Patent Grant
7169476
The present invention relates to a crystallized glass suitable for use as a substrate for reflectors (reflector substrate) for reflecting light from a light source lamp, and in particular, as a reflector substrate for illuminators or projector light sources.
In the light sources of projectors such as OHP (over head projectors) and liquid crystal projectors and in illuminators such as those used for spot illumination, reflectors are used for reflecting light that is emitted from light source lamps. The reflectors are members that are exposed to high temperatures resulting from the generation of heat by light source lamps such as ultra-high pressure mercury lamps, and are required to have a high heat resistance. Therefore, hitherto, reflectors have been used which comprise a reflector substrate composed of a heat-resisting glass having excellent heat resistance (e.g., PYREX (trademark) manufactured by Corning Glass Works) and having a reflective film formed on the substrate.
However, recently, the output and luminance of the light source lamps used for illuminators and projector light sources tend to be increased, and the level of heat resistance that is required is further enhanced. Under the circumstances, crystallized glasses that are superior to heat-resisting glasses in heat resistance are proposed as materials constituting reflector substrates.
For example, it has been proposed to use lithia-alumina-silica-based crystallized glasses (hereinafter sometimes referred to as “lithia-based crystallized glasses”) such as β-spodumene solid solution (β-spodumene: Li2O—Al2O3-4SiO2) and β-eucryptite solid solution (β-eucryptite: Li2O—Al2O3-2SiO2) (see, for example, JP-B-7-92527). Moreover, the inventors have also proposed using baria-alumina-silica-based crystallized glasses (hereinafter sometimes referred to as “baria-based crystallized glasses”) such as celsian (BaO—Al2O3-2SiO2) (see, for example, JP-A-2002-109923).
However, the lithia-based crystallized glass has such a problem in that it has a very small thermal expansion coefficient (JIS R1618: 40–400° C.) of about 0×10−7−20×10−7 (/° C.) and shows excellent heat resistance, but is inferior in meltability because of its high melting point of about 1500° C. or higher. Specifically, there are difficulties in that special equipment (such as a melting furnace) which can stand temperatures higher than 1500° C. are required for melting the glass and molding the glass to make the substrate for the reflector, which restricts the production conditions. On the other hand, the above-mentioned baria-based crystallized glass has a low melting point, namely, about 1450° C. and has no such high temperature production condition problems, but the thermal expansion coefficient (JIS R1618: 40—400° C.) is about 30×10−7−45×10−7 (/° C.), and further improvement is needed in the aspect of heat resistance.
The present invention has been made in order to solve the conventional technical problems and provides a crystallized glass which has a composition that is different from the above conventional crystallized glasses and has a higher efficiency, specifically a high heat resistance that is at least equivalent to that of baria-based crystallized glasses, preferably has excellent heat resistance equivalent to that of lithia-based crystallized glasses, has a low melting point like the baria-based glasses to provide good meltability.
As a result of intensive research conducted by the inventors, it has been found that the above object can be attained by including a specific modification component in a zinc oxide-alumina-silica-based crystallized glass, and the present invention has been accomplished. According to a first embodiment of the present invention, a zinc oxide-alumina-silica-based crystallized glass is provided, including zinc oxide (ZnO), alumina (Al2O3) and silica (SiO2) as main components, and zirconia (ZrO2) as a nucleating agent, wherein the main components comprise 20–30% by mass of zinc oxide, 15–25% by mass of alumina and 50–60% by mass of silica and the main components amount to 100% by mass in total. The nucleating agent is contained in an amount of 3–6 parts by mass based on 100 parts by mass of the main components. The composition also includes at least one component selected from the group consisting of lithium oxide (Li2O), sodium oxide (Na2O), potassium oxide (K2O), diphosphorus pentoxide (P2O5), niobium oxide (Nb2O5) and tantalum oxide (Ta2O5) as a modification component.
According to one aspect of the present invention, a crystalline phase is constituted of the main components and the main crystalline phase is a zinc petallite (Zn-petallite) solid solution or a β-quartz solid solution.
According to another aspect of the present invention, the modification component is included in an amount of 0.2–5.0 parts by mass based on 100 parts by mass of the main components.
According to yet another aspect of the present invention, tin dioxide is contained in place of apart of zirconia as the nucleating agent, and the content of tin dioxide is 0.5–4 parts by mass based on 100 parts by mass of the main components.
According to a second embodiment of the present invention, a reflector substrate is provided, which comprises a zinc oxide-alumina-silica-based crystallized glass according to any of the above-described aspects of the first embodiment and which has a main body having a concave for disposing a reflective film thereon and a metallic reticulate body embedded in the main body.
According to one aspect of the second embodiment of the present invention, the reticulate body comprises a metal mainly composed of at least one metal selected from the group consisting of nickel (Ni), cobalt (Co), stainless steel (SUS: Steel Use Stainless) and kobar.
According to a second aspect of the second embodiment of the present invention, the reticulate body comprises a metal mainly composed of at least one metal selected from the group consisting of gold (Au), platinum (Pt), silver (Ag) and copper (Cu) or has a surface film comprising the above metal.
The zinc oxide-alumina-silica-based crystallized glass (hereinafter sometimes referred to as “zinc oxide-based crystallized glass”) has a high heat resistance that is at least equivalent to that of baria-based crystallized glasses, an excellent heat resistance that is equivalent to that of lithia-based crystallized glasses depending on the conditions, and has a low melting point to provide good meltability like the baria-based glasses. Furthermore, it has superior crystal stability with a lapse of time under high temperature conditions compared to lithia-based crystallized glasses and exhibits an extremely small volumetric contraction even after being exposed to high temperatures for a long time.
a) is a side sectional view which shows a construction of the reflector substrate of the present invention.
b) is a side sectional view which shows a construction of the reflector substrate of the present invention.
c) is a side sectional view which shows a construction of the reflector substrate of the present invention.
