Zinc-containing phosphate glasses

Abstract: This invention is directed to the preparation of glasses exhibiting a transition temperature below 450°C, a working temperatures below 500°C, and excellent resistance to attack by water and mild aqueous alkaline solutions. The glasses consist essentially, in mole percent, of: P₂O₅ 28-40 ZnO 12-55 Al₂O₃ 0-6 Li₂O 0-25 Na₂O 0-25 K₂O 0-25 Li₂O+Na₂O+K₂O 10-35 F 0-5 B₂O₃ 0-8 PbO 0-35 SnO 0-35 PbO+SnO 0-35 CaO 0-10 MnO 0-10 MgO 0-10 CaO+Cu₂O+MgO 0-10 Cu₂O 0-15 At least two alkali metal oxides must be present.

Description: This invention relates to zinc-containing phosphate glasses. Research has been continuous to develop inorganic glasses exhibiting low transformation or transition temperatures (Tg), thereby making it possible to conduct melting and forming operations at low temperatures. Inasmuch as glass compositions wherein silica comprises the primary network or glass forming component customarily manifest transition temperatures considerably in excess of 450°C with forming temperatures greater than 800°C, the desire for glass compositions displaying low transition temperatures has typically resulted in the use of B₂O₃ and/or P₂O₅ as the principal network forming constituent. U. S. Patent No. 3,732,181 discloses three general areas of glass compositions, wherein P₂O₅ is the principal glass former, which exhibit transition temperatures within the interval of 100°-400°C: (a) 20-80 mole % PbO + P₂O₅ ≧95 mole % (b) 5-60 mole % PbO + 5-35 mole % R₂O + up to 85 mole % P₂O₅ ≧95 mole % (c) 5-30 mole % PbO + 5-30 mole % R₂O + 5-20 mole % B₂O₃ + 15-85 mole % P₂O₅ ≧95 mole %. It is stated that ZnO may replace part or all of the PbO. Unfortunately, phosphate-based glasses typically exhibit poorer chemical durability than silica-based glasses, and that characteristic commonly becomes more pronounced as the transition temperature of the glass becomes lower. Thus, the known low melting phosphate glasses are frequently readily attacked by boiling water and, in extreme instances, manifest hygroscopic behavior. As conventionally defined, the transition temperature of a glass is that temperature at which increases in specific heat and thermal expansion coefficient take place which are accompanied by a sharp drop in viscosity. Accordingly, the primary objective of the present invention was to develop glasses exhibiting transition temperatures below 450°C, preferably below 350°C, with working temperatures (temperatures at which the glass demonstrates a viscosity of about 10³-10⁶ kPa.s (10⁴-10⁷ poises)) below 500°C, preferably between about 350°-450°C, which glasses display exceptional chemical durability when contacted with boiling water and mild aqueous alkaline solutions. Summary of the Invention That objective can be achieved in glasses having compositions within a specifically-defined region of the R₂O-ZnO-P₂O₅ system, wherein R₂O consists of Li₂O, Na₂O, and/or K₂O, and wherein PbO and/or SnO can replace a portion of the ZnO content. Hence, because PbO and/or SnO can be substituted for ZnO in amounts up to 25 mole percent, the broad composition area operable in the present invention consists essentially, expressed in terms of mole percent on the oxide basis, of 12-25% R₂O, wherein R₂O consists of at least two alkali metal oxides in the indicated proportions of 3-12% Li₂O, 4-18% Na₂O, and 0-12% K₂O, 30-49% ZnO, 28-36% P₂O₅, and, optionally, up to 30% RO, wherein RO consists of 0-30% PbO and 0-30% SnO. The inclusion of at least two alkali metal oxides has been found necessary since laboratory experience has indicated that the presence of Li₂O alone hazards devitrification in the glass, Na₂O alone renders the glass insufficiently durable or too difficult to melt, and K₂O alone raises the Tg of the glass too high. Additions of Al₂O₃ in amounts ranging about 0.75-6% and/or B₂O₃ at levels about 1-8% are particularly useful in enhancing the chemical durability of the glass and/or improving glass stability, the total of those