preferably from 95 mass % to 99.5 mass %.
In this embodiment, the third molten salt m3 is a molten salt formed only of KNO3. However, the third molten salt m3 is not limited thereto, and may be, for example, a mixed salt containing NaNO3 and KNO3 as main components.
The content ratio of an alkali metal ion having a small ionic radius (e.g., a Li ion or a Na ion, in particular, a Na ion) in the third molten salt m3 is preferably smaller than that in the first molten salt m1. With this configuration, it becomes easier to increase the concentration of a large alkali metal ion in the outermost surface while increasing the depth of layer. The sizes of alkali metal ions satisfy the following relationship: Li ion<Na ion<K ion (potassium ion)<Ce ion<Rb ion.
An ion exchange treatment temperature in the first ion exchange step S1 and an ion exchange treatment temperature in the second ion exchange step S2 are preferably higher than an ion exchange treatment temperature in the third ion exchange step S3. The ion exchange treatment temperature means the temperature of the molten salt.
Specifically, the ion exchange treatment temperature in each of the first ion exchange step S1 and the second ion exchange step S2 is preferably 420° C. or more, more preferably 430° C. or more, still more preferably from 440° C. to 500° C. The ion exchange treatment temperature in the first ion exchange step S1 is preferably higher than the ion exchange treatment temperature in the second ion exchange step S2. A difference between the ion exchange treatment temperatures in the first ion exchange step S1 and the second ion exchange step S2 is preferably 5° C. or more, more preferably from 5° C. to 50° C. The ion exchange treatment temperature in the first ion exchange step S1 is more preferably from 440° C. to less than 490° C., still more preferably from 450° C. to 470° C. The ion exchange treatment temperature in the second ion exchange step S2 is more preferably from 400° C. to 480° C., still more preferably from 420° C. to 460° C.
An ion exchange treatment temperature in the third ion exchange step S3 is lower than the ion exchange treatment temperature in the first ion exchange step S1 by preferably 10° C. or more, 20° C. or more, 30° C. or more, or 30° C. or more, particularly preferably 50° C. or more. Specifically, the ion exchange treatment temperature in the third ion exchange step S3 is preferably from 350° C. to less than 410° C. or from 360° C. to less than 400° C., particularly preferably from 380° C. to less than 400° C.
Anion exchange treatment time in each of the first ion exchange step S1 and the second ion exchange step S2 is preferably 3 or more times, more preferably 5 or more times, still more preferably from 10 times to 200 times as long as an ion exchange treatment time in the third ion exchange step S3.
The ion exchange treatment time in each of the first ion exchange step S1 and the second ion exchange step S2 is preferably 2 hours or more, more preferably 3 hours or more, still more preferably from 4 hours to 20 hours. When the ion exchange treatment times in the first ion exchange step S1 and the second ion exchange step S2 are lengthened, the compressive stress layer can be formed so as to be deep. Accordingly, the treatment times are preferably lengthened to the extent that productivity does not lower. The ion exchange treatment time in the first ion exchange step S1 is preferably longer than the ion exchange treatment time in the second ion exchange step S2. A difference between the ion exchange treatment times in the first ion exchange step S1 and the second ion exchange step S2 is preferably 2 hours or more, more preferably from 3 hours to 7 hours.
The ion exchange treatment time in the third ion exchange step S3 is preferably 2 hours or less, more preferably 3 hours or less, from 0.2 hour to 2 hours, from 0.3 hour to 1 hour, or from 0.3 hour to 0.5 hour. When the total time of the ion exchange treatments is controlled to be short, the tensile stress in the tensile stress layer 3 is easily controlled to a small value.
The glass to be tempered that is immersed in the molten salt in each of the ion exchange steps S1 to S3 may be preheated to the temperature of the molten salt in the ion exchange treatment of each ion exchange step in advance, or may be immersed in each molten salt while being in a normal temperature (e.g., from 1° C. to 40° C.) state.
A washing step of washing the glass to be tempered that has been drawn out of the molten salt is preferably provided between the first ion exchange step S1 and the second ion exchange step S2, and/or between the second ion exchange step S2 and the third ion exchange step S3. When the washing is performed, it becomes easier to remove a deposit adhering to the glass to be tempered, and hence the ion exchange treatment can be more uniformly performed in the second ion exchange step S2 and/or the third ion exchange step S3.
