Glass fiber yarn and method for manufacturing the same

Abstract

This invention provides glass fiber yarn and a method for producing the same. [Solution] The method for manufacturing glass fiber yarn includes a coating step, a mixing step, and a drawing step. In the coating step, silicon nitride powder is coated onto the surface of a plurality of inorganic particles to form a plurality of modified inorganic particles. Assuming the total weight of each modified inorganic particle is 100 wt%, the content of the silicon nitride powder is 0.01 wt% to 5 wt%, and the content of the inorganic particles is 95 wt% to 99.99 wt%. In the mixing step, the plurality of modified inorganic particles are mixed into a molten glass raw material. In the drawing step, the plurality of modified inorganic particles are drawn out from the glass raw material to form glass fiber yarn.

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 silicon nitride and a method for manufacturing the same.

Background Art

[0002] Glass fiber yarns manufactured by conventional methods for manufacturing glass fiber yarns have had the problem that their dielectric loss is too high.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The technical problem to be solved by the present invention is to effectively improve the problem that the dielectric loss of glass fiber yarns manufactured by conventional methods for manufacturing glass fiber yarns is high, in view of the deficiencies of the prior art, and to provide a glass fiber yarn and a method for manufacturing the same.

Means for Solving the Problems

[0004] To solve the above technical problems, one of the technical means adopted by the present invention is to provide a method for manufacturing glass fiber yarns. The method for manufacturing glass fiber yarns includes a coating step of forming a plurality of modified inorganic particles by coating silicon nitride powder on the surfaces of a plurality of inorganic particles, a mixing step of mixing the plurality of modified inorganic particles with a molten glass raw material, and a drawing step of drawing the glass raw material mixed with the plurality of modified inorganic particles to form glass fiber yarns. In the coating step, with the total weight of each of the modified inorganic particles being 100 wt%, the content of the silicon nitride powder is 0.01 wt% to 5 wt%, the content of the inorganic particles is 95 wt% to 99.99 wt%, with the total weight of the glass fiber yarns being 100 wt%, the content of the modified inorganic particles is 0.01 wt% to 5 wt%, and the content of the glass raw material is 95 wt% to 99.99 wt%.

[0005] Preferably, the average particle diameter of the modified inorganic particles is 0.01 μm to 50 μm.

[0006] Preferably, with a total weight of 100 wt%, the glass raw materials consist of 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% ferric trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide.

[0007] Preferably, the inorganic particles are selected from at least one of the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica.

[0008] Preferably, in the coating step, the first nitrogen compound is dissolved in a first solvent, a first silicon source is added to the first solvent, and then the first nitrogen compound, the first solvent, and the first silicon source are heated at a first heating temperature of 1,200°C to 1,400°C to react the first nitrogen compound and the first silicon source to form the silicon nitride powder, and then the inorganic particles are added to the silicon nitride powder to coat the surface of the inorganic particles with the silicon nitride powder to form the modified inorganic particles.

[0009] Preferably, the first nitrogen compound is urea, the first solvent is water, ethanol, or isopropanol, and the first silicon source is silicon powder.

[0010] Preferably, in the coating step, a second nitrogen compound is dissolved in a second solvent, a second silicon source is added to the second solvent and stirred to form a gel, the gel is then sprayed onto the surface of the inorganic particles, and the inorganic particles on which the gel has formed on their surface are heated at a second heating temperature of 1,200°C to 1,400°C to react the second nitrogen compound with the second silicon source to form the silicon nitride powder, which is then coated onto the surface of the inorganic particles to form the modified inorganic particles.

[0011] Preferably, the second nitrogen compound is urea, the second solvent is water, ethanol, or isopropanol, and the second silicon source is selected from at least one of the group consisting of tetraethoxysilane, tetramethoxysilane, and methyltriethoxysilane.

[0012] Preferably, the glass fiber yarn has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz, and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz.