additions not exceeding 8%. Consequently, the preferred inventive glasses will contain one or both of those components. CaO, MgO, and MnO may be included in individual concentrations up to 10%, with the total of those constituents not exceeding 10%. Cu₂O may be present up to 15%. MnO and Cu₂O exhibit the capability of reducing the Tg of the glass while maintaining good chemical durability therein. Additions of other compatible oxides and fluoride (F₂) can be tolerated in amounts not exceeding about 5%. ZrO₂ is particularly useful in imparting a uniform white opal coloration to the glasses in amounts of about 1-5%. The sum of all optional components will not total more than about 30%. In the preferred compositions the sum of R₂O + Al₂O₃ and/or B₂O₃ + ZnO + P₂O₅ with, optionally, PbO and/or SnO will total at least 85%. The most preferred glasses also contain as ingredients 0-10% SnO, and 1-3.5% Al₂O₃, as well as 30-36% P₂O₅ with the proviso that, if present, the sum of CaO + MgO + F will not exceed 5%. Prior Art U. S. Patent No. 3,215,543 describes the production of articles composed of mica particles dispersed in a glassy matrix, the glassy matrix consisting essentially, in mole percent, of 6-20% RO, wherein RO consists of CaO, MgO, and/or ZnO, 22-42.5% R₂O, wherein R₂O consists of the alkali metal oxides, 6 to (16+ d / 6)% Al₂O₃, and (36- d / 3) to (56-d)% P₂O₅, where d comprises the percentage of RO. The Al₂O₃ content is in excess of that which can be tolerated in the present inventive compositions. U. S. Patent No. 3,407,091 discloses the preparation of sealing glasses consisting essentially, in weight percent, of 4-27% Na₂O and/or K₂O, 4-30% ZnO, 2-10% Al₂O₃, and 60-67% P₂O₅. The P₂O₅ concentration is greater than that which is permissible in the present inventive glasses. U. S. Patent No. 3,481,749 sets forth glasses suitable as lubricants for use, for example, in the extrusion of metallic bodies at elevated temperatures. That application requires a glass readily attacked by water to permit easy removal from the body by washing after use. The glasses consisted essentially, in molar percent, of 9-33% alkali metal oxide, 16-20% BaO, CaO, MgO, PbO, and/or ZnO, 10-20% Al₂O₃, and 29-61% P₂O₅. The Al₂O₃ level is far above that found operable in the present invention. Moreover, the poor chemical durability of the glasses would render them useless in the applications envisioned for the present inventive glasses. U. S. Patent No. 3,732,181 was reviewed in some detail above. Al₂O₃ is nowhere mentioned as a glass component and all of the working examples have compositions quite far removed from the ranges of the present invention. U. S. Patent No. 3,885,973 teaches the preparation of glasses having compositions consisting essentially, in mole percent, of 5-25% Li₂O, 5-30% ZnO, 58-76% P₂O₅, and 0-10% alkaline earth oxides, and may contain up to 5% by weight water. There is no requirement for the presence of at least two alkali metal oxides and no working example contained two, and the concentrations of P₂O₅ far exceed those found operable in the instant inventive glasses. U. S. Patent No. 3,926,649 describes the production of glasses having compositions consisting essentially, in mole percent, of 72.5-77.5% P₂O₅+B₂O₃ and 22.5-27.5% alkali metal oxides, alkaline earth metal oxides, and ZnO, and may contain up to 5% by weight water. There is no requirement for the inclusion of at least two alkali metal oxides and in all of the working examples the P₂O₅ content is much higher than can be tolerated in glasses of the present invention. U. S. Patent No. 3,935,018 discloses the formulation of glasses having compositions consisting essentially, in mole percent, of 1.2-3.5% B₂O₃, 50-72% P₂O₅, 0-30% PbO, 0-5% transition metal oxides, and the remainder alkali metal oxides, alkaline earth metal oxides, and/or ZnO, and may contain up to 5% by weight water. No working example contained ZnO and the P₂O₅ level is greater than that found operable in the present inventive