CRYSTALLIZED GLASS AND REINFORCED CRYSTALLIZED GLASS

Abstract

Provided are black crystallized glass that is safe and easy to produce, and reinforced crystallized glass of the black crystallized glass. Crystallized glass and reinforced crystallized glass containing, by wt % in terms of oxide, 40.0% to 70.0% of a SiO.sub.2 component, 11.0% to 25.0% of an Al.sub.2O.sub.3 component, 5.0% to 19.0% of a Na.sub.2O component, 0% to 9.0% of a K.sub.2O component, 1.0% to 18.0% of one or more components selected from a MgO component and a ZnO component, 0% to 3.0% of a CaO component, 1.0% to 3.5% of a TiO.sub.2 component, and 1.0% to 6.5% of a Fe.sub.2O.sub.3 component, and not containing a CoO component and a Co.sub.3O.sub.4 component.

Claims

1. A crystallized glass, comprising: by wt % in terms of oxide, 40.0% to 70.0% of a SiO.sub.2 component; 11.0% to 25.0% of an Al.sub.2O.sub.3 component; 5.0% to 19.0% of a Na.sub.2O component; 0% to 9.0% of a K.sub.2O component; 1.0% to 18.0% of one or more selected from a MgO component and a ZnO component; 0% to 3.0% of a CaO component; 1.0% to 3.5% of a TiO.sub.2 component; and 1.0% to 6.5% of a Fe.sub.2O.sub.3 component, and not comprising a CoO component and a Co.sub.3O.sub.4 component.

2. The crystallized glass according to claim 1, comprising: by wt % in terms of oxide, 45.0% to 65.0% of a SiO.sub.2 component; 13.0% to 23.0% of an Al.sub.2O.sub.3 component; 8.0% to 16.0% of a Na.sub.2O component; 1.0% to 7.0% of a K.sub.2O component; 2.0% to 15.0% of one or more selected from a MgO component and a ZnO component; 0.01% to 3.0% of a CaO component; 1.0% to 3.0% of a TiO.sub.2 component; 0% to 3.0% of one or more types selected from a group consisting of a Sb.sub.2O.sub.3 component, a SnO.sub.2 component, and a CeO.sub.2 component; and 1.0% to 6.5% of a Fe.sub.2O.sub.3 component.

3. The crystallized glass according to claim 1 wherein, by wt % in terms of oxide, a content of a B.sub.2O.sub.3 component is less than 2.0%.

4. The crystallized glass according to claim 1, wherein, by wt % in terms of oxide, a content of a Na.sub.2O component is 9.5% or more.

5. The crystallized glass according to claim 1, wherein a light transmittance including a reflection loss at a thickness of 1 mm is 0.20% or less in a wavelength range of 300 nm to 700 nm.

6. The crystallized glass according to claim 1, wherein a light transmittance including a reflection loss at a thickness of 1 mm is 0.50% or less at a wavelength of 900 nm.

7. The crystallized glass according to claim 1, comprising a color in CIELAB color space coordinates obtained from a reflection spectrum including specular reflection at an angle of incidence of 5° relative to a reflective surface measured with a spectrophotometer using CIE illuminant D65 at an observer angle of 2° and a thickness of 1 mm, without a white plate on a rear surface, the color having CIE a* in a range of −0.10 to 0.10, CIE b* in a range of −2.00 to 0.10, and CIE L* in a range of 20.0 to 30.0.

8. A reinforced crystallized glass comprising, as a base material, the crystallized glass according to claim 1, and a compressive stress layer formed in a surface of the reinforced crystallized glass.

Description

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0047] Embodiments and examples according to the present disclosure will be described below in detail, but the present disclosure is not limited to the following embodiments and examples, and may be implemented with appropriate changes within the scope of the object of the present disclosure.

[0048] As used herein, “A % to B %” represents A % or more and B % or less. Further, “0%” in “containing 0% to C %” refers to a content of 0%.

