Glass fiber yarn and method for manufacturing the same

Abstract

The present application discloses a glass fiber and a manufacturing method thereof. The manufacturing method of the glass fiber comprises a coating step, a sintering step, a mixing step and a drawing step. In the coating step, zirconia powder is coated on the surface of inorganic particles to form modified inorganic particles. In the sintering step, the modified inorganic particles are sintered in a nitrogen atmosphere at a temperature of 400-1000°C. In the mixing step, the sintered modified inorganic particles are mixed in glass raw materials in a molten state. In the drawing step, the glass raw materials mixed with the modified inorganic particles are drawn into a glass fiber. The glass fiber and the manufacturing method thereof can effectively improve the problem of poor thermal stability of the glass fiber manufactured by the existing manufacturing method.

Description

Technical Field

[0001] This invention relates to a glass fiber filament and its manufacturing method, and more particularly to a glass fiber filament containing zirconium oxide and its manufacturing method. Background Technology

[0002] Glass fiber filaments produced using existing manufacturing methods are prone to insufficient thermal stability. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a glass fiber filament and its manufacturing method to address the shortcomings of the prior art, which can effectively improve the problem that glass fiber filaments produced by the existing glass fiber filament manufacturing methods are prone to insufficient thermal stability.

[0004] To address the aforementioned technical problems, one technical solution adopted by the present invention is to provide a method for manufacturing glass fiber filaments, comprising: a coating step, wherein zirconium oxide powder is coated onto the surface of a plurality of inorganic particles to form a plurality of modified inorganic particles; wherein, based on the total weight of each of the modified inorganic particles being 100 wt%, the content of the zirconium oxide powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%; a sintering step, wherein the modified inorganic particles are sintered in a nitrogen atmosphere at a temperature of 400°C to 1000°C; a mixing step, wherein the sintered plurality of modified inorganic particles are mixed in a molten glass raw material; and a drawing step, wherein the glass raw material mixed with the plurality of modified inorganic particles is drawn into a glass fiber filament.

[0005] Optionally, the inorganic particles are selected from at least one of the materials group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and silica.

[0006] Optionally, the average particle size of the modified inorganic particles is between 0.01 micrometers and 50 micrometers.

[0007] Optionally, based on the total weight of the glass fiber filaments being 100 wt%, the content of the modified inorganic particles is between 0.1 wt% and 5 wt%, and the content of the glass raw material is between 95 wt% and 99.9 wt%.

[0008] Optionally, in the coating step, the zirconium oxide powder is dispersed in water to form a solution, and then the solution is sprayed onto a plurality of inorganic particles, so that the zirconium oxide powder coats the plurality of inorganic particles to form a plurality of modified inorganic particles.

[0009] Optionally, in the coating step, a zirconium compound is dissolved in water and the inorganic particles are added to the water so that the zirconium compound is formed on the surface of the plurality of inorganic particles. Then, the plurality of inorganic particles and the zirconium compound are heated at a heating temperature between 100°C and 140°C so that the zirconium compound reacts to form zirconium oxide powder and coats the surface of the plurality of inorganic particles, thereby forming a plurality of modified inorganic particles.

[0010] Optionally, the zirconium compound is selected from at least one of the materials group consisting of zirconium oxychloride, zirconium carbonate, zirconium hydroxide, zirconium nitrate, sodium zirconate, and zirconium silicate.

[0011] Optionally, based on a total weight of 100 wt% for the glass raw material, the glass raw material comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxides.

[0012] Optionally, the coefficient of thermal expansion of the glass fiber is between 2.88 PPM / ℃ and 3.34 PPM / ℃.

[0013] To solve the above-mentioned technical problems, another technical solution adopted by the present invention is to provide a glass fiber filament comprising: a glass raw material; and a plurality of modified inorganic particles dispersed in the glass raw material; wherein each of the modified inorganic particles comprises an inorganic particle and zirconium oxide powder coated on the inorganic particle; wherein, based on the total weight of each of the modified inorganic particles being 100 wt%, the content of the zirconium oxide powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%; wherein the inorganic particles are selected from at least one of the materials group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and silica.

[0014] Optionally, the average particle size of the modified inorganic particles is between 0.01 micrometers and 50 micrometers.

[0015] Optionally, based on the total weight of the glass fiber filaments being 100 wt%, the content of the modified inorganic particles is between 0.1 wt% and 5 wt%, and the content of the glass raw material is between 95 wt% and 99.9 wt%.

[0016] Optionally, based on a total weight of 100 wt% for the glass raw material, the glass raw material comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxides.

[0017] Optionally, the coefficient of thermal expansion of the glass fiber is between 2.88 PPM / ℃ and 3.34 PPM / ℃.