[0013] To solve the above technical problems, another technical means employed by the present invention is to provide glass fiber yarn. The glass fiber yarn comprises a glass raw material and a plurality of modified inorganic particles dispersed in the glass raw material, each of the modified inorganic particles comprising an inorganic particle and a silicon nitride powder coated on the inorganic particle, with the total weight of each of the modified inorganic particles being 100 wt%, the content of the silicon nitride powder being 0.01 wt% to 5 wt%, and the content of the inorganic particles being 95 wt% to 99.99 wt%, and the inorganic particles being silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, and carbon dioxide. At least one of the group consisting of calcium, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica is selected, and with the total weight of the glass fiber yarn being 100 wt%, the content of the modified inorganic particles is 0.01 wt% to 5 wt%, and the content of the glass raw material is 95 wt% to 99.99 wt%.

[0014] Preferably, the average particle size of the modified inorganic particles is 0.01 μm to 50 μm.

[0015] Preferably, with a total weight of 100 wt%, the glass raw materials consist of 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% ferric trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide.

[0016] Preferably, the glass fiber yarn has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz, and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz. [Effects of the Invention]

[0017] One of the advantageous effects of the present invention is that the glass fiber yarn and its manufacturing method according to the present invention effectively improve the problem of excessively high dielectric loss in glass fiber yarns manufactured by conventional glass fiber yarn manufacturing methods, due to technical features such as "the coating step, the mixing step, and the drawing step," "the content of the silicon nitride powder being 0.01 wt% to 5 wt% with a total weight of each of the modified inorganic particles being 100 wt%, and the content of the inorganic particles being 95 wt% to 99.99 wt%," and "multiple modified inorganic particles being dispersed in the glass raw material." [Brief explanation of the drawing]

[0018] [Figure 1] This is a flowchart of a method for producing glass fiber yarn according to an embodiment of the present invention. [Figure 2] This is a schematic diagram of a glass fiber yarn according to an embodiment of the present invention. [Figure 3] This is a schematic diagram of modified inorganic particles according to an embodiment of the present invention. [Modes for carrying out the invention]

[0019] To further understand the features and technical details of this invention, please refer to the following detailed description of the invention and the accompanying drawings. However, the accompanying drawings provided are for reference and illustrative purposes only and do not limit the scope of the claims of this invention.

[0020] The following describes the implementation of the "glass fiber yarn and its manufacturing method" according to the present invention by specific embodiments. Those skilled in the art can understand the advantages and effects of the present invention based on the content disclosed in this specification. The present invention can be implemented or applied by other different specific embodiments, and for each detail in this specification, various modifications and changes can be made based on different perspectives and applications without departing from the concept of the present invention. It is pre-stated that the attached drawings of the present invention are simple schematic illustrations and are not drawn based on actual sizes. The technical content of the present invention will be described in more detail based on the following embodiments, but the protection scope of the present invention is not limited by the disclosed content.

[0021] It should be understood that in this specification, terms such as "first", "second", "third", etc. may be used to describe various elements or signals, but these elements or signals are not limited by these terms. These terms are mainly used to distinguish one element from another element or one signal from another signal. Also, the term "or" used in this specification may include any one or a combination of multiple items listed in relation according to the actual situation.

[0022] [Manufacturing Method of Glass Fiber Yarn] As shown in FIGS. 1 to 3, FIG. 1 is a flowchart of the manufacturing method of the glass fiber yarn according to an embodiment of the present invention, FIG. 2 is a schematic diagram of the glass fiber yarn according to an embodiment of the present invention, and FIG. 3 is a schematic diagram of the modified inorganic particles according to an embodiment of the present invention. An embodiment of the present invention provides a manufacturing method of glass fiber yarn. The manufacturing method of the glass fiber yarn includes a coating step S110, a mixing step S120, and a drawing step S130. Of course, the manufacturing method of the glass fiber yarn may include other steps as needed, but the present invention is not limited thereto.

[0023] In the coating step S110, a silicon nitride powder (e.g., Si3N4 powder) is coated on the surfaces of a plurality of inorganic particles to form a plurality of modified inorganic particles 1. The modified inorganic particles 1 have a core-shell structure, and the core-shell structure includes a core layer 11 formed of the inorganic particles and a shell layer 12 formed of the silicon nitride powder. Taking the total weight of each of the modified inorganic particles 1 as 100 wt%, the content of the silicon nitride powder is 0.01 wt% to 5 wt%, and the content of the inorganic particles is 95 wt% to 99.99 wt%. The average particle diameter of the modified inorganic particles 1 is 0.01 μm to 50 μm, but the present invention is not limited thereto.

