glass surface treatments: commercial processes used in glass
TRANSCRIPT
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Glass Surface Treatments: Commercial Processes Used in Glass Manufacture
Carlo G Pantano Distinguished Professor of Materials
Science and Engineering Penn State University
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Outline • Applications > Glass Containers and Float Glass • Purpose of Surface Treatments > weathering and corrosion resistance/ scratch resistance • Process Technologies • Testing and Evaluation > surface and in-depth analysis • Other Surface Treatments (often secondary processing) • functional coatings > 2/26, 3/03 • polishing > 3/5 • silanization and sizing of fiberglass > 3/17 • ion exchange strengthening > 4/30 • acid etching, acid polishing, fire polishing
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Float Glass > soda-lime-silicate
Application • top and bottom surfaces • annealing lehr rollers
• treatment for stacked
float glass sheets
Purposes • weathering/corrosion
resistance • optical properties • electrical properties • resistance to roller damage
• weathering resistance in
storage and transport
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Glass Containers > soda-lime-silicate
Application • inside surface of beverage
containers • inside surface of pharma
vials and ampules • outside surface of beverage
and other containers intended for high-speed filling lines
Purposes • weathering/corrosion
resistance • minimize leaching and
contamination of the product
• strengthening?
• scratch resistance • lubricity
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Float Glass > soda-lime-silicate
Application • top and bottom surfaces • annealing lehr rollers • interleave treatment for
stacked glass sheets
Treatments • ‘sulfur’ ; SO2 ; sulfur dioxide >> de-alkalization > lower surface reflectivity > lower surface conductivity • acidic liquid or powdered
coating • inert polymer bead spacers >> acidify and minimize condensed water on and between stacked glass sheets
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Glass Containers > soda-lime-silicate
Application • inside surface of beverage
containers • inside surface of pharma
vials and ampules • outside surface of beverage
and other containers intended for high-speed filling lines
Treatments • ‘sulfur’ ; SO2 ; sulfur dioxide
• ‘fluorine’ ; fluorocarbon • ammonium bifluoride/
sulfuric acid >> de-alkalization • hot-end coating • cold-end coating >> strength retention
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Effects of Glass Corrosion • dissolution/etching/weight loss • leaching/ion-exchange/surface layer formation • hazing/ dimming/ pitting, staining/ VISUAL EFFECTS • roughening/microporosity/ REACTIVITY • increased susceptibility to soiling/difficulty cleaning • STRENGTH and FATIGUE
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water reaction
initially, neutral pH ∅ later
−++− ++−→≡+−≡ OHNaOHSiOHNaOSi 2
• in general, a two-stage attach (sometimes three-stage) • kinetics = f (interdiffusion, solubility, local pH, solution volume.....)
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Interaction glass-water vapor
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Na+ + 2H2O → H3O+ + NaOH
2NaOH + CO2 → Na2CO3 + H2O
Ca(OH)2 + CO2 → CaCO3 + H2O
These hydroxides then react with carbon dioxide from the atmosphere to form carbonates, as in the reaction
and the reaction
Weathering (leaching and corrosion by HUMIDITY)
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Surface Layer Formation by Humidity
Na leached surface layer >> silica gel layer
bulk glass
Na+,Ca++,
• water adsorption and condensation on the surface • hydroxylation and leaching ion exchange and water reaction • accumulation of reaction products on the surface eg, Na and Ca hydroxides and carbonates
<< hazy surface << delamination of the gel layer
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Glass Containers > soda-lime-silicate
Application • inside surface of beverage
containers • inside surface of pharma
vials and ampules • outside surface of beverage
and other containers intended for high-speed filling lines
Treatments • ‘sulfur’ ; SO2 ; sulfur dioxide
• ‘fluorine’ ; fluorocarbon • ammonium bifluoride/
sulfuric acid >> de-alkalization • hot-end coating • cold-end coating >> strength retention
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SO2 surface treatment
Na2O + SO3 Na2SO4
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SO2 surface treatment
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SO2 surface treatment
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SO3 is more reactive than SO2 and increases the reaction kinetics
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COMMON METHODS: - Sputter depth-profiling (XPS and AES) - SIMS depth-profiling - Rutherford backscattering (RBS) - Nuclear reaction analysis (NRA)
SURFACE AND IN-DEPTH ANALYSIS
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Fluorocarbon Surface Treatment
OHxCOONaFSiCHFCHegFreonNaOSi 22223 2),(2 +++−≡→+−≡ +−
(US Patent 3,314,772) Analysis does not support
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Fluorocarbon Surface Treatment
OyHxCOvolatileNaFSiOSiCHFCHegFreonNaOSi 2223 )(2),(2 +++≡−−→≡+−≡ +−
alternate mechanism JAmCerSoc, C124, 1983
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Figure 60. The blow-blow process (Moody 1977)
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Figure 59. The press-blow process (Moody 1977).