[0049] The crystallized glass of the present disclosure contains, by wt % in terms of oxide, [0050] 40.0% to 70.0% of a SiO.sub.2 component, [0051] 11.0% to 25.0% of an Al.sub.2O.sub.3 component, [0052] 5.0% to 19.0% of a Na.sub.2O component, [0053] 0% to 9.0% of a K.sub.2O component, [0054] 1.0% to 18.0% of one or more selected from a MgO component and a ZnO component, [0055] 0% to 3.0% of a CaO component, [0056] 1.0% to 3.5% of a TiO.sub.2 component, and [0057] 1.0% to 6.5% of a Fe.sub.2O.sub.3 component.

[0058] The crystallized glass of the present disclosure does not contain a CoO component and a Co.sub.3O.sub.4 component.

[0059] If such a composition is provided, it is possible to obtain a crystallized glass that is colored black and has high light-shielding properties. Furthermore, a glass that is a raw material of the crystallized glass of the present disclosure is less prone to devitrification and is easy to produce.

[0060] “In terms of oxide” means, if it is assumed that all the components included in the crystallized glass are dissolved and converted into oxides and a total weight of the oxides is 100 wt % (or 100 mol %), an amount of oxides in each of the components contained in the crystallized glass is expressed by wt % (or mol %). As used herein, contents of each component are expressed by wt % in terms of oxide unless otherwise specified.

[0061] The SiO.sub.2 component is preferably contained in an amount of 40.0% to 70.0%, more preferably 45.0% to 65.0%, and still more preferably 50.0% to 60.0%.

[0062] The Al.sub.2O.sub.3 component is preferably contained in an amount of 11.0% to 25.0%, and more preferably 13.0% to 23.0%.

[0063] The Na.sub.2O component is preferably contained in an amount of 5.0% to 19.0%, and more preferably 8.0% to 16.0%. The Na.sub.2O component may also be contained in an amount of 9.0% or more, 9.5% or more, or 10.5% or more. The Na.sub.2O component contributes to chemical strengthening.

[0064] The K.sub.2O component is preferably contained in an amount of 0% to 9.0%, more preferably 0.1% to 7.0%, and still more preferably 1.0% to 5.0%.

[0065] The one or more components selected from the MgO component and the ZnO component are preferably contained in an amount of 1.0% to 18.0%, more preferably 2.0% to 15.0%, still more preferably 3.0% to 13.0%, and particularly preferably 5.0% to 11.0%. The one or more components selected from the MgO component and the ZnO component may be the MgO component alone, the ZnO component alone, or both of the components, but preferably the MgO component alone. Also, the MgO component may be 2.7 mol % or more, 2.8 mol % or more, or 3.0 mol % or more.

[0066] The CaO component is preferably contained in an amount of 0% or more, more preferably 0.01% to 3.0%, and still more preferably 0.1% to 2.0%.

[0067] The TiO.sub.2 component is preferably contained in an amount of 3.5% or less, more preferably 1.0% to 3.0%, still more preferably 1.5% to 2.9%, and even more preferably 1.8% to 2.8%.

[0068] The Fe.sub.2O.sub.3 component is preferably contained in an amount of 1.0% or more, more preferably 1.5% to 6.5%, and still more preferably 2.0% to 4.5%.

[0069] A combined content of the TiO.sub.2 component and the Fe.sub.2O.sub.3 component is preferably 3.0% to 7.5%, and more preferably 4.0% to 6.8%.

[0070] The crystallized glass may contain 0% to 3.0% (0.01% to 2.0%, or 0.05% to 1.0%) of one or more selected from the Sb.sub.2O.sub.3 component, the SnO.sub.2 component, and the CeO.sub.2 component.

[0071] The above-mentioned blending amounts may be appropriately combined.