glasses. U. S. Patent No. 3,979,322 sets forth glasses suitable for laser applications consisting essentially, in mole percent, of 1-30% alkali metal oxides, 20-45% group II metal oxides, 0.1-25% Nd₂O₃, 35-49% P₂O₅ and 0-27% Al₂O₃, B₂O₃, Nb₂O₅ and/or PbO. There is no requirement that at least two alkali metal oxides be present and one of the working examples contained two. Moreover, the P₂O₅ contents and, where present, the alkaline earth metal oxides concentrations in the working examples were substantially in excess of those delimited in the glasses of the instant invention. U. S. Patent No. 4,026,714 discusses the production of glasses exhibiting anti-misting properties, the phenomenon of anti-misting being the result of the glasses being slightly hygroscopic. Such glasses would not be suitable for the purposes of the present invention. The glasses consisted essentially, in mole percent, of 4-30% alkali metal oxides, alkaline earth metal oxides, or ZnO, 1-12% PbO, 3.5-12% B₂O₃ and/or SiO₂ and/or Al₂O₃, and 52-72% P₂O₅. The P₂O₅ content is far in excess of that which is operable in the present invention. U. S. Patent No. 4,060,422 relates to sealing glasses for glass lasers consisting essentially, in mole percent, of 4-12% Li₂O, 5-25% PbO, 15-35% ZnO, 1-4% Al₂O₃, 2-10% V₂O₅, and 45-65% P₂O₅. The P₂O₅ level is higher than is suitable in the present inventive glasses. U. S. Patent No. 4,229,220 is concerned with glasses useful in coating glass laser discs consisting essentially, in mole percent of 0-20% Li₂O, 0-17% Na₂O, 8-20% Li₂O+Na₂O, 7-28% CuO, 4-10% Al₂O₃, 51-59% P₂O₅, 0-8% B₂O₃, 0-2% ZnO, 0-15% BaO, and 0-13% V₂O₅. The concentration of P₂O₅ exceeds that found operable in the present inventive glasses. U. S. Patent No. 4,239,645 is drawn to laser glasses consisting essentially, in mole percent, of 10-25% R₂O, wherein R₂O consists of 0-25% Li₂O, 0-25% Na₂O, and 0-8% K₂O, 5-15% RO, wherein RO consists of 0-15% BaO, 0-15% CaO, 0-15% MgO, 0-15% SrO, and 0-15% ZnO, 1-15% Al₂O₃, 55-70% P₂O₅, 0.01-5% Nd₂O₃, 0-5% Y₂O₃, 0-5% La₂O₃, 0-5% GeO₂, 0-5% CeO₂, 0-3% Nb₂O₅, 0-3% MnO₂, 0-2% Ta₂O₅, and 0-1% Sb₂O₃. The P₂O₅ content is greater than that specified in the present invention. U. S. Patent No. 4,248,732 refers to laser glasses consisting essentially, in mole percent, of 5-40% alkali metal oxides, 5-30% RO, wherein RO is at least one oxide selected from the group BaO, BeO, CaO, MgO, SrO, and ZnO, 0.01-15% R₂O₃, where R₂O₃ is at least one oxide selected from the group Al₂O₃, B₂O₃, Er₂O₃, La₂O₃, Tm₂O₃, and Y₂O₃, 0.01-7% Nd₂O₃, 35-65% P₂O₅, and 0.1-10% by weight of a solarization inhibiting oxide selected from the group of CeO₂, Nb₂O₅, Sb₂O₃, SiO₂, and TiO₂. Such ranges and the components making up those ranges are far broader and more diverse than can be tolerated in the present inventive glasses. Even excluding the required inclusion of Nd₂O₃ and the solarization inhibitor, none of the 29 working examples provided in the patent had a composition coming within the ranges delimited in the present invention. U. S. Patent No. 4,391,915 records glasses from which optical components can be pressed consisting essentially, in weight percent, of 5-20% K₂O, 0-3% Li₂O, 8-15% BaO, 0-6% MgO, 0-18% PbO, 4.5-9% ZnO, 3.5-9% Al₂O₃, 0-3% B₂O₃, 0-1% SiO₂, 0-2% TiO₂, 45-55% P₂O₅. The content of BaO exceeds that which can be tolerated in the present inventive glasses. Moreover, the level of P₂O₅ in mole percent in all of the working examples provided in the patent was higher than the maximum permitted in the present inventive glasses. U. S. Patent No. 4,439,530 reports optical glasses basically consisting essentially, in weight percent, of 3-30% R₂O, wherein R₂O consists of 0-30% Na₂O+0-30% K₂O, 8-65% PbO, 1-45% Ta₂O₅ and 18-38% P₂O₅. The patent also recites a large number of optional ingredients in varying amounts including 0-3% Al₂O₃ and 0-25% ZnO. Ta₂O₅ comprises no part of the present inventive glasses and, even ignoring the presence of Ta₂O₅, none of the working