The tempered glass 1 having the above-mentioned characteristics can be obtained by appropriately adjusting the treatment times and the treatment temperatures in the condition ranges of the first to third ion exchange steps S1 to S3 described above.
After the third ion exchange step S3, various kinds of processing, such as cutting processing, boring processing, surface polishing processing, chamfering processing, end surface polishing processing, etching processing, and film formation processing, may each be performed.
In addition, in the above-mentioned embodiment, an example in which the first to third ion exchange steps including two tempering steps and one relaxing step are performed has been described. However, two or four or more ion exchange steps including at least two tempering steps may be performed.
In the first embodiment, a method by which the tempered glass 1 is obtained through three ion exchange treatments has been given as an example. In a second embodiment, a method by which the tempered glass 1 is obtained through two ion exchange treatments is given as an example. Specifically, in a method of producing the tempered glass according to this embodiment, as illustrated in
In the first ion exchange step T1, the ion exchange treatment of the surface of the glass to be tempered is performed by: immersing the glass to be tempered in a treatment tank filled with a first molten salt n1 containing a second alkali metal ion b2 having a larger ionic radius than a first alkali metal ion b1 contained in the glass to be tempered; and holding the glass to be tempered at a predetermined temperature for a predetermined time. Thus, the first alkali metal ion b1 contained in the glass to be tempered and the second alkali metal ion b2 contained in the first molten salt n1 are subjected to ion exchange to introduce the second alkali metal ion b2 in the vicinity of the surface (in this embodiment, main surfaces and end surfaces) of the glass to be tempered. As a result, a compressive stress layer is formed in a surface layer portion of the glass to be tempered, and thus the glass to be tempered is tempered.
In the first ion exchange step T1, the first alkali metal ion b1 is a desorbed ion to be desorbed from the glass to be tempered, and the second alkali metal ion b2 is an introduced ion to be introduced into the glass to be tempered.
In the first ion exchange step T1, a region in which the second alkali metal ion b2 is introduced into the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 10% or more of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 12% or more, 14% or more, 15% or more, or 15% or more and 40% or less of the thickness T.
In the second ion exchange step T2, the ion exchange treatment of the surface of the glass to be tempered is performed by: immersing the glass to be tempered in a treatment tank filled with a second molten salt n2 containing a third alkali ion b3, which has a larger ionic radius than the second alkali metal ion b2 contained in the glass to be tempered, and the first alkali metal ion b1; and holding the glass to be tempered at a predetermined temperature for a predetermined time. Thus, the first alkali metal ion b1 is subjected to reverse ion exchange with the second alkali metal ion b2 contained in the glass to be tempered, to desorb at least part of the second alkali metal ion b2 from the glass to be tempered. Simultaneously with this, the third alkali metal ion b3 is subjected to ion exchange with the first alkali metal ion b1 or the second alkali metal ion b2 contained in the glass to be tempered, to introduce the third alkali metal ion b3 into the tempered glass to a region ranging from the surface and being shallower than 7% of the thickness T. That is, while the compressive stress formed in the surface layer portion of the glass to be tempered is relaxed through the reverse ion exchange, the glass to be tempered is tempered through the ion exchange, with the result that a high compressive stress is formed only in the vicinity of the surface in the surface layer portion.
In the second ion exchange step T2, a region in which the second alkali metal ion b2 is desorbed from the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 15% or less of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 14% or less, 13% or less, 12% or less, 11% or less, 10% or less, 1% or more and 10% or less, 2% or more and 10% or less, 3% or more and 10% or less, 4% or more and 10% or less, or 5% or more and 10% or less of the thickness T. In addition, in the second ion exchange step T2, a region in which the third alkali metal ion b3 is introduced into the glass to be tempered is preferably a region ranging from the surface of the glass to be tempered to a depth of 7% or less of the thickness T, more preferably a region ranging from the surface of the glass to be tempered to a depth of 6.5% or less, 6% or less, 5.5% or less, or 5% or less of the thickness T.
The tempered glass 1 having the above-mentioned characteristics can be obtained by appropriately adjusting the treatment times and the treatment temperatures in the condition ranges of the first and second ion exchange steps T1 and T2 described above.
In this connection, in the second ion exchange step T2, the rate of the above-mentioned reverse ion exchange is larger than the rate of the above-mentioned ion exchange, and hence the relaxation of the compressive stress in the surface layer portion first progresses to a deep site, and then a compressive stress is formed in the surface again. Accordingly, in the stress profile of the produced tempered glass 1, the first bottom B1 as shown in
After the second ion exchange step T2, various kinds of processing, such as cutting processing, boring processing, surface polishing processing, chamfering processing, end surface polishing processing, etching processing, and film formation processing, may each be performed.