[0018] One of the beneficial effects of the present invention is that the glass fiber filament and its manufacturing method provided by the present invention can effectively improve the problem of insufficient thermal stability of glass fiber filaments produced by existing glass fiber filament manufacturing methods through the technical solutions of "coating step, sintering step, mixing step and drawing step", "based on the total weight of each of the modified inorganic particles being 100wt%, the content of the zirconium oxide powder being between 0.01wt% and 5wt%, and the content of the inorganic particles being between 95 and 99.99wt%", and "multiple modified inorganic particles being dispersed in glass raw materials".

[0019] To further understand the features and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are for reference and illustration only and are not intended to limit the present invention. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating a method for manufacturing glass fiber filaments according to an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of glass fiber filaments according to an embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of the modified inorganic particles according to an embodiment of the present invention. Detailed Implementation

[0023] The following specific embodiments illustrate the implementation of the "glass fiber filament and its manufacturing method" disclosed in this invention. Those skilled in the art can understand the advantages and effects of this invention from the content disclosed in this specification. This invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of this invention. Furthermore, the accompanying drawings of this invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated beforehand. The following embodiments will further describe the relevant technical content of this invention in detail, but the disclosed content is not intended to limit the scope of protection of this invention.

[0024] It should be understood that while terms such as "first," "second," and "third" may be used in this document to describe various components or signals, these components or signals should not be limited by these terms. These terms are primarily used to distinguish one component from another, or one signal from another. Furthermore, the term "or" as used herein should, as appropriate, include any combination of one or more of the related listed items.

[0025] [Manufacturing method of glass fiber]

[0026] See Figures 1 to 3 As shown, Figure 1 This is a flowchart illustrating a method for manufacturing glass fiber filaments according to an embodiment of the present invention. Figure 2 This is a schematic diagram of glass fiber filaments according to an embodiment of the present invention, and Figure 3 This is a schematic diagram of the modified inorganic particles according to an embodiment of the present invention. An embodiment of the present invention provides a method for manufacturing glass fiber filaments. The method for manufacturing glass fiber filaments includes a coating step S110, a sintering step S120, a mixing step S130, and a drawing step S140. Of course, the method for manufacturing glass fiber filaments may include other steps as needed, and the present invention is not limited thereto.

[0027] In the coating step S110, zirconia powder is coated onto the surface of a plurality of inorganic particles to form a plurality of modified inorganic particles 1. Each modified inorganic particle 1 has a core-shell structure comprising a core layer 11 formed by the inorganic particles and a shell layer 12 formed by the zirconia powder. Based on a total weight of 100 wt% for each of the modified inorganic particles 1, the content of the zirconia powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%. The average particle size of the modified inorganic particles may be between 0.01 micrometers and 50 micrometers, but the present invention is not limited thereto.

[0028] It is worth mentioning that the inorganic particles must possess high-temperature resistance to prevent them from melting or breaking during the sintering step. Optionally, the inorganic particles are selected from at least one of the materials group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, alumina, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and smoked silica.

[0029] In one embodiment, the coating step S110 involves dispersing the zirconia powder in water to form a solution, and then spraying the solution onto a plurality of inorganic particles, thereby coating the zirconia powder onto the inorganic particles to form a plurality of modified inorganic particles 1. In this embodiment, the solution may, for example, be contained in a sprayer, and the solution is sprayed onto the inorganic particles while stirring the solution and the inorganic particles. The water is then dried to coat the zirconia powder onto the plurality of inorganic particles.

[0030] In another embodiment, in the coating step S110, a zirconium compound is dissolved in water and the inorganic particles are added to the water, so that the zirconium compound forms on the surface of the plurality of inorganic particles. Then, the plurality of inorganic particles and the zirconium compound are heated at a heating temperature between 100°C and 140°C, so that the zirconium compound reacts to form zirconium oxide powder, which is then coated on the surface of the plurality of inorganic particles, thereby forming a plurality of modified inorganic particles 1. The zirconium compound may be at least one selected from the group consisting of zirconium oxychloride, zirconium carbonate, zirconium hydroxide, zirconium nitrate, sodium zirconate, and zirconium silicate, but the present invention is not limited thereto.

[0031] In the sintering step S120, the modified inorganic particles 1 are sintered in a nitrogen atmosphere at a temperature of 400°C to 1000°C. The nitrogen atmosphere refers to a pure nitrogen environment. Sintering the modified inorganic particles 1 in a nitrogen atmosphere reduces the formation of byproducts. Through the sintering step S120, the modified inorganic particles 1 undergo lattice rearrangement, allowing zirconium oxide to insert into the lattice of the inorganic particles. In this way, zirconium oxide is less likely to detach from the surface of the inorganic particles.

[0032] In the mixing step S130, the sintered modified inorganic particles 1 are mixed with molten glass raw material 2. In this embodiment, based on a total weight of 100 wt% for the glass raw material 2, the glass raw material comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxide, but the invention is not limited thereto. The alkali metal oxide is selected from at least one of the materials group consisting of lithium oxide, sodium oxide, potassium oxide, rubidium oxide, and cesium oxide.

