U.S. patent application number 15/480463 was filed with the patent office on 2017-08-31 for fusion formable sodium containing glass.
The applicant listed for this patent is CORSAM TECHNOLOGIES LLC. Invention is credited to Bruce Gardiner AITKEN, James Edward DICKINSON, JR., Timothy J. KICZENSKI, Michelle Diane PIERSON-STULL.
Application Number | 20170250296 15/480463 |
Document ID | / |
Family ID | 43218847 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170250296 |
Kind Code |
A1 |
AITKEN; Bruce Gardiner ; et
al. |
August 31, 2017 |
Fusion Formable Sodium Containing Glass
Abstract
Sodium-containing aluminosilicate and boroaluminosilicate
glasses are described herein. The glasses can be used as substrates
for photovoltaic devices, for example, thin film photovoltaic
devices such as CIGS photovoltaic devices. These glasses can be
characterized as having strain points .gtoreq.540.degree. C.,
thermal expansion coefficient of from 6.5 to 9.5 ppm/.degree. C.,
as well as liquidus viscosities in excess of 50,000 poise. As such,
they are ideally suited for being formed into sheet by the fusion
process.
Inventors: |
AITKEN; Bruce Gardiner;
(Corning, NY) ; DICKINSON, JR.; James Edward;
(Corning, NY) ; KICZENSKI; Timothy J.; (Corning,
NY) ; PIERSON-STULL; Michelle Diane; (Painted Post,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CORSAM TECHNOLOGIES LLC |
Corning |
NY |
US |
|
|
Family ID: |
43218847 |
Appl. No.: |
15/480463 |
Filed: |
April 6, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12787711 |
May 26, 2010 |
9637408 |
|
|
15480463 |
|
|
|
|
61182386 |
May 29, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C01P 2006/40 20130101;
C03C 3/091 20130101; Y02E 10/543 20130101; C01B 19/007 20130101;
H01L 31/03925 20130101; Y02E 10/541 20130101; H01L 31/0296
20130101; C03C 3/087 20130101; H01L 31/0322 20130101; H01L 31/0445
20141201; H01L 31/03923 20130101 |
International
Class: |
H01L 31/0392 20060101
H01L031/0392; C03C 3/087 20060101 C03C003/087; H01L 31/0445
20060101 H01L031/0445; H01L 31/0296 20060101 H01L031/0296; H01L
31/032 20060101 H01L031/032; C03C 3/091 20060101 C03C003/091; C01B
19/00 20060101 C01B019/00 |
Claims
1. A glass comprising, in weight percent: 65 to 75 percent
SiO.sub.2; 1 to 20 percent Al.sub.2O.sub.3; 0 to 3 percent
TiO.sub.2; 0 to 8 percent B.sub.2O.sub.3; 12 to 25 percent total
M.sub.2O; 2 to 5 percent Na.sub.2O; 8 to 15 percent K.sub.2O; 1 to
6 percent CaO; and 1 to 29 percent total RO; and 0 to 6 percent
SrO, wherein, M is an alkali metal selected from Na, K, Li, Rb, and
Cs, wherein R is an alkaline earth metal selected from Mg, Ba, Ca,
and Sr, wherein the glass has a strain point of 540.degree. C. or
greater, wherein the glass has a liquidus viscosity greater than or
equal to 50,000 poise, wherein the glass has a specific gravity
greater than 2.42 and less than 2.60, and wherein said glass
comprises less than or equal to 0.05% by weight of ZrO.sub.2.
2. The glass according to claim 1, wherein the glass is free of
ZrO.sub.2.
3. The glass composition according to claim 1, comprising: 66.1 to
69.6 percent SiO.sub.2; 2.7 to 8.8 percent Al.sub.2O.sub.3; 2.8 to
4 percent Na.sub.2O; and 8 to 15 percent K.sub.2O, and wherein the
glass composition exhibits a liquidus viscosity of 630,000 Poise or
higher.
4. The glass according to claim 3, comprising: 67.8 percent
SiO.sub.2; 7.6 percent Al.sub.2O.sub.3; 0.9 percent B.sub.2O.sub.3;
3.8 percent Na.sub.2O; 11.7 percent K.sub.2O; 3.6 percent MgO; 1.9
percent CaO; 2.5 percent SrO; and 0 percent BaO.
5. The glass according to claim 3, comprising: 67.8 percent
SiO.sub.2; 7.6 percent Al.sub.2O.sub.3; 0.9 percent B.sub.2O.sub.3;
3.8 percent Na.sub.2O; 11.7 percent K.sub.2O; 3.6 percent MgO; 1.9
percent CaO; 2.5 percent SrO; and 0 percent BaO.
6. The glass according to claim 1, comprising: 67.8 percent
SiO.sub.2; 7.9 percent Al.sub.2O.sub.3; 2.5 percent B.sub.2O.sub.3;
3.0 percent Na.sub.2O; 14.1 percent K.sub.2O; 0.3 percent MgO; 4.4
percent CaO; 0 percent SrO; and 0 percent BaO.
7. The glass according to claim 1, comprising 69.6 percent
SiO.sub.2; 7.8 percent Al.sub.2O.sub.3; 2.3 percent B.sub.2O.sub.3;
2.8 percent Na.sub.2O; 13 percent K.sub.2O; 0.3 percent MgO; 4.0
percent CaO; 0 percent SrO; and 0 percent BaO.
8. The glass according to claim 1, comprising: 66.1 percent
SiO.sub.2; 5.2 percent Al.sub.2O.sub.3; 1.9 percent B.sub.2O.sub.3;
3.0 percent Na.sub.2O; 14.6 percent K.sub.2O; 4.4 percent MgO; 2.8
percent CaO; 1.7 percent SrO; and 0 percent BaO.
9. The glass according to claim 1, comprising: 67 percent
SiO.sub.2; 5.3 percent Al.sub.2O.sub.3; 1.9 percent B.sub.2O.sub.3;
3.1 percent Na.sub.2O; 14.8 percent K.sub.2O; 3.1 percent MgO; 2.9
percent CaO; 1.7 percent SrO; and 0 percent BaO.
10. The glass according to claim 1, comprising: 66.5 percent
SiO.sub.2; 7.45 percent Al.sub.2O.sub.3; 0.85 percent
B.sub.2O.sub.3; 3.76 percent Na.sub.2O; 8.6 percent K.sub.2O; 3.52
percent MgO; 1.9 percent CaO; 2.45 percent SrO; and 4.67 percent
BaO.
11. The glass according to claim 1, comprising: 66.4 percent
SiO.sub.2; 7.43 percent Al.sub.2O.sub.3; 0.43 percent
B.sub.2O.sub.3; 3.75 percent Na.sub.2O; 11.4 percent K.sub.2O; 3.52
percent MgO; 2.98 percent CaO; 3.78 percent SrO; and 0 percent
BaO.
12. The glass according to claim 1, comprising: 66.7 percent
SiO.sub.2; 7.47 percent Al.sub.2O.sub.3; 0 percent B.sub.2O.sub.3;
3.77 percent Na.sub.2O; 11.5 percent K.sub.2O; 3.53 percent MgO; 3
percent CaO; 3.8 percent SrO; and 0 percent BaO.
13. A glass, comprising 56.9 percent SiO.sub.2; 8.8 percent
Al.sub.2O.sub.3; 7.1 percent B.sub.2O.sub.3; 4.0 percent Na.sub.2O;
8.1 percent K.sub.2O; 0.9 percent MgO; 2.7 percent CaO; 0.15
percent SrO; and 11.4 percent BaO.
