Glass sheet with improved edge quality and method for producing same
阅读说明:本技术 具有提高的边缘质量的玻璃片及其生产方法 (Glass sheet with improved edge quality and method for producing same ) 是由 冯江蔚 裴家仁 詹姆斯·约瑟夫·普莱斯 万达·贾尼纳·沃尔查克 于 2018-12-10 设计创作,主要内容包括:一种制造和处理玻璃制品的方法,其中对所述制品的所述处理包括朝向所述制品的边缘表面导引等离子体流,如包括大气压力等离子体射流的等离子体流。这种处理可降低在所述制品的边缘表面上的颗粒密度。这种处理也可提高所述制品的边缘强度。(A method of making and treating a glass article, wherein the treating of the article comprises directing a plasma stream, such as a plasma stream comprising an atmospheric pressure plasma jet, toward an edge surface of the article. Such treatment may reduce the particle density on the edge surface of the article. Such treatment may also improve the edge strength of the article.)
1. A method for making a glass article, the method comprising:
forming the glass article, wherein the glass article comprises a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first major surface and the second major surface in a direction perpendicular to the first major surface and the second major surface; and
directing a plasma stream toward the edge surface, wherein directing the plasma stream toward the edge surface reduces a particle density on the edge surface to less than about 40 per 0.1 square millimeters.
2. The method of claim 1, wherein the plasma stream comprises an atmospheric pressure plasma jet.
3. The method of claim 1, wherein a distance in a direction of extension of the edge between the first major surface and the second major surface is less than or equal to about 0.5 millimeters, and an edge strength of the glass article after directing a plasma stream toward the edge surface is at least about 130MPa as measured by a four-point bending test.
4. The method of claim 1, wherein the plasma is generated at a power of at least about 300 watts.
5. The method of claim 1, wherein the plasma comprises at least one component selected from the group consisting of nitrogen, argon, oxygen, hydrogen, and helium.
6. The method of claim 1, wherein the edge surface is heated to a temperature of at least about 100 ℃ prior to directing the plasma stream toward the edge surface.
7. The method of claim 1, wherein the step of forming the glass article comprises separating a glass sheet from a glass ribbon by:
applying a scoring mechanism to the glass ribbon to apply a score line in a width direction across the glass ribbon; and
applying a pulling force sufficient to separate the glass sheet from the scored glass ribbon;
wherein a depth of the score line in a thickness direction of the glass ribbon is in a range from about 7% to about 10% of the thickness of the glass ribbon.
8. The method of claim 7, wherein the edge surface includes a scribe region R prior to directing the plasma stream toward the edge surfaceSAnd a non-scribed region RNSaid scribe region RSThe non-scribe region R extending between the first main surface and the depth of the scribe lineNExtending between the depth of the score line and the second major surface.
9. The method of claim 8, wherein said non-scribe region RNComprising a first surface region N1And a second surface region N2Said first surface region N1Having a first tangent T parallel to1The average slope of the second surface region N2Having a second tangent T parallel to2Of where T is1>T2And said first surface region N1At the depth and T of the scribe line1And T2Extend between the points of intersection, said second surface region N2At T1And T2With the non-scribed region RNHighest point H ofMAXExtending therebetween.
10. The method of claim 9, wherein N is at the first surface region1Is the maximum height difference H between the highest point and the lowest point ofALess than or equal to 2 microns, the second surface region N2Highest point of (2)Maximum height difference H between the lowest pointsBLess than or equal to 10 microns.
11. The method of claim 7, wherein the scribe region RSHaving an arithmetic mean surface roughness R of less than or equal to 0.35 micrometeraAnd a maximum peak R of less than or equal to 4.5 micronsy。
12. A method for treating a glass article, the glass article comprising:
a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first and second major surfaces in a direction perpendicular to the first and second major surfaces;
wherein the method comprises: directing a plasma stream toward the edge surface, wherein directing the plasma stream toward the edge surface reduces a particle density on the edge surface to less than about 40 per 0.1 square millimeters.
13. The method of claim 12, wherein the plasma stream comprises an atmospheric pressure plasma jet.
14. The method of claim 12, wherein a distance in a direction of extension of the edge between the first major surface and the second major surface is less than or equal to about 0.5 millimeters, and an edge strength of the glass article after directing a plasma stream toward the edge surface is at least about 130MPa as measured by a four-point bending test.
15. The method of claim 12, wherein the plasma is generated at a power of at least about 300 watts.
16. The method of claim 12, wherein the plasma comprises at least one component selected from the group consisting of nitrogen, argon, oxygen, hydrogen, and helium.
