초록

Method of making an article, the method comprising coalescing a plurality of the glass particles. Examples of articles include kitchenware (e.g., plates), dental brackets, and reinforcing fibers, cutting tool inserts, abrasives, and structural components of gas engines, (e.g., valves and bearings).

대표청구항 ▼

What is claimed is: 1. A method of making an article, the method comprising: providing a substrate having an outer surface; providing at least a glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the differe

What is claimed is: 1. A method of making an article, the method comprising: providing a substrate having an outer surface; providing at least a glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the first glass comprising one of a REO-Al2O3--ZrO2, Y2O3--Al2O3--ZrO2, REO-Al2O3--ZrO2--SiO2, Y2O3--Al2O3--ZrO2--SiO2 , REO-Al2O3, or Y2O3--Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; heating the glass above the Tg such that at least a portion of the glass wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of the glass. 2. The method according to claim 1 to increased the rate of densification of the glass is by a factor of at least 1.5. 3. The method according to claim 1, wherein, the heating of the glass is conducted in an atmosphere at a pressure of at least 1.25 atm. 4. The method according to claim 3, wherein the difference between the Tg and the Tx is at least 25K. 5. The method according to claim 4, wherein the glass has a T1, and wherein the ratio of the Tg to T1 is at least 0.5. 6. The method according to claim 5, wherein the glass comprises less than 40 percent by weight glass collectively SiO2, B2O3, and P2O5, based on the total weight of the glass. 7. The method according to claim 6, wherein the glass is a REO-Al2O3 glass. 8. The method according to claim 7, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3 and REO, based on the total weight of the glass. 9. The method according to claim 6, wherein the glass is a REO-Al2O3--ZrO2 glass. 10. The method according to claim 9, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3, REO, and ZrO2, based on the total weight of the glass. 11. The method according to claim 3 further comprises heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 12. The method according to claim 1, wherein, the heating of the glass is conducted in an atmosphere at a pressure of at least 2 atm. 13. A method of making an article, the method comprising: providing a substrate having an outer surface; providing at least a plurality of particles comprising glass, the particles comprising glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass comprising REO-Al2O3--ZrO2, Y2O3--Al2O3--ZrO2, REO-Al2O3--Zr2--SiO2, Y2O3--Al2O3--ZrO2--SiO2 , REO-Al2O3, or Y2O3--Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; heating the glass above the Tg such that at least a portion of the glass of the plurality of particles wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass. 14. The method according to claim 13 to increased the rate of densification of the glass is by a factor of at least 1.5. 15. The method according to claim 14, wherein, the heating of the glass is conducted in an atmosphere at a pressure of at least 1.25 atm. 16. The method according to claim 15, wherein the difference between the Tg and the Tx is at least 25K. 17. The method according to claim 16, wherein the glass has a T1, and wherein the ratio of the Tg to T1 is at least 0.5. 18. The method according to claim 17, wherein the glass comprises less than 40 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass. 19. The method according to claim 18, wherein the glass is a REO-Al2O3 glass. 20. The method according to claim 19, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3 and REO, based on the total weight of the glass. 21. The method according to claim 18, wherein the glass is a REO-Al2O3--ZrO2 glass. 22. The method according to claim 21, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3, REO, and ZrO2, based on the total weight of the glass. 23. The method according to claim 15, further comprises heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 24. The method according to claim 13, wherein, the heating of the glass is conducted in an atmosphere at a pressure of at least 2 atm. 25. A method of making an article, the method comprising: providing at least a first glass and second glass each having an outer surface, wherein the first glass comprises at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass comprising one of a REO-Al2O3--ZrO2, Y2O3--Al2O3--ZrO2, REO-Al2O3--Zr2--SiO2, Y2O3--Al2O3--ZrO2--SiO2 , REO-Al2O3, or Y2O3--Al2O3 composition, and the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; heating the first and second glasses above at least Tg1 and at least the first glass coalescing with the second glass to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses. 26. The method according to claim 25 to increased the rate of densification of the first glass is by a factor of at least 1.5. 27. The method according to claim 25, wherein, the heating of at least the first and second glasses is conducted in an atmosphere at a pressure of at least 1.25 atm. 28. The method according to claim 27, wherein the difference between the Tg1 and the Tx1 is at least 25K. 29. The method according to claim 28, wherein the first glass has a T1, and wherein the ratio of the Tg1 to T11 is at least 0.5. 30. The method according to claim 29, wherein the first glass comprises less than 40 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass. 31. The method according to claim 30, wherein the first glass is a REO-Al2O3 glass. 