In the second embodiment, the first alkali metal ion b1 is preferably a Li ion, the second alkali metal ion b2 is preferably a Na ion, and the third alkali metal ion b3 is preferably a K ion.
In particular, when the glass to be tempered is a lithium aluminosilicate glass comprising, in terms of mass %, 2% or more of Li2O and 5% or more of Na2O, a molten salt formed only of NaNO3 or a mixed salt containing NaNO3 and KNO3 as main components may be used as the first molten salt n1. The first molten salt n1 may contain LiNO3. In this case, the Li2O content of the glass to be tempered is preferably from 2.5 mass % to 5.0 mass %, more preferably from 2.8 mass % to 4.5 mass %.
In the second embodiment, it is preferred that the glass to be tempered comprise as a glass composition, in terms of mass %, 48% to 60% of SiO2, 21% to 29% of Al2O3, 0% to 10% of B2O3, 2% to 11% of Li2O, 5% to 20% of Na2O, 0% to 10% of K2O, 0% to 6% of MgO, 0% to 10% of ZnO, and 0% to 20% of P2O3.
In the second embodiment, the first molten salt n1 to be used in the first ion exchange step T1 is preferably a mixed salt of NaNO3 and KNO3. The first molten salt n1 containing a K ion is suitable for the control of the quality of the tempered glass to be obtained because it becomes easy to measure the stress of the glass to be tempered and the distribution thereof after the first ion exchange step T1. A NaNO3 concentration in the first molten salt n1 is, in terms of mass %, preferably from 100% to 20%, from 100% to 30%, from 100% to 40%, from 100% to 50%, or from 100% to 60%, and the balance is preferably KNO3. The NaNO3 concentration in the first molten salt n1 is preferably higher than a KNO3 concentration in the first molten salt n1. The first molten salt n1 may be configured to contain only NaNO3, and not to contain KNO3. An ion exchange treatment temperature in the first ion exchange step T1 is preferably from 350° C. to 480° C., more preferably from 360° C. to 430° C., still more preferably from 370° C. to 400° C., or from 370° C. to 390° C. An ion exchange treatment time in the first ion exchange step T1 is preferably from 1 hour to 20 hours, more preferably from 1.5 hours to 15 hours, still more preferably from 2 hours to 10 hours.
In the second embodiment, the second molten salt n2 to be used in the second ion exchange step T2 is preferably a mixed salt of LiNO3 and KNO3. A LiNO3 concentration in the second molten salt n2 is preferably lower than a KNO3 concentration in the second molten salt n2. Specifically, the LiNO3 concentration in the second molten salt n2 is, in terms of mass %, preferably from 0.1% to 5%, from 0.2% to 5%, from 0.3% to 5%, from 0.4% to 5%, from 0.5% to 5%, from 0.5% to 4%, from 0.5% to 3%, from 0.5% to 2.5%, from 0.5% to 2%, or from 1% to 2%, and the balance is preferably KNO3. In addition, a Li ion concentration in the second molten salt is preferably 100 ppm by mass or more. In this case, the Li ion concentration in the second molten salt n2 is determined by multiplying LiNO3 expressed in mass % by 0.101. An ion exchange treatment temperature in the second ion exchange step T2 is preferably from 350° C. to 480° C., more preferably from 360° C. to 430° C., still more preferably from 370° C. to 400° C., or from 370° C. to 390° C. An ion exchange treatment time in the second ion exchange step T2 is preferably shorter than the ion exchange treatment time in the first ion exchange step T1. The ion exchange treatment time in the second ion exchange step T2 is preferably 0.2 hour or more, more preferably from 0.3 hour to 2 hours, or from 0.4 hour to 1.5 hours, still more preferably from 0.5 hour to 1 hour.
Some embodiments of the present invention have been described above. Of course, however, the present invention is not limited to those embodiments, and various other embodiments are possible within the scope of the present invention.