17. The method of claim 12, wherein the edge surface is heated to a temperature of at least about 100 ℃ prior to directing the plasma stream toward the edge surface.
18. A glass article comprising a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first and second major surfaces in a direction perpendicular to the first and second major surfaces, wherein a particle density on the edge surface is less than about 40 per 0.1 square millimeter.
19. The glass article of claim 18, wherein a distance in a direction of extension of an edge between the first major surface and the second major surface is less than or equal to about 0.5 millimeters, and an edge strength of the glass article is at least about 130MPa as measured by a four-point bending test.
20. The glass article of claim 18, wherein the plasma stream has been directed toward the edge surface.
21. An electronic device comprising the glass article of claim 18.
Technical Field
The present disclosure relates generally to glass sheets having improved edge quality and methods of producing the same, and more particularly to glass sheets having less adhered particles and greater edge strength and methods of producing the same.
Background
In the production of glass articles, such as glass sheets for display applications, including televisions and handheld devices such as telephones and tablet computers, there are often multiple processing steps that may involve the generation of glass particles, such as when separating the glass sheet from the glass ribbon, and when subjecting the glass sheet to finishing processes such as edge grinding and polishing. In view of the trend toward higher resolution displays, it is desirable to minimize the number of particles present on these articles. In view of the trend toward thinner displays, it is also desirable to produce thin glass articles, such as glass sheets, that have sufficient mechanical resistance to breakage.
Disclosure of Invention
Embodiments disclosed herein include methods for making glass articles. The method includes forming the glass article, wherein the glass article includes a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first and second major surfaces in a direction perpendicular to the first and second major surfaces. The method also includes directing a plasma stream toward an edge surface, wherein directing the plasma stream toward the edge surface reduces a particle density on the edge surface to less than about 40 per 0.1 square millimeters.
Embodiments disclosed herein also include methods for treating a glass article comprising a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first and second major surfaces in a direction perpendicular to the first and second major surfaces. The method includes directing a plasma stream toward an edge surface, wherein directing the plasma stream toward the edge surface reduces a particle density on the edge surface to less than about 40 per 0.1 square millimeters.
Embodiments disclosed herein also include glass articles comprising a first major surface, a second major surface parallel to the first major surface, and an edge surface extending between the first and second major surfaces in a direction perpendicular to the first and second major surfaces, wherein a density of particles on the edge surface is less than about 40 per 0.1 square millimeter.
Additional features and advantages of the embodiments disclosed herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the disclosed embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description present embodiments that are intended to provide an overview or framework for understanding the nature and character of the embodiments of the application. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure, and together with the description serve to explain the principles and operations of the disclosure.
Drawings
FIG. 1 is a schematic diagram of an exemplary fusion downdraw glass making apparatus and process;
FIG. 2 is a schematic side view of a stage of an exemplary glass sheet separation process;
FIG. 3 is a schematic side view illustrating another stage of the glass sheet separation process;
FIG. 4 is a schematic side view of yet another stage of an exemplary glass sheet separation process;
FIG. 5 is a schematic side view illustrating yet another stage of the glass sheet separation process;
FIG. 6 is a perspective view of a glass sheet;
FIG. 7 is a perspective view of at least a portion of a beveling process of an edge surface of a glass sheet;
FIG. 8 is a perspective view of at least a portion of an edge treatment process using a plasma jet;
FIGS. 9A and 9B are Scanning Electron Microscope (SEM) images of an edge surface of a glass sheet before and after plasma jet treatment, wherein no edge beveling step was performed prior to plasma jet treatment;
10A and 10B are SEM images of an edge surface of a glass sheet before and after plasma jet treatment, wherein an edge bevel step is performed before plasma jet treatment;
FIG. 11 is a schematic cross-sectional side view of an edge region of a glass sheet, wherein the edge region is produced by a scoring (score) and breaking (break) process and the topographical features of the edge region are exaggerated for purposes of illustration; and
fig. 12 is a schematic perspective view of a portion of the edge region depicted in fig. 11.
Detailed Description
Reference will now be made in detail to the presently preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
Directional phrases used herein, such as, for example, upper, lower, right, left, front, rear, top, bottom, are made only with reference to the drawings as drawn and are not intended to imply absolute orientation.
Unless expressly stated otherwise, any method set forth herein is in no way intended to be construed as requiring that the steps of that method be performed in a specific order, nor in any device, specific orientation. Thus, where a method claim does not actually recite an order to be followed by the steps of the method, or where any apparatus claim does not actually recite an order or orientation to individual components, or where no further specific recitation in the claims or descriptions is intended to limit the steps to a specific order, or where a specific order or orientation to components of an apparatus is not recited, it is no way intended that an order or orientation be inferred in any respect. This applies to any possible non-express basis for interpretation, including: logical considerations regarding the arrangement of steps, operational flow, order of components, or orientation of components; simple meanings derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.
