Glass composition, fiberizable glass composition, and glass fibers made therefrom

Abstract

A glass composition suitable for fiber formation and glass fibers having a high modulus is disclosed. The glass composition can include about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. The glass composition can be used to form glass fibers and incorporated into various composites.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 272,866, filed October 28, 2021, the entire disclosure of which is hereby incorporated by reference herein.

[0002] Field Described herein are glass compositions, particularly glass compositions for forming fibers. [Background technology]

[0003] background Glass fibers have been used to reinforce various polymer resins for many years. Some commonly used glass compositions for use in reinforcement applications include the "E-glass", "R-glass" and "D-glass" families of compositions. "S-glass" is another commonly used family of glass compositions and includes, for example, glass fibers commercially available from AGY (Aiken, South Carolina) under the trademark "S-2 Glass".

[0004] Glass fibers are divided into two categories: general purpose and specialty. The most widely used glass fiber type is the general purpose type, also known as E-glass fiber. E-glass exhibits good overall mechanical, electrical and corrosion properties.

[0005] As the viable market applications for composites continue to grow, fiberglass users have been challenged to meet demands for performance, cost, reliability and durability, as well as an increased focus on sustainability and environmental stewardship. Such challenges include ever-increasing wind blade length requirements, power generation equipment seeking to maximize pipe and tank performance and life in harsh conditions and environments, the demand for fuel economy at the expense of performance is driving changes in the automotive industry, energy markets are looking at lighter, larger Compressed Natural Gas (CNG) tanks to reduce delivery costs, and continuing technology advances are requiring ever more robust circuit board signal speeds.

[0006] Fiberglass manufacturers continue to seek glass compositions that can be used to form glass fibers having desirable mechanical properties in a commercial manufacturing environment. Summary of the Invention [Means for solving the problem]

[0007] Abstract Various embodiments of the present disclosure provide glass compositions, fiberizable glass compositions, and glass fibers formed from such compositions, as well as fiberglass strands (rovings or chopped), yarns, fabrics, and thermoset and thermoplastic composites comprising such glass fibers, adapted for use in a variety of applications.

[0008] In one embodiment, a glass composition suitable for fiber formation can include about 48 to about 61 weight percent SiO, about 22 to about 27 weight percent AlO, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent YO, up to 2.5 weight percent LiO, and up to 1 weight percent BO.

[0009] In some embodiments, the composition may include a CaO to MgO ratio (CaO / MgO) less than about 1.5, a (SiO2+Al2O3) content may be greater than about 70 weight percent, a (Na2O+K2O) content may be less than about 0.5 weight percent, or a (MgO+CaO) content may range from about 12 to about 22.5 weight percent. In some embodiments, the composition may be substantially free of Li2O. In some embodiments, the composition may be substantially free of B2O3. In some embodiments, the composition may have an Al2O3 to RO ratio (Al2O3 / RO) less than 2.5, where RO is the sum of MgO and CaO. In some embodiments, the composition may include a (RO+Al2O3+SiO2) content greater than about 90 weight percent.

[0010] In any of the previous embodiments, an additional embodiment may include a plurality of glass fibers formed from the aforementioned glass composition. In any of the previous embodiments, the glass fibers have an elastic modulus of 90 GPa or greater, and the glass fibers have a modulus of 3 g / cm 3 The glass fibers may have a density of less than 3.5 mm, or the glass fibers may have a specific modulus of greater than 3.5 mm. In some embodiments, the glass fibers are formed into a roving, a yarn, a woven fabric, a nonwoven fabric, a unidirectional fabric, or chopped fiber glass strands.

[0011] Some embodiments of the present disclosure relate to fiberglass strands. Several fiberizable glass compositions are disclosed herein as part of the present disclosure, and it should be understood that various embodiments of the present disclosure may include glass fibers, fiberglass strands, yarns, and other products incorporating glass fibers formed from such compositions. In one embodiment, a plurality of glass fibers formed from a glass composition may include about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3, and have a Young's modulus of at least 90 GPa.

[0012] Some embodiments of the present disclosure relate to yarns formed from at least one fiberglass strand formed from the glass compositions described herein. Some embodiments of the present disclosure relate to fabrics incorporating at least one fiberglass strand formed from the glass compositions described herein. In some embodiments, the weft yarns used in the fabric can include at least one fiberglass strand. The warp yarns can include at least one fiberglass strand in some embodiments. In some embodiments, fiberglass strands can be used in both the weft and warp yarns to form a fabric according to the present disclosure. In some embodiments, the fabric of the present disclosure can include a plain weave fabric, a twill fabric, a crowfoot fabric, a satin weave fabric, a stitchbond fabric, or a 3D woven fabric.

[0013] Some embodiments of the present disclosure relate to a composite material comprising glass fibers formed from a polymeric resin and one of the various glass compositions described herein. The glass fibers can be obtained from fiber glass strands according to some embodiments of the present disclosure. In some embodiments, the glass fibers can be incorporated into a fabric, such as a woven fabric. For example, the glass fibers can be present in the weft and / or warp yarns that are woven to form the fabric. In embodiments in which the composite material comprises a fabric, the fabric can include a plain weave fabric, a twill weave fabric, a houndstooth weave fabric, a satin weave fabric, a stitch bonded fabric, or a 3D woven fabric.

[0014] Glass fibers can be incorporated into other forms of composites, which are discussed in more detail below.

[0015] The composites of the present disclosure can include one or more of a variety of polymeric materials (e.g., polymeric resins). In some embodiments, the polymeric resin can include at least one of polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic resin, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bis-maleimide, and thermosetting polyurethane resin. The polymeric resin can include an epoxy resin in some embodiments.

[0016] The composites of the present disclosure may be in a variety of forms and used in a variety of applications. Some examples of potential uses of composites according to some embodiments of the present disclosure include, but are not limited to, wind energy (e.g., wind turbine blades), automotive applications, safety / security applications (e.g., bulletproof armor), aerospace or aviation applications (e.g., airplane interior floors), high pressure vessels or tanks, missile casings, electronic devices, etc.

[0017] These and other embodiments of the invention are described in more detail in the detailed description that follows. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a diagram of liquidus temperature versus LiO content for glass fibers according to one or more embodiments described herein.

[0019] [Diagram 2] FIG. 2 is a diagram of Young's modulus versus LiO content for glass fibers according to one or more embodiments described herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Detailed Description The embodiments of the present disclosure generally relate to glass compositions. In one aspect, the present disclosure provides glass fibers formed from the glass compositions described herein. In some cases, the glass compositions can include one or more rare earth oxides (RE2O3), including but not limited to YO3. In some embodiments, the glass fibers of the present disclosure can have improved mechanical properties, such as Young's modulus, compared to, for example, conventional E-glass fibers. In some embodiments, the glass fibers can have an elastic modulus of 90 GPa or greater. In certain embodiments, the glass fibers can have an elastic modulus of greater than 100 GPa. In some embodiments, the glass fibers can have a modulus of 3 g / cm 3 In some embodiments, the glass fibers can have a liquidus temperature (T L In one particular embodiment, the glass fiber can have a viscosity of 1000 poise, T L The formation temperature (T F ) and the actual fiber formation temperature (T F 実際 ) is used to reduce or prevent the crystallization of the molten glass and the associated potential breakage of the fibers. L In certain embodiments, the glass composition may have a melting temperature (T) of less than 1500° C. M ).

[0021] As shown in FIGS. 1 and 2, the embodiments of the present disclosure have a lower T L and increased fiber Young's modulus. The use of lithium or lithium oxide (Li2O) can reduce the viscosity of the molten glass and aid in the glass melting process. Lithium can also be used to make glass-ceramic products. In some embodiments of the present disclosure, the use of Li2O demonstrates an unexpected and consistent correlation that increasing the amount of Li2O in a glass composition, whether sourced from spodumene, lithium carbonate, or other lithium-containing minerals, can result in lower liquidus temperatures and improved fiber modulus.

