Glass fiber yarn and method for manufacturing the same

Abstract

To provide glass fiber yarn capable of effectively improving that the glass fiber yarn is easily torn in a spinning process, and a method for manufacturing the same.SOLUTION: A method for manufacturing glass fiber yarn comprises steps of: dissolving a tungsten compound in a first organic solution to form tungsten compound gel; adding a sulfur source to the tungsten compound gel and agitating the sulfur source and the tungsten compound gel to form tungsten sulfide gel; holding the tungsten sulfide gel for 4-6 hours in the environment of 600-1200°C to form tungsten sulfide powder; coating the tungsten sulfide powder on the surfaces of a plurality of surface modified inorganic particles to form modified inorganic particles; mixing the plurality of modified inorganic particles with a melted glass raw material; and spinning the glass raw material including the plurality of modified inorganic particles to form glass fiber yarn.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to glass fiber yarns and a method for manufacturing the same, and more particularly, to glass fiber yarns containing tungsten sulfide and a method for manufacturing the same.

Background Art

[0002] In existing methods for manufacturing glass fiber yarns, the slipperiness of the glass fiber yarns is insufficient, and thus, the problem is that the glass fiber yarns are easily broken during the spinning process.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The technical problem to be solved by the present invention is to provide a new glass fiber yarn and a method for manufacturing the same that make up for the deficiencies of the existing technology. Specifically, it is to provide a glass fiber yarn and a method for manufacturing the same that can effectively improve the problem of breakage of glass fiber yarns during the spinning process.

Means for Solving the Problems

[0004] To solve the above technical problems, one of the technical solutions adopted by the present invention is a tungsten compound gel forming step of dissolving a tungsten compound in a first organic solution to form a tungsten compound gel, a tungsten sulfide gel forming step of adding a sulfur source to the tungsten compound gel and stirring the sulfur source and the tungsten compound gel to form a tungsten sulfide gel, a heat treatment step of maintaining the tungsten sulfide gel in an environment of 600°C to 1200°C for 4 hours to 6 hours to form tungsten sulfide powder, and a coating step of coating the tungsten sulfide powder on the surfaces of a plurality of inorganic particles to form surface-modified inorganic particles, wherein the content of the tungsten sulfide powder ranges from 0.01 wt% to 5 wt% based on the total weight of 100 wt% of the surface-modified inorganic particles, a mixing step of mixing a plurality of the surface-modified inorganic particles with a molten glass raw material, and a spinning step of spinning the glass raw material containing a plurality of the surface-modified inorganic particles to form a plurality of glass fiber yarns, so as to provide a method for manufacturing glass fiber yarns.

[0005] Preferably, after the tungsten sulfide gel forming step and before the heat treatment step, the method for manufacturing glass fiber yarns further includes a washing and drying step of performing washing and filtration on the tungsten compound gel a plurality of times, and then firing the tungsten compound gel.

[0006] Preferably, in the coating step, after dispersing the tungsten sulfide powder in a second organic solution, the tungsten sulfide powder and the second organic solution are added to a plurality of inorganic particles, and then the tungsten sulfide powder, the second organic solution and the plurality of inorganic particles are stirred so that the tungsten sulfide powder is coated on the surfaces of the plurality of inorganic particles to form a plurality of surface-modified inorganic particles.

[0007] Preferably, the tungsten compound is tungsten hexachloride.

[0008] Preferably, the weight ratio of the tungsten compound to the sulfur source ranges from 5:1 to 8:1.

[0009] Preferably, the inorganic particles are at least one selected from the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, and calcined kaolin.

[0010] Preferably, the particle diameter of each of the inorganic particles ranges from 0.01 μm to 50 μm.

[0011] Preferably, the content of the surface-modified inorganic particles ranges from 0.1 wt% to 5 wt% with respect to 100 wt% of the total weight of all the glass fiber yarns.

[0012] Preferably, each of the glass fiber yarns has a maximum static friction coefficient in the range of 0.39 to 0.48.