The reference numerals shown in the drawings correspond to the features of the present invention as follows:
The best mode for carrying out the crystallized glass of the present invention will be specifically explained below, which should not be construed as limiting the invention in any manner.
The crystallized glass of the present invention is a zinc oxide-based crystallized glass containing zinc oxide, alumina and silica as main components, and zirconia as a nucleating agent, wherein the constitutional ratio of zinc oxide, alumina and silica as main components and the content of zirconia as the nucleating agent are controlled to specific values, and furthermore a specific modification component is contained in addition to the main components and the nucleating agent.
(1) Main Components
The crystallized glass of the present invention contains zinc oxide, alumina and silica as the main components. The crystal glass of such a system can be expected to have a low thermal expansion coefficient and excellent heat resistance.
In a zinc oxide-alumina-silica-based crystallized glass, a crystalline phase is constituted of zinc oxide, alumina and silica as the main components. The crystalline phase includes zinc petallite (Zn-petallite: a mixture of ZnO.Al2O3.3SiO2, ZnO.2SiO2, ZnO.Al2O3.8SiO2) solid solution, β-quartz (β-quartz: SiO2) solid solution, gahnite (gahnite: ZnO.Al2O3), willemite (willemite: 2ZnO.SiO2), etc., and the thermal expansion coefficient of zinc petallite solid solution, β-quartz solid solution and willemite are relatively low while the thermal expansion coefficient of gahnite is conspicuously high.
Therefore, the crystallized glass of the present invention preferably contains as little gahnite as its crystalline phase as possible, and more preferably, contains substantially no gahnite (contains substantially 0% by mass of gahnite), and especially preferably, the main crystalline phase is a zinc petallite solid solution or a β-quartz solid solution. The “main crystalline phase” in the present invention means a crystalline phase having the strongest peak intensity of diffraction X-ray measured by a powder X-ray diffractometer (e.g., trademark: RINT 2500 manufactured by Rigaku Denki Co., Ltd.) at room temperature (25° C.)
In order to specifically form a zinc petallite solid solution or β-quartz solid solution in a zinc oxide-alumina-silica-based crystallized glass, it is necessary to control the constitutional ratio of the zinc oxide, alumina and silica which are contained as main components (hereinafter referred to as “main component constitutional ratio”) to be a given value. Concretely, the zinc petallite solid solution or β-quartz solid solution specifically comprises the constitution shown by the part of oblique lines in the phase diagram of
Table 2 shows the results of the evaluation of the crystalline phase and the thermal expansion coefficient of the zinc oxide-alumina-silica-based crystallized glasses having the main component constitutional ratios shown by marks (I)— (VII) in the phase diagram of
Specifically, the crystalline phase was evaluated using a powder X-ray diffractometer having a rotating anode type target (Cu) and a graphite monochromator (trademark: RINT 2500 manufactured by Rigaku Denki Co., Ltd.) as a powder X-ray diffractometer under the conditions of X-ray source: CuKα ray, tube voltage: 50 kV, tube current: 30 mA, diffraction angle: 2θ=10°−40° and temperature: room temperature (25° C.). A crystalline phase having the strongest peak intensity of diffraction X-ray measured is taken as a main crystalline phase of the crystallized glass.
The thermal expansion coefficient was measured on a 3 mm×3 mm×20 mm sample cut out from the crystallized glass in the three temperature ranges of 40–400° C., 40–600° C. and 40–800° C. in accordance with the method of JIS R1618. The heat resistance was evaluated in the following manner. When a crystallized glass having a thermal expansion coefficient at 40–400° C. of not higher than that of lithia-based crystallized glass (not higher than 20×10−7 (/° C.)) was obtained, this is indicated by “∘”; when a crystallized glass having a thermal expansion coefficient at 40–400° C. of not higher than that of baria-based crystallized glass (not higher than 45×10−7 (/° C.)) was obtained, this is indicated by “Δ” and when a crystallized glass having a thermal expansion coefficient at 40–400° C. of more than that of baria-based crystallized glass (higher than 45×10−7 (/° C.)) was obtained, this is indicated by “x”.
Qu(Pe)
Qu(Pe,Wi)
Pe
Pe
Qu
Qu
Pe(Wi)
Pe(Wi)
Qu(Ga)
Pe(Qu, Wi, Ga)
Qu(Ga)
Qu(Pe,Wi)
Pe
Qu
Pe(Wi)
Qu(Ga)
Pe(Qu, Wi, Ga)
Qu(Ga, Wi)
As shown in Table 2, in the zinc oxide-alumina-silica-based crystallized glasses having the main component constitutional ratio shown by the marks (I)–(VII) in
As mentioned above, the zinc oxide-alumina-silica-based crystallized glasses in which the main components are constituted by 20–30% by mass of zinc oxide, 15–25% by mass of alumina and 50–60% by mass of silica, such that these components amount to 100% in total by mass, have a main crystalline phase of zinc petallite solid solution or β-quartz solid solution, and hence have a low thermal expansion coefficient and excellent heat resistance. Among them, the crystallized glass having a main component constitutional ratio employed in Reference Example 1 or 3 is preferred. The zinc oxide-alumina-silica-based crystallized glasses having the above main component constitutional ratios are preferred in that they have a very low thermal expansion coefficient and excellent heat resistance comparable to those of lithia-based crystallized glasses. In addition, they are semi-transparent glasses that exhibit less haze and easily transmit infrared rays, and hence hardly show a rising of the inner temperature due to heat accumulation in the case of being used as a reflector substrate. Furthermore, the resulting crystallized glasses are stably low in thermal expansion coefficient irrespective of the production conditions such as crystallizing temperature. Moreover, the crystallized glass having the main component constitutional ratio employed in Reference Example 1 is particularly preferred in that when made into reflector substrates, the difference between thermal expansion coefficient of the substrate and the reflective material to be vapor deposited thereon can be made small, and thus the occurrence of cracks in the reflective material can be effectively inhibited.