[0022] Alkali oxides can be modifiers or breakers of silicate glass network, which can reduce glass viscosity and weaken glass strength and modulus. For example, Na2O or K2O in glass can reduce the viscosity of molten glass, such as Li2O, while Na2O and K2O can increase the liquidus temperature of E-glass fiber and reduce fiber modulus, independent of silicate glass composition. In certain embodiments of the present disclosure, the dual function of Li2O, which improves fiber formation by reducing liquidus temperature and improves fiber modulus, can be opposite to that of Na2O and K2O. Definitions and Explanations

[0023] The terms "invention," "the invention," "the present invention," "embodiment," "certain embodiment," and the like, as used herein, are intended to broadly refer to all subject matter of this application and the following claims. Statements containing these terms should be understood not to limit the meaning or scope of the subject matter described herein or the following claims of the present invention. The terms "comprising," "having," "including," and "containing" should be construed as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise noted. Furthermore, it should be noted that, as used herein, the singular forms "a," "an," and "the" include plural referents unless clearly and unambiguously limited to one referent.

[0024] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, any range disclosed herein should be understood to encompass any and all subranges contained within that range. For example, a range defined as "1-10" should be considered to include any and all subranges between a minimum value of 1 and a maximum value of 10 (inclusive), i.e., all subranges beginning with a minimum value of 1 or greater, e.g., 1-6.1, and ending with a maximum value of 10 or less, e.g., 5.5-10. Moreover, any reference referred to as "incorporated herein" should be understood to be incorporated in its entirety.

[0025] The glass compositions are described in terms of weight percentage (wt.%) based on the total weight of the composition. Glass compositions and fibers

[0026] The present invention can be embodied in various ways. In some embodiments, a glass composition suitable for fiber formation can include SiO2, Al2O3, CaO, MgO, Y2O3, Li2O, and B2O3. In some embodiments, the composition can further include Fe2O3, Na2O, K2O, TiO2, and / or F2.

[0027] In certain embodiments, glass compositions suitable for fiber formation as described herein can include about 48 to about 61 weight percent (e.g., about 49 wt.% to about 58 wt.%, about 50 wt.% to about 60 wt.%, about 52 wt.% to about 58 wt.%, about 50 wt.% to about 57 wt.%) SiO2. For example, the composition can include about 48 wt.%, about 48.5 wt.%, about 49 wt.%, about 49.5 wt.%, about 50 wt.%, about 50.5 wt.%, about 51 wt.%, about 51.5 wt.%, about 52 wt.%, about 52.5 wt.%, about 53 wt.%, about 53.5 wt.%, about 54 wt.%, about 54.5 wt.%, about 55 wt.%, about 56 wt.%, about 57 wt.%, about 58 wt.%, about 59 wt.%, about 60 wt.%, about 62 wt.%, about 64 wt.%, about 65 wt.%, about 66 wt.%, about 67 wt.%, about 68 wt.%, about 69 wt.%, about 70 wt.%, about 71 wt.%, about 72 wt.%, about 73 wt.%, about 74 wt.%, about 75 wt.%, about 76 wt.%, about 77 wt.%, about 78 wt.%, about 79 wt.%, about 80 wt.%, about 81 wt.%, about 82 wt.%, about 83 wt.%, about 84 wt.%, about 85 wt.%, about 86 wt.%, about 87 wt.%, about 88 wt.%, about 89 wt.%, about 90 wt.%, about The SiO2 may be included in an amount of about 55 wt.%, about 55.5 wt.%, about 56 wt.%, about 56.5 wt.%, about 57 wt.%, about 57.5 wt.%, about 58 wt.%, about 58.5 wt.%, about 59 wt.%, about 59.5 wt.%, about 60 wt.%, about 60.5 wt.%, or about 61 wt.%.

[0028] In some examples, a glass composition suitable for fiber formation as described herein can include about 22 to about 27 weight percent Al2O3 (e.g., about 23 wt.% to about 25 wt.%, about 24 wt.% to about 26 wt.%, or about 22 wt.% to about 25 wt.%). For example, the composition can include Al2O3 in an amount of about 22 wt.%, about 22.5 wt.%, about 23 wt.%, about 23.5 wt.%, about 24 wt.%, about 24.5 wt.%, about 25 wt.%, about 25.5 wt.%, about 26 wt.%, about 26.5 wt.%, or about 27 wt.%.

[0029] In some embodiments, glass compositions suitable for fiber formation as described herein can include about 1 to about 11 weight percent CaO (e.g., about 2 wt.% to about 6 wt.%, about 1 wt.% to about 8 wt.%, about 4 wt.% to about 10 wt.%). For example, the composition can include CaO in an amount of about 1 wt.%, about 1.5 wt.%, about 2 wt.%, about 2.5 wt.%, about 3 wt.%, about 3.5 wt.%, about 4 wt.%, about 4.5 wt.%, about 5 wt.%, about 5.5 wt.%, about 6 wt.%, about 6.5 wt.%, about 7 wt.%, about 7.5 wt.%, about 8 wt.%, about 8.5 wt.%, about 9 wt.%, about 9.5 wt.%, about 10 wt.%, about 10.5 wt.%, or about 11 wt.%.

[0030] In some embodiments, glass compositions suitable for fiber formation as described herein can include about 5 to about 20 weight percent MgO (e.g., about 5.1 wt.% to about 18 wt.%, about 8 wt.% to about 15 wt.%, about 10 wt.% to about 18 wt.%, or about 6 wt.% to about 12 wt.%). For example, the composition may be about 5 wt.%, about 5.1 wt.%, about 5.2 wt.%, about 5.3 wt.%, about 5.4 wt.%, about 5.5 wt.%, about 6 wt.%, about 6.5 wt.%, about 7 wt.%, about 7.5 wt.%, about 8 wt.%, about 8.5 wt.%, about 9 wt.%, about 9.5 wt.%, about 10 wt.%, about 10.5 wt.%, about 11 wt.%, about 11.5 wt.%, about 12 wt.%, about 12.5 wt.%, about 13 wt.%, about 13.5 wt.%, about 14 wt.% The composition may include MgO in an amount of about 14.5 wt.%, about 15 wt.%, about 15.5 wt.%, about 16 wt.%, about 16.5 wt.%, about 17 wt.%, about 17.5 wt.%, about 18 wt.%, about 18.5 wt.%, about 19 wt.%, about 19.5 wt.%, or about 20 wt.%.

[0031] In some embodiments, glass compositions suitable for fiber formation as described herein can include LiO in an amount up to 2.5 weight percent. For example, the composition can include Li2O in an amount of about 0.2 wt.%, about 0.3 wt.%, about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.%, about 0.7 wt.%, about 0.8 wt.%, about 0.9 wt.%, about 1 wt.%, about 1.1 wt.%, about 1.2 wt.%, about 1.3 wt.%, about 1.4 wt.%, about 1.5 wt.%, about 1.6 wt.%, about 1.7 wt.%, about 1.8 wt.%, about 1.9 wt.%, up to 2 wt.%, about 2.1 wt.%, about 2.2 wt.%, about 2.3 wt.%, about 2.4 wt.%, or about 2.5 wt.%. In some embodiments, the composition can be substantially free of Li2O.

[0032] In some embodiments, glass compositions suitable for fiber formation as described herein can include Y2O3 in an amount up to 5.5 weight percent. For example, the composition can include Y2O3 in an amount up to about 0.5 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3 wt.%, 3.5 wt.%, 4 wt.%, 4.5 wt.%, 5 wt.%, or 5.5 wt.%. In some cases, Y2O3 can be present in an amount greater than 0 weight percent and less than 5.5 weight percent. In some cases, the composition can be substantially free of Y2O3.