examples provided in the patent had a composition within the ranges required in the present inventive glasses. U. S. Patent No. 4,544,974 recites glass compositions suitable for bonding metals or metal oxides into a composite structure. The glasses consist essentially, in mole percent, of 10-40% alkali metal or alkaline earth metal oxide, 0-25% CuO or ZnO, 5-15% Al₂O₃, 0-25% B₂O₃, 0-30% SiO₂, and 10-35% P₂O₅, wherein at least one of B₂O₃, CuO, SiO₂, and ZnO is present. B₂O₃ and SiO₂ are not required constituents in the present inventive glasses; the Al₂O₃ content of the glasses disclosed in the patent is higher than desired in the present inventive glasses; and, even ignoring the high Al₂O₃ levels, the working examples provided in the patent had compositions outside the ranges demanded in the present inventive glasses. "Oxide Glasses of Very Low Softening Point. Parts 1 and 2. Preparation and Properties of Some Lead Phosphate Glasses," N. H. Ray et al., Glass Technology 14 , No. 2, pages 50-59, April 1973, provides an extensive study of a wide variety of phosphate-based glasses, including R₂O-ZnO-P₂O₅ glasses. However, none of the glasses had a composition coming within the ranges of the present invention. Description of Preferred Embodiments Table I records a number of glass compositions, expressed in terms of mole percent on the oxide basis, operable in the present invention. Table IA reports the same compositions, but wherein the values of the individual components have been converted to weight percent. The actual batch ingredients for the glasses can comprise any materials, either the oxides or other compounds, which, upon being melted together, will be converted into the desired oxides in the proper proportions. For example, Li₂CO₃ is conveniently employed as the source of Li₂O. Because it is not known with which cation it is combined and because the amount included was relatively bite small, the fluoride content is simply recorded in percent in addition to the base glass composition. The batch materials were compounded, ballmilled together to aid in securing a homogeneous melt, and then charged into silica crucibles. After placing lids thereon, the crucibles were introduced into a furnace operating at about 1000°C and maintained at that temperature for about 3 hours. Each melt was poured into a steel mold to produce a rectangular glass slab having dimensions of about 203x102x13 mm (8"x4"x0.5") and the glass slab annealed overnight at 300°C. Rectangular tab-shaped pieces weighing about 30-40 grams were cut from the slabs and heat treated in cups of aluminum foil to temperatures within the range of 350°-450°C, and glass cane was hand drawn from each cup to obtain a close approximation of the working temperature of the glass. Whereas the above description reflects laboratory melting and forming practice only, it will be appreciated that the recited compositions are capable of being melted in large scale melting units and shaped into desired configurations utilizing forming techniques conventional in the glassmaking art. Samples having the approximate dimensions of 35 x 25 x 15 mm were cut from each glass slab and then ground and polished for testing the chemical durability thereof. In one test each sample was carefully weighed and then immersed into a bath of boiling water. After a residence time of six hours, the sample was removed from the bath, dried in the ambient environment, and thereafter weighed to determine any loss of weight by the sample. In a second test each sample was carefully weighed and then immersed into a bath operating at 75°C of a 0.3% by weight aqueous solution of SUPER SOILAX detergent marketed by Economics Laboratories, St. Paul, Minnesota, the solution exhibiting a pH of about 10. After a dwell period of 24 hours, the sample was removed from the bath, dried in the ambient environment, and reweighed to measure any weight loss. In a third test each sample was carefully weighed and then introduced into an autoclave. The