In comparison with the crystallized glass having a main component constitutional ratio employed in Reference Example 1 or 3, the crystallized glass having the main component constitutional ratio employed in Reference Example 5 has a somewhat higher thermal expansion coefficient and is somewhat inferior in heat resistance because gahnite is apt to be formed, and the crystallized glass having the main component constitutional ratio employed in Reference Examples 2 or 4 is a hazed white opaque glass and absorbs infrared light, and hence is apt to experience a rise of the inner temperature due to heat accumulation when used as a reflector substrate. Moreover, finding failures such as inner defects is difficult by visual examination. The crystallized glass having the main component constitutional ratio employed in Reference Examples 6 or 7 has the possibility that the thermal expansion coefficient varies greatly depending on the production conditions such as crystallizing temperature or the crystallization does not surely proceed.
It is needless to say that the crystallized glasses having these main component constitutional ratios also have a thermal expansion coefficient that is not higher than that of baria-based crystallized glass and have excellent heat resistance. It has been reported that even in the case of zinc oxide-alumina-silica-based crystallized glasses in which the main components are constituted of 20–30% by mass of zinc oxide, 15–25% by mass of alumina and 50–60% by mass of silica, those which contain no modification component mentioned hereinafter are low in melting point and insufficient in meltability although they are good in heat resistance. These crystallized glasses have a problem of being inferior in moldability. Therefore, for the crystallized glass of the present invention, it is an essential requirement for the crystallized glass to contain a specific modification component referred to hereinafter.
(2) Nucleating Agent
The crystallized glass of the present invention contains zirconia as a nucleating agent. The “nucleating agent” in this specification means a substance for acceleration of the precipitation of fine glass crystals.
Generally, titania (TiO2) or the like is contained as a nucleating agent for crystallized glass, while the nucleating agent in the crystallized glass of the present invention must contain zirconia. In a crystallized glass containing titania as a nucleating agent, gahnite having a very high thermal expansion coefficient is readily formed, the thermal expansion coefficient of the crystallized glass per se tends to increase and the crystallized glass is sometimes inferior in heat resistance. The crystallized glass containing zirconia as a nucleating agent is preferred because these problems are not caused.
Zirconia, as the nucleating agent, must be contained in an amount of 3–6 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, zirconia does not exhibit the effect as a nucleating agent and there is the possibility of insufficient glass crystallization, which is not preferred. If the content exceeds the above range, there is the possibility that melting the nucleating agent before crystallization becomes difficult, which is also not preferred.
The reflector substrate can be made from the crystallized glass of the present invention by preparing a glass raw material by mixing the main components, the nucleating agent and the modification component at a given ratio, melting the glass raw material to make molten glass, molding the molten glass to a desired shape, and subjecting the molded product to a heat treatment (crystallization treatment). During the steps of melting and molding of the glass raw material, devitrification phenomenon rarely occurs and an increase in the surface roughness of the molded product caused by recrystallization of zirconia as the nucleating agent rarely occurs.
The frequency of the occurrence of the above phenomena is not so high. However, the devitrification phenomenon may make the crystallized glass heterogeneous and an increase in the surface roughness of the molded product may deteriorate the reflective characteristics of reflector, and hence, it is preferred to inhibit the occurrence of these phenomena as much as possible.
Under the circumstances, the inventors have conducted intensive investigation and have found that adding tin dioxide (SnO2) as a nucleating agent in place of part of the zirconia as a nucleating agent effectively inhibits zirconia recrystallization during the steps of melting and molding the glass raw material, and accordingly inhibits the occurrence of the devitrification phenomenon and an increase of surface roughness of the molded product. That is, it is preferred that the crystallized glass of the present invention contains tin dioxide as a nucleating agent in place of a part of zirconia as a nucleating agent, and, if necessary, contains both zirconia and tin dioxide as nucleating agents in a total amount of 3–6 parts by mass based on 100 parts by mass of the main components.
In order to inhibit zirconia recrystallization during melting and molding of the glass raw material in crystallized glass containing only zirconia as the nucleating agent, it is effective to set the content of zirconia as the nucleating agent at 3 parts by weight or less based on 100 parts by mass of the main components. However, such crystallized glass tends to experience insufficient crystal nucleus formation due to the low content of the nucleating agent, and is sometimes inferior in crystallinity.
On the other hand, in the case of the crystallized glass containing tin dioxide as a nucleating agent in place of a part of zirconia as a nucleating agent, zirconia recrystallization during melting and molding of the glass raw material can be inhibited while maintaining good crystallinity, and in addition, the melting temperature of the glass can be lowered and the meltability can be improved, which is preferred.
Tin dioxide as a nucleating agent is preferably contained in an amount of 0.5–4 parts by mass, more preferably 0.5–2 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of inhibiting zirconia recrystallization cannot be exhibited, which is not desired. If the content is more than the above range, tin oxide per se is apt to be recrystallized, and there is the possibility that the devitrification phenomenon will occur as well as an increase in the surface roughness of the molded product as in the case of zirconia.