[0033] Rare earth oxides may be included in the glass compositions of the present disclosure in amounts above those present solely as tramps or impurities in batch materials included with the glass batch to provide another component. Without being bound by theory, the inclusion of Y2O3 in the glass composition can have a desirable effect on the glass softening temperature and glass transition temperature, as well as the elastic modulus, tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0034] In some embodiments, glass compositions suitable for fiber formation as described herein may include B2O3 in an amount up to 1 weight percent. For example, the composition may include B2O3 in an amount of about 0.1 wt.%, about 0.2 wt.%, about 0.3 wt.%, about 0.4 wt.%, about 0.5 wt.%, about 0.6 wt.%, about 0.7 wt.%, about 0.8 wt.%, about 0.9 wt.%, or about 1 wt.%. In some embodiments, the glass composition may be substantially free of B2O3, meaning that any B2O3 present in the glass composition may result from B2O3 present as a trace impurity in the batch materials.

[0035] Less than 0.5 weight percent sulfate (denoted as SO3) and / or less than 1.0 weight percent cerium oxide (denoted as CeO2) may also be present as refining agents. Both sulfate and cerium oxide may be present in the glass composition. CeO2 and Y2O3 belong to the family of rare earth oxides. If the glass composition includes CeO2, the amount of Y2O3 may be reduced. Small amounts of impurities such as SrO, BaO, Cl2, P2O5, Cr2O3, or NiO (not limited to these specific chemical forms) may be present from raw materials or from contamination during the melting process. Other refining agents and / or processing aids such as As2O3, MnO, MnO2, or Sb2O3 (not limited to these specific chemical forms) may also be present. These impurities and refining agents, if present, are each typically present in an amount less than 0.1 weight percent of the total glass composition.

[0036] In some embodiments, glass compositions suitable for fiber formation as described herein can include a ratio of CaO to MgO ("CaO / MgO") of up to about 1.5 (e.g., up to about 1.2, up to about 0.8, or up to about 0.4). For example, the composition can include CaO / MgO in an amount of about 0.01, about 0.02, about 0.03, about 0.04, about 0.05, about 0.06, about 0.07, about 0.08, about 0.09, about 0.1, about 0.15, about 0.2, about 0.25, about 0.3, about 0.35, about 0.4, about 0.45, about 0.5, about 0.55, about 0.6, about 0.65, about 0.7, about 0.75, about 0.8, about 0.85, about 0.9, about 0.95, about 1, about 1.05, about 1.1, about 1.15, about 1.2, about 1.25, about 1.3, about 1.35 about 1.4, about 1.45, or about 1.5.

[0037] In some embodiments, glass compositions suitable for fiber formation as described herein can include a combined SiO2 and Al2O3 content ("SiO2+Al2O3") of greater than about 70 wt.% (e.g., greater than about 71 wt.%, greater than about 74 wt.%, greater than about 78 wt.%, greater than about 85 wt.%, or greater than about 70.05 wt.%). For example, the composition may be greater than about 70 wt.%, greater than about 70.5 wt.%, greater than about 71 wt.%, greater than about 71.5 wt.%, greater than about 72 wt.%, greater than about 72.5 wt.%, greater than about 73 wt.%, greater than about 73.5 wt.%, greater than about 74 wt.%, greater than about 74.5 wt.%, greater than about 75 wt.%, greater than about 75.5 wt.%, greater than about 76 wt.%, greater than about 76.5 wt.%, greater than about 77 wt.%, greater than about 77.5 wt.%, greater than about 78 wt.%, greater than about 78.5 wt.%, greater than about 79 wt.%, greater than about 79. The composition may include (SiO2 + Al2O3) in an amount of greater than 5 wt.%, greater than about 80 wt.%, greater than about 80.5 wt.%, greater than about 81 wt.%, greater than about 81.5 wt.%, greater than about 82 wt.%, greater than about 82.5 wt.%, greater than about 83 wt.%, greater than about 83.5 wt.%, greater than about 84 wt.%, greater than about 84.5 wt.%, greater than about 85 wt.%, greater than about 85.5 wt.%, greater than about 86 wt.%, greater than about 86.5 wt.%, greater than about 87 wt.%, greater than about 87.5 wt., or greater than about 88 wt.%.

[0038] In some embodiments, glass compositions suitable for fiber formation as described herein can include. In some embodiments, the composition can have a ratio of Al2O3 to RO ("Al2O3 / RO") less than 2.5 (e.g., less than about 2, less than about 1.3, or less than about 1), where RO is the sum of MgO and CaO. For example, the composition can include Al2O3 / RO in an amount of about 0.02, about 0.05, about 0.07, about 0.1, about 0.15, about 0.2, about 0.25, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, about 1, about 1.1, about 1.2, about 1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about 1.9, about 2, about 2.1, about 2.2, about 2.3, about 2.4, or about 2.5.

[0039] In some embodiments, glass compositions suitable for fiber formation as described herein can include a combined MgO and CaO content ("MgO+CaO") of about 12 wt.% to about 22.5 wt.% (e.g., about 13 wt.% to about 20 wt.%, about 15 wt.% to about 18 wt.%, or about 14 wt.% to about 19 wt.%). For example, the composition can include (MgO+CaO) in an amount of about 12 wt.%, about 12.5 wt.%, about 13 wt.%, about 13.5 wt.%, about 14 wt.%, about 14.5 wt.%, about 15 wt.%, about 15.5 wt.%, about 16 wt.%, about 16.5 wt.%, about 17 wt.%, about 17.5 wt.%, about 18 wt.%, about 18.5 wt.%, about 19 wt.%, about 19.5 wt.%, about 20 wt.%, about 20.5 wt.%, about 21 wt.%, about 21.5 wt.%, about 22 wt.%, or about 22.5 wt.%.

[0040] In some embodiments, glass compositions suitable for fiber formation as described herein may include a combined Na2O and K2O content ("Na2O+K2O") in an amount of less than 0.5 weight percent. For example, the composition may include (Na2O+K2O) in an amount of about 0.1 wt.%, about 0.15 wt.%, about 0.2 wt.%, about 0.25 wt.%, about 0.3 wt.%, about 0.35 wt.%, about 0.4 wt.%, about 0.45 wt.%, or about 0.5 wt.%. In some embodiments, the glass composition may be substantially free of Na2O.

[0041] In some embodiments, glass compositions suitable for fiber formation as described herein can include a combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") of greater than about 90 wt.% (e.g., greater than about 93 wt.%, greater than about 95 wt.%, or greater than about 98 wt.%), where RO includes CaO and MgO. For example, the composition can include an amount of (RO+Al2O3+SiO2) greater than about 90 wt.%, greater than about 90.5 wt.%, greater than about 91 wt.%, greater than about 91.5 wt.%, greater than about 92 wt.%, greater than about 92.5 wt.%, greater than about 93 wt.%, greater than about 93.5 wt.%, greater than about 94 wt.%, greater than about 94.5 wt.%, greater than about 95 wt.%, greater than about 95.5 wt.%, greater than about 96 wt.%, greater than about 96.5 wt.%, greater than about 97 wt.%, greater than about 97.5 wt.%, greater than about 98 wt.%, or greater than about 98.5 wt.%.

[0042] In some embodiments, a glass composition suitable for fiber formation can include about 44.5 to about 64 weight percent SiO2, about 12 to about 32 weight percent Al2O3, about 0.1 to about 15.5 weight percent CaO, about 5 to about 22 weight percent MgO, less than 1 weight percent Fe2O3, less than 2 weight percent TiO2, up to 4 weight percent ZnO, and less than 3 weight percent Na2O. In some embodiments, the composition can further include up to 12 weight percent RE2O3. In some embodiments, the composition can further include less than 1 weight percent Li2O and less than 4.5 weight percent B2O3.

[0043] In some cases, a glass composition suitable for fiber formation can include about 48 to about 61 weight percent SiO, about 22 to about 27 weight percent AlO, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent YO, up to 2.5 weight percent LiO, and up to 1 weight percent BO.

[0044] It should be understood that any component of the glass composition described as being present in an amount between about 0 weight percent and another weight percent is not necessarily required in all embodiments. Such components may be optional in some embodiments. Similarly, in some embodiments, the glass composition may be substantially free of some components, and any amount of a component present in the glass composition may result from a component present as a trace impurity in the batch materials. A component present as a trace impurity may not be intentionally added to the glass composition, but may be present in the glass compositions described herein because it is present as an impurity in a starting material added to the glass composition. Generally, trace impurities are present in the glass composition in an amount of about 0.1 weight percent or less, although some trace impurities may be present in the glass composition in an amount up to about 0.5 weight percent.