14. A glass, comprising: 59.6 percent SiO.sub.2; 7.4 percent
Al.sub.2O.sub.3; 5.6 percent B.sub.2O.sub.3; 3.1 percent Na.sub.2O;
10.2 percent K.sub.2O; 0 percent MgO; 3.2 percent CaO; 0.1 percent
SrO; and 8.5 percent BaO.
15. The glass according to claim 1, having a T.sub.200 less than
1580.degree. C. and a liquidus viscosity of 1,500,000 poise or
greater.
16. The glass according to claim 1, wherein the glass is in the
form of a sheet.
17. The glass according to claim 15, wherein the sheet has a
thickness in the range of from 0.5 mm to 3.0 mm.
18. A photovoltaic device comprising the glass according to claim
1.
19. The photovoltaic device according to claim 17, wherein the
glass is in the form of a sheet and is a substrate or a
superstrate.
20. The photovoltaic device according to claim 18, comprising a
functional layer comprising copper indium gallium diselenide or
cadmium telluride adjacent to the substrate or superstrate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/787,711 filed on May 26, 2010 which claims
the benefit of U.S. Provisional Application No. 61/182,386 filed on
May 29, 2009.
BACKGROUND
[0002] Field
[0003] Embodiments relate generally to sodium containing glasses
and more particularly to fusion formable sodium containing glasses
which may be useful in photochromic, electrochromic, Organic Light
Emitting Diode (OLED) lighting, or photovoltaic applications, for
example, thin film photovoltaics.
[0004] Technical Background
[0005] The fusion forming process typically produces flat glass
with optimal surface and geometric characteristics useful for many
electronics applications, for instance, substrates used in
electronics applications, for example, display glass for LCD
televisions.
[0006] Over the last 10 years, Corning fusion glass products
include 1737F.TM. 1737G.TM., Eagle2000F.TM., EagleXG.TM., Jade.TM.,
and Codes 1317 and 2317 (Gorilla Glass.TM.). Efficient melting is
generally believed to occur at a temperature corresponding to a
melt viscosity of about 200 poise (p). These glasses share in
common 200 p temperatures in excess of 1600.degree. C., which can
translate to accelerated tank and electrode corrosion, greater
challenges for fining due to still more elevated finer
temperatures, and/or reduced platinum system life time,
particularly around the finer. Many have temperatures at 3000 poise
in excess of about 1300.degree. C., and since this is a typical
viscosity for an optical stirrer, the high temperatures at this
viscosity can translate to excessive stirrer wear and elevated
levels of platinum defects in the body of the glass.
[0007] Many of the above described glasses have delivery
temperatures in excess of 1200.degree. C., and this can contribute
to creep of isopipe refractory materials, particularly for large
sheet sizes.
[0008] These attributes combine so as to limit flow (because of
slow melt rates), to accelerate asset deterioration, to force
rebuilds on timescales much shorter than product lifetimes, to
force unacceptable (arsenic), expensive (capsule) or unwieldy
(vacuum fining) solutions to defect elimination, and thus
contribute in significant ways to the cost of manufacturing
glass.
[0009] In applications in which rather thick, comparatively
low-cost glass with less extreme properties is required, these
glasses are not only overkill, but prohibitively expensive to
manufacture. This is particularly true when the competitive
materials are made by the float process, a very good process for
producing low cost glass with rather conventional properties. In
applications that are cost sensitive, such as large-area
photovoltaic panels and OLED lighting, this cost differential is so
large as to make the price point of LCD-type glasses
unacceptable.
[0010] To reduce such costs, it is advantageous to drive down the
largest overall contributors (outside of finishing), and many of
these track directly with the temperatures used in the melting and
forming process. Therefore, there is a need for a glass that melts
at a lower temperature than those aforementioned glasses.
[0011] Further, it would be advantageous to have a glass useful for
low temperature applications, for instance, photovoltaic and OLED
light applications. Further, it would be advantageous to have a
glass whose processing temperatures were low enough that the
manufacturing of the glass would not excessively consume the energy
that these applications are aiming to save.
SUMMARY
[0012] A compositional range of fusion-formable, high strain point
sodium-containing aluminosilicate and boroaluminosilicate glasses
useful, for example, for thin-film photovoltaic applications are
described herein. More specifically, these glasses are advantageous
materials to be used in copper indium gallium diselenide (CIGS)
photovoltaic modules where the sodium required to optimize cell
efficiency is to be derived from the substrate glass. Current CIGS
module substrates are typically made from soda-lime glass sheet
that has been manufactured by the float process. However, use of
higher strain point glass substrates can enable higher temperature
CIGS processing, which is expected to translate into desirable
improvements in cell efficiency. Moreover, it may be that the
smoother surface of fusion-formed glass sheets yields additional
benefits, such as improved film adhesion, etc.
[0013] Accordingly, the sodium-containing glasses described herein
can be characterized by strain points .gtoreq.540.degree. C. so as
to provide advantage with respect to soda-lime glass and/or
liquidus viscosity .gtoreq.50,000 poise to allow manufacture via
the fusion process. In order to avoid thermal expansion mismatch
between the substrate and CIGS layer, the inventive glasses are
further characterized by a thermal expansion coefficient in the
range of from 6.5 to 9.5 ppm/.degree. C. In one embodiment, the
glass is fusion formable and has a strain point of 540.degree. C.
or greater, a coefficient of thermal expansion of
50.times.10.sup.-7 or greater, and having a liquidus viscosity of
150,000 poise or greater.
[0014] One embodiment is a glass comprising, in weight percent:
[0015] 50 to 75 percent SiO.sub.2; [0016] 1 to 20 percent
Al.sub.2O.sub.3; [0017] 0 to 3 percent TiO.sub.2; [0018] 0 to 10
percent B.sub.2O.sub.3; [0019] 8 to 25 percent total M.sub.2O; and
[0020] 0 to 50 percent total RO;
[0021] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0022] Another embodiment is a glass consisting essentially of, in
weight percent: [0023] 50 to 75 percent SiO.sub.2; [0024] 1 to 20
percent Al.sub.2O.sub.3; [0025] 0 to 3 percent TiO.sub.2; [0026] 0
to 10 percent B.sub.2O.sub.3; [0027] 8 to 25 percent total
M.sub.2O; and [0028] 0 to 50 percent total RO;
[0029] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0030] A glass comprising, in weight percent: [0031] 50 to 75
percent SiO.sub.2; [0032] 1 to 20 percent Al.sub.2O.sub.3; [0033] 0
to 3 percent TiO.sub.2; [0034] 0 to 4 percent MgO; [0035] 0 to 10
percent B.sub.2O.sub.3; [0036] 8 to 25 percent total M.sub.2O; and
[0037] less than 14 percent total RO;
[0038] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr, wherein the glass is fusion formable and has a
strain point of 540.degree. C. or greater, a coefficient of thermal
expansion of 50.times.10.sup.-7 or greater, and having a liquidus
viscosity of 150,000 poise or greater.
[0039] Additional features and advantages will be set forth in the
detailed description which follows, and in part will be readily
apparent to those skilled in the art from the description or
recognized by practicing the invention as described in the written
description and claims hereof.
[0040] It is to be understood that both the foregoing general
description and the following detailed description are merely
exemplary of the invention, and are intended to provide an overview
or framework for understanding the nature and character of the
invention as it is claimed.