[0072] A combined content of the one or more components selected from the SiO.sub.2 component, the Al.sub.2O.sub.3 component, the Na.sub.2O component, the MgO component, and the ZnO component; the TiO.sub.2 component; and the Fe.sub.2O.sub.3 component may be 90% or more, preferably 95% or more, more preferably 98% or more, and still more preferably 98.5% or more.

[0073] A combined content of the one or more components selected from the SiO.sub.2 component, the Al.sub.2O.sub.3 component, the Na.sub.2O component, the K.sub.2O component, the MgO component, and the ZnO component; the CaO component; the TiO.sub.2 component; the Fe.sub.2O.sub.3 component; and the one or more components selected from the Sb.sub.2O.sub.3 component, the SnO.sub.2 component, and the CeO.sub.2 component may be 90% or more, preferably 95% or more, more preferably 98% or more, and still more preferably 99% or more. These components may also account for 100% of the crystallized glass.

[0074] The crystallized glass may or may not contain a ZrO.sub.2 component as long as the effect of the present disclosure is not impaired. The blending amount of the ZrO.sub.2 component may be 0% to 5.0%, 0% to 3.0%, or 0% to 2.0%.

[0075] As long as the effect of the present disclosure is not impaired, the crystallized glass may or may not contain a B.sub.2O.sub.3 component, a P.sub.2O.sub.5 component, a BaO component, a SnO.sub.2 component, a Li.sub.2O component, a SrO component, a La.sub.2O.sub.3 component, a Y.sub.2O.sub.3 component, a Nb.sub.2O.sub.5 component, a Ta.sub.2O.sub.5 component, a WO.sub.3 component, a TeO.sub.2 component, and a Bi.sub.2O.sub.3 component. The blending amount of each of the components may be 0% to 2.0%, 0% or more and less than 2.0%, or 0% to 1.0%. The combined blending amount of the B.sub.2O.sub.3 component and the P.sub.2O.sub.5 component may be 3.5 mol % or less, 2.0 mol % or less, 1.0 mol % or less, or 0 mol %.

[0076] The crystallized glass may contain, as a clarifying agent, an As.sub.2O.sub.3 component, and one or more types selected from the group of F, NOx, and SOx, in addition to the Sb.sub.2O.sub.3 component, the SnO.sub.2 component, and the CeO.sub.2 component. An upper limit of the content of the clarifying agent is preferably 5.0%, more preferably 2.0%, and most preferably 1.0%. Note that SOx (x being 3 or the like) is unstable in redox reactions and thus may adversely affect coloring, so that it is preferable that the crystallized glass does not contain SOx.

[0077] As long as the characteristics of the crystallized glass according to the present disclosure are not impaired, the crystallized glass may or may not contain other components not described above. Examples of the other components include metal components such as Nb, Gd, Yb, Lu, V, Cr, Mn, Ni, Cu, Ag, and Mo (including metal oxides thereof).

[0078] Moreover, there is a tendency to refrain from using components of Pb, Th, Tl, Os, Be, Cl, and Se, which are considered in recent years as harmful chemical substances, and thus, it is preferable that these components are substantially not contained.

[0079] Generally, the crystal phase of the crystallized glass is determined by using a peak angle appearing in an X-ray diffraction pattern in X-ray diffraction analysis, and by using TEMEDX if necessary. The crystallized glass used in the present disclosure contains, for example, MgAl.sub.2O.sub.4, Mg.sub.2TiO.sub.5, MgTi.sub.2O.sub.5, Mg.sub.2TiO.sub.4, MgTi.sub.2O.sub.4, Mg.sub.2SiO.sub.4, MgSiO.sub.3, MgAl.sub.2Si.sub.2O.sub.8, Mg.sub.2Al.sub.4Si.sub.5O.sub.18, FeAl.sub.2O.sub.4, MgFe.sub.2O.sub.4, FeTi.sub.2O.sub.5, Fe.sub.2O.sub.3, Fe.sub.3O.sub.4, and one or more selected from solid solutions thereof, as the crystal phase.