For example, in each of the first and second embodiments described above, an example in which the tempered glass 1 comprises the compressive stress layer 2 on each of both front and back main surface 1a sides and the end surface 1b sides has been described. However, the tempered glass 1 may comprise the compressive stress layer 2 only in part of the surface layer portion thereof, and for example, may comprise the compressive stress layer 2 only on one main surface 1a side. As a method of forming the compressive stress layer 2 only in part of the surface layer portion of the tempered glass 1, there is given, for example, a method comprising: forming in advance a suppressive film (e.g., a SiO2 film), which is configured to suppress the permeation of an introduced ion in ion exchange treatment, in a region of the glass to be tempered in which the compressive stress layer is not to be formed; and locally performing ion exchange treatment on part of the glass to be tempered free of the suppressive film.
In addition, in each of the above-mentioned embodiments, the tempered glass 1 has a flat sheet shape. However, the concept of sheet shape in the present invention also encompasses the form of a curved sheet shape having a curved surface.
The tempered glass according to the present invention is hereinafter described based on Examples. The following Examples are merely illustrative. The present invention is by no means limited to these Examples.
A sample was produced as described below. First, glasses to be tempered having compositions A to T shown in Tables 1 and 2 as glass compositions were prepared.
For each composition, glass raw materials were blended, and were melted with a platinum pot at 1,600° C. for 21 hours. After that, the resultant molten glasses were subjected to flow-down forming from a refractory forming body by using an overflow down-draw method to be formed into sheet shapes having predetermined thicknesses shown in Tables 3 to 18.
Next, the glasses to be tempered were subjected to ion exchange treatments by being immersed in molten salt baths under conditions shown in Tables 3 to 18 to provide sheet-shaped tempered glasses. With regard to the molten salt baths, in a step marked with “NaNO3/KNO3”, a weight concentration ratio between NaNO3 and KNO3 in a molten salt was adjusted to concentrations shown in the tables by adding a NaNO3 molten salt to a KNO3 molten salt. With regard to the molten salt baths, in a step marked with “LiNO3/KNO3”, a weight concentration ratio between LiNO3 and KNO3 in a molten salt was adjusted to concentrations shown in the tables by adding a LiNO3 molten salt to a KNO3 molten salt.
Samples Nos. 1 to 10 were each subjected to a total of three ion exchange treatments, that is, a first ion exchange step (tempering step), a second ion exchange step (relaxing step), and a third ion exchange step (tempering step). Meanwhile, Sample No. 11 was subjected to a total of one ion exchange treatment, that is, only the first ion exchange step (tempering step), and Samples Nos. 12 to 160 were each subjected to a total of two ion exchange treatments, that is, the first ion exchange step (tempering step) and the second ion exchange step (tempering step). Samples Nos. 1 to 10 and Nos. 13 to 160 are Examples of the present invention, and Samples Nos. 11 and 12 are Comparative Examples.
Various characteristics and strength test results of the tempered glasses thus obtained, which were measured as described below, are shown in Tables 3 to 18.
First, the stress profile of each of the samples was measured. The stress profile of each of Samples Nos. 1 to 10 and Nos. 13 to 160 was measured with a surface stress meter FSM-6000LE and SLP-1000 manufactured by Orihara Industrial Co., Ltd. Measurement results were synthesized using a data synthesis application pmc preloaded on the above-mentioned apparatus to yield a retardation profile. The coverage of each set of data in the synthesis was set as follows: from the surface to 10 μm for FSM-6000LE; and 30 μm or more from the surface for SLP-1000. A stress profile was determined from the yielded retardation profile through such analysis as described below. First, initial values were set as shown in the following table, and the following expression R(x) at each depth x in the yielded retardation profile was calculated. In this case, the following setting was adopted: Δ=0.01 [um]. The sum of squared differences between the R(x) and the yielded retardation profile was calculated, and various variables A1, A2, A3, B1, B2, B3, and C1 were set so that the sum of squared differences became minimum. More specifically, with use of “GRG Nonlinear” as a solving method in the Solver function of Excel, approximation was performed by applying ranges and restriction conditions to the various variables in accordance with the following table. The approximation calculation was repeated until a correlation coefficient between the R(x) and the retardation profile exceeded 0.9995. When the correlation coefficient did not reach 0.9995, measurement with SLP-1000 was performed a plurality of times, and the analysis was performed using averaged measurement data from the plurality of times of measurement. The following expression σ(x) expressed using the various variables obtained as described above was adopted as the stress profile. The stress profile of each of Sample No. 11 and Sample No. 12 was measured with the surface stress meter FSM-6000LE manufactured by Orihara Industrial Co., Ltd. An optical elastic constant C [nm/cm/MPa] was measured for each sample by using an optical heterodyne interference method, more specifically, by using PEL-3A-XR manufactured by Uniopt Co., Ltd. An apparatus constant k is a constant calculated in SLP-1000 by inputting the refractive index of each sample into the apparatus, more specifically, a value obtained by dividing a kDP value described in a measurement result file by a stress calibration coefficient. The refractive index was measured for each sample by using a V-block method, more specifically, by using KPR-2000 manufactured by Shimadzu Corporation.