DETAILED DESCRIPTION
[0041] Reference will now be made in detail to various embodiments
of the invention.
[0042] As used herein, the term "substrate" can be used to describe
either a substrate or a superstrate depending on the configuration
of the photovoltaic cell. For example, the substrate is a
superstrate, if when assembled into a photovoltaic cell, it is on
the light incident side of a photovoltaic cell. The superstrate can
provide protection for the photovoltaic materials from impact and
environmental degradation while allowing transmission of the
appropriate wavelengths of the solar spectrum. Further, multiple
photovoltaic cells can be arranged into a photovoltaic module.
Photovoltaic device can describe either a cell, a module, or
both.
[0043] As used herein, the term "adjacent" can be defined as being
in close proximity. Adjacent structures may or may not be in
physical contact with each other. Adjacent structures can have
other layers and/or structures disposed between them.
[0044] One embodiment is a glass comprising, in weight percent:
[0045] 50 to 75 percent SiO.sub.2; [0046] 1 to 20 percent
Al.sub.2O.sub.3; [0047] 0 to 3 percent TiO.sub.2; [0048] 0 to 10
percent B.sub.2O.sub.3; [0049] 8 to 25 percent total M.sub.2O; and
[0050] 0 to 50 percent total RO;
[0051] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0052] A glass comprising, in weight percent: [0053] 50 to 75
percent SiO.sub.2; [0054] 1 to 20 percent Al.sub.2O.sub.3; [0055] 0
to 3 percent TiO.sub.2; [0056] 0 to 4 percent MgO; [0057] 0 to 10
percent B.sub.2O.sub.3; [0058] 8 to 25 percent total M.sub.2O; and
[0059] less than 14 percent total RO; [0060] wherein, M is an
alkali metal selected from Na, K, Li, Rb, and Cs and wherein the
glass comprises at least 1 weight percent Na.sub.2O; and wherein, R
is an alkaline earth metal selected from Mg, Ca, Ba, and Sr,
wherein the glass is fusion formable and has a strain point of
540.degree. C. or greater, a coefficient of thermal expansion of
50.times.10.sup.-7 or greater, T.sub.200 less than 1630.degree. C.,
and having a liquidus viscosity of 150,000 poise or greater.
[0061] According to one embodiment, the glass comprises: [0062] 53
to 72 percent SiO.sub.2; [0063] 2 to 17 percent Al.sub.2O.sub.3;
[0064] 0 to 3 percent TiO.sub.2; [0065] 0 to 8 percent
B.sub.2O.sub.3; [0066] 8 to 25 percent total M.sub.2O; and [0067] 0
to 50 percent total RO.
[0068] According to another embodiment, the glass comprises: [0069]
55 to 72 percent SiO.sub.2; [0070] 2 to 9 percent Al.sub.2O.sub.3;
[0071] 0 to 3 percent TiO.sub.2; [0072] 0 to 8 percent
B.sub.2O.sub.3; [0073] 8 to 20 percent total M.sub.2O; and [0074] 0
to 30 percent total RO;
[0075] wherein, the glass comprises at least 2 weight percent
Na.sub.2O.
[0076] In another embodiment, the glass comprises: [0077] 1 to 8
percent Na.sub.2O; [0078] 5 to 16 percent K.sub.2O; [0079] 0 to 8
percent MgO; [0080] 0 to 7 percent CaO; [0081] 0 to 7 percent SrO;
and [0082] 0 to 21 percent BaO.
[0083] In another embodiment, the glass comprises: [0084] 2 to 5
percent Na.sub.2O; [0085] 8 to 15 percent K.sub.2O; [0086] 0 to 5
percent MgO; [0087] 1 to 6 percent CaO; [0088] 0 to 6 percent SrO;
and [0089] 0 to 12 percent BaO.
[0090] In another embodiment, the glass comprises: [0091] 53 to 71
SiO.sub.2; [0092] 2 to 17 Al.sub.2O.sub.3; [0093] 8 to 22 total
M.sub.2O; and [0094] 0 to 40 total RO;
[0095] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0096] In another embodiment, the glass comprises: [0097] 53 to 71
SiO.sub.2; [0098] 2 to 17 Al.sub.2O.sub.3; [0099] 8 to 22 total
M.sub.2O; and [0100] 0 to 40 total RO;
[0101] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0102] In another embodiment, the glass comprises: [0103] 65 to 76
SiO.sub.2; [0104] 1 to 7 Al.sub.2O.sub.3; [0105] 2.5 to 5
Na.sub.2O; [0106] 5.5 to 11 K.sub.2O; [0107] 0 to 8 MgO; [0108] 1
to 7 CaO; and [0109] 0 to 6 BaO.
[0110] The glass, in one embodiment, is rollable. The glass, in one
embodiment, is down-drawable. The glass can be slot drawn or fusion
drawn, for example. According to another embodiment the glass can
be float formed.
[0111] The glass can further comprise 3 weight percent or less, for
example, 0 to 3 weight percent, for example, greater than 0 to 3
weight percent, for example, 1 to 3 weight percent of TiO.sub.2,
MnO, ZnO, Nb.sub.2O.sub.5, MoO.sub.3, Ta.sub.2O.sub.5, WO.sub.3,
ZrO.sub.2, Y.sub.2O.sub.3, La.sub.2O.sub.3, HfO.sub.2, CdO,
SnO.sub.2, Fe.sub.2O.sub.3, CeO.sub.2, As.sub.2O.sub.3,
Sb.sub.2O.sub.3, Cl, Br, or combinations thereof. In some
embodiments, the glass is substantially free of ZrO.sub.2. In some
embodiments, the glass is substantially free of ZnO. The glass, in
one embodiment, comprises 3 weight percent or less, for example, 0
to 3 weight percent, for example, greater than 0 to 3 weight
percent, for example, 1 to 3 weight percent of TiO.sub.2.
[0112] As mentioned above, the glasses, according some embodiments,
comprise 0 to 10 weight percent, for example, greater than 0 to 10
weight percent B.sub.2O.sub.3, for example, 0.5 to 10 weight
percent B.sub.2O.sub.3, for example 1 to 10 weight percent
B.sub.2O.sub.3. B.sub.2O.sub.3 is added to the glass to reduce
melting temperature, to decrease liquidus temperature, to increase
liquidus viscosity, and to improve mechanical durability relative
to a glass containing no B.sub.2O.sub.3.
[0113] The glass, according to one embodiment, comprises greater
than 0 to 50 percent RO, for example, 0.5 to 50 percent RO, for
example, 1 to 50 percent RO wherein, R is an alkaline earth metal.
The glass, according to one embodiment, comprises less than 14
percent RO, for example, 0.5 to less than 14 percent RO, for
example, 0.5 to 13 percent RO.
[0114] The glass can comprise, for example, 0 to 8, greater than 0
to 8 weight percent, for example, 1 to 8 weight percent MgO. The
glass can comprise, for example, 0 to 5, greater than 0 to 5 weight
percent, for example, 1 to 5 weight percent MgO, for example, 1 to
4 percent MgO. MgO can be added to the glass to reduce melting
temperature and to increase strain point. It can disadvantageously
lower CTE relative to other alkaline earths (e.g., CaO, SrO, BaO),
and so other adjustments may be made to keep the CTE within the
desired range. Examples of suitable adjustments include increase
SrO at the expense of CaO, increasing alkali oxide concentration,
and replacing a smaller alkali oxide (e.g., Na.sub.2O) in part with
a larger alkali oxide (e.g., K.sub.2O).