[0045] In some embodiments, the glass compositions of the present disclosure may be fiberizable. In some embodiments, the glass compositions have a desirable forming temperature (T F As used herein, the term "formation temperature" or T F means the temperature (or "log3 temperature") at which a glass composition has a viscosity of 1000 poise.

[0046] The glass composition, in some embodiments, is formed at a forming temperature (T F) (defined as a viscosity of 1000 poise for the molten glass). In another embodiment, the glass composition has a forming temperature in the range of about 1275° C. to about 1330° C. In some embodiments, the glass composition has a forming temperature (T F ) can be used. For example, T F may be about 1250°C, about 1255°C, about 1260°C, about 1265°C, about 1270°C, about 1275°C, about 1280°C, about 1285°C, about 1290°C, about 1295°C, about 1300°C, about 1305°C, about 1310°C, about 1315°C, about 1320°C, about 1325°C, about 1330°C, about 1335°C, about 1340°C, about 1345°C, or about 1350°C, rounded to the nearest 5°C.

[0047] In some embodiments, the glass composition has a liquidus temperature in the range of about 1200° C. to about 1250° C. (e.g., about 1205° C., about 1210° C., about 1215° C., about 1220° C., about 1225° C., about 1230° C., about 1235° C., about 1240° C., about 1245° C.). In some embodiments, the glass composition has a liquidus temperature in the range of about 1250° C. to about 1300° C. (e.g., about 1255° C., about 1260° C., about 1265° C., about 1270° C., about 1275° C., about 1280° C., about 1285° C., about 1290° C., about 1295° C.). In some embodiments, the glass composition has a liquidus temperature in the range of about 1300° C. to about 1350° C. (e.g., about 1305° C., about 1310° C., about 1315° C., about 1320° C., about 1325° C., about 1330° C., about 1335° C., about 1340° C., about 1345° C.). In some embodiments, the glass composition has a liquidus temperature in the range of about 1350° C. to about 1450° C. (e.g., greater than 1350° C., about 1355° C., about 1360° C., about 1365° C., about 1370° C., about 1375° C., about 1380° C., about 1390° C., about 1395° C., about 1400° C., about 1405° C., about 1410° C., about 1415° C., about 1420° C., about 1425° C., about 1430° C., about 1435° C., about 1440° C., about 1445° C., less than 1450° C.).

[0048] In some embodiments, the forming temperature of the glass composition (T F ) and liquidus temperature (TL ) may be desirable for commercial fiberglass manufacturing operations. For example, in some embodiments of the glass composition, T F and T L ("delta T" or "ΔT") may be less than about 95°C (e.g., less than 70°C, less than 50°C). For example, delta T may be less than about 0°C, less than about 5°C, less than about 10°C, less than about 15°C, less than about 20°C, less than about 25°C, less than about 30°C, less than about 35°C, less than about 40°C, less than about 45°C, less than about 50°C, less than about 55°C, less than about 60°C, less than about 65°C, less than about 70°C, less than about 75°C, less than about 80°C, less than about 85°C, less than about 90°C, less than about 95°C. In some embodiments, the glass composition may have a delta T of less than 60°C.

[0049] In some embodiments, the glass composition has a T F When determined using a log3-based T, the actual glass fiber forming process may have a delta T value less than 60° C. or even negative, i.e., less than 0° C. For these cases, the actual glass fiber forming process may have a delta T value less than 60° C. or even negative, i.e., less than 0° C., when determined using a log3-based T F and T L The actual fiber drawing temperature (T F 実際 ), i.e., T F 実際 =T L It can be set to +60℃.

[0050] In some embodiments, the glass composition has a melting temperature (T M ) can be used. For example, T Mmay be about 1345°C, about 1350°C, about 1360°C, about 1365°C, about 1370°C, about 1375°C, about 1380°C, about 1385°C, about 1390°C, about 1395°C, about 1400°C, about 1405°C, about 1410°C, about 1415°C, about 1420°C, about 1425°C, about 1430°C, about 1435°C, about 1440°C, about 1445°C, about 1450°C, about 1455°C, about 1460°C, about 1465°C, about 1470°C, about 1475°C, about 1480°C, about 1485°C, about 1490°C, about 1495°C, or about 1500°C.

[0051] In some embodiments, the glass fibers can be formed from the glass compositions described herein. If desired, the glass fibers can be arranged into a cloth. In some embodiments, the glass fibers can be provided in other forms, including, for example and not limited to, continuous strands, chopped strands (dry or wet), yarns, rovings, prepregs, and the like. Various embodiments of the glass compositions (and any fibers formed therefrom) can be used in a variety of applications. In some embodiments, the fibers can be fiberglass strands, and in other embodiments, yarns including fiberglass strands. Some embodiments of the yarns may be particularly suitable for textile applications. In some embodiments, the fibers can be fiberglass cloth. Some embodiments of the fiberglass cloth of the present disclosure are particularly suitable for use in reinforcement applications, especially where high modulus, high strength, and / or high elongation are important.

[0052] Some embodiments of the present disclosure may relate to composites incorporating fiberglass strands, fiberglass yarns, and fiberglass fabrics, such as fiber reinforced polymer composites. Some composites may be particularly suitable for use in reinforcement applications, particularly where high modulus, high strength, and / or high elongation are important, such as wind energy (e.g., wind turbine blades), automotive applications, safety / security applications (e.g., bulletproof armor or armor panels), aerospace or aviation applications (e.g., airplane interior floors), high pressure vessels or tanks, missile casings, and the like.

[0053] Some embodiments of the present disclosure relate to composites suitable for use in wind energy applications. Composites of the present disclosure may be suitable for use in wind turbine blades, especially long wind turbine blades that are lighter yet stronger compared to other long wind turbine blades. Lighter weight and greater stability of wind energy blades are very important considerations for composite material selection. Wind energy blade design has changed over time to pursue longer blades to obtain more energy. Some blades are 82 meters long and can benefit from improved fiber composites. Stronger fiberglass composites, such as those disclosed herein, may be useful to achieve larger wind blade sizes while providing the strength and weight required to stay within the load design of the wind turbine. Lighter and stronger materials, such as those disclosed herein, can increase energy yield, improve operating costs, reduce installation costs, ease of transportation, and improve safety.

[0054] Still other embodiments of the present disclosure may relate to automotive composites. Some embodiments of the present disclosure may relate to aerospace composites. Other embodiments of the present application may relate to aviation composites. Some embodiments of the present disclosure may relate to composites for safety / security applications, such as armor panels. Other embodiments of the present disclosure may relate to composites for high pressure vessels or storage tanks. Some embodiments of the present disclosure may relate to composites for missile casings. Other embodiments of the present disclosure may relate to composites for use in high temperature insulation applications. Some embodiments of the present disclosure may relate to printed circuit boards, such as substrates for chip packaging, where a lower coefficient of thermal expansion is particularly desirable. Some embodiments of the present disclosure may relate to prepregs. Some embodiments of the present disclosure may relate to long fiber reinforced thermoplastics (LFTs) for various automotive parts. Some embodiments of the present disclosure may relate to pipes or tanks for chemical transport and storage. Some embodiments of the present disclosure may relate to non-woven textured fibers for thermal and acoustic management applications, such as mufflers for motorcycles, cars, and trucks. Some embodiments of the present disclosure may relate to electrical insulation rods or cables. Some embodiments of the present disclosure may relate to composite rebar to replace steel rebar for road infrastructure, bridges, and buildings.

[0055] Some embodiments of the present disclosure relate to fiber glass strands. In some embodiments, the fiber glass strands of the present disclosure include a plurality of glass fibers. In some embodiments, the plurality of glass fibers may be formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") of the composition may be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") of the composition may be less than about 2.5, where RO is the amount of CaO and MgO in the composition. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%.