σ(x)=A1erfc(B1·x)+A2·erfc(B2·x)+A3·erfc(B3·x)+C1
Examples from the measured stress profiles are shown in
Characteristics shown in Tables 3 to 18 were calculated on the basis of the stress profiles measured as described above.
In Tables 3 to 18, CSmax represents the stress at the first peak P1, that is, the maximum compressive stress in the compressive stress layer 2. CTmax represents the stress at the second bottom B2, that is, the minimum tensile stress in the tensile stress layer 3. CSb represents the stress (local minimum value) at the first bottom B1, and DOLb represents the depth of the first bottom. B1. CSp represents the stress (local maximum value) at the second peak P2, and DOLp represents the depth of the second peak P2. DOLzero represents the depth of a point at which the stress becomes zero between the second peak P2 and the second bottom B2.
The simulated casing drop strength represents, as illustrated in
Next, the sandpaper 30 is bonded to the other main surface (main surface on the opposite side to the main surface bonded to the simulated casing) of the glass sample 20 so that a surface (surface on which an abrasive material is arranged) of the sandpaper 30 abuts thereon. The sandpaper 30 has the dimensions of a width of 60 mm and a length of 120 mm, and is placed at the central portion of the other main surface of the glass sample 20. At this time, the sandpaper 30 is placed so that peripheral edge portions of the glass sample 20 may project from the sandpaper 30. The thus projecting peripheral edge portions of the back surface (surface on which the abrasive material is not arranged) of the glass sample 20 are bonded to both end portions of the sandpaper 30 at a plurality of sites with a plurality of plastic tape pieces 60, to thereby bond the sandpaper 30 to the glass sample 20. The plastic tape pieces 60 each measure 19 mm wide by 10 mm long by 0.1 mm thick, and the bonded sites are the respective central portions of the short sides of the sandpaper 30. SiC SANDPAPER P180, P120, P100, and P80, different from each other in abrasive grain coarseness (grain size), manufactured by Riken Corundum Co., Ltd. were each used as the sandpaper 30, and the simulated casing drop strength was measured for each case.
The test body thus obtained was held in a horizontal posture so that the sandpaper 30 was directed downward, and the test body was repeatedly dropped toward the surface plate 40 while a drop height was raised until the glass sample 20 broke. In more detail, in the present application, a test was performed by: clamping the test body with a clamping part formed of an air cylinder; starting the dropping of the test body together with the clamping part; and releasing the clamping with the air cylinder at a position 20 cm above the surface plate 40 to drop the test body toward the surface plate 40 while causing the test body to maintain the horizontal posture. The sandpaper 30 was replaced with a new one every time one drop test was performed. The drop height was set as follows: the drop height was measured with respect to a height of 20 cm from the drop surface, and when the glass sample 20 did not break, the drop height was raised by 10 cm.
All Examples for each of which the simulated casing drop strength was measured (e.g., Samples No. 1 to No. 4) had higher simulated casing drop strengths than Comparative Examples (Samples Nos. 11 and 12), and hence were recognized to have high impact resistances.
In addition, those simulated casing drop strengths were recognized to have some degree of correlation with the following calculated strength.
∫0TP(x)·σf(x)dx
In the expression, P(x) represents the probability density function of a flaw having a depth x generated in the drop test, and σf (x) represents the following sum of a stress intensity factor and a compressive stress value.
In the equation, Kc represents the breaking toughness value of mother glass, and σ(x) represents a compressive stress value at the depth x generated by tempering. The depth of the flaw generated in the drop test was sequentially observed to determine the P(x) and the calculated strength, and the correlation thereof with the breaking height in the simulated casing drop test was as shown in a graph shown in
In the tempered glass of the present invention, the calculated strength for P180 is preferably 35 MPa or more, more preferably from 40 MPa to 200 MPa. In addition, the calculated strength for P120 is preferably 10 MPa or more, more preferably from 20 MPa to 150 MPa. The calculated strength for P100 is preferably 5 MPa or more, more preferably from 10 MPa to 100 MPa. The calculated strength for P80 is preferably −13 MPa or more, more preferably from −10 MPa to 50 MPa.