[0013] In order to solve the above technical problems, another technical solution adopted by the present invention is to provide a glass fiber yarn including a glass raw material and a plurality of surface-modified inorganic particles dispersed in the glass raw material. Here, each of the surface-modified inorganic particles includes an inorganic particle and a tungsten compound coated on the inorganic particle. Further, the content of the tungsten sulfide powder ranges from 0.01 wt% to 5 wt% with respect to 100 wt% of the total weight of all the surface-modified inorganic particles. The inorganic particles are at least one selected from the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, and calcined kaolin.

[0014] Preferably, the particle diameter of each of the inorganic particles ranges from 0.01 μm to 50 μm, and the content of the surface-modified inorganic particles ranges from 0.1 wt% to 5 wt% with respect to 100 wt% of the total weight of all the glass fiber yarns.

[0015] Preferably, the glass fiber yarn has a maximum static friction coefficient in the range of 0.39 to 0.48.

[0016] One beneficial effect of the present invention is that the glass fiber yarn and its manufacturing method provided by the present invention can effectively improve the problem that existing glass fiber yarns are easily broken during the spinning process through the technical solutions of "tungsten compound gel formation step, tungsten sulfide gel formation step, heat treatment step, coating step, mixing step and spinning step" and "a plurality of surface-modified inorganic particles are dispersed in the glass raw material".

[0017] In order to further deeply understand the features and technical content of the present invention, please refer to the following detailed description and drawings related to the present invention. However, these descriptions and drawings are illustrative of the present invention and do not limit the protection scope of the present invention in any way.

Brief Description of Drawings

[0018]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0019] The embodiments disclosed by the present invention in the specific examples of the "glass fiber yarn and its manufacturing method" according to the present application will be described below. Those skilled in the art can understand the advantages and effects of the present invention based on the disclosure of this specification. The present invention can be implemented or applied by other different embodiments. Each detail in this specification can also be equivalently modified and changed based on various viewpoints or applications without departing from the spirit of the present invention. In addition, the drawings of the present invention are for simple and schematic illustration and do not show actual dimensions. In the following embodiments, the technical matters related to the present invention will be further described, but the disclosed content does not limit the present invention. Also, the term "or" used in this specification can include any one or a combination of multiple related items according to the actual situation.

[0020] Throughout this specification, terms such as "first", "second", "third", etc. may be used to describe various components and signals, but it should be understood that these components and signals should not be limited by these terms. These terms are mainly used to distinguish one component from another component or one signal from another signal. Furthermore, the term "or" used in this specification can appropriately include any one or a combination of the related listed items.

[0021] [Manufacturing Method of Glass Fiber Yarn] As shown in FIGS. 1 to 3, FIG. 1 is a flowchart of the manufacturing method of glass fiber yarn in the embodiment of the present invention, FIG. 2 is a schematic diagram of glass fiber yarn in the embodiment of the present invention, and FIG. 3 is a schematic diagram of surface-modified inorganic particles in the embodiment of the present invention. The embodiment of the present invention provides a manufacturing method of glass fiber yarn including a tungsten compound gel formation step S110, a tungsten sulfide gel formation step S120, a heat treatment step S130, a coating step S140, a mixing step S150, and a spinning step S160.

[0022] In the tungsten compound gel formation step S110, a tungsten compound is dissolved in a first organic solution to form a tungsten compound gel. In this embodiment, the tungsten compound is, for example, tungsten hexachloride, and the first organic solution is, for example, ethanol or isopropanol, but the present invention is not limited thereto. In the tungsten compound gel formation step, it is not necessary to stir or heat the tungsten compound and the first organic solution.

[0023] In the tungsten sulfide gel formation step S120, a sulfur source is added to the tungsten compound gel, and the sulfur source and the tungsten compound gel are stirred to form a tungsten sulfide gel. The sulfur source is, for example, sulfur powder or hydrogen sulfide gas.