[0080] The reinforced crystallized glass of the present disclosure is obtained by strengthening the above-described crystallized glass to form a compressive stress layer on a surface.

[0081] A stress depth of the compressive stress layer of the reinforced crystallized glass is preferably 10 μm or more. When the compressive stress layer has such a thickness, even if a deep crack occurs in the reinforced crystallized glass, it is possible to prevent the crack from developing and a glass substrate from being broken.

[0082] A surface compressive stress of the compressive stress layer is preferably 750 MPa or more, more preferably 900 MPa or more, and still more preferably 950 MPa or more. An upper limit of the surface compressive stress may be, for example, 1300 MPa or less, 1200 MPa or less, or 1100 MPa or less. If the compressive stress layer has such a compressive stress value, it is possible to prevent a crack from developing and the mechanical strength can be increased.

[0083] In the crystallized glass and the reinforced crystallized glass (hereinafter, also simply referred to as crystallized glass) of the present disclosure, a light transmittance including reflection loss is preferably 0.20% or less at a thickness of 1 mm in a wavelength range of 300 to 700 nm.

[0084] The above-described light transmittance is more preferably 0.15% or less, and still more preferably 0.10% or less in the wavelength range of 300 to 700 nm.

[0085] Furthermore, the crystallized glass has a light transmittance including reflection loss of preferably 0.50% or less, more preferably 0.40% or less, and even more preferably 0.10% or less at a thickness of 1 mm and a wavelength of 900 nm.

[0086] The crystallized glass of the present disclosure preferably has a color in CIELAB color space coordinates obtained from a reflection spectrum including specular reflection at an angle of incidence of 5° relative to a reflective surface measured with a spectrophotometer using CIE illuminant D65 at an observer angle of 2° and a thickness of 1 mm, without a white plate on a rear surface, the color having [0087] CIE a* in a range of −0.10 to 0.10, [0088] CIE b* in a range of −2.00 to 0.10, and [0089] CIE L* in a range of 20.0 to 30.0.

[0090] The CIE a* is more preferably in a range of −0.09 to 0.05, and still more preferably in a range of −0.08 to 0.00.

[0091] The CIE b* is more preferably in a range of −1.50 to 0.05, and still more preferably in a range of −1.20 to 0.00.

[0092] The CIE L* is more preferably in a range of 22.0 to 29.0, and still more preferably in a range of 23.0 to 28.0.

[0093] Although a thickness of the crystallized glass is not particularly limited, the thickness is usually from 0.05 mm to 2.0 mm. Reinforced crystallized glass usually has a plate shape. The stress depth of the compressive stress layer on one side of the compressive stress layer is preferably 5% or more, and more preferably 8% to 20% of the thickness of the reinforced crystallized glass.

[0094] The crystallized glass and the reinforced crystallized glass of the present disclosure may be produced by the following method. That is, raw materials are uniformly mixed so that the components satisfy a predetermined content range, and are melted and shaped to produce raw glass. Next, the raw glass is crystallized to manufacture crystallized glass. Further, the crystallized glass is chemically strengthened.

[0095] The raw glass is subjected to heat treatment to precipitate crystals in the glass. The heat treatment may be performed at a one-stage temperature or a two-stage temperature.

[0096] The two-stage heat treatment includes a nucleation step of firstly treating the raw glass by heat at a first temperature and a crystal growth step of treating, after the nucleation step, the glass by heat at a second temperature higher than that in the nucleation step.

[0097] In the one-stage heat treatment, the nucleation step and the crystal growth step are continuously performed at the one-stage temperature. Typically, the temperature is raised to a predetermined heat treatment temperature, is maintained for a certain period of time after reaching the predetermined heat treatment temperature, and is then lowered.

[0098] The first temperature of the two-stage heat treatment is preferably 600° C. to 750° C. A retention time at the first temperature is preferably 30 minutes to 2000 minutes, and more preferably 180 minutes to 1440 minutes.

[0099] The second temperature of the two-stage heat treatment is preferably 650° C. to 850° C. A retention time at the second temperature is preferably 30 minutes to 600 minutes, and more preferably 60 minutes to 300 minutes.

[0100] When the heat treatment is performed at the one-stage temperature, the heat treatment temperature is preferably 600° C. to 800° C., and more preferably 630° C. to 770° C. A retention time at the heat treatment temperature is preferably 30 minutes to 500 minutes, and more preferably 60 minutes to 400 minutes.

[0101] A compact is manufactured from the crystallized glass by using, for example, grinding and polishing means. By processing the compact into a thin plate, it is possible to manufacture a plate-shaped crystallized glass. Further, the plate-shaped crystallized glass may be processed into a shape suitable for an application such as a housing.

[0102] Subsequently, in the present disclosure, a compressive stress layer is formed on the crystallized glass.

[0103] The chemical strengthening method may be implemented according to the following steps. During 10 minutes to 12 hours, a crystallized glass is contacted with or immersed in a molten salt of a salt containing potassium or sodium, for example, potassium nitrate (KNO.sub.3) and sodium nitrate (NaNO.sub.3), or a mixed salt thereof heated to 350° C. to 600° C. Thus, an ion exchange reaction between a component present in a glass phase near the surface and a component contained in the molten salt proceeds. As a result, the compressive stress layer is formed on a surface portion of the crystallized glass.

[0104] In particular, a crystallized glass base material is chemically strengthened in a first stage using a mixed molten salt of a potassium salt and a sodium salt (mixed bath) or a single molten salt of a sodium salt (single bath). After the first stage, the crystallized glass base material is chemically strengthened in a second stage using a single molten salt of a potassium salt (single bath). Therefore, it is possible to further increase the surface compressive stress relative to the central compressive stress. As a result, it is possible to obtain a crystallized glass that has high impact resistance and is less likely to break into small fragments (explosive breakage) even if broken upon impact. Specifically, for example, during 90 minutes or longer, the crystallized glass base material is contacted with or immersed in a molten salt of a salt containing potassium or sodium, for example, a mixed salt or a composite salt of potassium nitrate and sodium nitrate heated to 350° C. to 600° C. A mixing ratio of the potassium salt and the sodium salt is, for example, 1:1 to 100:1, or 10:1 to 75:1 expressed as a weight ratio. Subsequently, during a short period of time, the crystallized glass base material is preferably contacted with or immersed in a molten salt obtained by heating a salt containing potassium, for example, potassium nitrate to 380° C. to 550° C. The short period of time is, for example, 1 minute or more, or 3 to 100 minutes.

EXAMPLES

Examples 1 and 2, and Comparative Example 1

[0105] Raw materials such as oxides, hydroxides, carbonates, nitrates, fluorides, chlorides, and metaphosphate compounds corresponding to a raw material of each component of the crystallized glass were selected, and the selected raw materials were weighed and mixed uniformly to obtain the compositions described in Table 1.

[0106] Next, the mixed raw materials were fed into and melted in a platinum crucible. Subsequently, the molten glass was stirred and homogenized, cast into a mold, and slowly cooled to manufacture raw glass.

[0107] The obtained raw glass was subjected to heat treatment at 705° C. during five hours for nucleation and crystallization to manufacture crystallized glass.

[0108] The manufactured crystallized glass was cut and ground, and opposing sides of the obtained crystallized glass were further polished in parallel to achieve a thickness of 1 mm Next, the crystallized glass was used as a base material and immersed into a molten salt of KNO.sub.3 at 500° C. for 30 minutes to chemically strengthen the crystallized glass and obtain reinforced crystallized glass.

[0109] The obtained crystallized glass and the reinforced crystallized glass were evaluated as follows. The results are shown in Table 2. Table 2 also shows the specific gravity of the crystallized glass.