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ASTM C225-73 Chemical Durability Test 1 HOUR at 121.5C -water (or relevant test solutions*)
* for example, protein based drugs which are stabilized in high pH solutions
UNTREATED FLUORINE SULFUR
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Glass Containers > soda-lime-silicate
Application • inside surface of beverage
containers • inside surface of pharma
vials and ampules • outside surface of beverage
and other containers intended for high-speed filling lines
Treatments • ‘sulfur’ ; SO2 ; sulfur dioxide
• ‘fluorine’ ; fluorocarbon • ammonium bifluoride/
sulfuric acid >> de-alkalization • hot-end coating • cold-end coating >> strength retention
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Hot End and Cold End Coatings to Provide Damage Resistance - Tin oxide at the hot end - Lubricious polyethylene at the cold end
* the surface of clean, dry, freshly-made glass exhibits high friction*
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Figure 5.15. Horse-shoe shaped cracks in the surface of glass produced by a small ball, sliding from left to right.
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Figure 6.7. (a) Surface damage produced by light abrasion of one glass rod on another
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Coatings for Glass Containers
THREE COMMON PRECURSORS for the SnO2 Hot-End Coating - anhydrous stannic chloride >> SnO2 + x HCl - dimethyl tin dichloride >> SnO2 + x HCl + y CO2 + z H2O - butyl tin chloride >> SnO2 + x HCl + y CO2 + z H2O
~450C
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Properties
Property Soda Lime Silica Glass Tin Oxide
Hardness (GPa) 6.3 10–14 (Ref. 24)
Young’s Modulus (GPa) 72 263 (Ref. 25)†
Poisson’s ratio 0.23 0.294 (Ref. 25)
Thermal Expansion
Coefficient (/0C)
8.3 4.13* (Ref. 27)
Density (Mg/m3) 2.53 6.990
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V
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2.0nm 3.0nm 4.0nm
tin-oxide (pyrolytic) coatings on glass containers
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Coatings for Glass Containers
COMMON Materials for Cold-End Coatings - stearates, silicones, glycerides, oleic acid, polyethylene emulsions - thickness ~100 nm + 50% - ~12.5 ug/cm2
~65-180C
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~450-500N force
= thickness
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High Speed Filling-Line Simulator … subject container surfaces to abrasive contact
Pressure Tester ….puts the outside surface in tension.
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Strength retention >>> NOT strengthening …. light-weighting the container is an outcome.
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Thin Solid Films, 77(1981)41-50
UNCOATED DRY
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Damage resistance of dual-end coated glass containers
•Mechanical effects - abrasion/sliding friction = f (roughness, chemistry) - contact/Hertzian Efilm vs Esubstrate, thickness - impact E, H, thickness •Chemical effects - tin oxide is an adhesion promoter for the CE-coating - aqueous attack of the glass is reduced (diffusion barriers) - Sn diffusion modifies the glass properties (Si-O-Sn) ?
Materials Research Institute
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H2O Contact Angle vs SnO2
0 200 400 600 800 100020
25
30
35
40
45
50
55
60
65
H 2O C
onta
ct A
ngle
(°)
SnO2 Thickness (Å)
CGW 1737 P16 sls
0 10 20 30 40 50 60 70 80 90 1000
1000
2000
3000
4000
5000
6000
7000
8000
9000
C3H6O2+
C3F2+
C2H5O+
C2H3+
C2H5+
H2O+
CH3+
CF+
C5H9+
C4H5O+
CF3+
41K+
C3H5+
C4H7+
C4H9+
39K+
Na+
C3H7+
C2H3O+
H+
X+ Inte
nsity
m/e
TOF-SIMS spectra shows corresponding hydrocarbon adsorption
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H2O Contact Angle vs SnO2
0 200 400 600 800 100020
25
30
35
40
45
50
55
60
65
H 2O C
onta
ct A
ngle
(°)
SnO2 Thickness (Å)
CGW 1737 P16 sls
Sn Sn Sn Sn
OH OH OH OH
organic species
….. suggests that the SnO2 surface is more hydrophobic than the glass, and thereby provides strong adhesion of the organic (cold-end) coating.
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Figure 6. Wear test on SnO2 films on P16 SLS before and after 2 passes at 20µN normal force .
Figure 7. Wear test on SnO2 films on P16 SLS after 2 and 4 passes at 50µN.
WEAR RESISTANCE OF TIN-OXIDE ON GLASS
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Float Glass
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‘sulfur treatment for surface DEALKALIZATION’
2Na+ + SO2 + H2O + ½ O2 >> Na2SO4 + 2H +
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Hydrogen in-depth profiles before and after SO2 treatment
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Chemical Evaluation of Leachable Sodium
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Acid Interleave Coatings
Acid interleave coatings are widely used in float glass industry to separate sheets and protect from damage in transit & storage Physical damage: glass-to-glass contact, trapped particulate Chemical damage: corrosion, weathering, “stain”
Applied to surfaces of fresh float glass after final inspection but before stacking
Most common is a blend of powdered adipic acid and polymer beads; new products recently introduced
New and emerging applications of glass require control of glass surface properties at the nanoscale for optical coating, display electronics and bio-substrates.