[0024] When sulfur powder is used as the sulfur source, the weight ratio of the tungsten compound to the sulfur source is in the range of 5:1 to 8:1. The amount of the tungsten compound used is in the range of 400 weight units to 800 weight units, and the amount of the sulfur source used is in the range of 75 weight units to 115 weight units. More preferably, the amount of the tungsten compound used is in the range of 500 weight units to 700 weight units, and the amount of the sulfur source used is in the range of 85 weight units to 105 weight units. Even more preferably, the amount of the tungsten compound used is about 600 weight units, and the amount of the sulfur source used is about 96.8 weight units. Also, the weight ratio of the tungsten compound to the first organic solution is in the range of 1:1.5 to 1:2.5, and the amount of the first organic solution used is in the range of 900 weight units to 1500 weight units. More preferably, the amount of the first organic solution used is about 1200 weight units.

[0025] After the step S120 of forming tungsten sulfide gel and before the heat treatment step S130, the method for manufacturing glass fiber yarns further includes a washing and drying step S121, in which the tungsten compound gel is washed and filtered multiple times and then the tungsten compound gel is fired. Specifically, in the washing and drying step S121, the tungsten compound gel is washed with a washing liquid to remove unreacted impurities and residual solution (for example, the first organic solution). The washing liquid is, for example, water, ethanol, isopropanol, etc., but the present invention is not limited thereto. Further, in the washing and drying step, the temperature and time for firing the tungsten compound gel are respectively in the range of 80°C to 120°C and 1 hour to 10 hours, but the present invention is not limited thereto.

[0026] In the heat treatment step S130, tungsten sulfide gel is maintained in an environment of 600°C to 1200°C for 4 hours to 6 hours to form tungsten sulfide powder. The temperature and time of the heat treatment step S130 affect the crystal structure and properties of the formed tungsten sulfide powder. Specifically, if the temperature is too low, the conversion rate of the formed tungsten sulfide is low and the crystal orientation becomes non-uniform. The temperature of the heat treatment step S130 needs to be within a specific range so that the crystal orientation of the formed tungsten sulfide powder is concentrated, the signal intensity of the crystal plane is strong, and the physical properties (improvement of lubricity and wear resistance) of the tungsten sulfide powder are good. The temperature of the heat treatment step S130 is particularly preferably in the range of 650°C to 900°C.

[0027] Furthermore, if the time of the heat treatment step S130 is too long, the hardness of the tungsten sulfide powder becomes too high and it becomes difficult to coat the carrier of silicon dioxide. If the time of the heat treatment step S130 is too short, the impurities of the formed tungsten sulfide increase.

[0028] Furthermore, the heat treatment step S130 can be performed in an atmosphere of argon gas or nitrogen gas. The atmosphere of argon gas or nitrogen gas here refers to a pure argon environment. If the heat treatment step S130 is not performed in an atmosphere of argon gas or nitrogen gas, oxygen in the environment may oxidize the tungsten sulfide powder, thereby affecting the maximum static friction coefficient of the glass fiber yarn 100.

[0029] In the coating step S140, tungsten sulfide powder is coated on the surfaces of a plurality of inorganic particles to form a plurality of surface-modified inorganic particles 1. The surface-modified inorganic particles 1 have a core-shell structure, and the core-shell structure includes a core layer 11 formed from inorganic particles and a shell layer 12 formed from tungsten sulfide powder. With respect to the total weight of all the surface-modified inorganic particles being 100 wt%, the content of tungsten sulfide powder ranges from 0.01 wt% to 5 wt%, and the content of inorganic particles ranges from 95 wt% to 99.9 wt%. The particle diameter of each inorganic particle ranges from 0.01 μm to 50 μm.

