A method of processing glass fibers

Abstract

The application discloses a glass fiber processing method, which comprises the following steps: preheating glass fiber raw materials by using the heat generated by self-propagating powder reaction to obtain glass liquid; and preparing the glass liquid into glass fiber under heating. In the melting process of the glass fiber raw materials, the exothermic heating method of self-propagating reaction is creatively used in the preheating stage, no electricity is used, resources are saved, and the method is green and efficient. Meanwhile, the heat of the self-propagating reaction is sufficient and can fully meet the temperature requirement in the preheating stage. The application provides a new way for the processing and manufacturing of glass fiber, can provide a new idea for the industrialized production of glass fiber, has a wide market prospect, and has remarkable economic benefits. In addition, the glass fiber raw materials of the application can be waste old glass, so that the waste is recycled and treated; and the carbon dioxide cleaning method is used, so that the use of water resources is reduced, and the effect of energy saving and emission reduction is achieved from another aspect.

Description

Technical Field

[0001] This invention relates to the field of glass fiber production and manufacturing, and in particular to a glass fiber processing method. Background Technology

[0002] Glass fiber is a high-performance inorganic non-metallic material with numerous varieties. Its advantages include excellent insulation, strong heat resistance, good corrosion resistance, and high mechanical strength. The diameter of its monofilaments ranges from a few micrometers to over twenty micrometers, equivalent to 1 / 20 to 1 / 5 the diameter of a human hair. Each bundle of fiber consists of hundreds or even thousands of monofilaments. Glass fiber is commonly used as a reinforcing material in composite materials, an electrical insulation material, a thermal insulation material, and in various sectors of the national economy, including circuit boards. It is mainly used to manufacture untwisted rovings, untwisted roving fabrics, glass fiber mats, ground fibers, and glass fiber fabrics. When used as a reinforcing material for reinforced plastics, its most significant characteristic is its high tensile strength. The tensile strength is 6.3–6.9 g / d under standard conditions and 5.4–5.8 g / d under wet conditions. It has good heat resistance, with no effect on strength at temperatures up to 300℃. It possesses excellent electrical insulation properties, making it a high-grade electrical insulation material, and is also used in thermal insulation and fireproof shielding materials. It is generally only corroded by concentrated alkalis, hydrofluoric acid, and concentrated phosphoric acid. In some manufacturing fields, it is gradually replacing carbon fiber, becoming a cheaper and more practical material.

[0003] The preparation of glass fibers typically involves drawing molten glass into fibers after it has been sprayed out. Melting the raw materials into molten glass often consumes a significant amount of electrical energy. Therefore, it is necessary to reduce energy consumption during the process. Summary of the Invention

[0004] To address the problems of existing technologies, this invention utilizes the heat generated by the self-propagating powder reaction to preheat the glass fiber raw material. After obtaining the molten glass, it is transferred to a melting crucible for drawing, which can significantly reduce the electrical energy required for the melting process.

[0005] To achieve the above objectives, the present invention provides a method for processing glass fibers, comprising,

[0006] The heat generated by the self-propagating powder reaction is used to preheat the glass fiber raw material to obtain molten glass;

[0007] The molten glass is heated to prepare glass fibers.

[0008] Furthermore, the self-propagating powder comprises 15-20 wt.% aluminum powder, 68-70 wt.% dehydrated gypsum, 8-10 wt.% calcium oxide, 0-3 wt.% silicon oxide, and 0-3 wt.% aluminum oxide powder.

[0009] Furthermore, the particle size of the self-propagating powder is 50–125 mesh. Formulations outside this range are either prone to expansion and explosion causing safety accidents, or the heat is insufficient to maintain glass preheating. The mixture can be made by combining aluminum powder, dehydrated gypsum, calcium oxide, silicon dioxide, and alumina with a particle size of 50–125 mesh.

[0010] Furthermore, the mass ratio of the self-propagating powder to the glass fiber raw material is 1:3 to 1:4.

[0011] Furthermore, the glass fiber raw material includes waste glass;

[0012] The waste glass includes colored waste glass and colorless waste glass;

[0013] Among them, colored waste glass requires decolorization treatment when it is melted using the heat generated by the self-propagating powder reaction. The decolorization treatment uses conventional methods in the field, adding halides and composite clarifying agents during melting to remove the color.

[0014] Furthermore, the size of the waste glass is 10-35mm.