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Weathering • glass corrosion often described by two primary stages:
– “Stage I”: Ion-exchange (leaching) of mobile alkali with H+/H3O+, forming SiO2-rich layer (with potential for static pH rise)
– “Stage II”: Dissolution of silica network at pH >9 with degradation of surface, formation of insoluble precipitates
R. A. Schaut, Pantano C.G., The Glass Researcher (2005)
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Application Process
PMMA beads typically, 200 mg/m2 of acid powder
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Testing and Evaluation -Laboratory and Field-
CYCLIC weathering conditions: 60°C/25°C/5°C cycles 75% R.H. constant 0, 4, 12, 30, 60, 90 day samples
Based on conditions experienced during overseas transport
Visible periods of condensation
60°C
25°C
5°C
(Repeat)
24h 12h 6h 18h
85°C (Repeat)
24h 12h 6h 18h
75% R.H.
85% R.H.
STATIC weathering conditions: Constant 85°C, 85% R.H. 0, 1, 2, 3, 4 day samples
Higher T, humidity → more aggressive
Condensation-runoff unlikely
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Testing and Evaluation – visual
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Commercial Float Glass
Leached for one hour at 96ºC into 30mL of DI – H2O
0.0
1.0
2.0
3.0
4.0
5.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Approx. Sputter Depth (nm)
[Na]
(Ato
m %
)90d
60d
30d
12d4dAs Rec'd
700mg/m2 - CYCLIC
Coating coverage required can depend on the product and its application.
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FT-IRRS of Treated Surfaces
-1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
Leached Layer Thickness (nm)
FT-IR
RS
Peak
Shi
ft (c
m-1
)
BORIC 700 CYCLIC BORIC 200 CYCLIC NO ACID CYCLIC ADIPIC CYCLICBORIC 700 STATIC BORIC 200 STATIC NO ACID STATIC
Average: 0.1 cm-1/nm
As Rec'd
90 days60 days
4 days
30 days12 days
10401050106010701080
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Commercial Float Glass
Exposed to 98% RH at 60ºC – Top Side
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SUMMARY • SO2 and fluorine treatment for the internal surface of
glass containers is widely practiced; but it costs the customer extra.
• The visible effects of the ‘SO2 treatment’ (ie, before washing off the Na-sulfate crystals can be a plus.
• New drugs are creating renewed interest in SO2 treatments because some drugs can attack the glass.
• The non-uniformity of the SO2 dealkalization, especially for float glass, is a factor for some applications.
• The inherent non-uniformity of ‘acid interleave coatings’ is also a factor for some applications.
• Dual-end coatings on glass containers (ie, hot-end and cold-end) are also widely applied; most products require at least the cold-end coating.
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Fluorocarbon Surface Treatment
OHxCOONaFSiCHFCHegFreonNaOSi 22223 2),(2 +++−≡→+−≡ +−
(US Patent 3,314,772)
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High temperature fluorocarbon treatments of glass containers
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Integrated and Interfaced with other materials
A substrate for biomolecules and cell growth
Glass Surfaces, Coatings and Interfaces
< Stability of the Glass Surface and Glass/Coating Interface>
A substrate for electronics… including flexible electronics
A substrate for optical coatings…low-E, reflective and anti-reflective
Strength determining
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organo-functionalization of a glass surface
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Si OCH2CH3H3CH2CO
NH2
H3CH2CO
Silanes
• γ-aminopropyltriethoxysilane
• 3-aminopropyldimethylethoxysilane
• Aminoalkylsilsesquioxane
H2C
H2CCH2
SiO
HH2N
OOH
Si O
OH
NH2
Si O
CH3
OH
m
Si CH2
CH2
CH2
H2NH
O
OH
n
H3CH2CO Si
CH3
CH3
NH2
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organic polymer coatings • hydrophobic/hydrophilic • patternable for microfluidics • anti-bacterial/anti-fouling • substrates for biotechnology (ELISA, super-aldehyde, GAPS, etc.) • molecular electronics (OLEDs, conductors, transistors) • fiberglass sizing/ coupling layers • ‘precursors for inorganic coating
IPGR, Jacksonville, FL, March 16, 2004 Materials Research Institute
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Thin Solid Films, 77 ( 1981 ) 23-39 METALLURGICAL AND PROTECTIVE COATINGS “EXPERIENCE IN THE CONTROL AND EVALUATION OF COATINGS ON GLASS CONTAINERS”
JAmCerSoc, C124, 1983