[0024] It should be noted that the inorganic particles need to have the property of high heat resistance. Preferably, the inorganic particles are selected from at least one of the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica.

[0025] In the coating step S110 of a certain embodiment, a first nitrogen compound is dissolved in a first solvent, and after a first silicon source is added to the first solvent, the first nitrogen compound, the first solvent, and the first silicon source are heated at a first heating temperature of 1,200°C to 1,400°C to react the first nitrogen compound with the first silicon source to form the silicon nitride powder. Then, the inorganic particles are added to the silicon nitride powder to coat the silicon nitride powder on the surfaces of the inorganic particles, thereby forming the modified inorganic particles 1.

[0026] That is, the silicon nitride powder in this embodiment may be coated onto the surface of inorganic particles by a dry method to form the modified inorganic particles 1. In this embodiment, the first nitrogen compound is urea, the first solvent is water, ethanol, or isopropanol, and the first silicon source is silicon powder, but the present invention is not limited thereto.

[0027] In the coating step S110 of another embodiment, a second nitrogen compound is dissolved in a second solvent, a second silicon source is added to the second solvent and stirred to form a gel, the gel is then sprayed onto the surface of the inorganic particles, and the inorganic particles on which the gel has formed on their surface are heated at a second heating temperature of 1,200°C to 1,400°C to react the second nitrogen compound with the second silicon source to form the silicon nitride powder, which is then coated onto the surface of the inorganic particles to form the modified inorganic particles 1. Notably, in the coating step S110 of this embodiment, the second nitrogen compound and the second silicon source react on the inorganic particles to form the silicon nitride powder.

[0028] That is, the silicon nitride powder in this embodiment may be coated onto the surface of inorganic particles by a wet process to form the modified inorganic particles 1. In this embodiment, the second nitrogen compound is urea, the second solvent is water, ethanol, or isopropanol, and the second silicon source is selected from at least one of the group consisting of tetraethoxysilane (TEOS), tetramethoxysilane (TMOS), and methyltriethoxysilane (MTES), but the present invention is not limited thereto.

[0029] In the mixing step S120, a plurality of the modified inorganic particles 1 are mixed with the glass raw material 2. Assuming the total weight of the glass raw material 2 is 100 wt%, the glass raw material 2 contains 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% iron trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide, but the present invention is not limited thereto.

[0030] In the drawing process S130, glass fiber yarn 100 is formed by drawing out the glass raw material 2, which is a mixture of multiple modified inorganic particles 1. Assuming the total weight of the glass fiber yarn 100 is 100 wt%, the content of the modified inorganic particles 1 is 0.01 wt% to 5 wt%, and the content of the glass raw material 2 is 95 wt% to 99.99 wt%.

[0031] Silicon nitride has low dielectric loss characteristics, particularly in high-frequency applications. Silicon nitride exhibits good stability in high-frequency electric fields and exhibits weak polarization, resulting in reduced electrical energy loss in glass fiber yarns. Consequently, the glass fiber yarn 100 has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz.

[0032] [Glass fiber yarn] In embodiments of the present invention, a glass fiber yarn 100 is provided. The glass fiber yarn 100 is obtained by carrying out the glass fiber yarn manufacturing method described above, but the present invention is not limited thereto.

[0033] The glass fiber yarn 100 comprises a glass raw material 2 and a plurality of modified inorganic particles 1 dispersed in the glass raw material 2. Each of the modified inorganic particles 1 comprises an inorganic particle and a silicon nitride powder coated on the inorganic particle. Assuming the total weight of each of the modified inorganic particles is 100 wt%, the content of the silicon nitride powder is 0.01 wt% to 5 wt%, and the content of the inorganic particles is 95 wt% to 99.99 wt%.

[0034] The inorganic particles are selected from at least one of the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica. The average particle size of the modified inorganic particles 1 is 0.01 μm to 50 μm, but the present invention is not limited thereto.