[0015] In an optional embodiment of the present invention, the waste glass is first screened by size, and then those that do not meet the size requirements are crushed. The crushing of waste glass involves allowing the glass to fall freely from a height into the top feed hopper of the glass crusher, where it impacts the glass crushing frame and breaks. The glass crushing frame is I-shaped and has a multi-layered structure, preferably three layers arranged in a staggered pattern. High-hardness diamond crushing nails are embedded in the glass crushing frame. After the glass is broken into fragments, it falls into the lower feeding channel. A reducer driven by a four-stage motor controls the falling speed of the glass fragments to prevent further breakage. The fragments then pass through a screen, which is also divided into two layers. The upper layer has a mesh size of approximately 40-45 mm, and the lower layer has a mesh size of approximately 10-15 mm, ensuring that the size of the filtered glass fragments is between 10-35 mm.

[0016] Furthermore, the waste glass is cleaned using solid and liquid carbon dioxide before use.

[0017] In an optional embodiment of the present invention, waste glass is cleaned by rotation in a turbine-type cleaning machine. The material is fed evenly, and the rotation speed is controlled at approximately 20-25 rpm. The cleaning agent is primarily carbon dioxide. By adding liquid carbon dioxide and dry ice particles to the cleaning tank, the dissolving power of carbon dioxide itself and its excellent penetrating ability dissolve and rinse away oily stains on the glass. Combined with the mechanical action of the cleaning machine and the dissolving effect of the chemical additives, further cleaning is achieved.

[0018] The preheated solid-liquid glass mixture is further melted by controlling the electrodes on both sides. To meet the requirements of the subsequent wire drawing process, the temperature inside the crucible needs to be precisely controlled by thermocouples. Different heating temperatures need to be controlled according to the different melting points of white glass and colored glass.

[0019] Furthermore, the heating temperature is 1000–1200°C.

[0020] Furthermore, the step of preparing the molten glass into glass fibers specifically includes,

[0021] Glass fibers are obtained by drawing molten glass into wires, winding the wires, combining the yarns, and drying them.

[0022] In an optional embodiment of the present invention, when drawing the molten glass into fibers, the speed of the drawing machine is controlled at 1000-1100 rpm, corresponding to a glass fiber diameter of approximately 0.02-0.03 mm. The generated glass fibers are wound around a graphite wheel coated with a sizing agent, and the sizing agent is then wound onto the drawing machine sleeve for drawing. The proportion of fibers produced from the crucible is ensured to be more than 95% of the total number of holes in the crucible, and the speed of the graphite wheel is 60-90 rpm.

[0023] The glass fibers, after being drawn and wound by the drawing machine, are then joined together using a yarn-jointing machine. Each yarn-jointing machine can simultaneously support six to seven drawing machines. The program of the yarn-jointing machine is adjusted to control its speed, ensuring consistent tension of the glass fibers during the joining process and preventing breakage. Furthermore, as the spindle diameter increases, the linear speed of the joining process increases from an initial 250 cm / revolution to approximately 820 cm / revolution, ultimately resulting in spindles with a diameter of approximately 25 cm, while ensuring the spindles are flat, have an accurate count, and are free of excess fuzz.

[0024] The spools of yarn after being combined are dried in a dryer. The drying temperature is controlled at 100-120℃ and the drying time is 8-9 hours to ensure that the strength and humidity of the glass fiber meet the standard requirements.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. This invention provides a new approach to the processing and manufacturing of glass fiber, offering new ideas for the industrial production of glass fiber, with broad market prospects and significant economic benefits.

[0027] 2. The raw material for manufacturing glass fiber in this invention is waste glass, which realizes the recycling and treatment of waste, saves resources and greatly reduces production costs.

[0028] 3. The glass cleaning process utilizes carbon dioxide, reducing water consumption. Furthermore, carbon dioxide can be obtained from other industrial byproducts, reusing what would otherwise be directly emitted carbon dioxide gas, thus achieving energy conservation and emission reduction. This method leverages the dissolving and cleaning properties of carbon dioxide without producing byproducts; the carbon dioxide ultimately evaporates as a gas, facilitating the recycling of remaining waste.