[0056] In some embodiments, the glass fiber or fibers of the present disclosure can exhibit desirable mechanical and other properties. The glass fibers of the present disclosure can exhibit one or more improved mechanical properties relative to glass fibers formed from E-glass in some embodiments. In some embodiments, the glass fibers of the present disclosure can provide one or more improved properties relative to glass fibers formed from R-glass and / or S-glass. Examples of desirable properties exhibited by some embodiments of the glass fibers of the present disclosure include, but are not limited to, tensile strength, Young's modulus, coefficient of thermal expansion, softening point, elongation, and dielectric constant.

[0057] In some embodiments, a glass fiber or glass fibers can be formed from the glass composition described herein. In certain embodiments, the glass fibers can have a desirable Young's modulus (E) value. In some cases, the glass fibers can have a Young's modulus of greater than about 90 GPa (e.g., greater than 92 GPa, greater than 95 GPa, greater than 100 GPa). For example, the Young's modulus can be about 90 GPa, about 91 GPa, about 92 GPa, about 93 GPa, about 94 GPa, about 95 GPa, about 96 GPa, about 97 GPa, about 98 GPa, about 99 GPa, about 100 GPa, about 101 GPa, about 102 GPa, about 103 GPa, about 104 GPa, about 105 GPa, about 106 GPa, about 107 GPa, about 108 GPa, about 109 GPa, or about 110 GPa. In some embodiments, the glass fibers can have a Young's modulus of greater than about 105 GPa. In certain embodiments, the glass fibers can have a Young's modulus of up to 110 GPa. In some embodiments, the glass fibers can have a Young's modulus of greater than about 105 GPa. In certain embodiments, the glass fibers can have a Young's modulus of up to 110 GPa.

[0058] In certain embodiments, the glass fibers can have a desirable specific modulus (Sp) value. In some cases, the glass fibers can have a specific modulus of elasticity of about 3.5×10 6 m (e.g., 3.6 × 10 6 >m, 3.9×10 6 For example, the specific modulus can be about 3.5×10 6 m, approx. 3.55×10 6 m, approx. 3.6×10 6 m, approx. 3.65×10 6 m, approx. 3.7×10 6 m, approx. 3.75×10 6 m, approx. 3.8×10 6 m, approx. 3.85×10 6 m, approx. 3.9×10 6 m, approx. 3.95×10 6 m, or approximately 4.0 × 10 6In some embodiments, the plurality of glass fibers may be about 4.0×10 6 It may have a specific modulus greater than m.

[0059] In certain embodiments, the glass fiber or fibers can have a desired density value. In some cases, the glass fibers can have a density of about 3 g / cm. 3 Less than (e.g., 2.8 g / cm 3 Less than 2.55g / cm 3 For example, the density may be about 2.5 g / cm 3 , about 2.55g / cm 3 , about 2.6g / cm 3 , about 2.65g / cm 3 , about 2.7g / cm 3 , about 2.75g / cm 3 , about 2.8g / cm 3 , about 2.85g / cm 3 , about 2.9g / cm 3 , about 2.95g / cm 3 , or about 3 g / cm 3 may be also possible.

[0060] The fiber glass strands can include glass fibers of various diameters depending on the desired application. In some embodiments, the fiber glass strands of the present disclosure can include at least one glass fiber having a diameter between about 5 and about 18 μm. In other embodiments, the at least one glass fiber has a diameter between about 5 and about 10 μm. In some embodiments, the fiber glass strands of the present disclosure can be formed into a roving. The roving can include assembled, multi-end, or single-end direct drawn rovings. The rovings including the fiber glass strands of the present disclosure can include direct drawn single-end rovings having various diameters and densities depending on the desired application. In some embodiments, the rovings including the fiber glass strands of the present disclosure exhibit a density of up to about 112 yd / lb. Some embodiments of the present disclosure relate to yarns including at least one fiber glass strand disclosed herein.

[0061] In some embodiments, the fiber glass strands may include a plurality of glass fibers of any one of the glass compositions described herein. For example, in some embodiments, the fiber glass strands may include a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") may be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") may be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%.

[0062] In other embodiments, the yarns of the present disclosure may include at least one fiber glass strand comprising one of the other glass compositions disclosed herein as part of the present disclosure.

[0063] In some embodiments, the yarn of the present disclosure can include at least one fiberglass strand as disclosed herein that is at least partially coated with a sizing composition. In some embodiments, the sizing composition can be compatible with a thermosetting polymer resin. In other embodiments, the sizing composition can include a starch-oil sizing composition.

[0064] The yarns can have a variety of linear mass densities depending on the desired application. In some embodiments, the yarns of the present disclosure can have a linear mass density of from about 5,000 yards / pound to about 10,000 yards / pound.

[0065] The yarns can have a variety of twist levels and directions depending on the desired application. In some embodiments, the yarns of the present disclosure can have a twist in the z-direction of about 0.5 to about 2 turns per inch. In other embodiments, the yarns of the present disclosure can have a twist in the z-direction of about 0.7 turns per inch.

[0066] A yarn can be made from one or more strands that are twisted together and / or plied, depending on the desired application. A yarn can be made from one or more strands that are twisted together but not plied, such yarns being known as "single yarns." A yarn of the present disclosure can be made from one or more strands that are twisted together but not plied. In some embodiments, a yarn of the present disclosure can include 1-4 strands that are twisted together. In other embodiments, a yarn of the present disclosure can include one strand that is twisted.

[0067] In some embodiments, the fiber glass strands can include a plurality of glass fibers of any one of the glass compositions described herein. For example, in some embodiments, the fiber glass strands can include a plurality of glass fibers formed from a glass composition that includes about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3.

[0068] In some embodiments, the roving may include a plurality of glass fibers of any one of the glass compositions described herein. For example, in some embodiments, the roving may include a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") may be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") may be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%.

[0069] In some embodiments, the yarn can include a plurality of glass fibers of any one of the glass compositions described herein. For example, in some embodiments, the yarn can include a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") can be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") can be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") can be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%.

[0070] Some embodiments of the present disclosure relate to a fabric comprising at least one fiber glass strand as disclosed herein. In some embodiments, the fabric may be woven. In other embodiments, the fabric may be a nonwoven fabric or a unidirectional fabric. In some embodiments, the fabric may comprise a plurality of glass fibers of any one of the glass compositions described herein. For example, in some embodiments, the fabric may comprise a plurality of glass fibers formed from a glass composition comprising about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") may be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") may be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be between about 12 wt.% and about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%.

[0071] In some embodiments of the present disclosure that include a fabric, the fiberglass fabric may be a fabric woven according to industrial fabric style no. 7781. In other embodiments, the fabric includes a plain weave, a twill weave, a houndstooth weave, a satin weave, a stitchbonded fabric (also known as a non-crimp fabric), or a "three-dimensional" woven fabric.

[0072] Some embodiments of the present disclosure relate to composites. In some embodiments, the polymer composites can include a polymer material and a plurality of glass fibers formed from a glass composition described herein. For example, in some embodiments, the polymer composites can include a polymer material and a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") can be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") can be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be between about 12 wt.% and about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%. In some embodiments, the plurality of glass fibers may be in the form of a nonwoven or unidirectional fabric. In some embodiments, the plurality of glass fibers may be in the form of a woven fabric. In some embodiments, the polymeric material may include a thermoplastic polymer. In some embodiments, the polymeric material may include a thermosetting polymer.

[0073] In other embodiments, the composites of the present disclosure can include a polymer resin and a plurality of glass fibers deposited on the polymer resin, where at least one of the plurality of glass fibers is formed from one of the other glass compositions disclosed herein as part of the present disclosure. In some embodiments, the composites can include a polymer resin and at least one fiberglass strand as disclosed herein deposited on the polymer resin. In some embodiments, the composites can include at least a portion of a roving comprising a polymer resin and at least one fiberglass strand as disclosed herein deposited on the polymer resin. In other embodiments, the composites can include a polymer resin and at least one yarn as disclosed herein deposited on the polymer resin. In yet other embodiments, the composites can include a polymer resin and at least one fabric as disclosed herein deposited on the polymer resin. In some embodiments, the composites can include at least one weft yarn comprising at least one fiberglass strand as disclosed herein and at least one warp yarn comprising at least one fiberglass strand as disclosed herein.