32. The method according to claim 31, wherein the first glass collectively comprises at least 80 percent by weight of the Al2O3 and REO, based on the total weight of the glass. 33. The method according to claim 30, wherein the first glass is a REO-Al2O3--ZrO2 glass. 34. The method according to claim 33, wherein the first glass collectively comprises at least 80 percent by weight of the Al2O3, REO, and ZrO2, based on the total weight of the glass. 35. The method according to claim 27, further comprises heat-treating at least the first and second glasses of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 36. The method according to claim 24, wherein, the heating of the first glass is conducted in an atmosphere at a pressure of at least 2 atm. 37. A method of making an article, the method comprising: providing at least a first glass and second glass each having an outer surface, wherein the first glass comprises at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass comprising one of a REO-Al2O3--ZrO2, Y2O3--Al2O3--ZrO2, REO-Al2O3--Zr2--SiO2, Y2O3--Al2O3--ZrO2--SiO2 , REO-Al2O3, or Y2O3--Al2O3 composition, and the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5, and wherein the second glass comprises at least two different metal oxides, wherein the second glass has a Tg2 and Tx2, and wherein the difference between the Tg2 and the Tx2 is at least 5K, the second glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; heating at least the first and second glasses above the higher of Tg1 or Tg2 and coalescing the first and second glasses to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses. 38. The method according to claim 37 to increased the rate of densification of the first glass is by a factor of at least 1.5. 39. The method according to claim 37, wherein, the heating of at least the first and second glasses is conducted in an atmosphere at a pressure of at least 1.25 atm. 40. The method according to claim 39, wherein the difference between each of Tg1 and Tx1 and Tg2 and Tx2 is at least 25K. 41. The method according to claim 40, wherein the ratio of each of Tg1 to Tx1 and Tg2 to Tx2 is at least 0.5. 42. The method according to claim 41, wherein each of the first and second glasses comprise less than 40 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass. 43. The method according to claim 42, wherein the first glass is a REO-Al2O3 glass. 44. The method according to claim 43, wherein the first glass collectively comprises at least 80 percent by weight of the Al2O3 and REO, based on the total weight of the glass. 45. The method according to claim 42, wherein the first glass is a REO-Al2O3--ZrO2 glass. 46. The method according to claim 45, wherein the first glass collectively comprises at least 80 percent by weight of the Al2O3, REO, and ZrO2, based on the total weight of the glass. 47. The method according to claim 40, wherein the first and second glasses have the same compositions. 48. The method according to claim 40, wherein the first and second glasses have different compositions. 49. The method according to claim 39, further comprising heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 50. The method according to claim 37, wherein, the heating of at least the first and second glasses is conducted in an atmosphere at a pressure of at least 2 atm. 51. A method of making an article, the method comprising: providing at least a first plurality of particles comprising glass, the particles comprising glass having an outer surface, wherein the glass comprises at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass comprising one of a REO-Al2O3--ZrO2, Y2O3--Al2O3--ZrO2, REO-Al2O3--Zr2--SiO2, Y2O3--Al2O3--ZrO2--SiO2 , REO-Al2O3, or Y2O3--Al2O3 composition, and the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; heating the glass above the Tg and coalescing at least a portion of the first plurality of particles to provide the article, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass. 52. The method according to claim 51 to increased the rate of densification of the glass is by a factor of at least 1.5. 53. The method according to claim 51, wherein, the heating of the glass is conducted in an atmosphere at a pressure of at least 1.25 atm. 54. The method according to claim 53, wherein the difference between the Tg and the Tx is at least 25K. 55. The method according to claim 54, wherein the glass has a T1, and wherein the ratio of the Tg to T1 is at least 0.5. 56. The method according to claim 55, wherein the glass comprises less than 40 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass. 57. The method according to claim 56, wherein the glass is a REO-Al2O3 glass. 58. The method according to claim 57, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3 and REO, based on the total weight of the glass. 59. The method according to claim 56, wherein the glass is a REO-Al2O3--ZrO2 glass. 60. The method according to claim 59, wherein the glass collectively comprises at least 80 percent by weight of the Al2O3, REO, and ZrO2, based on the total weight of the glass. 