[0115] According to another embodiment, the glass is substantially
free of BaO. For example, the content of BaO can be 0.05 weight
percent or less, for example, zero weight percent.
[0116] In some embodiments, the glass is substantially free of
Sb.sub.2O.sub.3, As.sub.2O.sub.3, or combinations thereof, for
example, the glass comprises 0.05 weight percent or less of
Sb.sub.2O.sub.3 or As.sub.2O.sub.3 or a combination thereof. For
example, the glass can comprise zero weight percent of
Sb.sub.2O.sub.3 or As.sub.2O.sub.3 or a combination thereof.
[0117] The glasses, in some embodiments, comprise 0 to 7 weight
percent CaO, for example, greater than 0, for example, 1 to 7
weight percent CaO, for example, 1 to 6 weight percent CaO.
Relative to alkali oxides or SrO, CaO contributes to higher strain
point, lower density, and lower melting temperature. It is a
primary component of certain possible devitrification phases,
particularly anorthite (CaAl.sub.2Si.sub.2O.sub.8), and this phase
has complete solid solution with an analogous sodium phase, albite
(NaAlSi.sub.3O.sub.8). High Na and Ca contents taken alone can
cause liquidus temperatures to be unacceptably high. However, the
chemical sources for CaO include limestone, a very inexpensive
material, so to the extent that high volume and low cost are
factors, it is typically useful to make the CaO content as high as
can be reasonably achieved relative to other alkaline earth
oxides.
[0118] The glasses can comprise, in some embodiments, 0 to 7 weight
percent SrO, for example, greater than zero to 7 weight percent,
for example, 1 to 7 weight percent SrO, or for example, 0 to 6
weight percent SrO, for example, greater than zero to 6 weight
percent, for example, 1 to 6 weight percent SrO. In some
embodiments, the glass comprises less than 15 weight percent SrO,
for example, 1 to 12 weight percent SrO. In certain embodiments,
the glass contains no deliberately batched SrO, though it may of
course be present as a contaminant in other batch materials. SrO
contributes to higher coefficient of thermal expansion, and the
relative proportion of SrO and CaO can be manipulated to improve
liquidus temperature, and thus liquidus viscosity. SrO is not as
effective as CaO or MgO for improving strain point, and replacing
either of these with SrO tends to cause the melting temperature to
increase.
[0119] Also as mentioned above, the glasses, according to some
embodiments, include 8 to 25 percent M.sub.2O, for example, 8 to 22
M.sub.2O, 8 to 20 M.sub.2O, where M is one of the alkali cations
Li, Na, K, Rb and Cs. The alkali cations raise the CTE steeply, but
also lower the strain point and, depending upon how they are added,
increase melting temperatures. The least effective alkali oxide for
CTE is Li.sub.2O, and the most effective alkali oxide is Cs.sub.2O.
As noted above, sodium can participate in one of the possible
devitrification phases of the inventive glasses, and while
adjustments in other components can be used to counteract this,
e.g., changing the CaO/(CaO+SrO) ratio, this tendency may make it
advantageous to replace sodium with other alkalis, or to use a mix
of alkalis instead of sodium alone. If high volume and low cost are
important, then it is desirable to as much as possible confine the
alkali oxides to Na.sub.2O and K.sub.2O or combinations
thereof.
[0120] In one embodiment, the glass comprises 1 to 8 weight percent
Na.sub.2O, for example, 2 to 8 weight percent Na.sub.2O, for
example, 3 to 8 weight percent Na.sub.2O, for example, 4 to 8
weight percent Na.sub.2O. In another embodiment, the glass
comprises 1 to 5 weight percent Na.sub.2O, for example, 1 to 4
weight percent Na.sub.2O, for example, 1 to 3 weight percent
Na.sub.2O, for example, 1 to 2 weight percent Na.sub.2O.
[0121] In some embodiments, the weight percent of the combination
of Na.sub.2O and K.sub.2O is greater than 3 percent, for example,
greater than 5 percent, for example, greater than 10 percent, for
example, greater than 12 percent.
[0122] Another embodiment is a glass consisting essentially of, in
weight percent: [0123] 50 to 75 percent SiO.sub.2; [0124] 1 to 20
percent Al.sub.2O.sub.3; [0125] 0 to 3 percent TiO.sub.2; [0126] 0
to 10 percent B.sub.2O.sub.3; [0127] 8 to 25 percent total
M.sub.2O; and [0128] 0 to 50 percent total RO;
[0129] wherein, M is an alkali metal selected from Na, K, Li, Rb,
and Cs and wherein the glass comprises at least 1 weight percent
Na.sub.2O; and wherein, R is an alkaline earth metal selected from
Mg, Ca, Ba, and Sr.
[0130] The glass, according to some embodiments, is down-drawable;
that is, the glass is capable of being formed into sheets using
down-draw methods such as, but not limited to, fusion draw and slot
draw methods that are known to those skilled in the glass
fabrication arts. Such down-draw processes are used in the
large-scale manufacture of ion-exchangeable flat glass.
[0131] The fusion draw process uses a drawing tank that has a
channel for accepting molten glass raw material. The channel has
weirs that are open at the top along the length of the channel on
both sides of the channel. When the channel fills with molten
material, the molten glass overflows the weirs. Due to gravity, the
molten glass flows down the outside surfaces of the drawing tank.
These outside surfaces extend down and inwardly so that they join
at an edge below the drawing tank. The two flowing glass surfaces
join at this edge to fuse and form a single flowing sheet. The
fusion draw method offers the advantage that, since the two glass
films flowing over the channel fuse together, neither outside
surface of the resulting glass sheet comes in contact with any part
of the apparatus. Thus, the surface properties are not affected by
such contact.
[0132] The slot draw method is distinct from the fusion draw
method. Here the molten raw material glass is provided to a drawing
tank. The bottom of the drawing tank has an open slot with a nozzle
that extends the length of the slot. The molten glass flows through
the slot/nozzle and is drawn downward as a continuous sheet
therethrough and into an annealing region. Compared to the fusion
draw process, the slot draw process provides a thinner sheet, as
only a single sheet is drawn through the slot, rather than two
sheets being fused together, as in the fusion down-draw
process.
[0133] In order to be compatible with down-draw processes, the
aluminoborosilicate glass described herein has a high liquidus
viscosity. In one embodiment, the glass has a liquidus viscosity of
50,000 poise or greater, for example, 150,000 poise or greater, for
example, 200,000 poise or greater, for example, 250,000 poise or
greater, for example, 300,000 poise or greater, for example,
350,000 poise or greater, for example, 400,000 poise or greater,
for example, greater than or equal to 500,000 poise. The liquidus
viscosities of some exemplary glasses are closely correlated with
the difference between the liquidus temperature and the softening
point. For downdraw processes, some exemplary glasses
advantageously have liquidus--softening point less than about
230.degree. C., for example, less than 200.degree. C.
[0134] Accordingly, in one embodiment, the glass has a strain point
of 540.degree. C. or greater, for example, 540.degree. C. to
600.degree. C. In some embodiments, the glass has a coefficient of
thermal expansion of 50.times.10.sup.-7 or greater, for example,
60.times.10.sup.-7 or greater, for example, 70.times.10.sup.-7 or
greater, for example, 80.times.10.sup.-7 or greater. In one
embodiment, the glass has a strain point of from 50.times.10.sup.-7
to 90.times.10.sup.-7.
