Fining of boroalumino silicate glasses
Glasses are disclosed which can be used to produce substrates for flat panel display devices, e.g., active matrix liquid crystal displays (AMLCDs). The glasses have MgO concentrations in the range from 1.0 mole percent to 3.0 mole percent and Σ[RO]/[Al 2 O 3 ] ratios greater than or equal to 1.00, where [Al 2 O 3 ] is the mole percent of Al 2 O 3 and Σ[RO] equals the sum of the mole percents of MgO, CaO, SrO, and BaO. These compositional characteristics have been found to improve the melting properties of batch materials used to produce the glass, which, in turn, allows the glasses to be fined (refined) with more environmentally friendly fining agents, e.g., tin as opposed to arsenic and/or antimony.
1. A method for producing alkali-free glass sheets by a downdraw process comprising:
(A) selecting, melting, and fining batch materials so that the glass making up the sheets comprises SiO 2 , Al 2 O 3 , B 2 O 3 , MgO, and CaO, and, on an oxide basis, has:
(i) a Σ[RO]/[Al 2 O 3 ] ratio greater than or equal to 1.0, where [Al 2 O 3 ] is the mole percent of Al 2 O 3 and Σ[RO] is the sum of the mole percents of MgO, CaO, SrO, and BaO; and
(ii) a MgO content greater than or equal to 1.0 mole percent;
(B) producing the glass sheets from the melted and fined batch materials;
wherein:
(a) on an oxide basis, the glass making up the glass sheets comprises at most 0.005 mole percent As 2 O 3 ;
(b) on an oxide basis, the glass making up the glass sheets comprises at most 0.005 mole percent Sb 2 O 3 ;
(c) SnO 2 is used in the fining and the glass making up the glass sheets has an SnO 2 content which in mole percent on an oxide basis satisfies the relationship:
0.01≦SnO 2 ; and
(d) the glass making up the glass sheets has a liquidus viscosity that is greater than or equal to 100,000 poise.
2. The method of claim 1 wherein the glass making up the glass sheets has an SnO 2 content which in mole percent on an oxide basis satisfies the relationship:
SnO 2 ≦0.15.
3. The method of claim 1 wherein the MgO content is between 1.2 and 2.8 mole percent.
4. The method of claim 1 wherein the glass making up the glass sheets is substantially free of BaO.
5. The method of claim 1 wherein the glass making up the glass sheets has a density that is less than or equal to 2.41 grams/cm 3 .
6. The method of claim 1 wherein the glass making up the glass sheets has a linear coefficient of thermal expansion (CTE) over the temperature range 0-300° C. which satisfies the relationship:
28×10 −7 /° C.≦CTE≦34×10 −7 /° C.
7. The method of claim 1 wherein the glass making up the glass sheets has a liquidus temperature less than or equal to 1170° C.
8. The method of claim 1 wherein the glass making up the glass sheets has a strain point that is greater than or equal to 650° C.
9. The method of claim 1 wherein the downdraw process is a fusion process.
10. The method of claim 1 wherein a population of 50 sequential glass sheets produced by the downdraw process from the melted and fined batch materials has an average gaseous inclusion level of less than 0.05 gaseous inclusions/cubic centimeter, where each glass sheet in the population has a volume of at least 500 cubic centimeters.
11. The method of claim 1 wherein the glass making up the glass sheets has a liquidus viscosity that is greater than or equal to 200,000 poise.