[0029] 4. During the glass melting process, the preheating stage utilizes an exothermic self-propagating reaction heating method, which does not use electricity, saves resources, and is green and efficient. Furthermore, the heat generated by the self-propagating reaction is sufficient, and the high temperature is maintained for a long time, fully meeting the temperature requirements of the preheating stage. In addition, self-propagating powder can be added continuously or intermittently depending on the quality of the glass, avoiding the drawback of existing technologies where heating cannot be stopped once production begins. Attached Figure Description

[0030] Figure 1 A flowchart of a glass fiber processing method according to an embodiment of the present invention is shown;

[0031] Figure 2 A schematic diagram of the preheating of glass fiber raw materials in an embodiment of the present invention is shown;

[0032] In the picture:

[0033] 1. Glass fiber raw material; 2. Inner crucible; 3. Outlet port; 4. Exothermic reaction chamber; 5. Self-propagating powder; 6. Outer crucible. Detailed Implementation

[0034] The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0035] The technical solutions of the present invention will be clearly and completely described below with reference to specific embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Example

[0037] like Figure 1 As shown, a glass fiber processing method comprises the following steps:

[0038] Step 1. Screening of glass raw materials: Select colorless waste glass, perform simple screening, check for other impurities, and obtain colorless waste glass with a size of 30mm and a size greater than 30mm.

[0039] Step 2. Glass Crushing: Colorless waste glass larger than 30mm is allowed to fall freely from a height into the top feed hopper of the glass crusher. Inside the crusher, it collides with the glass crushing frame, causing it to break. The glass crushing frame is I-shaped and consists of three intersecting layers, embedded with high-hardness diamond crushing nails. The colorless waste glass larger than 30mm is broken into fragments that fall into the lower feeding channel. A four-stage motor-driven reducer controls the falling speed of the glass fragments to prevent further breakage. The fragments then pass through a two-layer screen; the upper layer has a 40mm aperture, and the lower layer has a 10mm aperture. The final filtered fragments are approximately 30mm in size and are then combined with the 30mm colorless waste glass from Step 1.

[0040] Step 3. Cleaning: The colorless waste glass with a size of about 30mm obtained in Step 2 is put into a turbine cleaning machine. The colorless waste glass is cleaned by rotation, and the rotation speed is controlled at about 25 rpm. The main cleaning agent is carbon dioxide. By adding liquid carbon dioxide and dry ice particles to the cleaning tank, the oily stains on the glass are dissolved and rinsed out by the dissolving ability of carbon dioxide itself and the good penetrating ability of liquid carbon dioxide. Combined with the mechanical action of the cleaning machine and the dissolving effect of chemical additives, the cleaning is completed, and glass fiber raw material is obtained.

[0041] Step 4. Melt to obtain molten glass, such as Figure 2 As shown, 4 kg of glass fiber raw material 1 is uniformly added to the inner crucible 2. An exothermic reaction chamber 4 exists between the inner crucible 2 and the outer crucible 6. The exothermic reaction chamber 4 is used to generate heat during the reaction when self-propagating powder 5 is added, thereby preheating the inner crucible. 1 kg of 100-mesh self-propagating powder is added to the exothermic reaction chamber 4. The self-propagating powder consists of 15 wt.% aluminum powder, 70 wt.% dehydrated gypsum, 10 wt.% calcium oxide, 3 wt.% silicon oxide, and 2 wt.% alumina powder. The heat generated by the self-propagating reaction technology melts the glass fiber raw material 1 in the inner crucible 2 into molten glass, which flows out from the outlet hole 3 below the inner crucible 2 and the outer crucible 6. The molten glass enters the melting crucible, and the electrodes on both sides of the melting crucible are controlled to maintain the temperature at 1000℃, ensuring that the temperature of the molten glass meets the requirements of the subsequent wire drawing process.

[0042] Step 5. Wire Drawing: The molten glass is drawn into wires through the crucible holes of the melting crucible. Each melting crucible has 150 holes with a diameter of 2.5 mm. The wire drawing machine speed is controlled at 1050 rpm, corresponding to a glass fiber diameter of 0.02 mm. The generated glass fibers are wound around a graphite wheel coated with a sizing agent. The sizing agent is then wound onto the wire drawing machine sleeve for drawing. The goal is to ensure that the number of wires exiting the crucible is at least 95% of the total number of crucible holes. The graphite wheel speed is 70 rpm.

[0043] Step 6. Yarn Joining: The glass fibers drawn and arranged by the drawing machine are joined together using a yarn joining machine. Each yarn joining machine can simultaneously support six drawing machines. The program of the yarn joining machine is adjusted to control its speed, ensuring consistent tension of the glass fibers during the joining process to prevent breakage. Furthermore, as the spindle diameter increases, the linear speed of yarn joining increases from the initial 250 cm / rpm to approximately 820 cm / rpm, ultimately resulting in a 25 cm diameter spindle. This process ensures the spindle is flat, the number of fibers is accurate, and there are no excess fuzz.