[0074] The composites of the present disclosure can include a variety of polymer resins depending on the desired properties and applications. In some embodiments, the polymer resin can include an epoxy resin. In other embodiments, the polymer resin can include polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic resin, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bis-maleimide, or thermoset polyurethane resin.

[0075] In certain embodiments, an article of manufacture may include a plurality of glass fibers formed from any one of the glass compositions described herein. For example, in some embodiments, an article of manufacture may include a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") may be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") may be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%. In some embodiments, the plurality of glass fibers may be in the form of a non-woven or unidirectional fabric. In some embodiments, the plurality of glass fibers may be in the form of a woven fabric.

[0076] In other embodiments, an article of manufacture can include a polymeric material and a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") can be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") can be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") can be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be about 12 wt.% to about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%. In some embodiments, the plurality of glass fibers may be in the form of a nonwoven or unidirectional fabric. In some embodiments, the plurality of glass fibers may be in the form of a woven fabric. In some embodiments, the polymeric material may include a thermoplastic polymer. In some embodiments, the polymeric material may include a thermosetting polymer.

[0077] Some embodiments of the present disclosure relate to aerospace composites. In some embodiments, the aerospace composites can exhibit properties such as high strength, high elongation, high modulus, and / or low density that are desirable for use in aerospace applications. In some embodiments, the aerospace composites can include a plurality of glass fibers from a glass composition described herein. For example, in some embodiments, the aerospace composites can include a polymeric material and a plurality of glass fibers formed from a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") can be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") may be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O ("Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be between about 12 wt.% and about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%. In some embodiments, the plurality of glass fibers may be in the form of a nonwoven or unidirectional fabric. In some embodiments, the plurality of glass fibers may be in the form of a woven fabric. In some embodiments, the polymeric material may include a thermoplastic polymer. In some embodiments, the polymeric material may include a thermoset polymer.

[0078] Examples of parts in which the composites of the present disclosure may be used include, but are not limited to, aerospace parts such as floor panels, bins, galleys, seat backs, and other interior compartments potentially subject to impact, as well as exterior parts such as helicopter rotor blades; automotive parts such as structural parts, bodies, and bumpers; wind energy parts such as wind turbine blades; high pressure vessels and / or tanks; safety and / or security applications; high mechanical stress applications; high energy impact applications such as bulletproof or blast resistant applications; armor applications such as the manufacture of armor panels; casings for missiles and other explosive delivery devices; applications in the oil and gas industry, other applications related to transportation and infrastructure, applications in alternative energy, high temperature insulation (i.e., heat shielding) applications (due to higher strength, higher modulus of elasticity, higher softening temperature, and higher glass transition temperature). In some embodiments, the composites may have a sheet-like physical dimension or shape and may be panels.

[0079] Some embodiments of the present disclosure relate to prepregs. In some embodiments, the prepregs can include a plurality of glass fibers from the glass compositions described herein. For example, in some embodiments, the prepregs can include a plurality of glass fibers formed from a polymeric material and a glass composition including about 48 to about 61 weight percent SiO2, about 22 to about 27 weight percent Al2O3, about 1 to about 11 weight percent CaO, about 5 to about 20 weight percent MgO, less than 5.5 weight percent Y2O3, up to 2.5 weight percent Li2O, and up to 1 weight percent B2O3. In some embodiments, the ratio of CaO to MgO ("CaO / MgO") can be less than about 1.5. In some embodiments, the ratio of Al2O3 to RO ("Al2O3 / RO") can be less than about 2.5, where RO is the amount of CaO and MgO. In some embodiments, the combined content of Na2O and K2O (Na2O+K2O") may be less than about 0.5 wt.%. In some embodiments, the combined content of MgO and CaO ("MgO+CaO") may be between about 12 wt.% and about 22.5 wt.%. In some embodiments, the combined content of Al2O3 and SiO2 ("Al2O3+SiO2") may be greater than about 70 wt.%. In some embodiments, the combined content of RO, Al2O3, and SiO2 ("RO+Al2O3+SiO2") may be greater than about 90 wt.%. In some embodiments, the plurality of glass fibers may be in the form of a nonwoven or unidirectional fabric. In some embodiments, the plurality of glass fibers may be in the form of a woven fabric. In some embodiments, the polymeric material may include a thermoplastic polymer. In some embodiments, the polymeric material may include a thermosetting polymer.

[0080] While many of the applications for the glass fibers described herein are reinforcing applications, some embodiments of the glass fibers can be utilized in electronic applications, such as printed circuit boards ("PCBs").

[0081] More specifically, some embodiments relate to glass fiber reinforced materials that have electrical properties that enable enhanced performance of PCBs. For example, some embodiments can have a dielectric constant (Dk) that is desirable for electronics applications. The dielectric constant (Dk) of a material, also known as the "dielectric constant," is a measure of the material's ability to store electrical energy. Materials used as capacitors desirably have a relatively high Dk, while materials used as part of a PCB substrate desirably have a low Dk, especially for high speed circuits. Dk is the ratio of the charge that can be stored in a given material between two metal plates (i.e., capacitance) to the amount of charge that can be stored by the void (air or vacuum) between the same two metal plates. As another example, some embodiments can have a coefficient of thermal expansion that is desirable for electronics applications. Thus, some embodiments can be used in a variety of electrical applications, including, but not limited to, printed circuit boards, precursors to printed circuit boards (e.g., fabrics, laminates, prepregs, etc.). In such embodiments, a printed circuit board or other composite used in an electrical application can include a polymeric resin and a plurality of glass fibers in contact with the polymeric resin, where at least one of the plurality of glass fibers is formed from any of the glass compositions disclosed herein as part of the present disclosure. The polymeric resin can include any of the polymeric resins known to those of skill in the art for use in printed circuit boards or other electrical applications.

[0082] Turning now to the method of manufacture of the glass fibers and related products of the present disclosure, the glass fibers of the present disclosure can be prepared in a conventional manner known in the art by blending the raw materials used to provide the specific oxides that form the fiber composition. The glass fibers according to various embodiments of the present disclosure can be formed using any method known in the art for forming glass fibers, more desirably any method known in the art for forming essentially continuous glass fibers. For example, the glass fibers according to non-limiting embodiments of the present disclosure can be formed using, but are not limited to, direct melt or indirect melt fiber forming methods. These methods are well known in the art and further discussion thereof is not believed to be necessary in view of the present disclosure. See, for example, KL Loewenstein, The Manufacturing Technology of Continuous Glass Fibers, 3rd Ed., Elsevier, NY, 1993 at pages 47-48 and 117-234.

[0083] After the glass fibers are formed, the primary sizing composition can be applied to the glass fibers using any suitable method known to those skilled in the art. Those skilled in the art can select one of many commercially available sizing compositions for glass fibers based on several factors, including, for example, the performance characteristics of the sizing composition, the desired flexibility of the resulting fabric, cost, and other factors.

[0084] The fiberglass strands of the present disclosure can be prepared by any suitable method known to those skilled in the art. The fiberglass fabrics of the present disclosure can generally be made by any suitable method known to those skilled in the art, including, but not limited to, interlacing a weft yarn (also called a "fill yarn") with a plurality of warp yarns.

[0085] Composites of the present disclosure can be prepared by any suitable method known to those skilled in the art, including, but not limited to, vacuum assisted resin infusion molding, extrusion compounding, compression molding, resin transfer molding, filament winding, prepreg / autoclave curing, and pultrusion. Composites of the present disclosure can be prepared using such molding techniques as known to those skilled in the art. In particular, composite embodiments of the present disclosure incorporating woven fiberglass fabrics can be prepared using techniques known to those skilled in the art for preparing such composites.