temperature within the autoclave was raised to 125°C and a steam atmosphere of 228 kPa (33 psi) generated. After an exposure of four hours, the sample was removed from the autoclave, dried in the ambient environment, and again weighed to determine any loss in weight. The Tg of the glass was measured utilizing standard differential scanning calorimetry techniques. Table II reports the percent weight loss in the boiling water test (H₂O), the percent weight loss in the SUPER SOILAX test (SUPER), the percent weight loss in the steam test (Steam), the Tg of the glass in °C, and the working temperature of the glass in °C as determined by pulling cane (Pull). In certain instances, the samples exhibited a frosted appearance after exposure to the steam test. That phenomenon is noted by the designation (Fr). One example crystallized (Cryst) during the pull test. The measures of resistance to attack by water exhibited by Examples 1-24 are very exceptional for phosphate-based glass compositions, and are particularly noteworthy since the glasses demonstrate such low transition and working temperatures. The sharp deterioration in chemical durability occurring in glass compositions even slightly outside the ranges prescribed in the inventive glasses is immediately evident with a review of Examples 25-27. Hence, in Example 25 additions of Al₂O₃ and/or substitutions of Cu₂O for R₂O and/or ZnO would be required to improve their durability to the level of that exhibited by Example 3 which is lower in P₂O₅ content and within the most preferred region of compositions. Example 26 clearly illustrates the need for at least two alkali metal oxides in the glass. In Example 27 the level of P₂O₅ is too high. The high resistance to moisture attack renders the inventive glasses eminently suitable for a wide range of applications including, for example, food service, electronic devices, optical and ophthalmic lenses, and coatings for optical waveguides. Furthermore, because the viscosity relationships exhibited by the inventive glasses at relatively low working temperatures render them capable of being shaped into articles of complex configurations through extrusion, injection molding, and other techniques conventionally employed in the plastic forming art, the range of products for which the inventive glass-ceramics are useful is greatly broadened.

Claims: A glass characterised in that it exhibits a transition temperature below 450°C, a working temperature below 500°C, and excellent resistance to attack by water and mild aqueous alkaline solutions, and consists, expressed in terms of mole percent on the oxide basis, of 30-49% ZnO, 28-36% P₂O₅, and 12-25% R₂O, wherein R₂O consists of at least two alkali metal oxides in the indicated proportions selected from the group consisting of 3-12% Li₂O, 4-13% Na₂O, and 0-12% K₂O, and up to 30% total of optional ingredients in the indicated proportions selected from the group consisting of 0-6% Al₂O₃, 0-8% B₂O₃, 0-8% Al₂O₃+B₂O₃, 0-15% Cu₂O, 0-5% F, 0-30% PbO, 0-30% SnO, 0-30% PbO+SnO, 0-5% ZrO₂, and 0-10% MgO+CaO+MnO, consisting of 0-10% MgO, 0-10% CaO, and 0-10% MnO. A glass according to claim 1 containing 0.75-6% Al₂O₃ and/or 1-8% B₂O₃, the total Al₂O₃+B₂O₃ not exceeding 8%. A glass according to claim 1 or claim 2 wherein the sum of R₂O+Al₂O₃ and/or B₂O₃+ZnO+P₂O₅ with, optionally, PbO and/or SnO will total at least 85%. A glass according to any of claims 1 to 3 containing 0-10% SnO, 1-3.5% Al₂O₃, 30-36% P₂O₅, and 0-5% CaO+MgO+F. A method for the preparation of a glass as claimed in any of claims 1 to 4 wherein the suitable batch ingredients for the glasses, as oxides or other compounds, which, upon being melted together are converted to the desired oxides, are melted together in the proper proportions to produce the desired glass.

Inventors: BEALL GEORGE HALSEY, QUINN CANDACE JO, BEALL, GEORGE HALSEY, QUINN, CANDACE JO
Applicants: CORNING INC, CORNING INCORPORATED
Application year: 1989
Main classification: C03C3
IPC codes: C03C3, C03C4