[0044] Step 7. Drying: Dry the combined yarn spindles in a dryer at a temperature of around 120°C for 8 hours. Then, conduct quality inspection to ensure that the strength and humidity of the glass fiber meet the standard requirements.

[0045] Comparative Example 1

[0046] The method is basically the same as that in the embodiment, except that: in step 3, the cleaning agent used in the cleaning is water; in step 4, the inner crucible 2 is heated by electric heating to melt the glass fiber raw material in the melt obtained by melting.

[0047] In Comparative Example 1, approximately 3 tons of clean water were needed for repeated washing of every 800 kg of colorless waste glass. In contrast, this example uses carbon dioxide as a cleaning agent, eliminating the need for water and saving water. Furthermore, the collected carbon dioxide can be recycled. In the comparative example, the inner crucible was heated electrically at a power of 6 kW. After reaching the preheating temperature in 2 minutes, 4 kg of glass fiber raw material was added, and preheating for approximately 1 minute caused the glass to melt. This example utilizes a self-propagating reaction exothermic heating method, eliminating the need for electricity and meeting the temperature requirements of the preheating stage.

[0048] Comparative Example 2

[0049] The method is basically the same as in the example, except that the particle size of the self-propagating powder added in step 4 is 40 mesh. The results show that the heat is insufficient to maintain glass preheating; that is, 1 kg of 40-mesh self-propagating powder (composed of 15 wt.% aluminum powder, 70 wt.% dehydrated gypsum, 10 wt.% calcium oxide, 3 wt.% silicon dioxide, and 2 wt.% alumina powder) is insufficient to maintain melting during preheating for each batch of 4 kg of glass fiber raw material, requiring the addition of more 40-mesh self-propagating powder.

[0050] Comparative Example 3

[0051] The method is basically the same as in the example, except that the particle size of the self-propagating powder added in step 4 is 150 mesh (composed of 15 wt.% aluminum powder, 70 wt.% dehydrated gypsum, 10 wt.% calcium oxide, 3 wt.% silicon oxide, and 2 wt.% alumina powder). Because the particle size of the self-propagating powder is too fine, the exothermic reaction is too rapid, which could easily lead to an explosion and compromise safe production.

[0052] In summary, the glass fiber processing method of this invention utilizes carbon dioxide cleaning in the glass washing process, reducing water consumption. Furthermore, carbon dioxide can be obtained from other industrial byproducts, reusing carbon dioxide gas that would otherwise be directly emitted, thus achieving energy conservation and emission reduction. It utilizes the dissolving and cleaning properties of carbon dioxide without producing byproducts, ultimately evaporating as a gas, which facilitates the recycling of residual waste. During the glass melting process, the exothermic heating method of a self-propagating reaction is used in the preheating crucible stage. Adjusting the particle size of the self-propagating powder ensures a stable reaction and maintains normal preheating production. This preheating of raw materials does not require electricity, saving resources and being green and efficient. Simultaneously, the heat from the self-propagating reaction is sufficient to fully meet the temperature requirements of the preheating stage. Overall, this method provides a new approach to glass fiber processing and manufacturing, offering new ideas for the industrial production of glass fiber, with broad market prospects and significant economic benefits.

[0053] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A glass fiber processing method, characterized in that, include, The heat generated by the self-propagating powder reaction is used to preheat the glass fiber raw material to obtain molten glass; The molten glass is heated to prepare glass fibers. The self-propagating powder is composed of 15-20 wt.% aluminum powder, 68-70 wt.% dehydrated gypsum, 8-10 wt.% calcium oxide, 0-3 wt.% silicon oxide, and 0-3 wt.% aluminum oxide powder. The particle size of the self-propagating powder is 50-125 mesh; The mass ratio of the self-propagating powder to the glass fiber raw material is 1:3 to 1:

4.

2. The glass fiber processing method according to claim 1, characterized in that, The glass fiber raw material includes waste glass; The waste glass includes colored waste glass and colorless waste glass; Among them, colored waste glass needs to undergo decolorization treatment when it is melted using the heat generated by the self-propagating powder reaction.

3. The glass fiber processing method according to claim 2, characterized in that, The waste glass is cleaned using solid and liquid carbon dioxide before use.

4. The glass fiber processing method according to claim 3, characterized in that, The size of the waste glass is 10~35mm.

5. The glass fiber processing method according to claim 1, characterized in that, The heating temperature is 1000~1200℃.

6. The glass fiber processing method according to claim 1, characterized in that, The process of preparing the molten glass into glass fibers specifically includes: Glass fibers are obtained by drawing molten glass into yarns, spinning them, and drying them.

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