[0035] Assuming the total weight of the glass fiber yarn 100 is 100 wt%, the content of the modified inorganic particles 1 is 0.01 wt% to 5 wt%, and the content of the glass raw material 2 is 95 wt% to 99.99 wt%, but the present invention is not limited thereto.

[0036] Assuming the total weight of the glass raw material 2 is 100 wt%, the glass raw material 2 contains 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% iron trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide, but the present invention is not limited thereto.

[0037] The glass fiber yarn 100 has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz, and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz. [Examples]

[0038] The present invention will be described in detail below with reference to Examples 1 to 8 and Comparative Example 1. However, these examples are merely means to understand the present invention, and the present invention is not limited thereto.

[0039] In Comparative Example 1, no modified inorganic particles were added. In the glass fiber yarns of Examples 1 to 4, with the total weight of the glass fiber yarn being 100 wt%, the content of the modified inorganic particles was 0.01 wt%, 0.05 wt%, 0.1 wt%, and 1 wt%, respectively, and the content of the glass raw material was 99.99 wt%, 99.95 wt%, 99.9 wt%, and 99 wt%, respectively.

[0040] In Example 5, silicon nitride powder was coated onto inorganic particles by a dry method, while in Examples 6 to 8, silicon nitride powder was coated onto inorganic particles by a wet method. In Examples 6 to 8, tetraethoxysilane (TEOS), tetramethoxysilane (TMOS), and methyltriethoxysilane (MTES) were used as silicon sources, respectively. In the glass fiber yarn manufacturing methods of Examples 5 to 8, with a total weight of glass fiber yarn of 100 wt%, the content of the modified inorganic particles was 0.1 wt%, and the content of the glass raw material was 99.9 wt%.

[0041] The relative permittivity (Dk) and dielectric loss tangent (Df) were measured using a dielectric analyzer (Keysight Technologies) at a frequency of approximately 10 GHz.

[0042] [Table 1]

[0043] [Table 2]

[0044] [Review of measurement results] As can be seen from Comparative Example 1 and Examples 1-4, in Comparative Example 1, no modified inorganic particles were added to the glass fiber yarn, and the relative permittivity (Dk) and dielectric loss tangent (Df) of the glass fiber yarn were relatively high. As can be seen from Comparative Example 1 and Examples 5-8, silicon nitride powder is coated onto inorganic particles by a dry or wet method, and tetraethoxysilane, tetramethoxysilane, and methyltriethoxysilane are used as silicon sources in the wet method.

[0045] [Advantageous effects of the embodiment] One of the advantageous effects of the present invention is that the glass fiber yarn and its manufacturing method according to the present invention effectively improve the problem of excessively high dielectric loss in glass fiber yarns manufactured by conventional glass fiber yarn manufacturing methods, due to technical features such as "the coating step, the mixing step, and the drawing step," "the content of the silicon nitride powder being 0.01 wt% to 5 wt% with a total weight of each of the modified inorganic particles being 100 wt%, and the content of the inorganic particles being 95 wt% to 99.99 wt%," and "multiple modified inorganic particles being dispersed in the glass raw material."

[0046] The information disclosed above represents only preferred and implementable embodiments of the present invention, and the claims of the present invention are not limited thereto. Therefore, any equivalent technical modifications made using the description and drawings of the present invention are all included within the scope of the claims of the present invention. [Explanation of Symbols]

[0047] 100...glass fiber yarn 1...Modified inorganic particles 11... Core Layer 12... Shell layer 2...Glass raw materials S110...Coating process S120...Mixing process S130...Drawing process

Claims

1. A coating step involves forming multiple modified inorganic particles by coating the surface of multiple inorganic particles with silicon nitride powder, A mixing step involves mixing a plurality of the modified inorganic particles into a molten glass raw material, A method for producing glass fiber yarn, comprising a drawing step of drawing out a glass raw material which is a mixture of a plurality of modified inorganic particles to form glass fiber yarn, In the coating process, with the total weight of each modified inorganic particle being 100 wt%, the content of the silicon nitride powder is 0.01 wt% to 5 wt%, and the content of the inorganic particles is 95 wt% to 99.99 wt%. A method for producing glass fiber yarn, characterized in that, with the total weight of the glass fiber yarn being 100 wt%, the content of the modified inorganic particles is 0.01 wt% to 5 wt%, and the content of the glass raw material is 95 wt% to 99.99 wt%.