[0030] Specifically, in the coating step S140, first, the tungsten sulfide powder is dispersed in a second organic solution, and then the tungsten sulfide powder and the second organic solution are added to a plurality of inorganic particles. Further, the tungsten sulfide powder, the second organic solution, and the plurality of inorganic particles are stirred so that the tungsten sulfide powder is coated on the surfaces of the plurality of inorganic particles, and a plurality of surface-modified inorganic particles 1 are formed. More specifically, in the coating step S140, the tungsten sulfide powder is not dissolved but dispersed in the second organic solution. The method of dispersing the tungsten sulfide powder in the second organic solution is, for example, mechanical grinding or ultrasonic treatment, etc., but the present invention is not limited thereto. The second organic solution containing the tungsten sulfide powder is added dropwise to the stirred inorganic particles, and after further stirring, the tungsten sulfide powder, the second organic solution, and the plurality of inorganic particles are dried to obtain a plurality of surface-modified inorganic particles 1.

[0031] The second organic solution is, for example, isopropanol, and the inorganic particles are at least one selected from the group of materials composed of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, and calcined kaolin, etc., but the present invention is not limited thereto.

[0032] In the mixing step S150, a plurality of surface-modified inorganic particles 1 are mixed into the molten glass raw material 2. With respect to the total weight 100 wt% of the glass raw material, the glass raw material 2 can contain, for example, 54 wt% to 63 wt% of silicon dioxide, 15 wt% to 24 wt% of aluminum oxide, 6 wt% to 13 wt% of magnesium oxide, 3.4 wt% to 14 wt% of calcium oxide, 0.5 wt% to 9 wt% of boron oxide, and 0 wt% to 7 wt% of rhenium oxide, but the present invention is not limited to the specific components contained in the glass raw material 2 and the content of each component.

[0033] In the spinning step S160, the glass raw material 2 containing a plurality of surface-modified inorganic particles 1 is spun to form a plurality of glass fiber yarns. With respect to the total weight 100 wt% of each glass fiber yarn 100, the content of the surface-modified inorganic particles 1 is in the range of 0.1 wt% to 5 wt%, and the content of the glass raw material 2 is in the range of 95 wt% to 99.9 wt%.

[0034] Notably, after the spinning step S160, since the plurality of glass fiber yarns 100 have excellent slipperiness, there is no need to further add a lubricant to the surface of the plurality of glass fiber yarns 100 after the spinning step S160. Also, in the present invention, the surface-modified inorganic particles 1 are uniformly dispersed not only on the surface of the glass fiber yarns 100, and the glass fiber yarns 100 are less likely to break in the spinning step S160.

[0035] In other words, a method for manufacturing glass fiber yarns in which a lubricant is added after the spinning step, or glass fiber yarns in which the lubricant is present only on the surface, are not as suitable as the method for manufacturing glass fiber yarns and the glass fiber yarns 100 of the present invention. Furthermore, when the lubricant is added only to the surface of the glass fiber yarns, the lubricity inside the glass fiber yarns is not improved, so the glass fiber yarns are likely to break during the spinning process.

[0036] Furthermore, when tungsten sulfide powder is directly added to the glass raw material 2, the tungsten sulfide powder is not uniformly dispersed in the glass fiber yarns 100. Therefore, in the method for manufacturing glass fiber yarns of the present invention, first, the tungsten sulfide powder is coated on the surface of the inorganic particles to form surface-modified inorganic particles 1, and then the surface-modified inorganic particles 1 are dispersed in the glass raw material 2 so that the surface-modified inorganic particles 1 are uniformly dispersed in the glass fiber yarns 100.

[0037] Each glass fiber yarn 100 has a maximum static friction coefficient in the range of 0.39 to 0.48. Furthermore, it should be noted that since the melting point of tungsten sulfide is in the range of about 1500°C to 1550°C, the glass fiber yarns 100 containing the surface-modified inorganic particles 1 have excellent thermal stability.

[0038] [Glass fiber yarns] The present invention also provides glass fiber yarns 100. The glass fiber yarns 100 are manufactured by the method for manufacturing glass fiber yarns described above, but are not limited thereto. The glass fiber yarns 100 include a glass raw material 2 and a plurality of surface-modified inorganic particles 1 dispersed in the glass raw material 2.