As used herein, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to a "component" includes aspects having two or more of the components described above, unless the context clearly dictates otherwise.
As used herein, the term "plasma" refers to a free gas (ionizidgas) that includes positive ions and free electrons.
As used herein, the term "atmospheric pressure plasma jet" refers to a plasma stream discharged from an aperture, wherein the plasma pressure approximately matches the pressure of the surrounding atmosphere, including conditions where the plasma pressure is between 90% and 110% of 101.325 kilopascals (standard atmospheric pressure).
As used herein, the term "particle" refers to any type of particle that may be present on a surface, such as glass particles and dust particles.
As used herein, the phrase "edge strength measured by a four point bending test" refers to the edge strength in the case where 10% of the samples are expected to fail using the glass flexible clamp four point test specified in JIS R1601.
FIG. 1 is an exemplary
The
In some examples, a glass melting furnace can be incorporated as a component of a glass manufacturing apparatus to manufacture glass substrates, e.g., a continuous length of glass ribbon. In some examples, the glass melting furnace of the present disclosure may be incorporated as a component of a glass manufacturing apparatus including a slot draw (slot draw) apparatus, a float bath (float bath) apparatus, a down-draw (down-draw) apparatus (e.g., a fusion process), an up-draw (up-draw) apparatus, a press-rolling apparatus, a tube drawing (tube drawing) apparatus, or any other glass manufacturing apparatus that would benefit from aspects disclosed herein. By way of example, FIG. 1 schematically depicts a
The glass manufacturing apparatus 10 (e.g., the fusion downdraw apparatus 10) can optionally include an upstream glass manufacturing apparatus 16, the upstream glass manufacturing apparatus 16 being located upstream relative to the
As shown in the illustrated example, the upstream glass manufacturing apparatus 16 may include a storage bin (storage bin)18, a raw
The
The downstream
Bubbles can be removed from
The downstream
The downstream
The downstream
Fig. 2 illustrates a schematic side view of stages of an example glass sheet separation process. As shown in FIG. 2, the
Although the
The
FIG. 3 illustrates a schematic side view of another stage of the example glass sheet separation process in which the
As shown in fig. 3, although the
Fig. 5 illustrates a schematic side view of a further stage of the example glass sheet separation process in which the holding
Fig. 6 illustrates a perspective view of
Fig. 7 illustrates a perspective view of at least a portion of a beveling process of an
Downstream processing of
Fig. 8 illustrates a perspective view of at least a portion of a treatment process for
The plasma jet 402 may be directed toward the
In certain exemplary embodiments, the plasma jet 402 is generated via a direct current high voltage discharge that produces a pulsed arc, such as a voltage discharge of at least about 5kV, such as from about 5kV to about 15 kV. In certain exemplary embodiments, the plasma jet 402 is generated at a frequency of at least about 10kHz, such as from about 10kHz to about 100 kHz. In certain exemplary embodiments, the plasma jet can have a beam length of from about 5 millimeters to about 40 millimeters and a widest beam width of from about 0.5 millimeters to about 15 millimeters.
In certain exemplary embodiments, the distance between the portions of the plasma showerhead 400 closest to the edge surface 166 (referred to herein as the "gap distance") is at least about 1 mm, such as at least about 2 mm, and further such as at least about 4 mm, and still further such as at least about 5 mm, such as from about 1 mm to about 10 mm, including from about 5 mm to about 10 mm.
In certain exemplary embodiments, the relative rate of movement (referred to herein as the "scan rate") between the plasma torch 400 and the
In certain exemplary embodiments, the number of times the plasma showerhead 400 is moved relative to the entire length of the edge surface 166 (referred to herein as the "scan times") may be at least 1 time, such as at least 2 times, and further such as at least 3 times, and further such as at least 4 times, including 1 time to 10 times, and further including from 2 times to 6 times.
In certain exemplary embodiments, the plasma includes at least one component selected from the group consisting of nitrogen, argon, oxygen, hydrogen, and helium, which is excited and at least partially converted into a plasma state. In certain exemplary embodiments, the plasma includes at least one component selected from the group consisting of nitrogen, argon, and hydrogen, such as at least two components selected from the group consisting of nitrogen, argon, and hydrogen, and further such as embodiments wherein the plasma includes each of nitrogen, argon, and hydrogen. When the plasma includes at least one of nitrogen, argon, and hydrogen, the nitrogen content may, for example, be in a range from about 50 mol% to about 100 mol%, such as from about 60 mol% to about 90 mol%, the argon content may, for example, be in a range from about 0 mol% to about 20 mol%, such as from about 5 mol% to about 15 mol%, and the hydrogen content may, for example, be in a range from about 0 mol% to about 10 mol%, such as from about 1 mol% to about 5 mol%.