[0135] In one embodiment, the glass has a coefficient of thermal
expansion of 50.times.10.sup.-7 or greater and a strain point of
540.degree. C. or greater.
[0136] According to one embodiment, the glass is ion exchanged in a
salt bath comprising one or more salts of alkali ions. The glass
can be ion exchanged to change its mechanical properties. For
example, smaller alkali ions, such as lithium or sodium, can be
ion-exchanged in a molten salt containing one or more larger alkali
ions, such as sodium, potassium, rubidium or cesium. If performed
at a temperature well below the strain point for sufficient time, a
diffusion profile will form in which the larger alkali moves into
the glass surface from the salt bath, and the smaller ion is moved
from the interior of the glass into the salt bath. When the sample
is removed, the surface will go under compression, producing
enhanced toughness against damage. Such toughness may be desirable
in instances where the glass will be exposed to adverse
environmental conditions, such as photovoltaic grids exposed to
hail. A large alkali already in the glass can also be exchanged for
a smaller alkali in a salt bath. If this is performed at
temperatures close to the strain point, and if the glass is removed
and its surface rapidly reheated to high temperature and rapidly
cooled, the surface of the glass will show considerable compressive
stress introduced by thermal tempering. This will also provide
protection against adverse environmental conditions. It will be
clear to one skilled in the art that any monovalent cation can be
exchanged for alkalis already in the glass, including copper,
silver, thallium, etc., and these also provide attributes of
potential value to end uses, such as introducing color for lighting
or a layer of elevated refractive index for light trapping.
[0137] According to another embodiment, the glass can be float
formed as known in the art of float forming glass.
[0138] In one embodiment, the glass is in the form of a sheet.
The glass in the form of a sheet can be thermally tempered.
[0139] In one embodiment, an Organic Light Emitting Diode device
comprises the glass in the form of a sheet.
[0140] The glass, according to one embodiment, is transparent.
[0141] In one embodiment, a photovoltaic device comprises the glass
in the form of a sheet. The photovoltaic device can comprise more
than one of the glass sheets, for example, as a substrate and/or as
a superstrate. In one embodiment, the photovoltaic device comprises
the glass sheet as a substrate and/or superstrate, a conductive
material adjacent to the substrate, and an active photovoltaic
medium adjacent to the conductive material. In one embodiment, the
active photovoltaic medium comprises a CIGS layer. In one
embodiment, the active photovoltaic medium comprises a cadmium
telluride (CdTe) layer. In one embodiment, the photovoltaic device
comprises a functional layer comprising copper indium gallium
diselenide or cadmium telluride. In one embodiment, the
photovoltaic device the functional layer is copper indium gallium
diselenide. In one embodiment, the functional layer is cadmium
telluride.
[0142] In one embodiment, the glass sheet is transparent. In one
embodiment, the glass sheet as the substrate and/or superstrate is
transparent.
[0143] According to some embodiments, the glass sheet has a
thickness of 4.0 mm or less, for example, 3.5 mm or less, for
example, 3.2 mm or less, for example, 3.0 mm or less, for example,
2.5 mm or less, for example, 2.0 mm or less, for example, 1.9 mm or
less, for example, 1.8 mm or less, for example, 1.5 mm or less, for
example, 1.1 mm or less, for example, 0.5 mm to 2.0 mm, for
example, 0.5 mm to 1.1 mm, for example, 0.7 mm to 1.1 mm. Although
these are exemplary thicknesses, the glass sheet can have a
thickness of any numerical value including decimal places in the
range of from 0.1 mm up to and including 4.0 mm.
[0144] In one embodiment, an electrochromic device comprises the
glass in the form of a sheet. The electrochromic device can be, for
example, an electrochromic window. In one embodiment, the
electrochromic window comprises one or more of the glass sheets,
such as in a single, double, or triple pane window.
[0145] The fusion formable glasses of this invention, by virtue of
their relatively high strain point, represent advantaged substrate
materials for CIGS photovoltaic modules. When manufactured by the
fusion process, their superior surface quality relative to that of
float glass may also result in further improvements to the
photovoltaic module making process. Advantageous embodiments of
this invention are characterized by liquidus viscosity in excess of
400,000 poise, thereby enabling the fabrication of the relatively
thick glass sheet that may be required by some module
manufacturers. Finally, the most advantageous embodiments of this
invention comprise glasses for which the 200 poise temperature is
less than 1580.degree. C., providing for the possibility of
significantly lower cost melting/forming.
Examples
[0146] The following is an example of how to fabricate a sample of
an exemplary glass, according to one embodiment of the invention,
as shown in Table 1. This composition corresponds to composition
number 12 shown in Table 4.
TABLE-US-00001 TABLE 1 oxide mol % SiO.sub.2 74.75 Al.sub.2O.sub.3
1.76 MgO 5.23 CaO 5.66 SrO 2.78 Na.sub.2O 3.00 K.sub.2O 6.72
SnO.sub.2 0.10
In some embodiments, the total does not add up to 100%, since
certain tramp elements are present at non-negligible
concentrations.
[0147] Batch materials, as shown in Table 2 were weighed and added
to a 4 liter plastic container:
TABLE-US-00002 TABLE 2 Batch Components batch weight sand 1656.84
alumina 65.71 Magnesia 79.80 Limestone 221.90 Strontium carbonate
161.38 Sodium carbonate 117.06 Potassium carbonate 353.91 10%
SnO.sub.2 and 90% sand 57.6
[0148] It should be appreciated that in the batch, limestone,
depending on the source can contain tramp elements and/or vary
amounts of one or more oxides, for example, MgO and/or BaO. The
sand is advantageously beneficiated so that at least 80% by mass
passes 60 mesh, for example 80 mesh, for example 100 mesh. The
SnO.sub.2 added, in this example, was pre-mixed with sand at a
level of 10% by weight so as to ensure homogeneous mixing with the
other components. The bottle containing the batch materials was
mounted to a tumbler and the batch materials were mixed so as to
make a homogeneous batch and to break up soft agglomerates. The
mixed batch was transferred to a 1800 cc platinum crucible and
placed into a high-temperature ceramic backer. The platinum in its
backer was loaded into a glo-bar furnace idling at a temperature of
1600.degree. C. After 16 hours, the crucible+backer was removed and
the glass melt was poured onto a cold surface, such as a steel
plate, to form a patty, and then transferred to an annealer held at
a temperature of 615.degree. C. The glass patty was held at the
annealer temperature for 2 hours, then cooled at a rate of
1.degree. C. per minute to room temperature.
[0149] Table 3, Table 4, Table 5, Table 6, Table 7, Table 8, and
Table 9 show exemplary glasses, according to embodiments of the
invention, and made according to the above example. Properties data
for some exemplary glasses are also shown in Table 3, Table 4,
Table 5, Table 6, Table 7, Table 8, and Table 9.
[0150] In the Tables T.sub.str(.degree. C.) is the strain point
which is the temperature when the viscosity is equal to 10.sup.14.7
P as measured by beam bending or fiber elongation.
T.sub.ann(.degree. C.) is the annealing point which is the
temperature when the viscosity is equal to 10.sup.13.18 P as
measured by beam bending or fiber elongation. T.sub.s(.degree. C.)
is the softening point which is the temperature when the viscosity
is equal to 10.sup.7.6 P as measured by beam bending or fiber
elongation. .alpha.(10.sup.-7/.degree. C.) or a(10.sup.-7/.degree.
C.) in the Tables is the coefficient of thermal expansion (CTE)
which is the amount of dimensional change from either 0 to
300.degree. C. or 25 to 300.degree. C. depending on the
measurement. CTE is typically measured by dilatometry. r(g/cc) is
the density which is measured with the Archimedes method (ASTM
C693). T.sub.200(.degree. C.) is the two-hundred Poise (P)
temperature. This is the temperature when the viscosity of the melt
is 200 P as measured by HTV (high temperature viscosity)
measurement which uses concentric cylinder viscometry.
T.sub.liq(.degree. C.) is the liquidus temperature. This is the
temperature where the first crystal is observed in a standard
gradient boat liquidus measurement (ASTM C829-81). Generally this
test is 72 hours but can be as short as 24 hours to increase
throughput at the expense of accuracy (shorter tests could
underestimate the liquidus temperature). .eta..sub.liq(.degree. C.)
is the liquidus viscosity. This is the viscosity of the melt
corresponding to the liquidus temperature.
TABLE-US-00003 TABLE 3 Example 1 2 3 4 5 6 7 8 9 10 11 Composition
(mol %) Na.sub.2O 6 2 3 3 2 3 3.92 3.92 3.16 3.16 3.14 K.sub.2O 6
10 9 9 10.5 9.5 7.83 7.83 10.03 9.03 9.95 MgO 5.74 5.74 6.25 5.5 11
11 5.63 5.62 7.08 7.07 7.02 CaO 2.23 2.23 6.75 5.9 3.1 3.1 3.43
3.43 3.27 3.93 3.25 SrO 1.55 1.55 3.3 2.9 1 1 2.35 2.35 1.05 1.39
1.04 BaO 0 0 2 4 0 0 0 0 0 0 0 TiO.sub.2 0 0 0 0 0 0 0 0 0 0 0
B.sub.2O.sub.3 0.8 0.8 0 0 1.65 1.65 0.78 0.78 0.72 0.72 1.5
Al.sub.2O.sub.3 4.8 4.8 2.35 2.35 3.15 3.15 4.7 6.66 4.34 4.35 5.3
SiO.sub.2 72.81 72.81 67.25 67.25 67.5 67.5 71.29 69.34 70.25 70.25
68.7 SnO.sub.2 0.07 0.07 0.1 0.1 0.1 0.1 0.07 0.07 0.1 0.1 0.1
Composition (wt %) Na.sub.2O 5.81 1.9 2.81 2.73 1.95 2.94 3.74 3.7
3.03 3.04 2.99 K.sub.2O 8.84 14.5 12.8 12.5 15.6 14.2 11.4 11.3
14.7 13.2 14.4 MgO 3.62 3.55 3.81 3.26 6.98 7.03 3.51 3.46 4.43
4.44 4.36 CaO 1.96 1.92 5.73 4.87 2.74 2.76 2.97 2.94 2.84 3.43
2.81 SrO 2.52 2.47 5.18 4.42 1.64 1.65 3.76 3.72 1.69 2.24 1.66 BaO
0 0 4.64 9.02 0 0 0 0 0 0 0 TiO.sub.2 0 0 0 0 0 0 0 0 0 0 0
B.sub.2O.sub.3 0.87 0.86 0 0 1.81 1.82 0.84 0.83 0.78 0.78 1.61
Al.sub.2O.sub.3 7.66 7.51 3.63 3.53 5.07 5.09 7.4 10.4 6.86 6.9
8.32 SiO.sub.2 68.5 67.1 61.1 59.4 63.9 64.2 66.2 63.5 65.4 65.7
63.5 SnO.sub.2 0.17 0.16 0.23 0.22 0.24 0.24 0.16 0.16 0.23 0.23
0.23 T.sub.str (.degree. C.) 548 581 552 544 573 559 560 577 560
567 562 T.sub.ann (.degree. C.) 595 632 599 591 622 607 609 627 611
617 612 T.sub.s (.degree. C.) 824 879 796 787 a (10.sup.-7/.degree.
C.) 79.2 80.5 90.4 92.5 83 83.9 82.2 82.2 r (gm/cc) 2.457 2.448
2.635 2.699 2.474 2.479 2.489 2.497 2.467 2.476 2.469 T.sub.200
(.degree. C.) 1392 1499 1575 1616 1581 1569 1570 T.sub.liq
(.degree. C.) 970 995 1015 970 1115 1060 1000 1100 1035 1062 1077
h.sub.liq (kp) 105 56 351 88 175 101 71
TABLE-US-00004 TABLE 4 Example 12 13 14 15 16 17 18 19 20 21 22
Composition (mol %) Na.sub.2O 3 3 3 3 3 3 3.75 3.75 3.75 4.61 3.95
K.sub.2O 7.17 7.17 6.97 6.65 6.59 6.59 6.96 6.69 6.43 6 7.89 MgO
6.59 6.59 6.47 5.18 5.13 5.13 5.01 4.82 4.63 4.31 6.67 CaO 5.54
5.54 5.42 5.6 5.55 5.55 5.41 5.2 4.99 4.66 3.46 SrO 2.47 2.47 2.41
2.75 2.72 2.72 3.67 3.53 3.38 3.16 2.37 BaO 0 0 0 1 2 2 0 0 0 0 0
TiO.sub.2 0 0 0 0 0 0 0 0 0 0 0 B.sub.2O.sub.3 0 0 0 0 0 0 0.7 0.67
0.64 0.6 0 Al.sub.2O.sub.3 1.88 3.38 2.38 2.74 1.72 2.72 4.18 4.02
3.86 5.3 4.39 SiO.sub.2 73.25 71.75 73.25 72.98 73.19 72.19 70.24
71.24 72.24 71.28 71.2 SnO.sub.2 0.1 0.1 0.1 0.1 0.1 0.1 0.08 0.08
0.08 0.08 0.07 Composition (wt %) Na.sub.2O 2.94 2.91 2.94 2.87
2.85 2.83 3.58 3.59 3.6 4.39 3.8 K.sub.2O 10.7 10.6 10.4 9.7 9.54
9.48 10.1 9.74 9.39 8.7 11.6 MgO 4.22 4.17 4.13 3.24 3.18 3.16 3.12
3.01 2.9 2.68 4.18 CaO 4.93 4.88 4.81 4.87 4.79 4.76 4.67 4.51 4.34
4.03 3.02 SrO 4.07 4.02 3.96 4.42 4.34 4.31 5.86 5.65 5.42 5.04
3.82 BaO 0 0 0 2.38 4.72 4.69 0 0 0 0 0 TiO.sub.2 0 0 0 0 0 0 0 0 0
0 0 B.sub.2O.sub.3 0 0 0 0 0 0 0.75 0.72 0.69 0.64 0
Al.sub.2O.sub.3 3.04 5.42 3.84 4.33 2.7 4.24 6.57 6.33 6.1 8.32
6.95 SiO.sub.2 69.8 67.7 69.6 67.9 67.6 66.3 65.1 66.2 67.3 65.9
66.5 SnO.sub.2 0.24 0.24 0.24 0.23 0.23 0.23 0.19 0.19 0.19 0.19
0.16 T.sub.str (.degree. C.) 567 580 573 569 557 567 563 563 563
565 564 T.sub.ann (.degree. C.) 618 632 623 620 607 617 611 611 611
614 615 T.sub.s (.degree. C.) a (10.sup.-7/.degree. C.) 79 78.8
79.2 78.5 79.9 79.9 81.7 81.1 78.9 79.4 83.3 r (gm/cc) 2.496 2.503
2.494 2.541 2.584 2.584 2.541 2.529 2.521 2.516 2.494 T.sub.200
(.degree. C.) 1542 1570 1559 1549 ~1520 1529 ~1530 1546 ~1565 1585
1585 T.sub.liq (.degree. C.) 1020 1075 1030 1045 955 1015 1055 1055
1050 1030 1020 h.sub.liq (kp) 194 92 190 121 ~630 194 ~70 80 ~110
175 292
TABLE-US-00005 TABLE 5 Example 23 24 25 26 27 28 29 30 31 32 33
Composition (mol %) Na.sub.2O 3.1 3.12 3.62 3.2 3.33 3.02 4.3 4 3
3.98 4.3 K.sub.2O 8.59 8.64 7.25 10.14 7.52 6.82 7.6 4.93 6 6.88
9.75 MgO 10.06 10.11 6.25 5 3.12 2.86 3.3 4.22 0 9.06 4.5 CaO 2.85
2.86 4.55 3.31 5.22 4.73 5.6 7.77 0 2.56 1.75 SrO 0.91 0.91 2.18
1.07 0.36 0.34 1 2.4 0.21 1.76 0.8 BaO 0 0 0 0 0 0 0 1.43 10.12
1.44 1.05 TiO.sub.2 0 0 0 0 0 0 0 0 0 0 1 B.sub.2O.sub.3 1.51 1 1
1.76 2.71 2.46 2.4 2.51 7.83 0.88 1.15 Al.sub.2O.sub.3 2.88 2.9 4.8
5.36 4.59 4.54 7.2 5.42 6 4.44 7.1 SiO.sub.2 70 70.36 70.25 70.08
73.06 75.24 68.5 66.89 66.83 68.9 68.6 SnO.sub.2 0.15 0.15 0.1 0.08
0.1 0.1 0.1 0.1 0.1 0.1 0 Composition (wt %) Na.sub.2O 3.05 3.07
3.48 3.02 3.21 2.91 4.05 3.78 2.47 3.8 3.96 K.sub.2O 12.9 13 10.6
14.6 11 10 10.9 7.09 7.52 10 13.7 MgO 6.46 6.49 3.92 3.08 1.96 1.8
2.03 2.6 0 5.64 2.7 CaO 2.54 2.56 3.97 2.84 4.56 4.13 4.78 6.66 0
2.22 1.46 SrO 1.5 1.5 3.51 1.7 0.58 0.54 1.58 3.8 0.29 2.82 1.23
BaO 0 0 0 0 0 0 0 3.35 20.7 3.41 2.4 TiO.sub.2 0 0 0 0 0 0 0 0 0 0
1.19 B.sub.2O.sub.3 1.67 1.11 1.08 1.87 2.94 2.67 2.55 2.67 7.26
0.95 1.19 Al.sub.2O.sub.3 4.68 4.71 7.61 8.35 7.29 7.22 11.2 8.44
8.14 6.99 10.8 SiO.sub.2 66.9 67.3 65.6 64.3 68.4 70.5 62.7 61.4
53.4 63.9 61.4 SnO.sub.2 0.24 0.24 0.23 0.18 0.02 0.23 0.23 0.23
0.2 0.23 0 T.sub.str (.degree. C.) 560 561 571 562 561 571 565 568
551 562 553 T.sub.ann (.degree. C.) 609 611 620 611 607 621 610 612
590 608 601 T.sub.s (.degree. C.) 831 a (10.sup.-7/.degree. C.)
81.6 82.4 79.7 86 76.7 69.9 80.2 75.7 74.9 79.1 87.3 r (gm/cc)
2.462 2.462 2.498 2.463 2.445 2.421 2.472 2.582 2.796 2.538 2.498
T.sub.200 (.degree. C.) 1558 1549 1595 1610 1613 1660 1584 1410
1548 1623 T.sub.liq (.degree. C.) 1065 1070 1095 1010 1020 1040
1070 1090 930 1050 1100 h.sub.liq (kp) 90 81 71 344 142 270 69 124
110 67
TABLE-US-00006 TABLE 6 Example 34 35 36 37 38 39 40 41 42 43 44
Composition (mol %) Na.sub.2O 4.2 3.5 4.2 4.2 3 3 3.3 4 4 6.42 7.15
K.sub.2O 6.2 7.5 6.2 6.2 7 7 6.8 7.5 6.5 6.06 5.7 MgO 6 0 6 6 5.4
5.4 5.5 4.9 5.3 0 0 CaO 2.3 0 2.3 2.3 5.8 5.8 4.9 4.9 5.3 5.34 5.7
SrO 1.6 0.18 1.6 1.6 2.9 2.9 2.6 0.05 0.05 0.05 0.04 BaO 2.1 8.62
2.1 2.1 0 0 0.5 2.35 2.55 2.29 1.91 TiO.sub.2 1 0 2 2 2 2 2 0 0 0 0
B.sub.2O.sub.3 0.8 6.6 0.8 0.8 0 0 0.2 0.8 0.8 3.36 2.8
Al.sub.2O.sub.3 5 6 6 7 1.9 2.9 3.4 7 7 9.8 11 SiO.sub.2 70.8 67.6
68.8 67.8 72 71 70.8 68.5 68.5 65.48 64.7 SnO.sub.2 0 0 0 0 0 0 0 0
0 0 0 Composition (wt %) Na.sub.2O 3.93 2.92 3.9 3.87 2.91 2.89
3.16 3.7 3.72 5.76 6.42 K.sub.2O 8.85 9.55 8.77 8.71 10.4 10.3 9.91
10.6 9.2 8.29 7.81 MgO 3.66 0 3.63 3.61 3.42 3.4 3.43 2.96 3.21 0 0
CaO 1.95 0 1.94 1.92 5.11 5.07 4.25 4.12 4.47 4.35 4.65 SrO 2.51
0.25 2.49 2.47 4.72 4.69 4.17 0.08 0.08 0.08 0.06 BaO 4.88 17.9
4.83 4.8 0 0 1.19 5.4 5.88 5.1 4.26 TiO.sub.2 1.21 0 2.4 2.38 2.51
2.49 2.47 0 0 1.39 1.16 B.sub.2O.sub.3 0.84 6.21 0.84 0.83 0 0 0.22
0.83 0.84 3.4 2.83 Al.sub.2O.sub.3 7.72 8.27 9.18 10.6 3.04 4.61
5.37 10.7 10.7 14.5 16.3 SiO.sub.2 64.4 54.9 62 60.8 67.9 66.6 65.8
61.6 61.9 57.1 56.5 SnO.sub.2 0 0 0 0 0 0 0 0 0 0 0 T.sub.str
(.degree. C.) 563 546 571 580 567 574 568 567 574 555 559 T.sub.ann
(.degree. C.) 611 585 618 628 615 622 616 617 623 599 603 T.sub.s
(.degree. C.) a (10.sup.-7/.degree. C.) 77.2 80.5 77.3 76.9 77.2 77
77.3 83.1 78 81.1 82.9 r (gm/cc) 2.546 2.747 2.565 2.566 2.525
2.532 2.538 2.536 2.547 2.543 2.537 T.sub.200 (.degree. C.) 1597
1423 1595 1603 1513 1536 1555 1596 1587 1571 1611 T.sub.liq
