Glass powders, methods for producing glass powders and devices fabricated from same

Abstract

Glass powders and methods for producing glass powders. The powders preferably have a small particle size, narrow size distribution and a spherical morphology. The method includes forming the particles by a spray pyrolysis technique. The invention also includes novel devices and products formed from the glass powders.

1 . An aerosol method for making glass particles, the method comprising:
 generating an aerosol stream, as generated the aerosol stream comprising droplets comprising a liquid and at least one precursor for glass material; and   in the aerosol stream, forming glass particles comprising the glass material, the glass particles having a weight average particle size of not greater than 5 microns.   
     
     
         2 - 9 . (canceled) 
     
     
         10 . The method of  claim 1 , wherein the forming comprises heating the aerosol stream in a thermal reactor. 
     
     
         11 . The method of  claim 10 , wherein the thermal reactor is a tubular furnace reactor. 
     
     
         12 . The method of  claim 10 , wherein the thermal reactor is a flame reactor. 
     
     
         13 . The method of  claim 10 , wherein the thermal reactor is a plasma reactor. 
     
     
         14 . The method of  claim 1 , wherein during the heating, the aerosol stream reaches a maximum average stream temperature of greater than 800° C. 
     
     
         15 - 29 . (canceled) 
     
     
         30 . The method of  claim 1 , wherein the glass material is silicate glass. 
     
     
         31 . The method of  claim 1 , wherein the glass material is borate glass. 
     
     
         32 . The method of  claim 1 , wherein the glass material is phosphate glass. 
     
     
         33 . (canceled) 
     
     
         34 . The method of  claim 1 , wherein the glass material is aluminosilicate glass. 
     
     
         35 . The method of  claim 1 ,wherein the glass material is borosilicate glass. 
     
     
         36 . The method of  claim 1 , wherein the glass material is lead borosilicate glass. 
     
     
         37 - 50 . (canceled) 
     
     
         51 . The method of  claim 1 , comprising processing the glass particles, wherein the processing comprises forming a coating on the particles, the coating comprises a coating material that is different than the glass material. 
     
     
         52 - 55 . (canceled) 
     
     
         56 . The method of  claim 51 , wherein the coating material is a metal phase. 
     
     
         57 - 76 . (canceled) 
     
     
         77 . A method for making a glass layer on a substrate, the method comprising:
 making the glass particles according to the method of  claim 1 ;   depositing the glass particles on a substrate; and   sintering the glass particles.   
     
     
         78 - 86 . (canceled) 
     
     
         87 . The method of  claim 77 , wherein the glass particles comprise a complex glass. 
     
     
         88 - 121 . (canceled)