The tempered glass of the present invention may be utilized as apart for, for example, a cellular phone (in particular, a smartphone), a tablet computer, a digital camera, a touch panel display, or a large-screen television.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-191054 | Oct 2018 | JP | national |
| 2018-231539 | Dec 2018 | JP | national |
| 2018-240718 | Dec 2018 | JP | national |
| 2019-096352 | May 2019 | JP | national |
| 2019-096572 | May 2019 | JP | national |
| 2019-144811 | Aug 2019 | JP | national |
| 2019-164611 | Sep 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/039632 | 10/8/2019 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2020/075708 | 4/16/2020 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 9054250 | Murata | Jun 2015 | B2 |
| 20100009154 | Allan et al. | Jan 2010 | A1 |
| 20100167091 | Tachiwana et al. | Jul 2010 | A1 |
| 20120321898 | Meinhardt et al. | Dec 2012 | A1 |
| 20130224492 | Bookbinder et al. | Aug 2013 | A1 |
| 20140370264 | Ohara et al. | Dec 2014 | A1 |
| 20160023944 | Bookbinder et al. | Jan 2016 | A1 |
| 20160122239 | Amin et al. | May 2016 | A1 |
| 20160347655 | Meinhardt et al. | Dec 2016 | A1 |
| 20170197876 | Oram et al. | Jul 2017 | A1 |
| 20170217824 | Ohara et al. | Aug 2017 | A1 |
| 20170295657 | Gross et al. | Oct 2017 | A1 |
| 20170297956 | Bookbinder et al. | Oct 2017 | A1 |
| 20170341973 | Gross et al. | Nov 2017 | A1 |
| 20170355640 | Oram et al. | Dec 2017 | A1 |
| 20180037498 | Ohara et al. | Feb 2018 | A1 |
| 20180044232 | Ohara et al. | Feb 2018 | A1 |
| 20180105461 | Schneider | Apr 2018 | A1 |
| 20180186685 | Murayama et al. | Jul 2018 | A1 |
| 20190016627 | Li | Jan 2019 | A1 |
| 20190161386 | Gross et al. | May 2019 | A1 |
| 20190276355 | Meinhardt et al. | Sep 2019 | A1 |
| 20200109083 | Imakita et al. | Apr 2020 | A1 |
| 20200156993 | Kinoshita et al. | May 2020 | A1 |
| Number | Date | Country |
|---|---|---|
| 2011-527661 | Nov 2011 | JP |
| 2011527661 | Aug 2012 | JP |
| 2015-511573 | Apr 2015 | JP |
| 2017-535498 | Nov 2017 | JP |
| 201733954 | Oct 2017 | TW |
| 2007142324 | Dec 2007 | WO |
| 2010005578 | Jan 2010 | WO |
| 2013088856 | Jun 2013 | WO |
| 2013130653 | Sep 2013 | WO |
| 2017123596 | Jul 2017 | WO |
| 2017126607 | Jul 2017 | WO |
| 2017177109 | Oct 2017 | WO |
| 2017218475 | Dec 2017 | WO |
| 2019004124 | Jan 2019 | WO |
| 2019021930 | Jan 2019 | WO |
| Entry |
|---|
| Taiwanese Office Action issued May 4, 2021 in the counterpart Taiwanese patent application No. 108136510 with the English translation of the Search Report. |
| Notice of Reasons for Refusal issued May 2, 2023 in corresponding Japanese Patent Application No. 2020-551165, with English language translation. |
| International Search Report issued Dec. 24, 2019 in International (PCT) Application PCT/JP2019/039632. |
| Office Action issued Sep. 6, 2022 in U.S. Appl. No. 17/417,523. |
| Office Action issued Mar. 29, 2022 in U.S. Appl. No. 17/417,523. |
| International Search Report issued Dec. 24, 2019 in International (PCT) Patent Application No. PCT/JP2019/039632. |
| International Preliminary Report on Patentability and Written Opinion of the International Searching Authority issued Apr. 8, 2021 in International (PCT) Patent Application No. PCT/JP2019/039632. |
| Request for the Submission of an Opinion issued Apr. 19, 2024 in corresponding Korean Patent Application No. 10-2021-7022729, with English translation. |
| Number | Date | Country | |
|---|---|---|---|
| 20210387904 A1 | Dec 2021 | US |