(.degree. C.) 1000 950 1040 1070 1015 1065 1020 1100 1125 1030 1060
h.sub.liq (kp) 364 78 164 111 140 67 162 65 43 98 106
TABLE-US-00007 TABLE 7 Example 45 46 47 48 49 50 51 Composition
(mol %) Na.sub.2O 4 4 4.3 3.93 3.95 3.2 2.95 K.sub.2O 8 6 6.45 7.86
7.89 9.81 9.04 MgO 5.74 5.74 6.16 5.65 5.67 0.51 0.46 CaO 2.23 2.23
2.39 3.44 3.46 5.09 4.69 SrO 1.55 1.55 1.65 2.36 2.37 0 0 BaO 0 2
2.15 0 0 0 0 TiO.sub.2 0 0 0 0 0 0 0 B.sub.2O.sub.3 0.8 0.8 0.86
0.4 0 2.34 2.15 Al.sub.2O.sub.3 4.8 4.8 5.15 4.72 4.74 5.06 4.97
SiO.sub.2 72.81 72.78 70.78 71.57 71.85 74.01 75.65 SnO.sub.2 0.07
0.1 0.1 0.07 0.07 0.1 0.1 Composition (wt %) Na.sub.2O 3.83 3.76
4.02 3.75 3.77 3.02 2.79 K.sub.2O 11.7 8.6 9.18 11.4 11.5 14.1 13
MgO 3.59 3.52 3.76 3.52 3.53 0.31 0.28 CaO 1.94 1.9 2.03 2.98 3
4.35 4.02 SrO 2.49 2.45 2.61 3.78 3.8 0 0 BaO 0 4.67 4.99 0 0 0 0
TiO.sub.2 0 0 0 0 0 0 0 B.sub.2O.sub.3 0.86 0.85 0.91 0.43 0 2.49
2.29 Al.sub.2O.sub.3 7.59 7.45 7.93 7.43 7.47 7.87 7.76 SiO.sub.2
67.8 66.5 64.3 66.4 66.7 67.8 69.6 SnO.sub.2 0.16 0.23 0.23 0.16
0.16 0.02 0.23 T.sub.str (.degree. C.) 560 560 555 558 564 560 565
T.sub.ann (.degree. C.) 609 614 605 608 616 605 613 T.sub.s
(.degree. C.) 846 856 839 a (10.sup.-7/.degree. C.) 80.4 75.3 77.7
83.2 83.3 80.7 77.4 r (gm/cc) 2.521 2.528 2.551 2.489 2.488 2.435
2.425 T.sub.200 (.degree. C.) 1630 1613 1588 1607 1622 1603 1660
T.sub.liq (.degree. C.) 930 990 1000 905 990 910 930 h.sub.liq (kp)
2843 705 429 5378 781 1524 1679
TABLE-US-00008 TABLE 8 Example 52 53 54 55 56 57 58 59 Composition
(mol %) Na.sub.2O 3.13 3.2 3 3.95 4.5 4.2 3.5 3.5 K.sub.2O 9.93
10.14 6.72 7.89 6 6.2 7.5 7.5 MgO 7 5 5.23 5.67 1.6 6 0 0 CaO 3.24
3.31 5.66 3.46 3.4 23 3.9 3.9 SrO 1.04 1.07 2.78 3.37 0.1 1.6 0.08
0.08 BaO 0 0 0 0 5.2 2.1 3.82 3.82 TiO.sub.2 0 0 0 0 0 2 2 2
B.sub.2O.sub.3 1.72 1.76 0 0 7.1 0.8 5.6 5.6 Al.sub.2O.sub.3 3.29
3.36 1.76 4.39 6 5 5 6 SiO.sub.2 70.55 72.06 74.75 71.2 66.1 69.8
68.6 67.6 SnO.sub.2 0.1 0.1 0.1 0.07 0 0 0 0 Composition (wt %)
Na.sub.2O 3.02 3.06 2.93 3.76 3.98 3.92 3.13 3.11 K.sub.2O 14.6
14.8 10 11.4 8.09 8.82 10.2 10.2 MgO 4.4 3.12 3.34 3.52 0.92 3.65 0
0 CaO 2.83 2.87 5.01 2.99 2.73 1.95 3.16 3.14 SrO 1.68 1.72 4.56
5.37 0.15 2.5 0.12 0.12 BaO 0 0 0 0 11.4 4.86 8.47 8.42 TiO.sub.2 0
0 0 0 0 2.41 2.31 2.3 B.sub.2O.sub.3 1.87 1.9 0 0 7.08 0.84 5.64
5.6 Al.sub.2O.sub.3 5.23 5.3 2.84 6.88 8.76 7.7 7.37 8.79 SiO.sub.2
66.1 67 71 65.8 56.9 63.3 59.6 58.4 SnO.sub.2 0.24 0.23 0.24 0.16 0
0 0 0 T.sub.str (.degree. C.) 553 549 565 559 540 564 549 549
T.sub.ann (.degree. C.) 600 597 615 609 580 611 589 590 T.sub.s
(.degree. C.) a (10.sup.-7/.degree. C.) 84.8 86.3 77.4 84.8 78 76.2
77.5 77.9 r (gm/cc) 2.466 2.463 2.498 2.52 2.468 2.559 2.604 2.601
T.sub.200 (.degree. C.) 1529 1553 1568 1578 1425 1566 1476 1485
T.sub.liq (.degree. C.) 910 845 995 980 865 980 880 900 h.sub.liq
(kp) 1693 9012 422 514 650 468 933 518
TABLE-US-00009 TABLE 9 Example 60 61 62 Composition (mol %)
Na.sub.2O 3.2 3.07 3.71 K.sub.2O 9.14 8.77 7.16 MgO 5 4.8 5.28 CaO
4.06 3.89 4.77 SrO 1.32 1.27 0.94 BaO 0 0 4 TiO.sub.2 0 0 0
B.sub.2O.sub.3 1.76 5.76 1.55 Al.sub.2O.sub.3 5.36 5.14 4.71
SiO.sub.2 70.08 67.23 67.8 SnO.sub.2 0.08 0.08 0.08 Composition (wt
%) Na.sub.2O 3.03 2.9 3.39 K.sub.2O 13.21 12.63 9.96 MgO 3.09 2.96
3.14 CaO 3.49 3.34 3.95 SrO 2.1 2.02 1.44 BaO 0 0 9.06 TiO.sub.2 0
0 0 B.sub.2O.sub.3 1.88 6.14 1.59 Al.sub.2O.sub.3 8.39 8.01 7.09
SiO.sub.2 64.6 61.77 60.16 SnO.sub.2 0.18 0.18 0.18 T.sub.str
(.degree. C.) 565 558 561 T.sub.ann (.degree. C.) 614 602 609
T.sub.s (.degree. C.) a (10.sup.-7/.degree. C.) 83.3 75.2 78 r
(gm/cc) 2.472 2.46 2.63 T.sub.200 (.degree. C.) 1601 1537 1514
T.sub.liq (.degree. C.) 1000 1020 980 h.sub.liq (kp) 405 104
257
[0151] It will be apparent to those skilled in the art that various
modifications and variations can be made to the present invention
without departing from the spirit or scope of the invention. Thus,
it is intended that the present invention cover the modifications
and variations of this invention provided they come within the
scope of the appended claims and their equivalents.
* * * * *