2. The method for producing glass fiber yarn according to claim 1, wherein the average particle size of the modified inorganic particles is 0.01 μm to 50 μm.

3. A method for producing glass fiber yarn according to claim 1, wherein the total weight of the glass raw materials is 100 wt%, and the glass raw materials consist of 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% ferric trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide.

4. The method for producing glass fiber yarn according to claim 1, wherein the inorganic particles are selected from at least one of the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica.

5. The method for producing glass fiber yarn according to claim 1, wherein in the coating step, a first nitrogen compound is dissolved in a first solvent, a first silicon source is added to the first solvent, and then the first nitrogen compound, the first solvent and the first silicon source are heated at a first heating temperature of 1,200°C to 1,400°C to react the first nitrogen compound and the first silicon source to form the silicon nitride powder, and then the inorganic particles are added to the silicon nitride powder to coat the surface of the inorganic particles with the silicon nitride powder to form the modified inorganic particles.

6. The method for producing glass fiber yarn according to claim 5, wherein the first nitrogen compound is urea, the first solvent is water, ethanol, or isopropanol, and the first silicon source is silicon powder.

7. The method for producing glass fiber yarn according to claim 1, wherein in the coating step, a second nitrogen compound is dissolved in a second solvent, a second silicon source is added to the second solvent and stirred to form a gel, the gel is then sprayed onto the surface of the inorganic particles, and the inorganic particles on which the gel has been formed on the surface are heated at a second heating temperature of 1,200°C to 1,400°C to react the second nitrogen compound with the second silicon source to form the silicon nitride powder, and the modified inorganic particles are formed by coating the surface of the inorganic particles with the silicon nitride powder.

8. The method for producing glass fiber yarn according to claim 7, wherein the second nitrogen compound is urea, the second solvent is water, ethanol, or isopropanol, and the second silicon source is selected from at least one of the group consisting of tetraethoxysilane, tetramethoxysilane, and methyltriethoxysilane.

9. The method for manufacturing a glass fiber yarn according to claim 1, wherein the glass fiber yarn has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz.

10. Glass raw materials and A glass fiber yarn comprising a plurality of modified inorganic particles dispersed in the glass raw material, Each of the modified inorganic particles comprises inorganic particles and silicon nitride powder coated on the inorganic particles, with the total weight of each of the modified inorganic particles being 100 wt%, the content of the silicon nitride powder being 0.01 wt% to 5 wt%, and the content of the inorganic particles being 95 wt% to 99.99 wt%. The inorganic particles are selected from at least one of the group consisting of silicon dioxide, titanium dioxide, aluminum hydroxide, magnesium hydroxide, calcium carbonate, aluminum oxide, magnesium oxide, talc, aluminum nitride, boron nitride, silicon carbide, zinc oxide, zirconium oxide, quartz, diamond powder, diamond-like powder, graphite, calcined kaolin, and fumed silica. A glass fiber yarn characterized in that, with a total weight of 100 wt%, the content of the modified inorganic particles is 0.01 wt% to 5 wt%, and the content of the glass raw material is 95 wt% to 99.99 wt%.

11. The glass fiber yarn according to claim 10, wherein the average particle size of the modified inorganic particles is 0.01 μm to 50 μm.

12. The glass fiber yarn according to claim 10, wherein the total weight of the glass raw materials is 100 wt%, and the glass raw materials comprise 52 wt% to 58 wt% silicon dioxide, 10 wt% to 18 wt% aluminum(III) oxide, 0.1 wt% to 5 wt% calcium oxide, 0.1 wt% to 5 wt% magnesium oxide, 20 wt% to 30 wt% diboron trioxide, 0.1 wt% to 0.3 wt% ferric trioxide, 0.1 wt% to 4 wt% strontium oxide, and 0.1 wt% to 2 wt% titanium dioxide.

13. The glass fiber yarn according to claim 10, wherein the glass fiber yarn has a relative permittivity (Dk) of 4.24 to 4.36 measured at 10 GHz, and a dielectric loss tangent (Df) of 0.0017 to 0.0019 measured at 10 GHz.

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