[0033] In the drawing step S140, the glass raw material 2 mixed with a plurality of the modified inorganic particles 1 is drawn to form a glass fiber filament 100. In this embodiment, based on the total weight of each glass fiber filament 100wt%, the content of the modified inorganic particles 1 is between 0.1wt% and 5wt%, and the content of the glass raw material 2 is between 95wt% and 99.9wt%, but the present invention is not limited thereto.

[0034] It is worth mentioning that in the manufacturing method of the glass fiber filament, the zirconium oxide powder is first coated onto the surface of a plurality of inorganic particles to form a plurality of modified inorganic particles 1, and then the plurality of modified inorganic particles 1 are mixed into the glass raw material 2 so that the zirconium oxide powder can be uniformly dispersed in the glass raw material 2. As a result, the glass fiber filament 100 has high thermal stability, and the coefficient of thermal expansion of the glass fiber filament 100 is between 2.88 PPM / ℃ and 3.34 PPM / ℃.

[0035] [Glass fiber filaments]

[0036] This invention also provides a glass fiber filament 100. The glass fiber filament 100 may be obtained by performing the aforementioned glass fiber filament manufacturing method, but this invention is not limited thereto.

[0037] The glass fiber 100 comprises a glass raw material 2 and a plurality of modified inorganic particles 1 dispersed in the glass raw material 2. Each modified inorganic particle 1 comprises an inorganic particle and zirconium oxide powder coated on the inorganic particle. Based on a total weight of 100 wt% for each modified inorganic particle 1, the content of the zirconium oxide powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%.

[0038] The inorganic particles are selected from at least one of the materials group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and silica fume. The average particle size of the modified inorganic particles 1 may be between 0.01 micrometers and 50 micrometers, but the present invention is not limited thereto.

[0039] Based on the total weight of each of the glass fiber filaments 100 being 100 wt%, the content of the modified inorganic particles 1 being between 0.1 wt% and 5 wt%, and the content of the glass raw material 2 being between 95 wt% and 99.9 wt%, but the present invention is not limited thereto.

[0040] Based on the total weight of the glass raw material 2 being 100 wt%, the glass raw material 2 comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxides, but the present invention is not limited thereto.

[0041] It is worth mentioning that zirconia has a high melting point and excellent thermal stability, thus maintaining structural stability at high temperatures and not easily expanding or deforming. Furthermore, zirconia can transform between different crystal phases at different temperatures to absorb heat. Therefore, the coefficient of thermal expansion of the glass fiber can be between 2.88 PPM / ℃ and 3.34 PPM / ℃.

[0042] [Experimental Data Testing]

[0043] The present invention will now be described in detail with reference to Examples 1 to 10 and Comparative Example 1. However, the following examples are provided only to help understand the present invention, and the scope of the present invention is not limited to these examples.

[0044] In Comparative Example 1, no modified inorganic particles were added. In the glass fiber manufacturing methods of Exemplary Examples 1 to 5, based on a total weight of 100 wt% for the glass fiber, the content of the modified inorganic particles was 0.01 wt%, 0.05 wt%, 0.1 wt%, 0.5 wt%, and 1 wt%, respectively, and the content of the glass raw material was 99.99 wt%, 99.95 wt%, 99.9 wt%, 99.5 wt%, and 99 wt%, respectively. In the glass fiber manufacturing methods of Exemplary Examples 6 to 10, zirconium silicate, zirconium oxychloride, zirconium carbonate, zirconium hydroxide, and zirconium nitrate were used as zirconium compounds, respectively. In the glass fiber manufacturing methods of Exemplary Examples 6 to 10, based on a total weight of 100 wt% for the glass fiber, the content of the modified inorganic particles was 0.1 wt%, and the content of the glass raw material was 99.9 wt%.

[0045] Thermal expansion coefficient test: measured according to ASTM E831 standard using a thermomechanical analyzer (TMA).

[0046] [Table 1 contains glass fiber filaments with different contents of modified inorganic particles and their coefficients of thermal expansion]

[0047]

[0048] [Table 2 Glass fiber filaments with different zirconium compound compositions and their coefficients of thermal expansion]

[0049]

[0050] [Discussion of Test Results]

[0051] As can be seen from Comparative Examples 1 and Exemplary Examples 1 to 5, the glass fiber in Comparative Example 1 did not contain any modified inorganic particles, resulting in a higher coefficient of thermal expansion for the glass fiber filament. As can be seen from Comparative Examples 1 and Exemplary Examples 6 to 10, zirconium silicate, zirconium oxychloride, zirconium carbonate, zirconium hydroxide, and zirconium nitrate can be used as zirconium compounds, and the coefficient of thermal expansion of the glass fiber filament in Exemplary Examples 6 to 10 is lower than that of the glass fiber filament in Comparative Example 1.