When tin dioxide as a nucleating agent is contained in place of all of the zirconia as a nucleating agent (namely, when only tin dioxide is contained as the nucleating agent), the devitrification phenomenon during the glass raw material melting and moldings steps can be avoided and an increase in the surface roughness of the molded product can also be sometimes avoided. However, since the formation of gahnite (having a very high thermal expansion coefficient) and willemite (higher in thermal expansion coefficient than zinc petallite solid solution or β-quartz solid solution) may be brought about, the thermal expansion coefficient of the crystallized glass per se increases, sometimes causing deterioration of heat resistance.
In the crystallized glass containing tin dioxide as a nucleating agent, it is preferred that zirconia as the nucleating agent is contained in an amount of 2–3 parts by mass based on 100 parts by mass of the main components. When the content is as mentioned above, recrystallization of zirconia at the steps of melting and molding of the glass raw material can be inhibited with maintaining the good crystallinity.
Taking the above facts into consideration, the crystallized glass of the present invention most preferably contains 3 parts by mass of zirconia and 2 parts by mass of tin dioxide as nucleating agents based on 100 parts by mass of the main components. In the case of such recrystallized glass, the recrystallization of zirconia during the steps of melting and molding of the glass raw material can be effectively inhibited with maintaining the good crystallinity, and the main crystalline phase can also be zinc petallite solid solution or β-quartz solid solution and hence, the thermal expansion coefficient of the recrystallized glass is low and it exhibits a heat resistance comparable to that of lithia-based crystallized glasses.
(3) Modification Component
The crystallized glass of the present invention contains one component selected from the group consisting of lithium oxide, sodium oxide, potassium oxide, diphosphorus pentoxide, niobium oxide and tantalum oxide as a modification component. The “modification component” in this specification means a substance which electrostatically bonds to uncross linked oxygen in the crystal structure formed of the main components to affect various physical properties of the glass.
Usually, the modification components include, for example, oxides of alkali metals (lithium, sodium, potassium, rubidium, cesium, and the like), oxides of alkaline earth metals (magnesium, calcium, strontium, barium, and the like), oxides of transition metals (yttrium, vanadium, niobium, tantalum, molybdenum, and the like), oxides of nonmetals (boron, phosphorus, and the like), and furthermore bismuth oxide (Bi2O3), but it is necessary that the crystallized glass of the present invention contains at least one component selected from the group consisting of lithium oxide, sodium oxide, potassium oxide, diphosphorus pentoxide, niobium oxide and tantalum oxide (hereinafter sometimes abbreviated as the “6 components”) as a modification component.
The crystallized glasses containing at least one of the above 6 components as a modification component having a more stable thermal expansion coefficient and more excellent heat resistance, meltability and moldability than a crystallized glass that does not contain any of the above 6 components. Among them, the crystallized glass containing lithium oxide as a modification component has an especially low melting point (about 1450–1500° C.) and good meltability, and, hence, when the glass is molten and molded into a reflector substrate, no special equipment (melting furnace or the like) designed to withstand high temperatures of higher than 1500° C. is needed, and there are less restrictions on the production conditions. That is, the reflector substrate can be very simply produced. Furthermore, crystallized glasses containing oxides of alkali metals, such as lithium oxide, sodium oxide and potassium oxide as modification components have better crystallinity than those containing diphosphorus pentoxide as a modification component. Moreover, crystallized glasses containing niobium oxide or tantalum oxide have good meltability in addition to a low crystallizing temperature and good crystallinity.
The total content of the 6 components as modification components is preferably 0.2–5.0 parts by mass, more preferably 0.5–4.6 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the modification component will not exert any effect, which is not preferred, and if it exceeds the above range, there is the possibility that the thermal expansion coefficient will increase, which is also not preferred.
The preferred content of lithium oxide is 0.3–0.75 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving the meltability of the glass by lithium oxide cannot be achieved, which is undesirable. If the content exceeds the above range, there is the possibility that the crystallization is insufficient due to the low crystallinity of the glass, which is also undesirable.
The preferred content of diphosphorus pentoxide is 1–3 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving the meltability of the glass by diphosphorus pentoxide cannot be achieved, which is undesirable. If the content exceeds the above range, there is the possibility that the crystallization would be insufficient due to the low crystallinity of the glass, which is also not preferred.
The preferred content of sodium oxide is 0.4–1 part by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving the crystallinity of the glass by sodium oxide cannot be obtained, which is also not preferred.
The preferred content of potassium oxide is 0.5–1.5 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving the crystallinity by potassium oxide cannot be exerted, which is not preferred.
The preferred content of niobium oxide is 0.1–0.5 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving meltability, lowering crystallizing temperature and improving crystallinity by niobium oxide cannot be achieved, which is not preferred.
The preferred content of tantalum oxide is 0.1–0.5 parts by mass based on 100 parts by mass of the main components. If the content is less than the above range, there is the possibility that the effect of improving meltability, lowering crystallizing temperature and improving crystallinity by tantalum oxide cannot be exerted, which is not preferred.
The crystallized glass of the present invention may contain other modification components so long as it contains at least one of the above 6 components as a modification component. For example, it is preferred to contain about 0.1–0.5 parts by mass of vanadium oxide (V2O5) or molybdenum oxide (MoO3) as a modification component based on 100 parts by mass of the main components. However, the content of these other modification components should be limited to a range without damaging the preferred effects of the crystallized glass of the present invention, namely, the effects of having a thermal expansion coefficient of not higher than that of baria-based crystallized glasses and having excellent heat resistance.
An important point in the crystallized glass of the present invention is that when it contains oxides of alkaline earth metals (magnesium oxide (MgO), calcium oxide (CaO), strontium oxide (SrO), barium oxide (BaO), boron oxide (B2O3), yttrium oxide (Y2O3), bismuth oxide (Bi2O3)) which are generally suitably used as modification components of crystallized glasses, the effect of improving heat resistance is rather reduced. This is because if these components are contained as modification components, since formation of crystalline phase (gahnite, spinel (MgO.Al2O3), or the like) of high thermal expansion coefficient is readily brought about, the thermal expansion coefficient of the glass increases and the heat resistance decreases. Particularly, crystallized glass containing boron oxide as a modification component shows a more conspicuous increase of the thermal expansion coefficient and decrease of the heat resistance. Therefore, it is preferred for the crystallized glass of the present invention to contain substantially no boron oxide as at least a modification component (contain substantially 0% by mass of boron oxide as a modification component).
(4) Additives
The crystallized glass of the present invention may contain additives depending on purpose in addition to the main components, nucleating agent and modification component. For example, adding antimony oxide (Sb2O3) in an amount of about 0.5 parts by mass based on 100 parts by mass of the main components as a glass clarifier is preferred in that it can reduce bubbles generated while the glass is melting and allow hardly any bubbles to remain in the glass.
(5) Crystallized Glass
The crystallized glass of the present invention can be obtained by mixing the above-mentioned main components, nucleating agent and modification component at a given ratio to prepare a glass raw material, melting the glass raw material to make a glass, and subjecting the glass to a heat treatment (crystallization treatment) at a high temperature of about 800–900° C. for about 2–4 hours.
The crystallized glass can also be obtained by producing the glass raw material by using, in place of the above main components, nucleating agent and modification component, precursors which can be converted to these components by heating (for example, carbonates, nitrates, and the like), mixing them so as to give a given ratio in terms of oxides to prepare a glass raw material, melting the glass raw material to make a glass, and subjecting the glass to a heat treatment (crystallization treatment) under the similar conditions to those mentioned above.
If the treating temperature and time are less than the above ranges, there is the possibility that crystallization of glass would not sufficiently proceed, resulting in decrease of crystallinity, which is not preferred. If they exceed the above ranges, a crystalline phase (gahnite, willemite, or the like) having a high thermal expansion coefficient is readily formed, the thermal expansion coefficient of the glass increases, and the heat resistance decreases, which is not preferred.
The crystallized glass of the present invention obtained as mentioned above has a high heat resistance, a low melting point and good meltability, and, furthermore, has superior crystal stability over time under high temperature conditions and an extremely small volumetric contraction even after being exposed to high temperatures for a long time.
On the other hand, when the same test was conducted on lithia-based crystallized glasses, as shown in
The reason for the lithia-based crystallized glasses taking such behavior is that the crystalline phase changes over time because they are kept under high temperature conditions. Specifically, the reasons may be due to (i) an increase of the density (contraction of volume) due to the growth of crystal grains, (ii) a change of the crystalline phase from a β-eucryptite solid solution (thermal expansion coefficient ≦0) to a β-spodumene solid solution (thermal expansion coefficient ≧0), etc. That is, since the lithia-based crystallized glasses have insufficient crystal stability over time under high temperature conditions, they show a volumetric contraction upon being exposed to high temperatures for a long time.
Therefore, when a reflector substrate is formed of a lithia-based crystal glass, the growth of crystal grains proceeds during long-term use and volumetric contraction occurs, and hence, there is the possibility that the shape of the reflector substrate will change. Such a shape change is not desirable because is causes a deterioration of the reflective characteristics or a deviation in the condensation point.
Being different from the lithia-based crystallized glass, the crystallized glass of the present invention exhibits less of the above-mentioned defects and, hence, is suitable as material for constructing a reflector substrate which is required to have such endurance as to withstand long-term uses of 5000–10000 hours under high temperature conditions greater than 600° C. It is needless to say that the crystallized glass of the present invention is a very useful material, considering that recently, light source lamps used for illuminators and projector light sources have an increased output and luminance, and thus the reflector substrate tends to be exposed to the higher temperatures.
(6) Reflector Substrate
As already mentioned above, the crystallized glass of the present invention is suitably usable as a reflector substrate constituting a reflector for reflecting the light of a light source lamp, particularly, as a material constituting a reflector substrate of an illuminator or a projector light source.
The reflector substrate is a member having a concave formed for disposing a reflective film thereon. The shape of the concave has no limitation so long as the desired reflecting characteristics can be obtained when the reflective film is disposed thereon. Usually, the concave is in the form of a rotating second-order surface (e.g., paraboloid, ellipsoid, etc.), and an ellipsoid having excellent in condensation efficiency for reflected light is preferred.
There are no particular limitations on the construction of the parts of the reflector substrate other than the concave part, and various constructions can be used depending on the purpose. As a general construction, mention may be made of reflector substrate 10 shown in
The above reflector substrate can be produced, for example, by using a mold to press mold a mold a molten glass mass (called a “gob”) that is prepared by melting a glass raw material at a high temperature.