[0039] The surface-modified inorganic particles include inorganic particles and tungsten sulfide powder coated on the inorganic particles. The surface-modified inorganic particle 1 has a core-shell structure, and the core-shell structure includes a core layer 11 formed by the inorganic particles and a shell layer 12 formed by the tungsten sulfide powder. The content of the tungsten sulfide powder ranges from 0.01 wt% to 5 wt% based on the total weight 100 wt% of all the surface-modified inorganic particles. The inorganic particles are at least one selected from the group of materials composed of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, calcined kaolin, etc.

[0040] The particle size of each inorganic particle ranges from 0.01 μm to 50 μm. The content of the surface-modified inorganic particles ranges from 0.1 wt% to 5 wt% based on the total weight 100 wt% of all the glass fiber yarns.

[0041] The glass fiber yarn has a maximum static friction coefficient in the range of 0.39 to 0.48.

[0042] [Experimental data test] Hereinafter, with reference to Examples 1 to 3 and Comparative Example 1, the content of the present invention will be described in detail. However, the following examples are for understanding the present invention, and the scope of the present invention is not limited to these examples.

[0043] In Comparative Example 1, no surface-modified inorganic particles were added. In the manufacturing methods of the glass fiber yarns of Examples 1 to 3, the content of the surface-modified inorganic particles was 0.2 wt%, 1 wt%, and 2 wt%, respectively, based on the total weight 100 wt% of the glass fiber yarns.

[0044] Data on the maximum static friction coefficient, abrasion resistance, thermal stability, and conductivity of the glass fiber yarns produced according to Comparative Example 1 and Examples 1 to 3 are shown in Table 1 below, and the related test methods are as follows.

[0045] Test of the maximum static friction coefficient: Take two samples with a thickness of 5 millimeters composed of glass fiber yarns, and use a friction coefficient measuring instrument of model number CFT-400 to test the maximum static friction coefficient of the samples under a load condition of 200 grams.

[0046] Abrasion resistance test: Contact a sample made of glass fiber yarns with the grinding wheel of a grinder, and observe and evaluate the abrasion resistance of the sample.

[0047] Thermal stability test: Use a thermomechanical analyzer to test the coefficient of thermal expansion of a sample made of glass fiber yarns.

[0048] [Table 1]

[0049] [Regarding the test results] The more surface-modified inorganic particles are added, the lower the maximum static friction coefficient becomes, the abrasion resistance is improved, the structural integrity and appearance quality of the product can be maintained for a long time, and the service life of the product can be improved. In a high-friction environment, the abrasion resistance performance of glass cloth made of glass fiber yarns also contributes to reducing the generation of heat due to friction, preventing excessive temperature rise and material damage, and protecting the safety of equipment and structures.

[0050] The data of the coefficient of thermal expansion shows that the more surface-modified inorganic particles are added, the better the heat resistance. Glass cloth with strong heat resistance maintains the structural stability even at high temperatures and is less likely to melt or deform. This is very important for applications that require maintaining shape and strength in high-temperature environments, such as fire isolation materials and high-temperature screening processes. Therefore, the surface-modified inorganic particles provided by the present invention can improve the physical properties of glass fiber yarns.

[0051] [Beneficial effects according to the embodiment] One beneficial effect of the present invention is that the glass fiber yarn and its manufacturing method provided by the present invention can effectively improve the problem that existing glass fiber yarns are easily broken during the spinning process through the technical solutions of "tungsten compound gel formation step, tungsten sulfide gel formation step, heat treatment step, coating step, mixing step and spinning step" and "a plurality of surface-modified inorganic particles are dispersed in the glass raw material".

[0052] The content disclosed above is only a preferred embodiment of the present invention, and does not limit the scope of the claims of the present invention. Therefore, all equivalent technical deformations made based on the content of the specification and the attached drawings of the present invention shall be included in the scope of the claims of the present invention.