[0052] [Beneficial Effects of the Examples]

[0053] One of the beneficial effects of the present invention is that the glass fiber filament and its manufacturing method provided by the present invention can effectively improve the problem of insufficient thermal stability of glass fiber filaments produced by existing glass fiber filament manufacturing methods through the technical solutions of "coating step, sintering step, mixing step and drawing step", "based on the total weight of each of the modified inorganic particles being 100wt%, the content of the zirconium oxide powder being between 0.01wt% and 5wt%, and the content of the inorganic particles being between 95 and 99.99wt%", and "multiple modified inorganic particles being dispersed in glass raw materials".

[0054] The above-disclosed content is only a preferred and feasible embodiment of the present invention and is not intended to limit the patent scope of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention specification and drawings are included within the patent scope of the present invention.

Claims

1. A method for manufacturing glass fiber filaments, characterized in that, The method for manufacturing the glass fiber filaments includes: In a coating step, zirconium oxide powder is coated onto the surface of a plurality of inorganic particles to form a plurality of modified inorganic particles; wherein, based on the total weight of each of the modified inorganic particles being 100 wt%, the content of the zirconium oxide powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%. A sintering step involves sintering the modified inorganic particles in a nitrogen atmosphere at a temperature of 400°C to 1000°C. A mixing step involves mixing a plurality of the sintered modified inorganic particles into a molten glass raw material; and In the drawing step, the glass raw material mixed with multiple modified inorganic particles is drawn into a glass fiber filament.

2. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, The inorganic particles are selected from at least one of the following groups of materials: silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and smoked silica.

3. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, The average particle size of the modified inorganic particles is between 0.01 micrometers and 50 micrometers.

4. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, Based on the total weight of the glass fiber filaments being 100 wt%, the content of the modified inorganic particles being between 0.1 wt% and 5 wt%, and the content of the glass raw material being between 95 wt% and 99.9 wt%.

5. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, In the coating step, the zirconium oxide powder is dispersed in water to form a solution, and then the solution is sprayed onto a plurality of inorganic particles, so that the zirconium oxide powder coats the plurality of inorganic particles to form a plurality of modified inorganic particles.

6. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, In the coating step, a zirconium compound is dissolved in water and the inorganic particles are added to the water so that the zirconium compound forms on the surface of the inorganic particles. Then, the inorganic particles and the zirconium compound are heated at a temperature between 100°C and 140°C so that the zirconium compound reacts to form zirconium oxide powder and coats the surface of the inorganic particles, thereby forming a plurality of modified inorganic particles.

7. The method for manufacturing glass fiber filaments according to claim 6, characterized in that, The zirconium compound is selected from at least one of the materials group consisting of zirconium oxychloride, zirconium carbonate, zirconium hydroxide, zirconium nitrate, sodium zirconate, and zirconium silicate.

8. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, Based on a total weight of 100 wt% for the glass raw material, the glass raw material comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxides.

9. The method for manufacturing glass fiber filaments according to claim 1, characterized in that, The coefficient of thermal expansion of the glass fiber is between 2.88 PPM / ℃ and 3.34 PPM / ℃.

10. A glass fiber filament, characterized in that, The glass fiber filaments include: A glass raw material; and Multiple modified inorganic particles are dispersed in the glass raw material; wherein each modified inorganic particle comprises an inorganic particle and zirconium oxide powder coated on the inorganic particle; wherein, based on the total weight of each modified inorganic particle being 100 wt%, the content of the zirconium oxide powder is between 0.01 wt% and 5 wt%, and the content of the inorganic particles is between 95 and 99.99 wt%. The inorganic particles are selected from at least one of the materials group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and silica.

11. The glass fiber filament according to claim 10, characterized in that, The average particle size of the modified inorganic particles is between 0.01 micrometers and 50 micrometers.

12. The glass fiber filament according to claim 10, characterized in that, Based on the total weight of the glass fiber filaments being 100 wt%, the content of the modified inorganic particles being between 0.1 wt% and 5 wt%, and the content of the glass raw material being between 95 wt% and 99.9 wt%.

13. The glass fiber filament according to claim 10, characterized in that, Based on a total weight of 100 wt% for the glass raw material, the glass raw material comprises 59 wt% to 66 wt% silicon dioxide, 15 wt% to 26 wt% aluminum oxide, 8 wt% to 12 wt% magnesium oxide, 0.1 wt% to 4 wt% calcium oxide, 0.1 wt% to 10 wt% boron trioxide, and 0.1 wt% to 2 wt% alkali metal oxides.

14. The glass fiber filament according to claim 10, characterized in that, The coefficient of thermal expansion of the glass fiber is between 2.88 PPM / ℃ and 3.34 PPM / ℃.

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