[0086] Prepregs of the present disclosure can be prepared by any suitable means known to those of skill in the art, including, but not limited to, passing fiberglass strands, rovings, or fabric through a resin bath, using a solvent-based resin, or using a resin film.

[0087] As previously mentioned, the composites of the present disclosure may include a polymer resin in some embodiments. A variety of polymer resins may be used. In some embodiments, polymer resins known to be useful for reinforcement applications may be particularly useful. In some embodiments, the polymer resin may include a thermosetting resin. Thermosetting resin systems useful in some embodiments of the present disclosure may include, but are not limited to, epoxy resin systems, phenol-based resins, polyesters, vinyl esters, thermosetting polyurethanes, polydicyclopentadiene (pDCPD) resins, cyanate esters, and bis-maleimides. In some embodiments, the polymer resin may include an epoxy resin. In other embodiments, the polymer resin may include a thermoplastic resin. Thermoplastic polymers useful in some embodiments of the present disclosure include, but are not limited to, polyethylene, polypropylene, polyamides (including nylons), polybutylene terephthalates, polycarbonates, thermoplastic polyurethanes (TPUs), polyphenylene sulfides, and polyetheretherketeone (PEEK). Non-limiting examples of commercially available polymer resins useful in some embodiments of the present disclosure include EPIKOTE Resin MGS® RIMR 135 epoxy with Epikure MGS RIMH 1366 hardener (available from Momentive Specialty Chemicals Inc., Columbus, Ohio), Applied Poleramic MMFCS2 epoxy (available from Applied Poleramic, Inc., Benicia, California), and EP255 modified epoxy (available from Barrday Composite Solutions, Millbury, Mass.).

[0088] The following examples are intended to further describe the present disclosure through a series of specific embodiments, however, those skilled in the art will appreciate that the disclosure described herein is not necessarily limited to the examples described in this section, as many other embodiments are contemplated by the principles of the present disclosure. EXAMPLES

[0089] Table 1 provides data on several fiberizable glass compositions according to various embodiments of the present disclosure and various properties of such compositions. The glasses of these examples were made by melting a mixture of commercial and reagent grade chemicals in powder form (reagent grade chemicals were used only for rare earth oxides) in 10% Rh / Pt crucibles at temperatures between 1500°C and 1600°C (2732°F and 2912°F) for 4 hours. Each batch was approximately 1000 grams. After the 4-hour melting period had elapsed, the molten glass was poured onto a steel plate for quenching. Volatile species such as alkali oxides resulting from impurities in the ingredients used were not adjusted in the batches for diffusion losses due to their low concentration in the glass. The compositions of the examples represent the compositions of the batches as they are. Commercial ingredients were used in the preparation of the glasses. The batch calculations took into account the retention factors of the particular raw materials to calculate the oxides in each glass. The retention factors are based on the glass batch melting age and the oxide yield in the glass as measured. Therefore, the as-batch compositions illustrated in the examples are considered to be close to the measured compositions.

[0090] Melt viscosity and liquidus temperature as a function of temperature were determined using ASTM Test Methods C965 "Standard Practice for Measuring Viscosity of Glass Above the Softening Point" and C829 "Standard Practice for Measurement of Liquidus Temperature of Glass by the Gradient Furnace Method", respectively.

[0091] Table 1 shows the liquidus temperatures (T L ), the reference forming temperature (T F ) The difference between the formation temperature and the liquidus temperature (ΔT) is also shown.

[0092] For certain glass compositions in Table 1, the Young's modulus (sonic modulus) of the fibers was also measured using the following technique. Approximately 500 grams of glass cullet having a composition corresponding to the appropriate example in Table 1 was remelted in a 90Pt / 10Rh crucible at a melting temperature defined by 100 poise for 2 hours. The crucible was then transferred to an electrically heated furnace, which was a vertical tube. The temperature of the furnace was preset to a fiber drawing temperature close to or equal to the melt viscosity of 1000 poise. The glass was allowed to equilibrate at that temperature for 1 hour before the fibers were drawn. The top of the fiber drawing furnace had a cover with a hole in the center, on which was mounted a water-cooled copper coil to regulate the cooling of the fiber. A silica rod was then manually dipped into the melt through the cooling coil, and a fiber approximately 1 to 1.5 m long was drawn and collected. The fiber diameters ranged from about 100 μm at one end to about 1000 μm at the other end. Over that range, the value of the sonic modulus is independent of the fiber diameter. The specific modulus is calculated by the ratio of the measured sonic modulus and the bare fiber density. The measurement of the sonic modulus of the fiber follows the method by LC Lynnworth, "Ultrasonic Measurement of Elastic Moduli in Slender Specimens Using Extensional and Torsional Wave Pulses," Journal of Testing and Evaluation, JTEVA, Vol. 1, No. 2, March 1973, pp. 119-125. [Table 1-1] [Table 1-2] [Table 1-3]

[0093] Na2O and K2O have been shown in the literature to increase the liquidus temperature and decrease the sonic modulus of fibers, while Li2O has been shown to decrease the melt viscosity or melting and forming temperatures of glass fibers. In contrast to the reported effects of Na2O and K2O, Li2O can decrease the liquidus temperature and increase the sonic (Young's) modulus of fibers.

[0094] Table 2 provides comparable fiberizable glass compositions on a mole percent basis, and data regarding various properties of the compositions. The glasses of these examples were made by the same methods as those described in Table 1. Comparative Example 7 * The composition of Example 7 is the same as that of Example 7, except that Li2O has been replaced with Na2O on an equimolar basis. It can be understood that the final compositions in Table 2 are the same in terms of mole percent, but may differ in terms of weight percent. The molecular weight of Li2O is 29.88 g / mol, while the molecular weight of Na2O is 61.98 g / mol. Comparative Example 7, in which Li2O molecules are replaced by one equivalent of Na2O molecules, has a molar equivalent to Example 7, to compare the equivalence effect between Li2O and Na2O on the glass composition. * In the case of replacing 4.23 mol% Na2O, Comparative Example 7 * The composition in terms of wt. % is completely different from that of Example 7. [Table 2]

[0095] FIG. 1 includes several examples described herein and shows that increasing Li2O content decreases the liquidus temperature. FIG. 2 includes several examples described herein and shows that increasing Li2O content increases the Young's modulus. In FIGS. 1 and 2, Comparative Example 7 * indicates that the equivalent amount of Na2O to replace 2.1 wt.% Li2O is 4.17 wt.%.

[0096] The inclusion of Li2O in the glass composition allows for fibers to be made at lower liquidus temperatures and therefore lower fiber draw temperatures, while at the same time improving the fiber modulus.

[0097] Desirable features that may be exhibited by various embodiments, although not necessarily all of the present disclosure, may include, but are not limited to, providing products such as fiberglass, fiberglass strands, fiberglass cloth, prepregs, and other products useful for reinforcement applications. Exemplary embodiments of suitable compositions, fibers, composites, and articles

[0098] As used hereinafter, any reference to a composition, composite, or article should be understood as a disjunctive reference to each of those compositions, composites, or articles (e.g., "Exemplary Embodiments 1-4 should be understood as Exemplary Embodiments 1, 2, 3, or 4").

[0099] Exemplary embodiment 1 is a glass composition suitable for fiber formation that includes about 44.5 to about 64 weight percent SiO, about 12 to about 32 weight percent AlO, about 0.1 to about 15.5 weight percent CaO, about 5 to about 22 weight percent MgO, less than 1 weight percent FeO, less than 2 weight percent TiO, less than 3 weight percent NaO, up to 12 weight percent REO, up to 4 weight percent ZnO, less than 1 weight percent LiO, and less than 4.5 weight percent BO.

[0100] Exemplary embodiment 2 is the composition of any preceding or following exemplary embodiment, wherein the ratio of CaO to MgO (CaO / MgO) is less than 1.5.

[0101] Exemplary embodiment 3 is the composition of any exemplary embodiment described above or below, wherein the ratio of Al2O3 to RO (Al2O3 / RO) is less than 2.5, and RO includes CaO and MgO.