Description of Reference Numerals

[0053] 100 Glass fiber yarn 1 Surface-modified inorganic particle 11 Core layer 12 Shell layer S110 Tungsten compound gel formation step S120 Tungsten sulfide gel formation step S121 Washing and drying step S130 Heat treatment step S140 Coating step S150 Mixing step S160 Spinning step

Claims

1. A tungsten compound gel formation step of dissolving a tungsten compound in a first organic solution to form a tungsten compound gel; A tungsten sulfide gel formation step of adding a sulfur source to the tungsten compound gel and stirring the sulfur source and the tungsten compound gel to form a tungsten sulfide gel; A heat treatment step of maintaining the tungsten sulfide gel in an environment of 600°C to 1200°C for 4 to 6 hours to form tungsten sulfide powder; A coating step of coating the tungsten sulfide powder on the surfaces of a plurality of inorganic particles to form surface-modified inorganic particles, wherein the content of the tungsten sulfide powder ranges from 0.01 wt% to 5 wt% based on 100 wt% of the total weight of the surface-modified inorganic particles; A mixing step of mixing a plurality of the surface-modified inorganic particles into a molten glass raw material; A spinning step of spinning the glass raw material containing a plurality of the modified inorganic particles to form glass fiber yarns; comprising A method for manufacturing glass fiber yarns, characterized by the above.

2. After the tungsten sulfide gel formation step and before the heat treatment step, it includes a washing and drying step, and the washing and drying step comprises washing and filtering the tungsten compound gel multiple times, and then drying the tungsten compound gel. The method for manufacturing glass fiber yarns according to Claim 1.

3. In the coating step, first disperse the tungsten sulfide powder in a second organic solution, then add the tungsten sulfide powder and the second organic solution to a plurality of the inorganic particles, and then stir the tungsten sulfide powder, the second organic solution and the plurality of the inorganic particles so that the tungsten sulfide powder is coated on the plurality of the inorganic particles to form a plurality of the surface-modified inorganic particles. The method for manufacturing glass fiber yarns according to Claim 1.

4. The method for manufacturing glass fiber yarns according to Claim 1, wherein the tungsten compound is tungsten hexachloride.

5. The method for manufacturing glass fiber yarns according to Claim 1, wherein the weight ratio of the tungsten compound to the sulfur source ranges from 5:1 to 8:

1.

6. The method for manufacturing a glass fiber yarn according to claim 1, wherein the inorganic particles are at least one of a material group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, and fired kaolin.

7. The method for manufacturing a glass fiber yarn according to claim 1, wherein the particle diameter of the inorganic particles ranges from 0.01 μm to 50 μm.

8. The method for manufacturing a glass fiber yarn according to claim 1, wherein the content of the surface-modified inorganic particles ranges from 0.1 wt% to 5 wt% with respect to 100 wt% of the total weight of the glass fiber yarn.

9. The method for manufacturing a glass fiber yarn according to claim 1, wherein each of the glass fiber yarns has a maximum static friction coefficient in the range of 0.39 to 0.

48.

10. A glass fiber yarn comprising a glass raw material and a plurality of surface-modified inorganic particles dispersed in the glass raw material, wherein the surface-modified inorganic particles include inorganic particles and tungsten sulfide powder coated on the inorganic particles, based on 100 wt% of the total weight of the surface-modified inorganic particles, the content of the tungsten sulfide powder ranges from 0.01 wt% to 5 wt%, and the inorganic particles are at least one of a material group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, and fired kaolin. A glass fiber yarn, characterized in that.

11. The glass fiber yarn according to claim 10, wherein the particle diameter of the inorganic particles ranges from 0.01 μm to 50 μm, and based on 100 wt% of the total weight of the glass fiber yarn, the content of the surface-modified inorganic particles ranges from 0.1 wt% to 5 wt%.

12. The glass fiber yarn according to claim 10, wherein the maximum static friction coefficient of the glass fiber yarn ranges from 0.39 to 0.48.

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