[0110] (1) Transmittance

[0111] The light transmittance of the crystallized glass, including reflection loss at a thickness of 1 mm, was measured by using a spectrophotometer (U-4000 model, manufactured by Hitachi High Technology). Table 2 lists the transmittance (%) in the range of 300 nm to 1500 nm and a wavelength at which the transmittance is 5%.

[0112] (2) Chromaticity

[0113] The reflection spectrum of the crystallized glass and the reinforced crystallized glass, including specular reflection at an angle of incidence of 5° relative to a reflective surface, was measured by using a spectrophotometer (V-650, manufactured by JASCO Corporation). At this time, the thickness of the sample was 1 mm, and the measurement was performed without a white alumina plate placed on a back surface of the glass (opposite side of the glass surface irradiated by the light source). From the obtained spectrum, L*, a*, and b* were determined at an observer angle of 2° and CIE illuminant D65.

[0114] (3) Stress Measurement

[0115] A thickness of the compressive stress layer (DOL) and a compressive stress value (CS) (MPa) on a surface of the compressive stress layer were measured in the reinforced crystallized glass by using a glass surface stress meter FSM-6000LE manufactured by Orihara Manufacturing Co., LTD. A refractive index of 1.54 and an optical elastic constant of 29.658 [(nm/cm)/MPa] of the samples were used to calculate the thickness of the compressive stress layer and the surface compressive stress value. A central compressive stress value (CT) was evaluated by using curve analysis. The results are shown in Table 2.

TABLE-US-00001 TABLE 1 Comparative Example 1 Example 2 Example 1 Composition SiO.sub.2 54.12 54.17 52.91 (wt. %) Al.sub.2O.sub.3 17.84 17.86 17.44 Na.sub.2O 11.50 11.51 11.24 K.sub.2O 2.38 2.38 2.33 MgO 7.78 7.79 7.61 CaO 0.84 0.84 0.82 TiO.sub.2 2.48 2.48 4.55 Sb.sub.2O.sub.3 0.08 0.00 0.08 Fe.sub.2O.sub.3 2.97 2.98 2.91 Co.sub.3O.sub.4 0.00 0.00 0.11 CoO 0.00 0.00 0.00 Crystallization Crystallization 705 705 705 conditions temperature Retention 5 5 5 time (hr) Reinforcing Plate 1 1 1 conditions thickness (mm) Molten salt KNO.sub.3 KNO.sub.3 KNO.sub.3 Salt bath 500 500 500 temperature (° C.) Immersion 30 30 30 time (min)

TABLE-US-00002 TABLE 2 Comparative Example 1 Example 2 Example 1 Crystallized Specific gravity 2.56 2.56 2.58 glass Transmittance 300 nm 0.0 0.0 0.0 at 1 mm (%) 410 nm 0.0 0.0 0.0 500 nm 0.0 0.0 0.0 700 nm 0.0 0.0 0.0 850 nm 0.0 0.0 0.0 900 nm 0.0 0.0 0.0 1050 nm 0.0 0.0 0.0 1200 nm 0.1 0.1 0.2 1500 nm 2.7 2.4 4.5 Transmittance 5% Wavelength (nm) 1579 1596 1516 Chromaticity L* 25.93 25.91 26.34 (D65, 5°) a* −0.07 −0.08 −0.06 b* −0.92 −0.90 −0.99 Reinforced Compressive Surface stress 1057 1065 1109 crystallized stress layer (MPa) glass Strengthening 12.2 13.1 14.1 depth (μm) Center stress 12.4 13.3 13.4 (MPa) Chromaticity L* 26.02 25.94 26.55 (D65, 5°) a* −0.06 −0.06 −0.02 b* −0.87 −0.84 −1.06

[0116] From Tables 1 and 2, it can be seen that the crystallized glass and the reinforced crystallized glass in the Examples have a lower content of a titanium component and do not contain a cobalt component as compared with the Comparative Example, are black in color with good light-shielding properties and a high stress value similar to the Comparative Example.