[0102] Exemplary embodiment 4 is any composition of exemplary embodiments described above or below comprising a combined Na2O and K2O content (Na2O+K2O) of less than about 0.5 wt.%.

[0103] Exemplary embodiment 5 is any composition of exemplary embodiments described above or below that includes a combined MgO and CaO content (MgO+CaO) of 12 wt.% to 22.5 wt.%.

[0104] Exemplary embodiment 6 is any composition of exemplary embodiments described above or below that includes a combined Al2O3 and SiO2 content (Al2O3+SiO2) of greater than 70 wt.%.

[0105] Exemplary embodiment 7 is the composition of any of the preceding exemplary embodiments, comprising a combined content of RO, Al2O3, and SiO2 (RO+Al2O3+SiO2) of greater than 90 wt.%.

[0106] Exemplary embodiment 8 is a plurality of glass fibers formed from the glass composition of any of the exemplary embodiments described above.

[0107] Exemplary embodiment 9 is a plurality of glass fibers of any preceding or following exemplary embodiment, wherein said glass fibers have a Young's modulus of at least 90 GPa.

[0108] Exemplary embodiment 10 is a fiberglass fiber having a fiber thickness of 3 g / cm 3 The plurality of glass fibers of any preceding or following exemplary embodiment having a density of less than 100 μm.

[0109] Exemplary embodiment 11 is a glass fiber having a glass fiber melt melting temperature (MW) of 1000° C. to 1500° C. L ) at least 60°C above the actual fiber drawing temperature (T F 実際 ), the glass fibers of any of the exemplary embodiments described above or below.

[0110] Exemplary embodiment 12 is a glass fiber having a liquidus temperature (T L ) of any exemplary embodiment described above or below.

[0111] Exemplary embodiment 13 is a method for manufacturing a glass fiber having a melting temperature (T M ) of any exemplary embodiment described above or below.

[0112] Exemplary embodiment 14 is a method for manufacturing a glass fiber optic cable comprising: 6 a plurality of glass fibers of any exemplary embodiment described above or below having a specific modulus greater than m.

[0113] Exemplary embodiment 15 is a glass fiber having a diameter of 3.7×10 6 a plurality of glass fibers of any preceding exemplary embodiment having a specific modulus greater than m.

[0114] Exemplary embodiment 16 is a fiberglass strand comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0115] Exemplary embodiment 17 is a roving comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0116] Exemplary embodiment 18 is a yarn comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0117] Exemplary embodiment 19 is a woven fabric comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0118] Exemplary embodiment 20 is a nonwoven fabric comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0119] Exemplary embodiment 21 is a chopped fiber glass strand comprising a plurality of glass fibers as described in any of the previous exemplary embodiments.

[0120] Exemplary embodiment 22 is a polymer composite that includes a polymer material and a plurality of glass fibers of any of the exemplary embodiments previously described.

[0121] Exemplary embodiment 23 is the polymer composite of any exemplary embodiment described above or below, wherein the plurality of glass fibers is in the form of a nonwoven or unidirectional fabric.

[0122] Exemplary embodiment 24 is the polymer composite of any exemplary embodiment described above or below, wherein said plurality of glass fibers is in the form of a woven fabric.

[0123] Exemplary embodiment 25 is the polymer composite of any exemplary embodiment described above or below, wherein said polymeric material comprises a thermoplastic polymer.

[0124] Exemplary embodiment 26 is the polymer composite of any previous exemplary embodiment, wherein the polymeric material comprises a thermosetting polymer.

[0125] Exemplary embodiment 27 is an article of manufacture that includes a plurality of glass fibers of any of the exemplary embodiments described above.

[0126] Various embodiments of the present disclosure have been described herein. It should be recognized that these embodiments are merely illustrative of the present disclosure. Variations of these preferred embodiments may become apparent to those skilled in the art upon reading the foregoing description. The inventors expect that those skilled in the art will employ such variations as appropriate, and contemplate that the present disclosure may be implemented in ways other than those specifically described herein. Accordingly, the present disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the foregoing elements is encompassed by the present disclosure in all possible variations thereof unless otherwise specified or otherwise clearly contradicted by context.

[0127] It should be understood that the present description illustrates aspects of the present invention that are relevant for a clear understanding of the present invention. In order to simplify the present description, certain aspects of the present invention that should be obvious to those skilled in the art and therefore may not facilitate a more accurate understanding of the present invention are not presented. Although the present invention has been described in connection with certain embodiments, the present disclosure is not limited to the disclosed specific embodiments, and is intended to encompass modifications that are within the spirit and scope of the present disclosure.

Claims

1. 48 to 61 weight percent SiO ２ , 22 to 27 weight percent Al ２ O ３ , 1 to 11 weight percent CaO, 5 to 20 weight percent MgO, Less than 5.5 weight percent Y ２ O ３ , Up to 2.5 weight percent Li ２ O, and Up to 1 weight percent B ２ O ３ 1. A glass composition suitable for fiber formation, comprising:

2. 2. The glass composition of claim 1, wherein the ratio of CaO to MgO (CaO / MgO) is less than 1.

5.

3. Al ２ O ３ Ratio of to RO (Al ２ O ３ 2. The glass composition of claim 1, wherein R O (R O ) is less than 2.5 and R O comprises CaO and MgO.

4. The composition contains less than 0.5 wt. % Na ２ O and K ２ Combined content of O (Na ２ O+K ２ 10. The glass composition of claim 1, comprising:

5. 2. The glass composition of claim 1, wherein the composition comprises a combined content of MgO and CaO (MgO+CaO) of 12 wt.% to 22.5 wt.%.

6. The composition contains more than 70 wt.% Al ２ O ３ and SiO ２ The combined content of (Al ２ O ３ +SiO ２ 10. The glass composition of claim 1, comprising:

7. The composition contains more than 90 wt.% of RO, Al ２ O ３ , and SiO ２ The combined content (RO + Al ２ O ３ +SiO ２ 10. The glass composition of claim 1, comprising:

8. A plurality of glass fibers formed from the glass composition of claim 1.

9. 9. The plurality of glass fibers of claim 8, wherein the glass fibers have a Young's modulus of at least 90 GPa.

10. The glass fiber is 3 g / cm ３ 9. The plurality of glass fibers of claim 8 having a density of less than 1 / 2.

11. The glass fiber has a liquidus temperature (T Ｌ ) at least 60° C. above the actual fiber drawing temperature (T Ｆ 実際 9. The plurality of glass fibers of claim 8, wherein the plurality of glass fibers can be drawn by a

12. The glass fiber has a liquidus temperature (T Ｌ 9. The plurality of glass fibers of claim 8, having a

13. The glass fiber has a melting temperature (T Ｍ 9. The plurality of glass fibers of claim 8, having a

14. The glass fiber is 3.5 × 10 ６ 9. The plurality of glass fibers of claim 8 having a specific modulus greater than m.

15. A fiber glass strand comprising a plurality of the glass fibers of claim 8.

16. A roving comprising a plurality of glass fibers according to claim 8.

17. A yarn comprising a plurality of the glass fibers of claim 8.

18. A woven fabric comprising a plurality of the glass fibers of claim 8.

19. A nonwoven fabric comprising a plurality of the glass fibers of claim 8.

20. A chopped fiber glass strand comprising a plurality of glass fibers according to claim 8.

21. polymeric materials, and A plurality of glass fibers formed from the glass composition of claim 1. A polymer composite comprising:

22. 22. The polymer composite of claim 21, wherein the plurality of glass fibers is in the form of a nonwoven or unidirectional fabric.

23. 22. The polymer composite of claim 21, wherein the plurality of glass fibers is in the form of a woven fabric.

24. 22. The polymer composite of claim 21, wherein the polymer material comprises a thermoplastic polymer.

25. 22. The polymer composite of claim 21, wherein the polymer material comprises a thermosetting polymer.

26. An article of manufacture comprising a plurality of glass fibers formed from the glass composition of claim 1.

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