In certain exemplary embodiments, the treatment process including directing a plasma stream toward the
In certain exemplary embodiments, the treatment process includes directing a plasma stream toward the
Embodiments disclosed herein include embodiments in which the plasma jet 402 is applied toward the
Fig. 9A and 9B illustrate Scanning Electron Microscope (SEM) images of an edge surface of a glass sheet before and after plasma jet treatment, in which no edge beveling step (such as the exemplary edge beveling process shown in fig. 7) was performed before plasma jet treatment. In particular, the edge surfaces shown in fig. 9A and 9B are produced as a result of separating the glass sheet from the glass ribbon using a scoring and breaking process similar to that illustrated in fig. 2-5. Then, according to embodiments disclosed herein, the edge surface is treated with an atmospheric pressure plasma jet. As can be seen from comparing fig. 9A and 9B, the treated edges exhibit a substantially smoother surface topography.
Fig. 10A and 10B illustrate SEM images of an edge surface of a glass sheet before and after plasma jet treatment, wherein an edge bevel step (such as the exemplary edge bevel process shown in fig. 7) is performed before plasma jet treatment. In particular, after the edge beveling process, the edge surface is treated with an atmospheric pressure plasma jet according to embodiments disclosed herein. As can be seen from comparing fig. 10A and 10B, the treated edges exhibit a substantially smoother surface topography.
FIG. 11 illustrates a schematic side cross-sectional view of an edge region of a glass sheet, wherein the edge region results from a scoring and breaking process and the topographical features of the edge region are exaggerated for illustrative purposes. In particular, the
As shown in FIG. 11, the
More particularly, the non-scribed region RNComprising a first surface region N1And a second surface region N2First surface region N1Having a first tangent T parallel to1Average slope of, second surface region N2Having a second tangent T parallel to2The average slope of (c). As shown in FIG. 11, T1>T2And the first surface region N1At the depth of the scribe line and T1And T2Extend between the points of intersection, second surface region N2At T1And T2Cross point and non-scribed region R ofNHighest point H ofMAXExtend between (highest point H of non-scoring area)MAXIs the
Embodiments disclosed herein include embodiments wherein the depth of the score line in the thickness direction of the glass ribbon (i.e., a width score line such as shown in fig. 2) is in the range of from about 7% to about 10% of the thickness of the glass ribbon, which in turn results in inclusion of a score region RSAs shown in fig. 11, that extends from about 7% to about 10% of the thickness of the glass sheet 62 (i.e., the score region R)SExtend at the firstFrom about 7% to about 10% of the distance in the extending direction of the edge between the
Applicants have found that when scoring is controlled such that the depth of the score line is in the range of from about 7% to about 10% of the thickness of the glass ribbon, a topography can be achieved after the scoring and breaking process, wherein in the first surface region N1Is the maximum height difference H between the highest point and the lowest point ofALess than or equal to 2 microns, such as from 0.2 microns to 2 microns, and a second surface region N2Is the maximum height difference H between the highest point and the lowest point ofBLess than or equal to 10 microns, such as from 1 micron to 10 microns. As shown in FIG. 11, the highest points of the designated area are
Applicants have further discovered that when the above morphology is achieved (i.e., wherein H isALess than or equal to 2 microns and HBLess than or equal to 10 microns) that may enable improved edge quality after plasma treatment of the
By controlling the scribing parameters, not only the above-mentioned morphology but also the scribing region R is realizedSArithmetic average surface roughness RaYet less than or equal to 0.35 micron and a maximum peak RyAlso less than or equal to 4.5 microns, additional improvement in edge quality can be achieved. FIG. 12 illustrates a schematic perspective view of a portion of the edge region of the
The controllable scoring parameters include not only the score line depth as described above, but also the uniformity of the depth in the width direction, the choice of scoring wheel, and the choice of scoring force. Controlling the above parameters may mitigate the creation of lateral cracks during scribing and may create crack propagation from the scribe line with a more uniform intermediate depth. In certain exemplary embodiments, the scoring force may range from about 3 newtons to about 15 newtons, such as from about 5 newtons to about 10 newtons. Non-limiting examples of scoring wheels that may be used include those available from MDI Advanced Processing GmbHWheel andand (4) wheels.
In certain exemplary embodiments, prior to directing the plasma stream toward the
Examples of the invention
Embodiments herein are further illustrated with reference to the following non-limiting examples:
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