Examples of a mold that can be used for molding the reflector substrate include the reflector substrate molding mold 30 shown in
Using the reflector substrate molding mold 30 as mentioned above, the reflector substrate can be molded by the following method. First, a gob 38 is fed from a gob-feeding nozzle 35 ((a) in
Then, the ring 36 is put on the top face of the mold 32, core rod 34 is loosely inserted into the guide hole 36a of the ring 36, and there after the core rod 34 is downwardly pressed ((c)–(e) in
After completion of the molding, the reflector substrate 31 is sufficiently cooled, and then first the core rod 34 is pulled up. In this case, since the reflector substrate 31 is pressed downwardly by the ring 36, it is not pulled up together with the core rod 34 and is retained inside the mold 32. Then, the ring 36 is pulled upwardly to disjoint the mold, and the reflector substrate 31, which is the molded product, is removed from the mold 32. In this way, the reflector substrate 31, which is a molded product, can be obtained.
As shown in
The construction of the reflective film is not particularly limited as long as the desired reflecting characteristics can be obtained. For example, an alternate multilayer film comprising alternately laminated materials of high refractive index such as titania (TiO2) and those of low refractive index such as silica (SiO2) can be suitably used. Known film forming methods can be used to form the reflective films. In the case of the above alternate multilayer films, a material have a high refractive index and a material having a low refractive index can be alternately laminated using conventionally known film forming methods (such as PVD, CVD, and sputtering).
As shown in
In the above, the present invention has been explained referring to an example of a reflector substrate of a general construction, but it is also a preferred embodiment to use the crystallized glass of the present invention as a constituting material of a reflector substrate provided with a main body having a concave formed for disposing a reflective film and a metallic reticulate body embedded in the main body. That is, a reflector substrate 50 shown in
The characteristic construction of the above reflector substrate 50 is that a metallic reticulate body 52 is embedded in the main body of the reflector substrate 50. The reticulate body 52 is provided to inhibit the scattering of broken pieces if the reflector substrate per se is broken over its useful lifetime. Such a reflector substrate is preferred because it can improve the safety of the light emission apparatus during use and prevent other devices (for example, a liquid crystal projector) that are attached to the apparatus from being damaged.
The reticulate body 52 must be embedded inside the main body 17 of the reflector substrate 50, and the embedding position is not particularly limited. Therefore, it may be optionally provided in accordance with the purpose, and usually, it is embedded such that it wraps at least a part of the concave 12 along the concave 12.
The reticulate body 52 must be disposed so that it wraps the concave 12 of the main body 17 along the concave 12, but except for this point, there are no particular limitations in the position of disposing the reticulate body 52. Disposition of the reticulate body 52 to wrap the whole concave 12 as shown in
In the case of the main body being composed of the two parts of the bowl-shaped part 14 and the neck part 16 as in the reflector substrate 50 shown in
The metals constituting the reticulate body are not particularly limited, and it is preferred that the materials are selected in consideration of the main body which comprises a crystallized glass.
First, since the reticulate body is embedded in the main body of the reflector substrate, it contacts with a high temperature gob during production of the reflector substrate. Therefore, it is preferred to select a material having excellent oxidation resistance in order to produce the reflector substrate in an atmospheric environment without carrying out nitrogen purging. Furthermore, since the reflector substrate is used under high temperature conditions, it is preferred that the material of the reticulate body has a thermal expansion coefficient that is close to that of the crystallized glass constituting the main body, a high Young's modulus and excellent spreadability.
From the above viewpoints, the reticulate body preferably comprises at least one metal selected from the group consisting of nickel, cobalt, stainless steel and Kovar as a main constituent. By selecting the above metals, it becomes possible to produce the reflector substrate in an atmospheric environment without carrying out nitrogen purging, and the breakage of the reflector substrate due to a difference in thermal expansion behavior between the main body and the reticulate body can be effectively inhibited.
The “main constituent” means that the whole of the reticulate body is not required to be composed of the above metal, but it suffices that the reticulate body is mainly composed of the above metal. Specifically, it means that 30% by mass or more of the metal constituting the reticulate body is the above metal.
Furthermore, since the reflector substrate is subjected to a heat treatment (crystallization treatment) at high temperatures after molding, it is preferred to select a material that is capable of accelerating the crystallization. From this viewpoint, the reticulate body comprises preferably at least one metal selected from the group consisting of gold, platinum, silver and copper as a main constituent. These metals are preferred because they can be crystal nuclei of the glass and hence can accelerate crystallization of glass and fine the crystals. The same effect can be obtained when the reticulate body has a surface coat comprising the above metal.
The reticulate body must have a network structure, but other constructions can be optionally determined depending on the properties of the crystallized glass, the size of the reflector substrate and the effect of inhibiting the scattering of broken pieces. For example, the shape of the meshes can be square, rhombic, hexagonal, and the like, and the mesh size is suitably about 3–10 mm. The reticulate body is often formed of metal wires having a diameter of about 0.1–1.0 mmφ, and may be formed of metal foils having a width that is nearly the same as the above wire diameters.
The reflector substrate in which the above reticulate body is embedded can be produced in accordance with a method for producing a reflector substrate of general construction as shown in
The crystallized glass of the present invention will be specifically explained using the following examples, which should not be construed as limiting the crystallized glass of the present invention in any manner. The crystallized glasses of the examples and the comparative examples were evaluated based on the four characteristics of heat resistance, crystallinity, meltability and devitrification properties, and the overall evaluation was conducted based on the results of the above evaluations. The four characteristics of heat resistance, crystallinity, meltability and devitrification properties were evaluated using the following methods.
Heat Resistance
Measurement samples of 3 mm×3 mm×20 mm were cut out from the crystallized glass, and the thermal expansion coefficients were measured in three temperature ranges of 40–400° C., 40–600° C. and 40–800° C. in accordance with the method described in JIS R1618. The heat resistance was evaluated in the following manner. When a crystallized glass having a thermal expansion coefficient at 40–400° C. of not higher than that of lithia-based crystallized glass (not higher than 20×10−7 (/° C.)) was obtained, this is indicated by “∘”; when a crystallized glass having a thermal expansion coefficient at 40–400° C. of not higher than that of baria-based crystallized glass (not higher than 45×10−7 (/° C.)) was obtained, this is indicated by “Δ”; and when only such a crystallized glass as having a thermal expansion coefficient at 40–400° C. of higher than that of baria-based crystallized glass (higher than 45×10−7 (/° C.)) was obtained, this is indicated by “x”.
Crystallinity
The crystallinity is shown in the following manner. When the minimum temperature at which the glass could be crystallized was lower than 850° C., this is indicated by “∘”, when it was 850–900° C., this is indicated by “Δ”; and when it was higher than 900° C., this is indicated by “x”.
Meltability
As for the evaluation of meltability, when the melting temperature of the crystallized glass was lower than 1500° C., this is indicated by “∘”; when it was 1500–1530° C., this is indicated by “Δ”; and when it was higher than 1530° C., this is indicated by “x”.
Devitrification Properties
The devitrification properties were evaluated by the frequency of occurrence of devitrification phenomenon when the glass raw material for the crystallized glass was melted to make a molten glass and the molten glass was molded into the shape of the reflector substrate. In the case of producing 100 reflector substrates (samples), when no devitrification phenomenon occurred in any of the samples, this is indicated by “⊚”; when devitrification phenomenon occurred in two or less samples, this is indicated by “∘”; when it occurred in five or less samples, this is indicated by “Δ”; and when it occurred in six or more samples, this is indicated by “x”.
Overall Evaluation
As for the overall evaluation on the crystallized glasses of Examples 1–43 and Comparative Examples 1–10, when evaluation of the three characteristics of heat resistance, crystallinity and meltability were all “∘”, this is indicated by “⊚”; when evaluation of two of these characteristics were “∘”, this is indicated by “∘”; and other cases are indicated by “Δ”, but when at least one of the heat resistance and the meltability among the three characteristics was evaluated by “x”, the overall evaluation is indicated by “x” irrespective of the above criteria.
As for the overall evaluation of the crystallized glasses of Examples 44–50 and Comparative Examples 11–13, when on the evaluation of heat resistance, crystallinity and meltability were all “∘”and the evaluation of the devitrification properties was “⊚”, this is indicated by “⊚”when on the evaluation of heat resistance, crystallinity and meltability were all “∘” and the evaluation of the devitrification properties was “∘”, this is indicated by “∘”; and when at least one of the heat resistance and the devitrification properties was evaluated by “Δ”, the overall evaluation is indicated by “Δ”
The main components, the nucleating agent and the modification component described in Table 3 were mixed at the ratio as described in Table 3 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment (crystallizing treatment) at 875° C. or 900° C. for 4 hours to obtain the crystallized glasses of Examples 1–8 and Comparative Examples 1–4. The heat resistance, crystallinity and meltability of these crystallized glasses were evaluated and the results are shown in Table 4.
Evaluation
As shown in Table 3 and Table 4, the crystallized glasses of Examples 1–8 containing diphosphorus pentoxide as a modification component were superior in meltability compared to those of Comparative Examples 1–4 which contained no diphosphorus pentoxide as a modification component. Particularly, the crystallized glass of Example 5 which did not contain boron oxide and contained only 1 part by mass of diphosphorus pentoxide as a modification component, was superior in both heat resistance and crystallinity and thus showed even better results. On the other hand, the crystallized glass of Comparative Example 2 containing boron oxide as a modification component in a relatively large amount, namely, 3 parts by mass, was inferior in both heat resistance and meltability.
The main components, the nucleating agent and the modification component described in Table 5 were mixed at the ratios described in Table 5 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment (crystallizing treatment) at 825° C., 850° C., 875° C. or 900° C. for 4 hours to obtain crystallized glasses of Examples 9–19. The heat resistance, crystallinity and meltability of these crystallized glasses were evaluated and the results are shown in Table 6.
Evaluation
As shown in Table 5 and Table 6, the crystallized glass of Example 11 having a main component constitutional ratio indicated by mark (I) in
The main components, the nucleating agent and the modification component described in Table 7 were mixed at the ratios described in Table 7 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment crystallizing treatment) at 875° C. or 900° C. for 4 hours to obtain crystallized glasses of Comparative Examples 5–10. The heat resistance, crystallinity and meltability of these crystallized glasses were evaluated and the results are shown in Table 8.
Evaluation
As shown in Table 7 and Table 8, the crystallized glasses of Comparative Examples 5–10, containing bismuth oxide, calcium oxide, strontium oxide, magnesium oxide, barium oxide or yttrium oxide as a modification component in place of the modification components (6 components) specified in the present invention, were inferior in meltability.
The main components, the nucleating agent and the modification component described in Table 9 were mixed at the ratios described in Table 9 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment (crystallizing treatment) at 800° C., 825° C. or 850° C. for 4 hours to obtain crystallized glasses of Examples 20–29. The heat resistance, crystallinity and meltability of these crystallized glasses were evaluated and the results are shown in Table 10.
The main components, the nucleating agent and the modification component described in Table 11 were mixed at the ratios described in Table 11 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment (crystallizing treatment) at 825° C. or 850° C. for 4 hours to obtain crystallized glasses of Examples 30–43. The heat resistance, crystallinity and meltability of these crystallized glasses were evaluated and the results are shown in Table 12.
Evaluation
As shown in Table 9–Table 12, the crystallized glasses of Examples 21 and 24–43 containing niobium oxide or tantalum oxide in addition to alkali metal oxides as modification components, showed superior results with respect to all of the heat resistance, crystallinity and meltability characteristics that were evaluated, and showed very good results. Furthermore, the crystallized glasses of Examples 20 and 23, containing vanadium oxide or molybdenum oxide in addition to alkali metal oxides as modification components, also showed good results, but were somewhat inferior in crystallinity compared with the crystallized glasses of Examples 21 and 24–43, which showed very good results.
The main components, the nucleating agent and the modification component described in Table 13 were mixed at the ratio as described in Table 13 to prepare a glass raw material. This glass raw material was molten to make a glass, and the resulting glass was subjected to a heat treatment (crystallizing treatment) at 800° C. or 825° C. for 4 hours to obtain crystallized glasses of Examples 44–50 and Comparative Examples 11–13. The heat resistance, crystallinity, meltability and devitrification properties of these crystallized glasses were evaluated and the results are shown in Table 14.
Qu
Qu
Pe(Qu)
Qu(Ga, Wi)
Qu(Ga, Wi)
Qu(Ga, Wi)
Evaluation
As shown in Table 13–Table 14, the crystallized glass of Example 44, containing only 4 parts by mass of zirconia as a nucleating agent, showed superior results with respect to all of the characteristics of heat resistance, crystallinity and meltability that were measured, and showed very good results like the crystallized glasses of Examples 17–19, 21 and 24–43. When devitrification properties were examined, however, devitrification phenomenon caused by recrystallization of zirconia as a nucleating agent was seen in a part of the samples.
The crystallized glasses of Examples 45–48, which corresponded to the crystallized glass of Example 44 to which merely tin dioxide was added as a nucleating agent without changing the content of zirconia, did not show improved devitrification properties.
On the other hand, the crystallized glass of Example 49, in which the content of zirconia as the nucleating agent was reduced to 3 parts by mass and instead 1.5 parts by mass of tin dioxide as a nucleating agent was contained, showed improved devitrification properties and the crystallinity was not deteriorated. That is, in the case of the crystallized glass of Example 49, recrystallization of zirconia at the steps of melting and molding of the glass raw material could be inhibited while maintaining good crystallinity.
Furthermore, the crystallized glass of Example 50 in which the content of zirconia as a nucleating agent was reduced to 3 parts by mass and instead 2 parts by mass of tin dioxide as a nucleating agent was contained, showed markedly improved in devitrification properties and the crystallinity was not deteriorated. That is, in the case of the crystallized glass of Example 50, recrystallization of zirconia at the steps of melting and molding of the glass raw material could be inhibited while maintaining good crystallinity. Moreover, since its main crystalline phase was a zinc petallite solid solution, it had a low thermal expansion coefficient and excellent heat resistance that were comparable to that of lithia-based crystallized glass.
Furthermore, when tin dioxide as a nucleating agent was contained in place of all of the zirconia as a nucleating agent (namely, when only tin dioxide was included as a nucleating agent), the devitrification properties could be markedly improved while maintaining good crystallinity and heat resistance in some samples, as in the case of the crystallized glass of Comparative Example 11. But, in some cases, the thermal expansion coefficient of crystallized glass per se increased to deteriorate the heat resistance due to the formation of gahnite or willemite, as in the cases of the crystallized glasses of Comparative Examples 12 and 13. Moreover, in the crystallized glass of Comparative Example 13, in which the content of tin dioxide was 6 parts by mass, the devitrification phenomenon occurred as in the case of zirconia because the tin dioxide per se was readily recrystallized.
Stability of Crystal with Lapse of Time
Apart from the evaluation of the heat resistance, crystallinity, meltability and devitrification properties mentioned above, of the crystal stability over time was evaluated Evaluation of the crystal stability over time was conducted in the following manner. Measurement samples of 3 mm×3 mm×20 mm were cut out from the crystallized glass, and were kept under high temperatures of 600° C., 650° C., 700° C. and 750° C. for 20 hours, and the change of volume expansion coefficient over time was measured in accordance with the method described in JIS R1618. The subjects evaluated were the crystallized glass of Example 50 and commercially available lithia-based crystallized glass of which main crystalline phases were β-spodumene solid solution and β-eucryptite solid solution (referred to as “Comparative Example 14”). The crystallized glass of Comparative Example 14 had the composition as described in Table 15. The results are shown in
As can be seen from the graph of
On the other hand, as shown in
The zinc oxide-alumina-silica-based crystallized glass of the present invention is suitably usable as a reflector substrate which constitutes a reflector for reflecting lights of light source lamps, particularly, as a reflector substrate of illuminators or projector light sources.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-328537 | Sep 2003 | JP | national |
| 2003-357975 | Oct 2003 | JP | national |
This application is a continuation of International Application No. PCT/JP2004/013670 having an international filing date of Sep. 17, 2004, which designated the United States, the entirety of which is incorporated herein by reference. This application claims the benefit of Japanese Application 2003-328537 filed Sep. 19, 2003, and Japanese Application 2003-357975 filed Oct. 17, 2003, the entireties of which are incorporated herein by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3681097 | Beall et al. | Aug 1972 | A |
| 3854963 | Rittler | Dec 1974 | A |
| Number | Date | Country |
|---|---|---|
| 47-4979 | Mar 1972 | JP |
| 7-92527 | Oct 1995 | JP |
| 10-095641 | Apr 1998 | JP |
| 2002-109923 | Apr 2002 | JP |
| 2003-051210 | Feb 2003 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20050255984 A1 | Nov 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2004/013670 | Sep 2004 | US |
| Child | 11150906 | US |
