Surface Treatment Process for Glass Containers

Abstract

A glass container and a process for chemically modifying a surface portion of a glass container using an ion-exchange process. At least a portion of the glass container is immersed in or in contact with an aqueous electrolyte solution comprising salts of at least one group IA alkali metal and having a temperature of about 75 degrees Celsius such that exchangeable alkali metal ions in a surface portion of the glass container are exchanged or replaced by alkali metal ions in the electrolyte solution. The alkali metal ions that replace the exchangeable ions in the surface portion of the glass container have either a smaller or a larger atomic radius than the exchangeable ions.

1 . A surface treatment process for a glass container comprising:
 contacting at least a portion of the glass container with an aqueous electrolyte solution comprising salts of at least one group IA alkali metal, the aqueous electrolyte solution having a salt mass fraction in the range of 10-50%; and then   heating the glass container with the aqueous electrolyte solution to a temperature between 70 degrees Celsius and 100 degrees Celsius for a time sufficient to exchange alkali metal ions in a surface portion of the glass container with alkali metal ions in the electrolyte solution.   
     
     
         2 . A process as set forth in  claim 1  further comprising:
 removing the glass container from the aqueous electrolyte solution; and then 
 rinsing the glass container with a liquid to remove any residual salts therefrom. 
 
     
     
         3 . A process as set forth in  claim 1  wherein the glass container is heated with the aqueous electrolyte solution for 10 hours to 30 hours. 
     
     
         4 . A process as set forth in  claim 1  wherein the alkali metal ions in the electrolyte solution include lithium (Li + ), sodium (Na + ), potassium (K + ), or combinations thereof. 
     
     
         5 . A process as set forth in  claim 1  wherein the salts of at least one group IA alkali metal include lithium chloride (LiCl), lithium nitrate (LiNO 3 ), lithium sulfate (Li 2 SO 4 ), lithium carbonate (Li 2 CO 3 ), potassium chloride (KCl), potassium nitrate (KNO 3 ), potassium sulfate (K 2 SO 4 ), potassium carbonate (K 2 CO 3 ), or combinations thereof. 
     
     
         6 . A process as set forth in  claim 1 , wherein the glass container is made of soda-lime-silica glass, borosilicate glass, or aluminosilicate glass. 
     
     
         7 . A process as set forth in  claim 6 , wherein the glass container is heated with the aqueous electrolyte solution for a time sufficient to exchange sodium ions (Na + ) in a surface portion of the glass container with potassium (K + ) in the electrolyte solution. 
     
     
         8 . A glass container produced by the process set forth in  claim 1 . 
     
     
         9 . A process for producing a soda-lime-silica glass container including the steps of:
 (a) forming the glass container;   (b) annealing the glass container;   (c) immersing at least a portion of the glass container in an aqueous electrolyte solution containing salts of a group IA alkali metal to exchange ions in a surface portion of the glass container with at least a portion of the alkali metal ions in the electrolyte solution, the aqueous electrolyte solution having a temperature between 70 degrees Celsius and 100 degrees Celsius and a salt mass fraction in the range of 10-50%; and then   (d) applying a cold-end coating to an exterior surface of the glass container.   
     
     
         10 . A process as set forth in  claim 9 , wherein the cold-end coating of step (d) is a polyethylene, stearate, or oleic acid coating. 
     
     
         11 . A process as set forth in  claim 9 , wherein the glass container is immersed in the aqueous electrolyte solution of step (c) for 10 hours to 30 hours. 
     
     
         12 . A process as set forth in  claim 9 , wherein the salts of the group IA alkali metal of step (c) include lithium chloride (LiCl), lithium nitrate (LiNO 3 ), lithium sulfate (Li 2 SO 4 ), lithium carbonate (Li 2 CO 3 ), potassium chloride (KCl), potassium nitrate (KNO 3 ), potassium sulfate (K 2 SO 4 ), potassium carbonate (K 2 CO 3 ), or combinations thereof. 
     
     
         13 . A process as set forth in  claim 9 , wherein the group IA alkali metal of step (c) is lithium (Li), sodium (NO, or potassium (K + ). 
     
     
         14 . A process as set forth in  claim 9 , wherein the soda-lime-silica glass container comprises: 60-75 wt % SiO 2 , 7-15 wt % Na 2 O, 6-12 wt % CaO, 0.1-3.0 wt % Al 2 O 3 , 0-2.0 wt % MgO, and 0-2.0 wt % K 2 O. 
     
     
         15 . A process as set forth in  claim 14 , wherein the glass container is immersed in the aqueous electrolyte solution of step (c) for a time sufficient to exchange sodium ions (Na + ) in a surface portion of the glass container with potassium (K + ) ions in the electrolyte solution. 
     
     
         16 . A process as set forth in  claim 9  further including the steps of:
 (c1) maintaining the at least the portion of the glass container in contact with the aqueous electrolyte solution for a time sufficient to exchange at least a portion of the exchangeable metal ions in a surface portion of the glass container with at least a portion of the group IA alkali metal ions in the aqueous electrolyte solution; 
 (c2) removing the glass container from contact with the aqueous electrolyte solution; and 
 (c3) rinsing the glass container with a liquid to remove any residual salts therefrom, 
 wherein the forming step (a) includes forming the glass container to include exchangeable metal ions of sodium (Na + ) and calcium (Ca 2+ ), the immersing step (c) includes the alkali metal ions have ionic radii larger than that of sodium (Na + ) or calcium (Ca 2+ ), and the steps are carried out in the sequence set forth (a) through (d). 
 
     
     
         17 . The process set forth in  claim 16  wherein the group IA alkali metal ions in the aqueous electrolyte solution are potassium ions (K +1 ). 
     
     
         18 . The process set forth in  claim 16  wherein the aqueous electrolyte solution is maintained at a temperature between 70 degrees Celsius and 100 degrees Celsius during said step (c1). 
     
     
         19 . The process set forth in  claim 16  wherein a hot-end coating of tin oxide (SnO 2 ) or titanium dioxide (TiO 2 ) is not applied to the glass container. 
     
     
         20 . A surface treatment process for a silica-based glass container which comprises exchangeable metal ions of at least one of sodium (Na + ) and calcium (Ca 2+ ), the surface treatment process including:
 contacting at least a portion of the glass container with an aqueous electrolyte solution having a temperature between 70 degrees Celsius and 100 degrees Celsius and comprising group IA alkali metal ions having ionic radii larger than that of sodium (Na + ) or calcium (Ca 2+ ); and   maintaining contact between the glass container and the aqueous electrolyte solution for a time sufficient to exchange at least a portion of the exchangeable metal ions in the silica-based glass container with at least a portion of the group IA alkali metal ions in the aqueous electrolyte solution.   
     
     
         21 . A process as set forth in  claim 20 , wherein the group IA alkali metal ions in the aqueous electrolyte solution are potassium ions (K +1 ). 
     
     
         22 . A process as set forth in  claim 20 , wherein the glass container is in contact with the aqueous electrolyte solution for a time sufficient to form a compressive stress layer in a surface portion of the glass container. 
     
     
         23 . A silica-based glass container produced by the process set forth in  claim 22 , wherein the compressive stress layer formed in the surface portion of the glass container extends from an internal surface or an external surface of the glass container to a depth in the range of 1-100 μm. 
     
     
         24 . A silica-based glass container produced by the process set forth in  claim 20 .