61. The method according to claim 53, further comprising heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 62. The method according to claim 51, wherein the heating of the glass is conducted in an atmosphere at a pressure of at least 2 atm. 63. The method according to claim 1 wherein, the first glass further comprises at least one of BaO, CaO, Cr2O3, CoO, CuO, Fe2O3, GeO2, HfO2, Li2O, MgO, MnO, Nb205, NiO, Na2O, P2O5, Sc2O3, SrO, Ta2O5, TeO2, TiO2, V2O3, or ZnO. 64. The method according to claim 13, wherein, the glass further comprises at least one of at least one of BaO, CaO, Cr2O3, CoO, CuO, Fe2O3, GeO2, HfO2, Li2O, MgO, MnO, Nb2O5, NiO, Na2O, P2O5, Sc2O3, SrO, Ta2O5, TeO2, TiO2, V2O3, or ZnO. 65. The method according to claim 25, wherein, the First glass further comprises at least one of at least one of BaO, CaO, Cr2O3, CoO, CuO, Fe2O3, GeO2, HfO2, Li2O, MgO, MnO, Nb2O5, NiO, Na2O, P2O5, Sc2O3, SrO, Ta2O5, TeO2, TiO2, V2O3, or ZnO. 66. The method according to claim 37, wherein, the first glass further comprises at least one of at least one of BaO, CaO, Cr2O3, CoO, CuO, Fe2O3, GeO2, HfO2, Li2O, MgO, MnO, Nb2O5, NiO, Na2O, P2O5, Sc2O3, SrO, Ta2O5, TeO2, TiO2, V2O3, or ZnO. 67. The method according to claim 51, wherein, the glass further comprises at least one of at least one of BaO, CaO, Cr2O3, CoO, CuO, Fe2O3, GeO2, HfO2, Li2O, MgO, MnO, Nb2O5, NiO, Na2O, P2O5, Sc2O3, SrO, Ta2O5, TeO2, TiO2, V2O3, or ZnO. 68. A method of making an article, the method comprising: identifying a glass comprising at least two different metal oxides, wherein the class has a Tg and Tx, and wherein the difference between the Tg and the Tx of the class is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; providing at least the glass, wherein the glass has an outer surface: providing a substrate having an outer surface; and heating the glass above the Tg such that at least a portion of the glass wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of the glass. 69. The method according to claim 68, further comprising heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 70. A method of making an article, the method comprising: identifying a glass comprising at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; providing at least a plurality of particles comprising the glass, the particles comprising the glass having an outer surface; providing a substrate having an outer surface; and heating the glass above the Tg such that at least a portion of the glass of the plurality of particles wets at least a portion of the outer surface of the substrate and provides an article comprising the glass attached to the at least a portion of the outer surface of the substrate, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass. 71. The method according to claim 70, further comprises heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 72. A method of making an article, the method comprising: identifying a first glass comprising at least two different metal oxides, wherein the first glass has as a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; providing at least the first glass and a second glass each having an outer surface; and heating the first and second glasses above at least Tg1 and at least the first glass coalescing with the second glass to provide the article, wherein the heating of at least the first and second glasses is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glasses as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses. 73. The method according to claim 72, further comprises heat-treating at least the first and second glasses of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 74. A method of making an article, the method comprising: identifying a first glass comprising at least two different metal oxides, wherein the first glass has a Tg1 and Tx1, and wherein the difference between the Tg1 and the Tx1 is at least 5K, the first glass containing less than 20% by weight SiO2, less than 20% weight B2O3, and less than 40% by weight P2O5, and wherein the second glass comprises at least two different metal oxides, wherein the second glass has a Tg2 and Tx2, and wherein the difference between the Tg2 and the Tx2 is at least 5K, the second glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; providing at least the first glass and a second glass each having an outer surface; and heating at least the first and second glasses above the higher of Tg1 or Tg2 and coalescing the first and second glasses to provide the article, wherein the heating of at least the first and second classes is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glasses as compared to the same glasses heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surfaces of the first and second glasses. 75. The method according to claim 74, further comprising heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic. 76. A method of making an article, the method comprising: identifying a class comprising at least two different metal oxides, wherein the glass has a Tg and Tx, and wherein the difference between the Tg and the Tx of the glass is at least 5K, the glass containing less than 20% by weight SiO2, less than 20% by weight B2O3, and less than 40% by weight P2O5; providing at least a first plurality of particles comprising the glass, the particles comprising the class having an outer surface; and heating the glass above the Tg and coalescing at least a portion of the first plurality of particles to provide the article, wherein the heating of the glass is conducted in a gaseous atmosphere at a pressure greater than 1.1 atm. sufficient to increase the rate of densification of the glass as compared to the same glass heated in the same manner except the pressure during the later heating is conducted in an atmosphere at a pressure of 1.0 atm., and wherein the gaseous atmosphere at a pressure greater than 1.1 atm. is in direct contact with at least a portion of the outer surface of at least a portion the particles comprising glass. 77. The method according to claim 76, further comprising heat-treating the glass of the article to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic.