Glass compositions, fiberizable glass compositions, and glass fibers formed therefrom

Abstract

To provide glass compositions, fiberizable glass compositions, and glass fibers formed from such compositions, as well as glass strands, yarns, fabrics, and composite materials including such glass fibers adapted for use in various applications. [Solution] Embodiments of the present invention provide glass compositions, fiberizable glass compositions, and glass fibers formed from such compositions, as well as glass strands, yarns, fabrics, and composites including such glass fibers adapted for use in various applications. In some embodiments of the present invention, the glass compositions further include at least one rare earth oxide.

Description

[Technical Field]

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 62 / 047,967, filed September 9, 2014, which is incorporated by reference herein as if fully set forth herein.

[0002] Technical Field The present invention relates to glass compositions, and in particular to glass compositions for forming fibers. [Background technology]

[0003] 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 that includes, for example, glass fibers commercially available from AGY (Aiken, South Carolina) under the trade name "S-2 glass." Summary of the Invention [Problem to be solved by the invention]

[0004] In reinforcement and other applications, certain mechanical properties of glass fibers, or glass fiber-reinforced composites, can be important. However, in many cases, producing glass fibers with improved mechanical properties (e.g., higher strength, higher modulus, etc.) can result in higher costs, for example, due to higher batch material costs, higher manufacturing costs, or other factors. For example, the above-mentioned "S-2 glass" has improved mechanical properties compared to conventional E-glass, but also significantly higher costs as a result of significantly higher temperatures and energy demands for batch-to-glass conversion, melt fining, and fiber drawing. Fiber glass manufacturers continue to search for glass compositions that can be used to form glass fibers with desirable mechanical properties in a commercial manufacturing environment. [Means for solving the problem]

[0005] Various embodiments of the present invention relate to glass compositions, fiberizable glass compositions and glass fibers formed from such compositions, as well as fiberglass strands, yarns, fabrics, and the like. Fabrics and composites containing such glass fibers adapted for use in a variety of applications. Provide a composite material.

[0006] In one embodiment, a glass composition suitable for fiber formation comprises 56-68 wt% SiO, 11-20 wt% or less AlO, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-5 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% of other components. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt.%. In embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt.%. In some embodiments, the CaO content is less than about 5 wt.%. In some embodiments, the NaO+K2O+Li2O content is greater than 1 wt.%. In some embodiments, the Na2O+K2O content is less than about 0.5 wt.%. In some embodiments, the Al2O3 content is between about 14 and about 19 wt.%. In some embodiments, MgO is present in an amount between about 10 and about 16 wt.%. In some embodiments, Li2O is present in an amount between about 0.4 and about 2 wt.%. In some embodiments, the glass composition comprises at least about 60 wt.% SiO2. In some embodiments, ZnO is present in an amount of up to about 4 wt.%. In some embodiments, SnO is present in an amount of up to about 4 wt.%. In some embodiments, the at least one rare earth oxide includes CeO2, and CeO2 is present in an amount of up to about 4 wt. %. In some embodiments, both SnO2 and CeO2 are present in a combined amount of up to about 8 wt. %. In some embodiments, the glass composition further includes Nb2O5 in an amount of up to about 5 wt. %. In some embodiments, the glass composition is substantially free of B2O3.

[0007] In one embodiment, a glass composition suitable for fiber formation comprises 60-68 wt% SiO, 14-19 wt% AlO, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 1 wt% or greater, and a total of 0-11 wt% of other components. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %. In some embodiments, the Na2O+K2O+Li2O content is greater than 1 wt. %. In some embodiments, the Na2O+K2O content is less than about 0.5 wt. %. In some embodiments, Li2O is present in an amount between about 0.4 and about 2 wt. %. In some embodiments, ZnO is present in an amount of up to about 4 wt. %. In some embodiments, SnO2 is present in an amount of up to about 4 wt. %. In some embodiments, the at least one rare earth oxide includes CeO2, and CeO2 is present in an amount of up to about 4 wt. %. In some embodiments, both SnO2 and CeO2 are present in a combined amount of up to about 8 wt. %. In some embodiments, the glass composition further comprises Nb2O5 in an amount up to about 5 wt%. hi some embodiments, the glass composition is substantially free of B2O3.

[0008] In one embodiment, a glass composition suitable for fiber formation comprises 60-68 wt% SiO, 14-19 wt% AlO, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0.4-2 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt%, and a total of 0-11 wt% other components, where the NaO + KO content is less than about 0.5 wt%. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %. In some embodiments, NaO +K2O+Li2O is greater than 1 wt%. In some embodiments, ZnO is present in an amount up to about 4 wt%. In some embodiments, SnO2 is present in an amount up to about 4 wt%. In some embodiments, the at least one rare earth oxide includes CeO2, and CeO2 is present in an amount up to about 4 wt%. In some embodiments, both SnO2 and CeO2 are present in a combined amount up to about 8 wt%. In some embodiments, the glass composition further includes Nb2O5 in an amount up to about 5 wt%. In some embodiments, the glass composition is substantially free of B2O3.

[0009] In one embodiment, a glass composition suitable for fiber formation comprises 59-62 wt% SiO, 14-19 wt% AlO, 4-8 wt% CaO, 6-11 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-3 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-2 wt% CuO, 0-3 wt% SrO, at least one rare earth oxide in an amount of 3 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 4 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 5 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt.%. In some embodiments, the CaO content is less than about 8 wt.%. In some embodiments, the NaO+K2O+Li2O content is greater than 1 wt.%. In some embodiments, the Na2O+K2O content is less than about 0.5 wt.%. In some embodiments, the Al2O3 content is between about 15 and about 18 wt.%. In some embodiments, MgO is present in an amount between about 8 and about 10 wt.%. In some embodiments, Li2O is present in an amount between about 0.4 and about 2 wt.%. In some embodiments, the glass composition comprises at least about 61 wt.% SiO2. In some embodiments, SrO is present in an amount up to about 3 wt.%. In some embodiments, CuO is present in an amount up to about 2 wt.%. In some embodiments, the at least one rare earth oxide comprises Y2O3, and Y2O3 is present in an amount up to about 5 wt.%. In some embodiments, both Cu2O and Y2O3 are present in a combined amount up to about 7 wt.%. In some embodiments, the glass composition further comprises Nb2O5 in an amount up to about 5 wt.%. In some embodiments, the glass composition is substantially free of B2O3.

[0010] Some embodiments of the present invention relate to fiberglass strands. It should be understood that many fiberizable glass compositions are disclosed herein as part of the present invention, and various embodiments of the present invention can include glass fibers, fiberglass strands, yarns, and other products incorporating glass fibers formed from such compositions.

[0011] Some embodiments of the present invention relate to yarns formed from at least one fiberglass strand formed from the glass compositions described herein. Some embodiments of the present invention relate to fabrics incorporating at least one fiberglass strand formed from the glass compositions described herein. In some embodiments, the fill yarn used in the fabric can include at least one fiberglass strand. In some embodiments, the warp yarn can include at least one fiberglass strand. In some embodiments, fiberglass strands can be used in both the fill and warp yarns used to form the fabric according to the present invention. In some embodiments, the fabric of the present invention can include a plain weave fabric, a twill weave fabric, a crowfoot fabric, a satin weave fabric, a stitchbonded fabric, or a 3D woven fabric.

[0012] Some embodiments of the present invention relate to composite materials including a polymer resin and glass fibers formed from one of the various glass compositions described herein. The glass fibers may be from fiberglass strands according to some embodiments of the present invention. In some embodiments, the glass fibers may be incorporated into a fabric, such as a woven fabric. For example, the glass fibers may be in the weft and / or warp yarns woven to form the fabric. In embodiments in which the composite material includes a fabric, the fabric may include a plain weave fabric, a twill weave fabric, a crowfoot fabric, a satin weave fabric, a stitch-bonded fabric, or a 3D woven fabric.

[0013] Glass fibers can also be incorporated into other forms of composite materials as described in more detail below.

[0014] With respect to the polymer resin, the composite materials of the present invention can include one or more of a variety of polymer resins. In some embodiments, the polymer resin includes at least one of polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bismaleimide, and thermoset polyurethane resin. In some embodiments, the polymer resin can include an epoxy resin.

[0015] The composite materials of the present invention may be in a variety of forms and can be used in a variety of applications. Some examples of potential uses for composite materials according to some embodiments of the present invention include, but are not limited to, wind energy (e.g., wind turbine blades), automotive applications, safety / security applications (e.g., ballistics armor), aerospace or aviation applications (e.g., aircraft engines ... Examples include interior floors of aircraft, pressure vessels or tanks, missile casings, electronic equipment, etc.

[0016] These and other embodiments of the present invention are described in greater detail in the detailed description that follows. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a chart showing Young's modulus values ​​versus the amount of rare earth oxide (RE2O3) in various glass compositions.

[0018] [Figure 2] FIG. 2 is a chart showing pristine fiber tensile strength values ​​versus the amount of rare earth oxide (RE2O3) in various glass compositions.

[0019] [Figure 3] FIG. 3 is a chart showing softening and glass transition temperatures versus the amount of rare earth oxide (RE2O3) in various glass compositions.

[0020] [Figure 4] FIG. 4 is a chart showing the coefficient of linear thermal expansion versus the amount of scandium oxide (Sc2O3) in various glass compositions. DETAILED DESCRIPTION OF THE INVENTION

[0021] Unless indicated to the contrary, the numerical parameters set forth in the following specification are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding approaches.

[0022] 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. Any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein should be understood to encompass any and all subranges subsumed therein. For example, a range expressed as "1 to 10" should be considered to include any and all subranges between the minimum value of 1 and the maximum value of 10 (inclusive); that is, all subranges beginning at or above a minimum value of 1, e.g., 1 to 6.1, and ending at or below a maximum value of 10, e.g., 5.5 to 10. Furthermore, any reference to "incorporated herein" should be understood to be incorporated herein in its entirety.

[0023] It should further be noted that as used herein, the singular forms "a," "an," and "the" include plural referents unless expressly and unambiguously limited to one referent.

[0024] The present invention generally relates to glass compositions. In one aspect, the present invention provides glass fibers formed from the glass compositions described herein. In some embodiments, the glass fibers of the present invention can have improved mechanical properties, such as Young's modulus and early strength, compared to conventional E-glass fibers.

[0025] The glass compositions of the present invention contain rare earth oxides in addition to components typically found in glass compositions such as SiO, AlO, CaO, MgO, etc. Such glass compositions are fiberizable and therefore can be used to make fiber glasses in various embodiments. As will be understood by those skilled in the art, the term "rare earth oxide" refers to oxides incorporating rare earth metals, including oxides of scandium (ScO), yttrium (YO), and the lanthanide elements (lanthanum (LaO), cerium (CeO and CeO), praseodymium (PrO), neodymium (NdO), promethium (PmO), samarium (SmO), europium (EuO and EuO), gadolinium (GdO), terbium (TbO), dysprosium (DyO), holmium (HoO), erbium (ErO), thulium (TmO), ytterbium (YbO), and lutetium (LuO)). The rare earth oxides are included in the glass compositions of the present invention in amounts that exceed those present as mere contaminants or impurities in the batch materials in which the rare earth oxides are included in the glass batch to provide another component. In some embodiments, the glass compositions can include combinations of rare earth oxides (e.g., one or more of various rare earth oxides).

[0026] In some embodiments, the one or more rare earth oxides may be present in the glass composition in an amount of about 0.05 wt.% or greater. In some embodiments, the one or more rare earth oxides may be present in an amount of about 0.5 wt.% or greater. In some embodiments, the one or more rare earth oxides may be present in an amount greater than about 3 wt.%. In some embodiments, the one or more rare earth oxides may be present in an amount up to about 5 wt.%, although higher amounts may be used in other embodiments. In some embodiments, the one or more rare earth oxides may be present in an amount up to about 8 wt.%. In some embodiments, the one or more rare earth oxides may be present in an amount up to about 10 wt.%. In some embodiments, the one or more rare earth oxides may be present in an amount up to about 12 wt.%. In some embodiments, the one or more rare earth oxides may be present in an amount up to about 15 wt.%. In some embodiments, the one or more rare earth oxides may be present in an amount between about 0.05 and about 15 wt.%. In some embodiments, the one or more rare earth oxides can be present in an amount between about 0.5 and about 15 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 2.0 and about 15 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 3.0 and about 15 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 4.0 and about 15 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 5.0 and about 15 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 1 and about 8 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 3 and about 8 wt. %. In some embodiments, the one or more rare earth oxides can be present in an amount between about 1 and about 5 wt. %.

[0027] In some embodiments, the amount of rare earth oxide used can depend on the particular rare earth oxide used, whether or not other rare earth oxides are used in the composition, the melting characteristics of the composition, and the desired properties of the glass fibers to be formed from the composition, among other factors.

[0028] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include La2O3 in an amount between about 0.5 and about 15 weight percent. As shown above and in the examples below, other amounts of La2O3 can also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of La2O3 in a glass composition is believed to have a desirable effect on the glass softening temperature and glass transition temperature, as well as the tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0029] In some embodiments, the rare earth oxides used in the glass compositions of the present invention may include Y2O3 in an amount between about 0.5 and about 15 wt%. As shown above and in the examples below, other amounts of Y2O3 may also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of Y2O3 in a glass composition is believed to have a desirable effect on the glass softening temperature and glass transition temperature, as well as the modulus, tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0030] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include Sc2O3 in an amount between about 0.5 and about 4 wt. %. As shown above and in the examples below, other amounts of Sc2O3 can also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of Sc2O3 in a glass composition is believed to have a desirable effect on certain properties of glass fibers formed from the composition (e.g., glass softening temperature, glass transition temperature, coefficient of thermal expansion, etc.), although the presence of Sc2O3 has also been observed to increase the liquidus temperature of the composition.

[0031] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include Nd2O3 in an amount between about 0.5 and about 15 wt. %. As shown above and in the examples below, other amounts of Nd2O3 can also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of Nd2O3 in a glass composition is believed to have a desirable effect on the glass softening temperature and glass transition temperature, as well as the modulus, tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0032] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include SmO in an amount between about 0.5 and about 15 weight percent. As shown above and in the examples below, other amounts of SmO can also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of SmO in a glass composition is believed to have a desirable effect on the glass softening temperature and glass transition temperature, as well as the modulus, tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0033] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include GdO in an amount between about 0.5 and about 15 weight percent. As shown above and in the examples below, other amounts of GdO can also be included in glass compositions according to some embodiments. In some embodiments, the inclusion of GdO in a glass composition is believed to favorably affect the glass softening temperature and glass transition temperature, as well as the modulus, tensile strength, elongation, coefficient of thermal expansion, and other properties of glass fibers formed from the composition.

[0034] In some embodiments, the rare earth oxides used in the glass compositions of the present invention can include CeO2 in an amount between about 0.5 and about 15 wt. %. As shown above and in the examples below, other amounts of CeO2 can also be included in glass compositions according to some embodiments. For example, in some embodiments, CeO2 can be present in an amount between 0 and about 4 wt. %. While cerium oxide can be incorporated into the stable form of CeO2, when melted at high temperatures, most of the cerium in the glass is present in the form of CeO2. 4+ (CeO2) to Ce 3+ In this regard, the inclusion of cerium oxide not only improves the acoustic modulus and strength of glass fibers formed from the composition, but also reduces the amount of Ce in the melt. 4+ The ion is reduced to Ce 3+ As it becomes ionic, cerium oxide releases oxygen bubbles, which is believed to also increase glass quality through better fining of the glass upon melting.

[0035] Various combinations of rare earth oxides can also be used to achieve desired properties (e.g., tensile strength, modulus, specific strength, specific modulus, etc.). For example, the selection of specific rare earth oxides and their relative amounts can affect fiber density, which in turn can affect specific strength (tensile strength divided by density) and specific modulus (modulus divided by density). Similarly, the selection of specific rare earth oxides and their relative amounts can affect the melting characteristics of the glass composition. For example, as discussed above, the presence of Sc2O3 in certain amounts can increase the liquidus temperature of the glass composition. Similarly, cerium oxide (Ce2O3 and CeO2) can act as an oxidizer and a fining agent, so that in some embodiments, the amount of cerium oxide can be 4 wt. % or less. Finally, the selection of specific rare earth oxides and their relative amounts can affect the cost of making glass fibers because of their effect on melting properties and because of their cost as raw materials, as the cost of rare earth oxides varies substantially. Generally, for the same amount of rare earth oxide in the glass composition, the melting and mechanical properties of the glass are determined by the ratio z / r 2This can be controlled by selecting a combination of rare earth oxides with different electric field strengths defined by (z is the charge and r is the radius of the rare earth cation).

[0036] As mentioned above, the glass compositions of the present invention, particularly fiberizable glass compositions, also contain other components, including SiO2, Al2O3, CaO, MgO, and others.

[0037] In one embodiment, a glass composition suitable for fiber formation includes 51-65 wt% SiO, 12.5-19 wt% AlO, 0-16 wt% CaO, 0-12 wt% MgO, 0-2.5 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-3 wt% TiO, 0-3 wt% ZrO, 0-3 wt% BO, 0-3 wt% PO, 0-1 wt% FeO, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, the at least one rare earth oxide includes at least one of LaO, YO, ScO, and NdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %.

[0038] In one embodiment, the glass composition suitable for fiber formation is 51-65 wt. % SiO2, 1 The composition comprises 2.5-22 wt% Al2O3, 0-16 wt% CaO, 0-12 wt% MgO, 0-2.5 wt% Na2O, 0-1 wt% K2O, 0-2 wt% Li2O, 0-3 wt% TiO2, 0-3 wt% ZrO2, 0-3 wt% B2O3, 0-3 wt% P2O5, 0-1 wt% Fe2O3, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% other components, where the Na2O + K2O + Li2O content is greater than 1 wt%. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, and Nd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %.

[0039] In one embodiment, a glass composition suitable for fiber formation includes 51-63 wt% SiO, 14.5-19 wt% AlO, 0.5-10 wt% CaO, 0-12 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-3 wt% TiO, 0-3 wt% ZrO, 0-2 wt% BO, 0-3 wt% PO, 0-1 wt% FeO, at least one rare earth oxide in an amount of 0.5 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, the at least one rare earth oxide includes at least one of LaO, YO, ScO, and NdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %.

[0040] In one embodiment, a glass composition suitable for fiber formation comprises 56-68 wt% SiO, 11-20 wt% or less AlO, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-5 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% of other components. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %.

[0041] In one embodiment, a glass composition suitable for fiber formation comprises 60-68 wt% SiO, 14-19 wt% AlO, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 1 wt% or greater, and a total of 0-11 wt% of other components. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %.

[0042] In one embodiment, a glass composition suitable for fiber formation comprises 60-68 wt% SiO, 14-19 wt% AlO, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0.4-2 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt%, and a total of 0-11 wt% other components, where the NaO + KO content is less than about 0.5 wt%. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt %.

[0043] In one embodiment, a glass composition suitable for fiber formation comprises 59-62 wt% SiO, 14-19 wt% AlO, 4-8 wt% CaO, 6-11 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0-2 wt% LiO, 0-3 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-2 wt% CuO, 0-3 wt% SrO, at least one rare earth oxide in an amount between about 2 and about 6 wt%, and a total of 0-11 wt% other components, where the NaO + KO content is less than about 0.5 wt%. In some embodiments, the at least one rare earth oxide comprises at least one of LaO, YO, ScO, NdO, CeO, SmO, and GdO. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt %.

[0044] It should be understood that any component of a glass composition described as being present in an amount between about 0 wt. % and another wt. % is not necessarily required in all embodiments. In other words, in some embodiments, such a component may be optional, depending, of course, on the amounts of other components included in the composition. Similarly, in some embodiments, the glass composition may be substantially free of such a component. This means that any amount of the component present in the glass composition comes from components present as trace impurities in the batch materials.

[0045] Some embodiments of the present invention can be characterized by the amount of SiO2 present in the glass composition. In some embodiments, SiO2 can be present in an amount between about 51 and about 65 wt. % and between about 51 and about 63 wt. %. In some embodiments, SiO2 can be present in an amount between about 54 and about 65 wt. % and between about 54 and about 63 wt. %. In some embodiments, SiO2 can be present in an amount between about 59 and about 62 wt. % and between about 59 and about 65 wt. %. In some embodiments, SiO2 can be present in an amount between about 56 and about 68 wt. % and in other embodiments, between about 60 and 68 wt. %. In some embodiments, the glass composition can include at least 60 wt. % SiO2.

[0046] Some embodiments of the present invention can be characterized by the amount of Al2O3 present in the glass composition. In some embodiments, the glass composition can include 12.5-22 wt% Al2O3. In some embodiments, Al2O3 can be present in an amount between about 12.5 and about 19 wt%. In some embodiments, Al2O3 can be present in an amount between about 11-20 wt%. In some embodiments, Al2O3 can be present in an amount between about 14-19 wt%. In some embodiments, Al2O3 can be present in an amount between about 14.5-19 wt%. In some embodiments, Al2O3 can be present in an amount between about 15-19 wt% and about 15-18 wt%. do.

[0047] Some embodiments of the present invention can be characterized by the amount of CaO present in the glass composition. In some embodiments, CaO can be present in an amount between 0 and about 20 wt. %. In some embodiments, CaO can be present in an amount between 0 and about 16 wt. %. In some embodiments, CaO can be present in an amount between about 0.5 and about 15 wt. %. In some embodiments, the glass composition can comprise between about 0.5 and about 14 wt. %. In some embodiments, CaO can be present in an amount less than about 12 wt. %. In some embodiments, CaO can be present in an amount between about 0.5 and about 10 wt. %. In some embodiments, the glass composition can comprise less than about 5 wt. % CaO. In some embodiments, the glass composition can comprise between about 4 and about 8 wt. % CaO.

[0048] Some embodiments of the present invention can be characterized by the amount of MgO present in the glass composition. In some embodiments, the glass composition of the present invention includes between 0 and about 12 wt. % MgO. In some embodiments, MgO can be present in an amount up to about 9 wt. %. In some embodiments, MgO can be present in an amount between about 6 and about 9 wt. % or between about 6 and about 11 wt. %. In some embodiments, MgO can be present in an amount between about 7 and about 17 wt. %. In some embodiments, MgO can be present in an amount between about 10 and about 16 wt. %.

[0049] Some embodiments of the present invention can be characterized by the amount of Na2O present in the glass composition. In some embodiments, the glass composition of the present invention can include between about 0 and about 2.5 wt.% Na2O. In some embodiments, Na2O can be present in an amount between about 0 and about 1.5 wt.%. In some embodiments, Na2O can be present in an amount up to about 1.5 wt.%. In some embodiments, Na2O can be present in an amount up to about 1.0 wt.%. In some embodiments, Na2O can be present in an amount up to about 0.5 wt.%. In some embodiments, the glass composition of the present invention includes less than about 0.1 wt.% Na2O.

[0050] Some embodiments of the present invention can be characterized by the amount of KO present in the glass composition. In some embodiments, KO can be present in an amount between about 0 and about 1 wt. %. In some embodiments, KO can be present in an amount up to about 1 wt. %. In some embodiments, KO can be present in an amount up to about 0.5 wt. %. In some embodiments, the glass composition of the present invention comprises less than about 0.1 wt. % KO.

[0051] Some embodiments of the present invention can be characterized by the amount of Li2O present in the glass composition. In some embodiments, the glass composition of the present invention can include between about 0 and about 5 wt. % Li2O. In some embodiments, the glass composition of the present invention can include between about 0 and about 2 wt. % Li2O. In some embodiments, Li2O can be present in an amount between about 0.4 and about 2 wt. % Li2O can be present in an amount between about 0 and about 1 wt. % Li2O can be present in an amount up to about 1 wt. % Li2O.

[0052] Some embodiments of the present invention can be characterized by the total content of Na2O, K2O, and Li2O. In some embodiments, the content of Na2O+K2O+Li2O in the glass composition of the present invention is greater than 1 wt. In some embodiments, the content of Na2O+K2O+Li2O is at most about 2.5 wt. In some embodiments, the content of Na2O+K2O+Li2O is greater than about 1 wt. % and at most about 2.5 wt. %.

[0053] Some embodiments of the present invention can be characterized by the total content of Na2O and K2O. In some embodiments, the content of Na2O + K2O in the glass composition of the present invention is less than about 0.5 wt. %. In some embodiments, the content of Na2O + K2O is at most about 0.3 wt. %. In some embodiments, the content of Na2O + K2O is at most about 0.1 wt. %.

[0054] Some embodiments of the present invention can be characterized by the amount of B2O3 present in the glass composition. In some embodiments, B2O3 can be present in an amount between about 0 and about 3 wt. %. In some embodiments, B2O3 can be present in an amount between about 0 and about 2 wt. %. In some embodiments, B2O3 can be present in an amount between about 0 and about 1 wt. %. In some embodiments, the glass compositions of the present invention can be substantially free of B2O3, meaning that any B2O3 present in the glass composition comes from B2O3 present as a trace impurity in the batch materials. In other embodiments, the glass compositions of the present invention can include greater than about 1 wt. % B2O3. In some embodiments, B2O3 can be present in an amount up to about 10 wt. %.

[0055] Some embodiments of the present invention can be characterized by the amount of Fe2O3 present in the glass composition. In some embodiments, Fe2O3 can be present in an amount less than 1.0 wt. %. In some embodiments, Fe2O3 can be present in an amount between about 0 and about 0.5 wt. %. In some embodiments, Fe2O3 can be present in an amount up to about 0.4 wt. %.

[0056] Some embodiments of the present invention can be characterized by the amount of TiO2 present in the glass composition. In some embodiments, TiO2 can be present in an amount between about 0 and about 3 wt. %. In some embodiments, TiO2 can be present in an amount up to about 3 wt. %. In some embodiments, TiO2 can be present between 0 and about 2 wt. %.

[0057] Some embodiments of the present invention can be characterized by the amount of CuO present in the glass composition. In some embodiments, CuO can be present in an amount between about 0 and about 2 wt. %. In some embodiments, CuO can be present in an amount up to 2 wt. %. In some embodiments, CuO can be present between 0 and about 1.5 wt. %. CuO is present in an oxidation state, Cu, that is considered stable in the glass. 1+ ions and Cu 2+ A mixture of ions was used in the glass batch for molten glass. Without being bound by theory, monovalent Cu + The ions behave similarly to alkalis, with divalent Cu 2+ It is believed that Cu ions function similarly to ZnO, thereby improving the chemical durability of glass. + Cu from ions 2+ Oxidation to ions provides the benefit of higher glass and / or glass fiber strength, which is believed to result from the formation of a structural passivation layer that retards the penetration of water molecules from the ambient environment into the glass and / or glass fiber.

[0058] Some embodiments of the present invention can be characterized by the amount of SrO present in the glass composition. In some embodiments, SrO can be present in an amount between about 0 and about 3 wt. %. In some embodiments, SrO can be present in an amount up to 3 wt. %. In some embodiments, SrO can be present between 0 and 2.5 wt. %. SrO has the effect of reducing glass viscosity compared to either MgO or CaO. Thus, the addition of SrO, as opposed to either MgO or CaO, results in an improvement to the glass elastic modulus.

[0059] In some embodiments, the glass compositions of the present invention may include ZnO. In some embodiments of the glass compositions, ZnO can be used to replace or reduce the amount of CaO. In some embodiments, the inclusion of ZnO to at least partially replace CaO is believed to improve the acoustic modulus and tensile strength of glass fibers from such compositions. Furthermore, ZnO is believed to reduce CaO activity in the glass melt, thus reducing the risk of wollastonite (CaO·SiO2) and / or anorthite (CaO·Al2O3·2SiO3) crystallization in the melt. In some embodiments, glass fibers containing higher concentrations of ZnO may also provide improved resistance to acid corrosion. In embodiments where ZnO is included, ZnO may be present in an amount up to about 4 wt. %. In some embodiments where ZnO is included, ZnO may be present in an amount up to about 4 wt. % and the amount of CaO may be between about 0 and about 5 wt. %.

[0060] In some embodiments, the glass compositions of the present invention can include tin oxide. Tin oxide can be introduced in the form of SnO2, but when melted at high temperatures, most of the tin in the glass becomes SnO2. 4+ (from SnO2) to Sn 2+ In this regard, the inclusion of tin oxide not only improves the acoustic modulus and strength of glass fibers formed from the composition, but also reduces the amount of Sn in the melt. 4+ The ions are reduced to Sn2+ As tin oxide becomes ions, it releases oxygen bubbles, which is believed to also increase glass quality through better fining of the glass during melting. Furthermore, in some embodiments, the presence of SnO in the glass can allow for at least partial replacement of CaO. Furthermore, the presence of SnO is believed to reduce CaO activity in the glass melt, thus reducing the risk of wollastonite (CaO·SiO) and / or anorthite (CaO·Al2O3·2SiO3) crystallization in the melt. In this regard, in some embodiments, tin oxide can be added in the form of SnO without any potential impact on fining. In embodiments where tin oxide is included, the tin oxide can be present in an amount up to about 4 wt. %. In some embodiments where tin oxide is included, the tin oxide can be present in an amount up to about 4 wt. % and the amount of CaO can be between about 0 and about 5 wt. %.

[0061] In some embodiments, glass compositions of the present invention can be characterized by the amount of SnO2 and CeO2. Because these oxides can have similar effects on the glass melt and the fibers formed therefrom, some glass compositions can include both SnO2 and CeO2. In some embodiments, the SnO2 + CeO2 content can be up to about 8 wt%. In some embodiments, the SnO2 + CeO2 content can be up to about 6 wt%. In some embodiments, the SnO2 + CeO2 content can be up to about 4 wt%. In some embodiments, SnO2 can be present in an amount up to about 4 wt%, and CeO2 can also be present in an amount up to about 4 wt%.

[0062] Some embodiments of the present invention can be characterized by the amount of ZrO2 present in the glass composition. In some embodiments, ZrO2 can be present in an amount between about 0 and about 3 wt. %. In some embodiments, ZrO2 can be present in an amount up to about 2 wt. %. In some embodiments, the glass compositions of the present invention can be substantially free of ZrO2, meaning that any ZrO2 present in the glass composition comes from ZrO2 present as a trace impurity in the batch materials.

[0063] Some embodiments of the present invention can be characterized by the amount of P2O5 present in the glass composition. In some embodiments, P2O5 can be present in an amount between about 0 and about 3 wt. %. In some embodiments, P2O5 can be present in an amount up to about 2.5 wt. %. In some embodiments, the glass compositions of the present invention can be substantially free of P2O5, meaning that any P2O5 present in the glass composition is present in the presence of traces of P2O5 in the batch materials. This means that the SiO2 content comes from P2O5, which is present as an impurity in small amounts. P2O5 functions as a glass network former, and SiO2 forms tetrahedral units (PO4) in the glass. In some embodiments, P2O5 can be used to replace SiO2 to lower the liquidus temperature, especially for glasses containing high concentrations of rare earth oxides.

[0064] Some embodiments of the present invention can be characterized by the amount of niobium oxide (NbO) present in the glass composition. NbO functions as a glass network former, but forms octahedral units (NbO) as opposed to SiO, which forms tetrahedral units (SiO). Substituting NbO for some SiO is believed to lower the melt viscosity. With the presence of both NbO and SiO in an alkaline earth- or alkali-containing aluminosilicate glass, both 4x (AlO) and 6x (AlO) aluminum are present, with higher concentrations of AlO resulting in higher concentrations of NbO. This is believed to result in lower melt viscosity and higher acoustic modulus and tensile strength in glass fibers formed from the composition. In embodiments where NbO is included, NbO can be present in an amount of up to about 5 wt.%.

[0065] Sulfate (represented as SO3) is present as a refining agent. The glass may also contain small amounts of impurities from raw materials, such as SrO, BaO, Cl2, PO5, Cr2O3, or NiO (not limited to these specific chemical forms), or contaminants 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 amounts less than 0.5 wt. % of the total glass composition.

[0066] As noted above, glass compositions according to some embodiments of the present invention are fiberizable. In some embodiments, the glass compositions of the present invention have a forming temperature (T F As used herein, the "forming temperature" or T Fmeans the temperature (or "log3 temperature") at which the glass composition has a viscosity of 1000 poise. In some embodiments, the glass compositions of the present invention have a forming temperature (T) in the range of about 1250°C to about 1415°C. F In another embodiment, the glass composition of the present invention has a forming temperature in the range of about 1250°C to about 1350°C. In some embodiments, the glass composition has a forming temperature in the range of about 1250°C to about 1310°C.

[0067] In some embodiments, the glass compositions of the present invention have a liquidus temperature in the range of about 1150°C to about 1515°C. In some embodiments, the glass compositions of the present invention have a liquidus temperature in the range of about 1130°C to about 1235°C. In other embodiments, the glass compositions of the present invention have a liquidus temperature in the range of about 1190°C to about 1300°C. In some embodiments, the glass compositions of the present invention have a liquidus temperature in the range of about 1190°C to about 1260°C.

[0068] In some embodiments, the difference between the forming temperature and the liquidus temperature of the glass compositions of the present invention is desirable for commercial fiberglass manufacturing operations. For example, for some embodiments of the glass compositions, the difference between the forming temperature and the liquidus temperature ranges from about 35°C to greater than 60°C. In some embodiments, the difference between the forming temperature and the liquidus temperature of the glass compositions of the present invention is at least 50°C. In other embodiments, the difference between the forming temperature and the liquidus temperature of the glass compositions of the present invention ranges from about 70°C to about 190°C.

[0069] As provided herein, glass fibers are some embodiments of the glass compositions of the present invention.

[0013] Accordingly, embodiments of the present invention can include glass fibers formed from any of the glass compositions described herein. In some embodiments, the glass fibers can be made into a fabric. In some embodiments, the glass fibers of the present invention can be provided in other forms, including, for example, but not limited to, as continuous strands, chopped strands (dry or wet), yarns, rovings, prepregs, etc. In short, various embodiments of the glass compositions (and any fibers formed therefrom) can be used in a variety of applications.

[0070] Some embodiments of the present invention relate to fiberglass strands. Some embodiments of the present invention relate to yarns comprising fiberglass strands. Some embodiments of the yarns of the present invention are particularly suitable for weaving applications. Additionally, some embodiments of the present invention relate to fiberglass fabrics. Some embodiments of the fiberglass fabric of the present invention are particularly suitable for use in reinforcement applications, especially where high modulus, high strength, and / or high elongation are important. Additionally, some embodiments of the present invention relate to composites incorporating fiberglass strands, fiberglass yarns, and fiberglass fabrics, such as fiber-reinforced polymer composites. Some composites of the present invention are particularly suitable for use in reinforcement applications, especially 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., ballistic armor or armor panels), aerospace or aviation applications (e.g., aircraft interior floors), high-pressure vessels or tanks, missile casings, and the like. Some embodiments of the present invention relate to automotive composites. Some embodiments of the present invention relate to aerospace composites. Other embodiments of the present application relate to aviation composites. Still other embodiments of the present invention relate to composites suitable for use in wind energy applications. Some embodiments of the present invention relate to prepregs. Some embodiments of the present invention relate to composites for safety / security applications, such as armor panels. Other embodiments of the present invention relate to composite materials for high-pressure vessels or storage tanks. Some embodiments of the present invention relate to composite materials for missile casings. Other embodiments of the present invention relate to composite materials for use in high-temperature insulation applications. Some embodiments of the present invention relate to printed circuit boards where a lower coefficient of thermal expansion is particularly desirable, such as substrates for chip packaging.

[0071] Some embodiments of the present invention relate to fiberglass strands. In some embodiments, the fiberglass strands of the present invention comprise the following components: 51-65 wt% SiO2; 12.5-19 wt% Al2O3; 0-16 wt% CaO; 0-12 wt% MgO; 0-2.5 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% ZrO2; 0-3 wt% B2O3; 0-3 wt% P2O5; 0-1 wt% Fe2O3; at least one rare earth oxide in an amount of 0.05% by weight or greater; and Total of 0-11% by weight of other components The glass fiber further comprises a glass composition comprising:

[0072] In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, Y2O3, Sc2O3, and Nd2O3. The one rare earth oxide is present in an amount of at least 1 wt %. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt %.

[0073] In some embodiments, the fiber glass strands of the present invention comprise the following components: 51-65 wt% SiO2; 12.5-22 wt% Al2O3; 0-16 wt% CaO; 0-12 wt% MgO; 0-2.5 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% ZrO2; 0-3 wt% B2O3; 0-3 wt% P2O5; 0-1 wt% Fe2O3; at least one rare earth oxide in an amount of 0.05% by weight or greater; and Total of 0-11% by weight of other components wherein the content of Na2O+K2O+Li2O is greater than 1 wt%. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, and Nd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%.

[0074] In some embodiments, the fiber glass strands of the present invention comprise the following components: 51-63 wt% SiO2; 14.5-19 wt% Al2O3; 0.5-10 wt% CaO; 0-12 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% ZrO2; 0-2 wt% B2O3; 0-3 wt% P2O5; 0-1 wt% Fe2O3; at least one rare earth oxide in an amount of 0.5% by weight or greater; and Total of 0-11% by weight of other components The glass fiber further comprises a glass composition comprising:

[0075] In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, and Nd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %.

[0076] In some embodiments, the fiber glass strands of the present invention comprise the following components: 56-68 wt% SiO2; less than 11-20 wt% Al2O3; 12 wt.% or less CaO; 7-17 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-5 wt% Li2O; 0-2 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-4 wt% SnO2; 0-4 wt% ZnO; at least one rare earth oxide in an amount of 0.05% by weight or greater; and Total of 0-11% by weight of other components The glass fiber further comprises a glass composition comprising:

[0077] In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 1 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%.

[0078] In some embodiments, the fiber glass strands of the present invention comprise the following components: 60-68 wt% SiO2; 14-19 wt% Al2O3; 5 wt.% or less CaO; 10-16 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-2 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-4 wt% SnO2; 0-4 wt% ZnO; at least one rare earth oxide in an amount of 1% by weight or greater; and Total of 0-11% by weight of other components The glass fiber further comprises a glass composition comprising:

[0079] In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 15 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 8 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%.

[0080] In some embodiments, the fiber glass strands of the present invention comprise the following components: 60-68 wt% SiO2; 14-19 wt% Al2O3; 5 wt.% or less CaO; 10-16 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0.4-2 wt% Li2O; 0-2 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-4 wt% SnO2; 0-4 wt% ZnO; at least one rare earth oxide in an amount between about 1 and about 8 weight percent; and Total of 0-11% by weight of other components (wherein the Na2O+K2O content is less than about 0.5 wt.%). In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of at most about 5 wt.%.

[0081] In some embodiments, the fiber glass strands of the present invention comprise the following components: 59-62 wt% SiO2; 14-19 wt% Al2O3; 4-8 wt% CaO; 6-11 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-2 wt% Cu2O; 0-3 wt% SrO; at least one rare earth oxide in an amount between about 2 and about 6 weight percent; and Total of 0-11% by weight of other components (wherein the Na2O+K2O content is less than about 0.5 wt.%). In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt.%. In some embodiments, the at least one rare earth oxide is present in an amount of at most about 5 wt.%.

[0082] Many other glass compositions are disclosed herein as part of the present invention, and other embodiments of the present invention relate to fiber glass strands formed from such compositions.

[0083] In some embodiments, the glass fibers of the present invention can exhibit desirable mechanical and other properties. In some embodiments, the glass fibers of the present invention can exhibit one or more improved mechanical properties relative to glass fibers formed from E-glass. In some embodiments, the glass fibers of the present invention 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 present glass fibers include, but are not limited to, tensile strength, Young's modulus, coefficient of thermal expansion, softening point, elongation, and dielectric constant.

[0084] In some embodiments, the glass fibers of the present invention can have desirable Young's modulus (E) values. In some embodiments, fibers formed from the glass compositions of the present invention can have a Young's modulus of greater than about 87 GPa. In some embodiments, the glass fibers of the present invention can have a Young's modulus of greater than about 90 GPa. In some embodiments, fibers formed from the glass compositions of the present invention can have a Young's modulus of greater than about 92 GPa. In some embodiments, the glass fibers of the present invention can have a Young's modulus of greater than about 93 GPa. In some embodiments, the glass fibers of the present invention can have a Young's modulus of greater than about 95 GPa. Unless otherwise stated herein, the Young's modulus values ​​discussed herein are determined using the procedures set forth in the Examples section below.

[0085] In some embodiments, the glass fibers of the present invention can have a desirable tensile strength. In some embodiments, the glass fibers of the present invention can have a tensile strength of greater than 4000 MPa. In some embodiments, the glass fibers of the present invention can have a tensile strength of greater than 4,500 MPa. In some embodiments, the glass fibers of the present invention can have a tensile strength of greater than about 5000 MPa. In some embodiments, the glass fibers of the present invention can have a tensile strength of greater than about 5500 MPa or greater than about 5700 MPa. Unless otherwise stated herein, tensile strength values ​​are determined using the procedures set forth in the Examples section.

[0086] In some embodiments, the glass fibers of the present invention can have desirable elongation values. In some embodiments, the glass fibers of the present invention can have an elongation of at least 5.0%. In some embodiments, the glass fibers of the present invention can have an elongation of at least 5.5%. In other embodiments, the glass fibers of the present invention can have an elongation of at least 6.0%. Unless otherwise stated herein, elongation values ​​are determined using the procedures set forth in the Examples section.

[0087] In some embodiments, the glass fibers of the present invention can have a desirable coefficient of thermal expansion. In some embodiments, the glass fibers of the present invention can have a coefficient of thermal expansion of less than about 4.5 ppm / °C. In some embodiments, the glass fibers of the present invention can have a coefficient of thermal expansion of less than about 3.1 ppm / °C. Unless otherwise stated, the coefficient of thermal expansion is determined using the procedures set forth in the Examples section.

[0088] In some embodiments, the glass fibers of the present invention can have a desirable softening point. In some embodiments, the glass fibers of the present invention can have a softening point of at least about 900° C. In some embodiments, the glass fibers of the present invention can have a softening point of at least about 950° C. Unless otherwise stated, softening point values ​​are determined using the procedures set forth in the Examples section.

[0089] In some embodiments, the glass fibers of the present invention have desirable dielectric constant values ​​(D k In some embodiments, the glass fibers of the present invention may have a dielectric constant value (D) of less than about 6.0 at a frequency of 1 MHz. k ) Unless otherwise stated herein, the dielectric constant (D k ) is based on ASTM Test Method D150 - "Standard Test Method for AC Loss Characteristics and Dielectric Constant (Dielectric Constant) of Solid Electrical Insulating Materials" Test Methods for AC Loss Characteristics and Permittivity (Dielectric The "Constant of Solid Electrical Insulating Materials" Determined at ~1GHz.

[0090] Fiber glass strands can include glass fibers of various diameters depending on the desired application. In some embodiments, fiber glass strands of the present invention 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.

[0091] In some embodiments, the fiberglass strands of the present invention can be formed into rovings. Rovings can be assembled, multi-end, or single-end. Rovings comprising the fiber glass strands of the present invention can include directly drawn single-end rovings having various diameters and densities depending on the desired application. In some embodiments, rovings comprising the fiber glass strands of the present invention exhibit densities of up to about 112 yards per pound.

[0092] Some embodiments of the present invention relate to yarns comprising at least one fiber glass strand as disclosed herein. In some embodiments, the yarn of the present invention comprises at least one fiber glass strand comprising a glass composition comprising 56-68 wt% SiO2, 11-20 wt% or less Al2O3, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% Na2O, 0-1 wt% K2O, 0-5 wt% Li2O, 0-2 wt% TiO2, 0-3 wt% B2O3, 0-1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05 wt%, and a total of 0-11 wt% of other components. In some embodiments, the yarn comprises at least one fiber glass strand comprising a glass composition including 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 1 wt. %, and 0-11 wt. % total of other components. In some embodiments, the yarn of the present invention comprises at least one fiber glass strand comprising a glass composition comprising 60-68 wt% SiO, 14-19 wt% AlO, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% NaO, 0-1 wt% KO, 0.4-2 wt% LiO, 0-2 wt% TiO, 0-3 wt% BO, 0-1 wt% FeO, 0-4 wt% SnO, 0-4 wt% ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt%, and 0-11 wt% total other components (wherein the NaO + KO content is less than about 0.5 wt%). In other embodiments, the yarn of the present invention comprises at least one fiber glass strand comprising one of the other glass compositions disclosed herein as part of this invention.In some embodiments, the yarn of the present invention comprises at least one fiber glass strand comprising a glass composition including 59-62 wt% SiO2, 14-19 wt% Al2O3; 4-8 wt% CaO; 6-11 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-2 wt% Cu2O; 0-3 wt% SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt%; and a total of 0-11 wt% other components (wherein the Na2O + K2O content is less than about 0.5 wt%). In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %.

[0093] In some embodiments, the yarn of the present invention comprises a sizing composition as disclosed herein, wherein at least one fiber glass strand thereof is at least partially coated with a sizing composition. The sizing composition may comprise at least one fiberglass strand such as: In some embodiments, the sizing composition is compatible with a thermosetting polymer resin; In other embodiments, the sizing composition may comprise a starch-oil sizing composition.

[0094] The yarns have various linear mass densities depending on the desired application. In some embodiments, the yarns of the present invention have a linear mass density of from about 5,000 yards / pound to about 10,000 yards / pound.

[0095] Yarns can have various twist levels and directions depending on the desired application. In some embodiments, the yarns of the present invention 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 invention have a twist in the z-direction of about 0.7 turns per inch.

[0096] The yarns may be twisted and / or plied together depending on the desired application. (plied) Can be made from one or more strands. Such yarns can be made from one or more strands that are twisted together but not twisted; such yarns are known as "single." The yarns of the present invention can be made from one or more strands that are twisted together but not twisted. In some embodiments, the yarns of the present invention comprise 1 to 4 strands twisted together. In other embodiments, the yarns of the present invention comprise one twisted strand.

[0097] Some embodiments of the present invention relate to a fabric comprising at least one fiber glass strand. In some embodiments, the fabric comprises at least one fiber glass strand comprising a glass composition comprising 56-68 wt% SiO2, 11-20 wt% or less Al2O3, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% Na2O, 0-1 wt% K2O, 0-5 wt% Li2O, 0-2 wt% TiO2, 0-3 wt% B2O3, 0-1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, the fabric comprises at least one fiber glass strand comprising a glass composition including 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 1 wt. %, and a total of 0-11 wt. % other components. In some embodiments, the fabric comprises at least one fiber glass strand comprising a glass composition including 60-68 wt.% SiO2, 14-19 wt.% Al2O3, 5 wt.% or less CaO, 10-16 wt.% MgO, 0-1 wt.% Na2O, 0-1 wt.% K2O, 0.4-2 wt.% Li2O, 0-2 wt.% TiO2, 0-3 wt.% B2O3, 0-1 wt.% Fe2O3, 0-4 wt.% SnO2, 0-4 wt.% ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt.%, and a total of 0-11 wt.% other components (wherein the Na2O+K2O content is less than about 0.5 wt.%).In some embodiments, the fabric comprises at least one fiber glass strand comprising a glass composition including 59-62 wt% SiO2, 14-19 wt% Al2O3; 4-8 wt% CaO; 6-11 wt% MgO; 0-1 wt% Na2O; 0-1 wt% K2O; 0-2 wt% Li2O; 0-3 wt% TiO2; 0-3 wt% B2O3; 0-1 wt% Fe2O3; 0-2 wt% Cu2O; 0-3 wt% SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt%; and a total of 0-11 wt% other components (wherein the Na2O + K2O content is less than about 0.5 wt%). In some embodiments, the at least one rare earth oxide is at least one of La2O3, Y2O3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3% by weight. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5% by weight. In other embodiments, the fabric of the present invention can include at least one fiberglass strand comprising one of the other glass compositions disclosed herein as part of this invention. In some embodiments, the fabric of the present invention includes yarn as disclosed herein. In some embodiments, the fabric of the present invention can include at least one weft yarn comprising at least one fiberglass strand as disclosed herein. In some embodiments, the fabric of the present invention can include at least one warp yarn comprising at least one fiberglass strand as disclosed herein. In some embodiments, the fabric of the present invention 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.

[0098] In some embodiments of the invention that include a fabric, the fiberglass fabric is a fabric woven according to industrial fabric style No. 7781. In some embodiments, the fabric includes plain weave fabric, twill weave fabric, crowfoot fabric, satin weave fabric, stitch bonded fabric (also known as non-crimp fabric) or "three-dimensional" woven fabric.

[0099] Some embodiments of the present invention relate to composite materials. In some embodiments, the composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt% SiO2, 11-20 wt% or less Al2O3, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% Na2O, 0-1 wt% K2O, 0-5 wt% Li2O, 0-2 wt% TiO2, 0-3 wt% B2O3, 0-1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 0.05 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount of 1% or greater, and a total of 0-11% other components by weight. In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO, 14-19% AlO, 5% or less CaO, 10-16% MgO, 0-1% NaO, 0-1% KO, 0.4-2% LiO, 0-2% TiO, 0-3% BO, 0-1% FeO, 0-4% SnO, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and a total of 0-11% by weight of other components, where the NaO + KO content is less than about 0.5% by weight.In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % KO; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % BO3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components, wherein the Na2O + KO content is less than about 0.5 wt. %. The composite material of the present invention comprises a glass composition. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, the composite material of the present invention can comprise a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention. In some embodiments, the composite material of the present invention comprises a polymer resin and at least one fiber glass strand, as disclosed herein, disposed in the polymer resin. In some embodiments, the composite material of the present invention comprises at least a portion of a roving comprising a polymer resin and at least one fiber glass strand, as disclosed herein, disposed in the polymer resin. In other embodiments, the composite material of the present invention comprises a polymer resin and at least one yarn, as disclosed herein, disposed in the polymer resin. In yet other embodiments, the composite material of the present invention comprises a polymer resin and at least one fabric as disclosed herein disposed in the polymer resin. In some embodiments, the composite material of the present invention comprises 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.

[0100] The composite materials of the present invention can include a variety of polymer resins depending on the desired properties and application. In some composite embodiments of the present invention, the polymer resin includes an epoxy resin. In other composite embodiments of the present invention, the polymer resin can include polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bismaleimide, and thermoset polyurethane resins.

[0101] Some embodiments of the present invention relate to aerospace composites, which in some embodiments exhibit desirable properties for use in aerospace applications, such as high strength, high elongation, high modulus, and / or low density.

[0102] In some embodiments, an aerospace composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 56-68% SiO2, 11-20% Al2O3, 12% or less CaO, 7-17% MgO, 0-1% Na2O, 0-1% K2O, 0-5% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05% by weight, and a total of 0-11% by weight of other components. In some embodiments, an aerospace composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount equal to or greater than 1% by weight, and a total of 0-11% by weight of other components. In some embodiments, the aerospace composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers is composed of the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or more The glass composition includes less than 10% CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0.4-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and 0-11% total by weight of other components (wherein the Na2O + K2O content is less than about 0.5% by weight). In some embodiments, an aerospace composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 59-62% SiO, 14-19% AlO; 4-8% CaO; 6-11% MgO; 0-1% NaO; 0-1% KO; 0-2% LiO; 0-3% TiO; 0-3% BO; 0-1% FeO; 0-2% CuO; 0-3% SrO; at least one rare earth oxide in an amount between about 2 and about 6% by weight; and a total of 0-11% by weight of other components, where the NaO + KO content is less than about 0.5% by weight. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, the aerospace composites of the present invention can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0103] In some embodiments, aerospace composites of the present invention comprise a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In some embodiments, aerospace composites of the present invention comprise at least a portion of a roving comprising a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In other embodiments, aerospace composites of the present invention comprise a polymer resin and at least one yarn as disclosed herein disposed within the polymer resin. In yet other embodiments, aerospace composites of the present invention comprise a polymer resin and at least one fabric as disclosed herein disposed within the polymer resin. In some embodiments, aerospace composites of the present invention comprise 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.

[0104] The aerospace composites of the present invention can include various polymer resins depending on the desired properties and application. In some embodiments of the present invention, including aerospace composites, the polymer resin includes an epoxy resin. In other embodiments of the present invention, including aerospace composites, the polymer resin can include polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bismaleimide, and thermoset polyurethane resins. Examples of parts in which the aerospace composites of the present invention may be used include, but are not limited to, floor panels, overhead bins, galleys, seatbacks, and other interior compartments potentially susceptible to impact, as well as exterior components such as helicopter rotor blades.

[0105] Some embodiments of the present invention relate to aeronautical composite materials. In some embodiments, the aeronautical composite materials of the present invention exhibit desirable properties for use in aeronautical applications, such as high strength, high elongation, high modulus, lower density, high specific strength and / or high specific modulus. The present invention The high elongation of some of the aviation composites can make them particularly desirable for use in aviation applications where high impact resistance is important, such as aircraft interior applications. In some embodiments, the aviation composites of the present invention can exhibit enhanced impact performance compared to composites formed from E-glass fabrics. The aviation composites of the present invention can be suitable for use in aircraft interiors, including stowage bins, seats, and flooring, among others.

[0106] In some embodiments, an aeronautical composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt. % SiO2, 11-20 wt. % or less Al2O3, 12 wt. % or less CaO, 7-17 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-5 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05 wt. %, and a total of 0-11 wt. % other components. In some embodiments, an aeronautical composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 1 wt. %, and a total of 0-11 wt. % other components. In some embodiments, an aeronautical composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0.4-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and a total of 0-11% by weight of other components, where the Na2O + K2O content is less than about 0.5% by weight.In some embodiments, an aeronautical composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % KO; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % BO3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components (wherein the Na2O + KO content is less than about 0.5 wt. %). In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, the aeronautical composite of the present invention can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0107] In some embodiments, the aeronautical composites of the present invention comprise a polymer resin and at least one fiberglass strand as disclosed herein disposed in the polymer resin. In some embodiments, the aeronautical composites of the present invention comprise a polymer resin and at least one fiberglass strand as disclosed herein disposed in the polymer resin. In some embodiments, the aeronautical composites of the present invention comprise 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. In other embodiments, the aeronautical composites of the present invention comprise a polymer resin and at least one yarn as disclosed herein disposed in the polymer resin. In yet other embodiments, the aeronautical composites of the present invention comprise a polymer resin and at least one fabric as disclosed herein disposed in the polymer resin. In some embodiments, the aeronautical composites of the present invention comprise 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.

[0108] The aviation composites of the present invention can include various polymer resins depending on the desired properties and application. In some embodiments of the present invention, including aviation composites, the polymer resin includes a phenolic resin. In other embodiments of the present invention, including aviation composites, the polymer resin can include epoxy, polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bismaleimide, and thermoset polyurethane resins. Examples of parts in which the aviation composites of the present invention can be used include, but are not limited to, floor panels, bins, galleys, seatbacks, and other interior compartments potentially susceptible to impact, as well as exterior components such as helicopter rotor blades.

[0109] Some embodiments of the present invention relate to automotive composites. In some embodiments, the automotive composites of the present invention exhibit desirable properties for use in automotive applications, such as high strength, high elongation, and low fiber density. The combination of high strength and high elongation (or failure-to-strain) of some composites of the present invention makes such composites suitable for use in automotive structures. This can make them particularly desirable for use in automotive applications where high impact resistance is important, such as for structural parts, bodies, and bumpers. In some embodiments, the automotive composites of the present invention can exhibit enhanced impact performance compared to composites formed from E-glass fabric, R-glass fabric, and / or S-glass fabric.

[0110] In some embodiments, an automotive composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt. % SiO2, 11-20 wt. % Al2O3, 12 wt. % or less CaO, 7-17 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-5 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05 wt. %, and a total of 0-11 wt. % other components. In some embodiments, an automotive composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 1 wt. %, and a total of 0-11 wt. % other components. In some embodiments, an automotive composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0.4-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0.5% SiO2, 0.5% Al2O, 0.5% CaO, 0.5% MgO, 0.5% Na2O, 0.5% K2O, 0.5% Li2O, 0.5% TiO2, 0.5% B2O, 0.5% SiO2, 0.5% MgO, 0.5% Na2O, 0.5% K2O, 0.5% Li2O, 0.5% TiO2, 0.5% B2O, 0.5% Mg ... The glass composition includes: ~1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt%, and a total of 0-11 wt% of other components (wherein the Na2O+K2O content is less than about 0.5 wt%). In some embodiments, an automotive composite of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % KO; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % BO3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components, where the Na2O + KO content is less than about 0.5 wt. %. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, the automotive composite of the present invention can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0111] In some embodiments, the automotive composite of the present invention comprises a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In some embodiments, the automotive composite of the present invention comprises a polymer resin and at least a portion of a roving comprising at least one fiberglass strand as disclosed herein disposed within the polymer resin. In other embodiments, the automotive composite of the present invention comprises a polymer resin and at least one yarn as disclosed herein disposed within the polymer resin. In yet other embodiments, the automotive composite of the present invention comprises a polymer resin and at least one fabric as disclosed herein disposed within the polymer resin. In some embodiments, the automotive composite of the present invention comprises 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.

[0112] The automotive composites of the present invention can include various polymer resins depending on the desired properties and application. In some embodiments of the present invention including automotive composites, the polymer resin can include a thermoplastic resin or a thermosetting resin. Examples of common thermoplastic resins used in automotive composites include, but are not limited to, polypropylene, polyamide, high-temperature polyamide, polyester, and other thermoplastic resins known to those skilled in the art. Examples of common thermosetting resins used in automotive composites include, but are not limited to, epoxy, phenolic, polyester, and other thermosetting resins known to those skilled in the art. Examples of parts in which the automotive composites of the present invention can be used include, but are not limited to, automotive structural components, bodies, and bumpers.

[0113] Some embodiments of the present invention relate to composite materials that can be used in wind energy applications. In some embodiments, composite materials of the present invention suitable for use in wind energy applications exhibit properties desirable for use in wind energy applications, such as high modulus, high elongation, low fiber density, and / or high specific modulus. The composite materials of the present invention may be suitable for use in wind turbine blades, particularly long wind turbine blades that are lighter in weight yet still strong compared to other long wind turbine blades.

[0114] In some embodiments, a composite material of the present invention suitable for use in wind energy applications includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt. % SiO2, 11-20 wt. % Al2O3, 12 wt. % or less CaO, 7-17 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-5 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05 wt. %, and a total of 0-11 wt. % other components. In some embodiments, a composite material of the present invention suitable for use in wind energy applications includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 1 wt. %, and a total of 0-11 wt. % other components. In some embodiments, a composite material of the invention suitable for use in wind energy applications includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO, 14-19% AlO, 5% or less CaO, 10-16% MgO, 0-1% NaO, 0-1% KO, 0.4-2% LiO, 0-2% TiO, 0-3% BO, 0-1% FeO, 0-4% SnO, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and a total of 0-11% by weight of other components, where the NaO + KO content is less than about 0.5% by weight.In some embodiments, a composite material of the invention suitable for use in wind energy applications includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % KO; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % BO3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components (wherein the Na2O + KO content is less than about 0.5 wt. %). In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, composites of the invention suitable for use in wind energy applications can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0115] In some embodiments, composite materials of the present invention suitable for use in wind energy applications include a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In some embodiments, composite materials of the present invention suitable for use in wind energy applications include at least a portion of a roving including a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In other embodiments, composite materials of the present invention suitable for use in wind energy applications include a polymer resin and at least one yarn as disclosed herein disposed within the polymer resin. In still other embodiments, composite materials of the present invention suitable for use in wind energy applications include at least a portion of a roving including a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. Composite materials of the present invention suitable for use in wind energy applications include a polymer resin and at least one fabric as disclosed herein disposed in the polymer resin. In some embodiments, composite materials of the present invention suitable for use in wind energy applications 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.

[0116] Composite materials of the present invention suitable for use in wind energy applications can include a variety of polymer resins depending on the desired properties and application. In some embodiments of the present invention comprising composite materials suitable for use in wind energy applications, the polymer resin includes an epoxy resin. In other embodiments of the present invention comprising composite materials suitable for use in wind energy applications, the polymer resin can include a polyester resin, a vinyl ester, a thermoset polyurethane, or a polydicyclopentadiene resin.

[0117] Some embodiments of the present invention relate to composite materials for use in high pressure vessels and / or tanks. In some embodiments, the composite materials for use in high pressure vessels and / or tanks of the present invention exhibit desirable properties for use in such applications, such as high strength, high elongation, low density, and / or high strength-to-weight ratio.

[0118] In some embodiments, a composite material for use in a high-pressure vessel and / or tank of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt. % SiO2, 11-20 wt. % Al2O3, 12 wt. % or less CaO, 7-17 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-5 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount equal to or greater than 0.05 wt. %, and a total of 0-11 wt. % other components. In some embodiments, a composite material for use in a high-pressure vessel and / or tank of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount of 1 wt. % or greater, and a total of 0-11 wt. % other components. In some embodiments, a composite material for use in a high-pressure vessel and / or tank of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0.4-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and a total of 0-11% by weight of other components, where the Na2O+K2O content is less than about 0.5% by weight.In some embodiments, a composite material for use in a high-pressure vessel and / or tank of the invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers having the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % K2O; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % B2O3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; and between about 2 and about 6 wt. %. and 0-11 wt. % of other components, where the Na2O+K2O content is less than about 0.5 wt. %. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. %. In other embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0119] In some embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention comprise a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In some embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention comprise a polymer resin and at least a portion of a roving comprising at least one fiberglass strand as disclosed herein disposed within the polymer resin. In other embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention comprise a polymer resin and at least one yarn as disclosed herein disposed within the polymer resin. In yet other embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention comprise a polymer resin and at least one fabric as disclosed herein disposed within the polymer resin. In some embodiments, composite materials for use in high-pressure vessels and / or tanks of the present invention comprise 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.

[0120] Composite materials for use in the high-pressure vessels and / or tanks of the present invention can include a variety of polymer resins depending on the desired properties and application. In some embodiments of the present invention comprising composite materials for use in high-pressure vessels and / or tanks, the polymer resin can include a thermosetting resin. Examples of common thermosetting resins used in high-pressure vessels and / or tanks include, but are not limited to, epoxy, phenolic, polyester, vinyl ester, and other thermosetting resins known to those skilled in the art.

[0121] In some embodiments, the composite materials of the present invention may be useful in safety and / or security applications. For example, in some embodiments, the composite materials of the present invention are suitable for use in high mechanical stress applications, including, but not limited to, high-energy impact applications. Glass fibers useful in some embodiments of the present invention may exhibit properties particularly desirable for high-energy impact applications, such as ballistic or blast-resistant applications. Glass fibers useful in some embodiments of the present invention may exhibit a lower dielectric constant, lower dielectric loss, higher glass transition temperature, and / or lower thermal expansion compared to glass fibers, including E-glass.

[0122] In some embodiments, the composite materials of the present invention may be suitable for use in armor applications. For example, some embodiments of the composite materials may be used in the production of armor panels. In some embodiments, the composite materials of the present invention may be compliant with the U.S. Department of Defense Test Method Standard for V50 ballistic testing for armor, MIL-ST

[0023] The panel has a desirable FSP ("fragment simulating projectile") V50 value of 0.30 cal (e.g., about 2 lb / ft) when measured in accordance with MIL-STD-662F, December 1997 (hereinafter "MIL-STD-662F"), which is incorporated herein by reference in its entirety. 2 and a panel thickness of about 5-6 mm. In this regard, the term "composite material" generally refers to a material comprising a polymer resin and a plurality of glass fibers disposed within the polymer resin, while the term "panel" refers to a composite material having the physical dimensions or shape of a sheet. In other embodiments, the composite material of the present invention is such that the panel has a desirable FSP V50 value of 0.50 cal (e.g., about 4.8 to 4.9 lb / ft), as measured by MIL-STD-662F. 2The composites can be formed into panels that are expected to exhibit a V50 of at least about 1200 fps at a panel areal density of about 1000 fps and a panel thickness of about 13-13.5 mm. Because V50 values ​​can depend on the panel areal density and panel thickness, composites of the present invention can have different V50 values ​​depending on how the panel is constructed. One advantage of some embodiments of the present invention is the provision of composites that have higher V50 values ​​than similarly constructed composites assembled using E-glass fibers.

[0123] In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt. % SiO2, 11-20 wt. % Al2O3, 12 wt. % or less CaO, 7-17 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-5 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount of 0.05 wt. % or greater, and a total of 0-11 wt. % other components, wherein the composite material is adapted for use in ballistic or blast resistant applications. In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO2, 14-19 wt. % Al2O3, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % Na2O, 0-1 wt. % K2O, 0-2 wt. % Li2O, 0-2 wt. % TiO2, 0-3 wt. % B2O3, 0-1 wt. % Fe2O3, 0-4 wt. % SnO2, 0-4 wt. % ZnO, at least one rare earth oxide in an amount of 1 wt. % or greater, and a total of 0-11 wt. % other components, wherein the composite material is adapted for use in ballistic or blast resistant applications.In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 60-68 wt. % SiO, 14-19 wt. % AlO, 5 wt. % or less CaO, 10-16 wt. % MgO, 0-1 wt. % NaO, 0-1 wt. % KO, 0.4-2 wt. % LiO, 0-2 wt. % TiO, 0-3 wt. % BO, 0-1 wt. % FeO, 0-4 wt. % SnO, 0-4 wt. % ZnO, at least one rare earth oxide in an amount between about 1 and about 8 wt. %, and a total of 0-11 wt. % other components, wherein the NaO + KO content is less than about 0.5 wt. %, wherein the composite material is adapted for use in ballistic or blast-resistant applications. In some embodiments, a composite material of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % K2O; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % B2O3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components, wherein the Na2O + K2O content is less than about 0.5 wt. %. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt. %. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt. % and the composite is suitable for use in ballistic or blast-resistant applications. In other embodiments, composite materials of the present invention adapted for use in ballistic or blast resistant applications can include a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0124] Some embodiments of the present invention relate to panels, such as armor panels, comprising the composite material of the present invention. In some embodiments, the composite material of the present invention is such that the panel has a desirable FSP V50 value of 0.30 cal (e.g., about 2 lb / ft), as measured by MIL-STD-662F. 2 In another embodiment, the composite material of the present invention can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.30 cal (e.g., about 2 lb / ft ) when measured by MIL-STD-662F. 2 In yet another embodiment of the present invention, the composite material can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.30 cal (e.g., about 2 lb / ft), as measured by MIL-STD-662F. 2 and a panel thickness of about 5-6 mm. In some embodiments of the present invention, the composite material can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.30 cal (e.g., about 2 lb / ft), as measured by MIL-STD-662F. 2 The panel can be formed into a panel that is expected to exhibit a speed of about 900 fps to about 1140 fps at a panel areal density of about 1000 fps and a panel thickness of about 5 to 6 mm.

[0125] In some embodiments, the composite materials of the present invention are designed to provide panels thereof with a desirable FSP V50 value of 0.50 cal (e.g., about 4.8-4.9 lb / ft), as measured by MIL-STD-662F.2 and a panel thickness of about 13-13.5 mm. In another embodiment of the invention, the composite material can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.50 cal (about 4.8-4.9 lb / ft), as measured by MIL-STD-662F. 2 In yet another embodiment of the present invention, the composite material can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.50 cal (about 4.8 to 4.9 lb / ft), as measured by MIL-STD-662F. 2 and a panel thickness of about 13-13.5 mm. In some embodiments of the present invention, the composite material can be formed into panels that are expected to exhibit a desirable FSP V50 value of 0.50 cal (e.g., about 4.8-4.9 lb / ft), as measured by MIL-STD-662F. 2 The panel can be formed into a panel that is expected to exhibit a frame rate of about 1200 fps to about 1440 fps at a panel areal density of about 1000 fps and a panel thickness of about 13 to 13.5 mm.

[0126] Composite materials of the present invention adapted for use in ballistic or blast resistance can include various polymer resins. In some embodiments of the present invention, the composite material includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers comprising a glass composition as disclosed herein, the composite material can be formed into a panel, such as an armor panel, for ballistic or blast resistance, and the polymer resin comprises an epoxy resin. In some embodiments, the composite material includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, at least one of the plurality of glass fibers comprising a glass composition as disclosed herein, the composite material can be formed into a panel, such as an armor panel, for ballistic or blast resistance, and the polymer resin comprises a polydicyclopentadiene resin. In some embodiments of the present invention, the polymer resin is selected from the group consisting of polyethylene, polypropylene, polyamide (including nylon), polypropylene, and the like. It may include butylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, thermoset polyurethane, cyanate ester or bismaleimide resin.

[0127] Some embodiments of the present invention relate to composite materials for use in casings for missiles and other explosive launchers. In some embodiments, the composite materials for use in casings for missiles and other explosive launchers of the present invention exhibit desirable properties for use in such applications, such as high modulus, high strength, high elongation, low coefficient of thermal expansion, high glass softening temperature and / or high glass transition temperature.

[0128] In some embodiments, a composite material for use in casings for missiles and other explosive launchers of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 56-68% SiO2, 11-20% or less Al2O3, 12% or less CaO, 7-17% MgO, 0-1% Na2O, 0-1% K2O, 0-5% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount of 0.05% or greater, and a total of 0-11% other components by weight. In some embodiments, a composite material for use in casings for missiles and other explosive launchers of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount of 1% or greater, and a total of 0-11% other components by weight. In some embodiments, a composite material for use in casings for missiles and other explosive launchers of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO, 14-19% AlO, 5% or less CaO, 10-16% MgO, 0-1% NaO, 0-1% KO, 0.4-2% LiO, 0-2% TiO, 0-3% BO, 0-1% FeO, 0-4% SnO, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and a total of 0-11% by weight of other components, where the NaO + KO content is less than about 0.5% by weight.In some embodiments, a composite material for use in casings for missiles and other explosive launchers of the present invention includes a polymer resin and a plurality of glass fibers disposed in the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 59-62% SiO, 14-19% AlO; 4-8% CaO; 6-11% MgO; 0-1% NaO; 0-1% KO; 0-2% LiO; 0-3% TiO; 0-3% BO; 0-1% FeO; 0-2% CuO; 0-3% SrO; at least one rare earth oxide in an amount between about 2 and about 6% by weight; and a total of 0-11% by weight of other components, where the NaO + KO content is less than about 0.5% by weight. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, a composite material for use in casings for missiles and other explosive launchers of the present invention comprises a polymer resin and a plurality of glass fibers disposed in the polymer resin. At least one of the plurality of glass fibers may be formed from one of the other glass compositions disclosed herein as part of the present invention.

[0129] In some embodiments, composite materials for use in casings for missiles and other explosive launchers of the present invention comprise a polymer resin and at least one fiberglass strand as disclosed herein disposed within the polymer resin. In some embodiments, composite materials for use in casings for missiles and other explosive launchers of the present invention comprise a polymer resin and at least a portion of a roving comprising at least one fiberglass strand as disclosed herein disposed within the polymer resin. In other embodiments, composite materials for use in casings for missiles and other explosive launchers of the present invention comprise a polymer resin and at least one yarn as disclosed herein disposed within the polymer resin. In still other embodiments, composite materials for use in casings for missiles and other explosive launchers of the present invention comprise a polymer resin and at least one fabric as disclosed herein disposed within the polymer resin. In some embodiments, composite materials for use in casings for missiles and other explosive launchers of the present invention comprise 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.

[0130] Composite materials for use in casings for missiles and other explosive launchers of the present invention can include a variety of polymer resins depending on the desired properties and application. In some embodiments of the present invention, including composite materials for use in casings for missiles and other explosive launchers, the polymer resin can include a thermosetting resin. Examples of common thermosetting resins that can be used in such applications include, but are not limited to, epoxy, phenolic, polyester, and other thermosetting resins known in the art.

[0131] While many exemplary uses and applications for the composite materials of the present invention are described herein, one of ordinary skill in the art will be able to identify other potential uses for such composite materials, including, for example, other applications in the oil and gas industry, other applications related to transportation and infrastructure, other applications in alternative energy, other high temperature insulation (i.e., heat shielding) applications (due to higher strength, higher modulus, higher softening temperature, and higher glass transition temperature), etc.

[0132] Some embodiments of the present invention relate to prepregs. The prepregs of the present invention can include a polymer resin and at least one fiberglass strand as disclosed herein. In some embodiments, the prepregs of the present invention include a polymer resin and a plurality of glass fibers in contact with the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 56-68 wt% SiO2, 11-20 wt% or less Al2O3, 12 wt% or less CaO, 7-17 wt% MgO, 0-1 wt% Na2O, 0-1 wt% K2O, 0-5 wt% Li2O, 0-2 wt% TiO2, 0-3 wt% B2O3, 0-1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 0.05 wt% or more, and a total of 0-11 wt% other components. In some embodiments, the prepreg of the present invention comprises a polymer resin and a plurality of glass fibers in contact with the polymer resin, at least one of the plurality of glass fibers comprising a glass composition including the following components: 60-68 wt% SiO2, 14-19 wt% Al2O3, 5 wt% or less CaO, 10-16 wt% MgO, 0-1 wt% Na2O, 0-1 wt% K2O, 0-2 wt% Li2O, 0-2 wt% TiO2, 0-3 wt% B2O3, 0-1 wt% Fe2O3, 0-4 wt% SnO2, 0-4 wt% ZnO, at least one rare earth oxide in an amount of 1 wt% or greater, and a total of 0-11 wt% other components. In some embodiments, the prepreg of the present invention comprises a polymer resin and a plurality of glass fibers in contact with the polymer resin. wherein at least one of the plurality of glass fibers comprises a glass composition including the following components by weight: 60-68% SiO2, 14-19% Al2O3, 5% or less CaO, 10-16% MgO, 0-1% Na2O, 0-1% K2O, 0.4-2% Li2O, 0-2% TiO2, 0-3% B2O3, 0-1% Fe2O3, 0-4% SnO2, 0-4% ZnO, at least one rare earth oxide in an amount between about 1% and about 8% by weight, and 0-11% total by weight of other components, wherein the Na2O+K2O content is less than about 0.5% by weight. In some embodiments, a prepreg of the present invention comprises a polymer resin and a plurality of glass fibers in contact with the polymer resin, wherein at least one of the plurality of glass fibers comprises a glass composition including the following components: 59-62 wt. % SiO2, 14-19 wt. % Al2O3; 4-8 wt. % CaO; 6-11 wt. % MgO; 0-1 wt. % Na2O; 0-1 wt. % K2O; 0-2 wt. % Li2O; 0-3 wt. % TiO2; 0-3 wt. % B2O3; 0-1 wt. % Fe2O3; 0-2 wt. % Cu2O; 0-3 wt. % SrO; at least one rare earth oxide in an amount between about 2 and about 6 wt. %; and a total of 0-11 wt. % other components, wherein the Na2O + K2O content is less than about 0.5 wt. %. In some embodiments, the at least one rare earth oxide comprises at least one of La2O3, YO3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. In some embodiments, the at least one rare earth oxide is present in an amount of at least 3 wt%. In some embodiments, the at least one rare earth oxide is present in an amount of up to about 5 wt%. In other embodiments, the prepreg of the present invention can include a polymer resin and a plurality of glass fibers in contact with the polymer resin, at least one of the plurality of glass fibers being formed from one of the other glass compositions disclosed herein as part of the present invention.

[0133] In some embodiments, the prepreg of the present invention comprises a polymer resin and at least one fiberglass strand as disclosed herein in contact with the polymer resin. In some embodiments, the prepreg of the present invention comprises at least a portion of a roving comprising a polymer resin and at least one fiberglass strand as disclosed herein disposed in the polymer resin. In other embodiments, the prepreg of the present invention comprises a polymer resin and at least one yarn as disclosed herein in contact with the polymer resin. In yet other embodiments, the prepreg of the present invention comprises a polymer resin and at least one fabric as disclosed herein in contact with the polymer resin. In some embodiments, the prepreg of the present invention comprises 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.

[0134] The prepregs of the present invention can include a variety of polymer resins depending on the desired properties and application. In some embodiments of the present invention including prepregs, the polymer resin includes an epoxy resin. In other embodiments of the present invention including prepregs, the polymer resin can include polyethylene, polypropylene, polyamide, polyimide, polybutylene terephthalate, polycarbonate, thermoplastic polyurethane, phenolic, polyester, vinyl ester, polydicyclopentadiene, polyphenylene sulfide, polyether ether ketone, cyanate ester, bismaleimide, and thermoset polyurethane resins.

[0135] While many of the applications for glass fibers described herein are reinforcement applications, some embodiments of the glass fibers of the present invention can be utilized in electronic applications such as printed circuit boards ("PCBs"). More particularly, some embodiments of the present invention relate to glass fiber reinforcements having electrical properties that allow for enhanced performance of PCBs. For example, some embodiments of the glass fibers of the present invention have a dielectric constant (D kThe dielectric constant (D), also known as the "permittivity" of a material, can be k ) is the material that generates electrical energy. The material used as a capacitor has a relatively high D k whereas materials used as part of the PCB substrate should have low D, especially for high speed circuits. k It is desirable to have D k is the ratio of the charge stored (i.e., capacitance) of a given material between two metal plates to the amount of charge stored by the void (air or vacuum) between those same metal plates. As another example, some embodiments of the glass fibers of the present invention can have a desirable coefficient of thermal expansion for electronics applications. Accordingly, some embodiments of the present invention 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, the printed circuit board or other composite material to be used in the electrical application can include a polymer resin and a plurality of glass fibers in contact with the polymer resin, at least one of the plurality of glass fibers being formed from any of the glass compositions disclosed herein as part of the present invention. The polymer resin can include any known in the art for use in printed circuit boards or other electrical applications.

[0136] Turning now to methods for producing the glass fibers and related products of the present invention, the glass fibers of the present invention can be prepared in conventional manners known in the art by blending raw materials used to provide the particular oxides that form the fiber's composition. Glass fibers according to various embodiments of the present invention can be formed using any process known in the art for forming glass fibers, and more desirably, any process known in the art for forming essentially continuous glass fibers. For example, and without limiting the scope herein, glass fibers according to non-limiting embodiments of the present invention can be formed using direct melt or indirect melt fiber-forming methods. These methods are well known in the art, and further discussion thereof is not believed necessary in light of the present disclosure. See, for example, KL Loewenstein, The Manufacturing Technology of Continuous Glass Fibers, 3rd Edition, Elsevier, NY, 1993, pp. 47-48 and 117-234.

[0137] Following the formation of the glass fibers, the primary sizing composition can be applied to the glass fibers using any suitable method known to those skilled in the art. In some embodiments, the sizing composition can be applied immediately after the glass fibers are formed. Generally, the glass fibers used to form the fiberglass strands, fabrics, composites, laminates, and prepregs of the present invention will be at least partially coated with a sizing composition. Those skilled in the art can select one of many commercially available sizing compositions for glass fibers based on many factors, including, for example, the performance characteristics of the sizing composition, the desired flexibility of the resulting fabric, cost, and other factors. In some embodiments, the sizing composition does not include a starch-oil sizing composition. In some embodiments of the present invention that include a sizing composition that does not include a starch-oil sizing composition, the sized glass fibers or glass fiber strands do not need to be further treated with a slashing composition before using the fibers or strands in weaving applications. In other embodiments including sizing compositions that do not include a starch-oil sizing composition, the sized glass fibers or fiberglass strands can optionally be further treated with a slashing composition prior to using the fibers or strands in a weaving application. In some embodiments of the present invention including a primary sizing composition, the sizing composition can include a starch-oil sizing composition. In some embodiments of the present invention including a starch-oil sizing composition, the starch-oil sizing composition can be subsequently removed from a fabric formed from at least one sized glass fiber or fiberglass strand. In some embodiments, the starch-oil sizing composition can be removed from the fabric using any suitable method known to those skilled in the art, including, but not limited to, heat cleaning. In embodiments of the present invention including a fabric from which the starch-oil sizing composition has been removed, the fabric of the present invention can be treated with a finishing composition. The product may be further processed by coating.

[0138] Non-limiting examples of commercially available sizing compositions that can be used in some embodiments of the present invention include sizing compositions often used with single-end rovings, such as Hybon® 2026, Hybon® 2002, Hybon® 1383, Hybon® 2006, Hybon® 2022, Hybon® 2032, Hybon® 2016, and Hybon® 1062, as well as sizing compositions often used with yarns, such as 1383, 611, 900, 610, 695, and 690, each of which is directed to a sizing composition for a product commercially available from PPG Industries, Inc.

[0139] The fiberglass strands of the present invention can be prepared by any suitable method known to those skilled in the art. The fiberglass fabrics of the present invention are generally prepared using, but not limited to, weft yarns. The fabric can be made by any suitable method known to those skilled in the art, such as weaving a plurality of warp yarns (also called "weft yarns") into the warp yarns. Such weaving can be accomplished by positioning the warp yarns on a loom in a generally parallel, flat arrangement and then weaving the weft yarns into the warp yarns by passing the weft yarns over and under the warp yarns in a predetermined repeating pattern. The pattern used will depend on the desired fabric style.

[0140] Warp yarns can generally be prepared using techniques known to those skilled in the art. Warp yarns are formed by attenuating multiple streams of molten glass from bushings or spinners. The strands can be formed by applying a sizing composition to the individual glass fibers, which can then be gathered together to form strands. The strands can then be processed into yarns by transferring the strands through a twisting frame to a bobbin. During this transfer, twist can be imparted to the strands to help hold the bundle of fibers together. These twisted strands can then be wound onto bobbins, which can be used in a weaving process.

[0141] Positioning of warp yarns on a loom can generally be accomplished using techniques known to those skilled in the art. Positioning of warp yarns on a loom can be accomplished with a loom beam. A loom beam includes a specified number of warp yarns (also referred to as "ends") wound around a cylindrical core in an essentially parallel arrangement (also referred to as a "warp sheet"). Preparing a loom beam can include combining multiple yarn packages into a single package or loom beam, each package containing a fraction of the number of warp yarns required for the loom beam. For example, without intending to be limiting herein, a 50-inch (127 cm) wide 7781-style fabric utilizing DE75 yarn input typically requires 2,868 warp yarns. However, conventional equipment for forming loom beams does not allow for the transfer of all of these warp yarns from bobbins to a single beam in one operation. Therefore, producing multiple beams containing fractions of the required number of warp yarns, typically referred to as "section beams," can be accomplished. The section beams may be made into sections, which may then be brought together to form a loom beam. In a manner similar to a loom beam, a section beam may comprise a cylindrical core with a plurality of essentially parallel warp yarns wound around it. Those skilled in the art will appreciate that the section beam may contain any number of warp yarns necessary to form the final loom beam, although generally the number of warp yarns contained on a section beam is limited by the capacity of the warp creel. For a 7781 style fabric, four section beams of 717 warp yarns each made of DE75 yarn are typically provided, which, when brought together, provide the 2868 warp yarns required for the warp sheet, as discussed above.

[0142] The composite materials of the present invention can be manufactured by a variety of processes, including, but not limited to, vacuum assisted resin infusion molding, extrusion compounding, compression molding, resin transfer molding, filament winding, and the like. molding, prepreg / autoclave curing and pultrusion The composite materials of the present invention can be prepared by any suitable method known to those skilled in the art. The composite materials of the present invention can be prepared using such molding techniques known to those skilled in the art. In particular, composite embodiments of the present invention incorporating woven fiberglass fabric can be prepared using techniques known to those skilled in the art for preparing such composite materials.

[0143] As an example, some composite materials of the present invention can be made using vacuum-assisted compression molding, a technique well known to those skilled in the art and briefly described below. As known to those skilled in the art, in vacuum-assisted compression molding, a stack of pre-impregnated glass fabrics is placed into press platens. In some embodiments of the present invention, the stack of pre-impregnated glass fabrics can include one or more fabrics of the present invention as described herein cut to a desired size and shape. Once the stacking operation for the corresponding number of layers is completed, the press is closed and the platens are connected to a vacuum pump, whereby the upper platen compresses the stack of fabrics from above until the desired pressure is achieved. The vacuum assists in the evacuation of entrained air in the stack and also reduces the void content in the laminate. After connection of the platens to a vacuum pump, the temperature of the platens is then increased to a predetermined temperature setting specific to the resin being utilized to accelerate the conversion rate of the resin (e.g., thermosetting resin) and held at that temperature and pressure setting until the laminate reaches full cure. At this point, the heat is turned off and the platens are cooled by circulating water until they reach room temperature. The platens are then released and the laminate can be removed from the press.

[0144] As another example, some composite materials of the present invention can be made using vacuum-assisted resin infusion techniques as further described herein. A stack of fiberglass fabric of the present invention can be made by cutting to size and adding glass fibers that have been treated with silicone release. The stack can then be covered with a peel ply and The dynamic enhancement media can be combined and vacuum bagged using nylon bagging film. The so-called "lay up" is then subjected to a vacuum pressure of approximately 27 inches Hg. Separately, the polymer resin to be reinforced with fiberglass fabric can be prepared using techniques known to those skilled in the art for that particular resin. For example, for some polymer resins, an appropriate resin (e.g., an amine-curable epoxy resin) can be mixed with an appropriate curing agent (e.g., an amine for an amine-curable epoxy resin) in proportions recommended by the resin manufacturer or known to those skilled in the art. The combined resins can then be degassed in a vacuum chamber for 30 minutes and pumped through the fabric preform until substantially complete wetout of the fabric stack is achieved. At this point, the table can be covered with a heated blanket (set at a temperature of approximately 45-50°C) for 24 hours. The resulting rigid composite can then be demolded and post-cured in a programmable convection oven at approximately 250°F for 4 hours. However, as known to those skilled in the art, various parameters such as degassing time, heating time, and post-cure conditions can be varied based on the specific resin system used, and those skilled in the art will understand how to select such parameters based on the specific resin system.

[0145] The prepregs of the present invention can be prepared by any suitable means known to those skilled in the art, including, but not limited to, passing fiberglass strands, rovings, or fabrics through a resin bath using a solvent-based resin or resin film.

[0146] As mentioned above, in some embodiments, the composite materials of the present invention can include a polymer resin. A variety of polymer resins can be used. In some embodiments, polymer resins known to be useful in toughening applications can be particularly useful. In some embodiments, the polymer resin can include a thermosetting resin. Thermosetting resin systems useful in some embodiments of the present invention include, but are not limited to, epoxy resin systems, phenolic-based resins, and the like. The polymer resin may include, but is not limited to, polyethylene, polypropylene, polyamide (including nylon), polybutylene terephthalate, polycarbonate, thermoplastic polyurethane (TPU), polyphenylene sulfide, and polyether ether ketone (PEEK). In some embodiments, the polymer resin may include epoxy resin. In other embodiments, the polymer resin may include thermoplastic resin. Thermoplastic polymers useful in some embodiments of the present invention include, but are not limited to, polyethylene, polypropylene, polyamide (including nylon), polybutylene terephthalate, polycarbonate, thermoplastic polyurethane (TPU), polyphenylene sulfide, and polyether ether ketone (PEEK). Non-limiting examples of commercially available polymer resins useful in some embodiments of the present invention include EPIKOTE Resin MGS® RIMR 135 epoxy with Epikure MGS RIMH 1366 hardener (available from Momentive Specialty Chemicals Inc. of Columbus, Ohio), Applied Poleramic MMFCS2 epoxy (available from Applied Poleramic, Inc., Benicia, California), and EP255 modified epoxy (available from Barrday Composite Solutions, Millbury, Mass.).

[0147] The present invention will be illustrated by the following series of specific embodiments, but those skilled in the art will recognize that many other embodiments are contemplated by the principles of the invention. [Example]

[0148] Table 1 provides several fiberizable glass compositions according to various embodiments of the present invention and data related to various properties of such compositions. Examples 1, 20, 21, 25, 62, and 77 are comparative examples, while the remaining examples represent various embodiments of the present invention. Table 2 provides several fiberizable glass compositions according to various other embodiments of the present invention and data related to various properties of such compositions. Table 3 also provides several fiberizable glass compositions according to various other embodiments of the present invention and data related to various properties of such compositions.

[0149] The glasses in these embodiments were made by melting a mixture of powdered commercial chemicals and reagent-grade chemicals (reagent-grade chemicals were used only for the rare earth oxides) in 10% Rh / Pt crucibles at temperatures between 1500°C and 1550°C (2732°F and 2822°F) for 4 hours. Each batch was approximately 1000 grams. After the 4-hour melting period, the molten glass was poured onto a steel plate for quenching. Due to their low concentrations in the glass, volatile species such as fluoride and alkali oxides were not adjusted for their emission losses in the batches. The compositions in the examples represent the batch compositions. Commercially available raw materials were used in preparing the glasses. In the batch calculations, specific raw material retention factors were considered to calculate the oxides in each glass. These retention factors are based on years of glass batch melting and measured oxide yields in the glasses. Therefore, the batch compositions exemplified in the examples are believed to approximate the measured compositions. Melting Properties

[0150] 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 Practices for Measurement of Liquidus Temperature of Glass by the Gradient Furnace Method," respectively.

[0151] Tables 1 to 3 show the measured liquidus temperatures (T L ), 1000 pores The reference forming temperature (T F ) and the reference melting temperature (T m ) for some of the compositions. The difference between the forming temperature and the liquidus temperature (ΔT) is also shown. Tables 1-3 show the softening temperatures (T soft ), glass transition temperature (T g ) and coefficient of thermal expansion (CTE). soft The glass transition temperature (Tg) values ​​were measured according to ASTM Test Method C338-93, "Standard Test Method for Softening Point of Glass" (2008). The glass transition temperature (Tg) values ​​were measured according to ASTM Test Method C336-71, "Annealing Point and Strain Point by Fiber Elongation." Coefficient of thermal expansion (CTE) values ​​were determined according to ASTM E228-11 "Standard Test Method for Linear Thermal Expansion of Solid Materials with a Push-Rod Dilatometer." Mechanical properties

[0152] For fiber tensile strength testing, fiber samples from glass compositions were produced using a 10Rh / 90Pt single-tip fiber draw unit. Approximately 85 grams of cullet of a given composition was fed into a bushing melting unit and conditioned for two hours at a temperature near or equal to a 100 poise melt viscosity. The melt was then cooled to a temperature near or equal to a 1000 poise melt viscosity and allowed to stabilize for one hour before fiber drawing. Fiber diameter was controlled by controlling the speed of the fiber draw winder to produce fibers approximately 10 μm in diameter. All fiber samples were captured in air without contact with foreign objects. Fiber drawing was performed in a controlled humidity chamber between 40 and 45% RH.

[0153] Fiber tensile strength was measured using a Kawabata KES-G1 (Kato Tech Co. Ltd., Japan) tensile strength analyzer equipped with a Kawabata C-type load cell. Fiber samples were mounted on paper framing strips using a resin adhesive. A tensile force was applied to the fiber until failure, from which the fiber strength was determined based on the fiber diameter and breaking stress. Tests were performed at room temperature under controlled humidity between 40 and 45% RH. Average values ​​were calculated for each composition based on a sample size of 65 to 72 fibers. Tables 1 to 3 report the average tensile strength for fibers formed from portions of the compositions. Specific strength is expressed as the tensile strength value (N / m 2 in) to the corresponding density (g / m 3 This was calculated by dividing by (in).

[0154] Young's modulus was also measured for specific glass compositions in Tables 1 and 2 using the following procedure. Approximately 50 grams of glass cullet having a composition corresponding to the appropriate example in Tables 1, 2, or 3 was remelted in a 90Pt / 10Rh crucible at a melting temperature defined as 100 poise for two hours. The crucible was then transferred to a vertical tube, electrically heated furnace. The furnace temperature was preset to a fiber drawing temperature near or equal to a 1000 poise melt viscosity. The glass was allowed to equilibrate at that temperature for one hour before fiber drawing. The top of the fiber drawing furnace contained a cover with a center hole, on which a water-cooled copper coil was placed to control fiber cooling. A silica rod was then manually immersed in the melt through the cooling coil, and fibers were drawn and collected to lengths of approximately 1 to 1.5 m. Fiber diameters ranged from 100 μm at one end to 1000 μm at the other end.

[0155] For fibers drawn from glass melts, the elastic modulus was determined using an ultrasonic acoustic pulse technique (Panatherm 5010 unit from Panametrics, Inc., Waltham, Massachusetts). The extensional wave reflection time was measured using a 200 kHz pulse of 20 microsecond duration. The length of the sample was measured and the extensional wave velocity (V E ) was calculated. Fiber density (ρ) was measured using a Micromeritics AccuPyc 1330 pycnometer. Approximately 20 measurements were taken for each composition, and the average Young's modulus (E) was calculated using the following formula:

number

[0156] The modulus tester used a 1 mm diameter wave guide, which was set so that the fiber diameter on the contact side with the wave guide was approximately the same as the wave guide diameter. In other words, the end of a 1000 μm diameter fiber was connected to the contact side of the wave guide. Fibers with various diameters were tested for Young's modulus, and the results showed that fiber diameter between 100 and 1000 μm did not affect fiber modulus. The specific modulus value was calculated by dividing the Young's modulus value by the corresponding density.

[0157] The "Fiber Breaking Strain (%)" (i.e., fiber elongation) values ​​in Tables 1-3 were determined according to Hooke's Law by dividing the tensile strength value by the corresponding Young's modulus value (in the same units (e.g., all in MPa)) and multiplying by 100. [Table 1-1] [Table 1-2] [Table 1-3] [Table 1-4] [Table 1-5] [Table 1-6] [Table 1-7] [Table 1-8] [Table 1-9] [Table 1-10] [Table 1-11] [Table 1-12] [Table 1-13] [Table 1-14] [Table 1-15]

[0158] Some of these data are plotted in Figures 1-4. Figure 1 is a chart showing Young's modulus values ​​versus the amount of rare earth oxide (RE2O3) for the glass compositions of Examples 1-17, 22, and 23. Figure 2 is a chart showing initial fiber tensile strength values ​​versus the amount of rare earth oxide (RE2O3) for the glass compositions of Examples 1-17, 22, and 23. Figure 3 is a chart showing softening and glass transition temperatures versus the amount of rare earth oxide (RE2O3) for the glass compositions of Examples 81-89. Figure 4 is a chart showing linear thermal expansion coefficients versus the amount of scandium oxide (Sc2O3) for the glass compositions of Examples 81-89. [Table 2-1] [Table 2-2] [Table 2-3] [Table 2-4] [Table 2-5] [Table 2-6] [Table 3-1] [Table 3-2]

[0159] Desirable features that may be exhibited by various, but not necessarily all, embodiments of the present invention include, but are not limited to, the following: providing glass fibers, fiberglass strands, fiberglass fabrics, composite materials, and related products having relatively low density; providing glass fibers, fiberglass strands, fiberglass fabrics, composite materials, and laminates having relatively high tensile strength; providing glass fibers, fiberglass strands, fiberglass fabrics, composite materials, and related products having relatively low density; providing glass fibers, fiberglass strands, fiberglass fabrics, composite materials, and laminates having relatively high modulus; providing glass fibers, fiberglass strands, fiberglass fabrics, composite materials, and laminates having relatively high elongation; providing glass fibers, fiberglass strands, fiberglass fabrics, prepregs, and other products useful for reinforcement applications; and the like.

[0160] It should be understood that this description illustrates aspects of the invention that are relevant to a clear understanding of the invention. Certain aspects of the invention that would be apparent to those skilled in the art and, therefore, are unlikely to facilitate a better understanding of the invention have not been shown in order to simplify the description. Although the invention has been described in connection with specific embodiments, it is not limited to the particular embodiments disclosed, but is intended to encompass modifications within the spirit and scope of the invention.

[0161] According to a preferred embodiment of the present invention, for example, the following is provided: (Section 1) SiO256~68wt%; Al2O3 11-20 wt% or less; CaO 12% by weight or less; MgO 7~17% by weight; Na2O 0~1% by weight; K2O 0~1% by weight; Li2O 0~5wt%; TiO20~2% by weight; B2O30~3% by weight; Fe2O30~1wt%; SnO20~4% by weight; ZnO 0~4% by weight; at least one rare earth oxide in an amount of 0.05% by weight or greater; and Other components: 0 to 11% by weight in total 1. A glass composition suitable for fiber formation, comprising: (Section 2) Item 1. The glass composition according to item 1, wherein Al2O3 is present in an amount between about 14 and about 19 wt%. (Section 3) 2. The glass composition according to item 1, wherein MgO is present in an amount between about 10 and about 16% by weight. (Section 4) Item 1. The glass composition according to item 1, wherein the CaO content is less than about 5 wt. %. (Section 5) Item 1. The glass composition according to item 1, wherein the content of Na2O+K2O+Li2O is more than 1 wt%. (Section 6) 6. The glass composition according to item 5, wherein the content of Na2O+K2O is less than about 0.5 wt. %. (Section 7) Item 1. The glass composition according to item 1, wherein the content of Na2O+K2O is less than about 0.5 wt.%. (Section 8) Item 9. The glass composition according to item 1, wherein the LiO content is between about 0.4 and about 2% by weight. Item 1. The glass composition according to item 1, wherein the SiO2 content is at least 60% by weight. (Section 10) 2. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of at least 1 wt. %. (Section 11) 2. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of at least 3 wt. %. (Section 12) 2. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of up to about 8 wt. %. (Section 13) 2. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of up to about 5 wt. %. (Section 14) Item 1. The glass composition according to item 1, wherein the at least one rare earth oxide comprises at least one of La2O3, Y2O3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. (Section 15) Item 1. The glass composition according to item 1, wherein ZnO is present in an amount of up to about 4 wt. %. (Section 16) Item 1. The glass composition according to item 1, wherein SnO2 is present in an amount of up to about 4 wt. %. (Section 17) Item 1. The glass composition according to item 1, wherein CeO2 is present in an amount of up to about 4 wt. %. (Section 18) Item 1. The glass composition according to item 1, wherein both SnO2 and CeO2 are present in a total amount of up to about 8 wt.%. (Section 19) Item 1. The glass composition according to item 1, which is substantially free of B2O3. (Section 20) Item 1. The glass composition according to item 1, further comprising Nb2O5 in an amount of up to about 5 wt.%. (Section 21) SiO260~68wt%; Al2O314~19wt%; CaO 5% by weight or less; MgO 10~16% by weight; Na2O 0~1% by weight; K2O 0~1% by weight; Li2O 0~2wt%; TiO20~2% by weight; B2O30~3% by weight; Fe2O30~1wt%; SnO20~4% by weight; ZnO 0~4% by weight; at least one rare earth oxide in an amount of 1% by weight or greater; and Other components: 0 to 11% by weight in total 1. A glass composition suitable for fiber formation, comprising: (Section 22) 22. The glass composition according to claim 21, wherein the at least one rare earth oxide is present in an amount of at least 3 wt. %. (Section 23) 22. The glass composition of claim 21, wherein the at least one rare earth oxide is present in an amount of up to about 8 wt. %. (Section 24) 22. The glass composition of claim 21, wherein the at least one rare earth oxide is present in an amount of up to about 5 wt. %. (Section 25) 22. The glass composition according to claim 21, wherein the at least one rare earth oxide comprises at least one of La2O3, Y2O3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. (Section 26) 22. The glass composition according to claim 21, wherein ZnO is present in an amount of up to about 4 wt. %. (Section 27) 22. The glass composition of claim 21, wherein SnO2 is present in an amount of up to about 4 wt. %. (Section 28) 22. The glass composition according to claim 21, wherein CeO2 is present in an amount of up to about 4 wt. %. (Section 29) 22. The glass composition of claim 21, wherein both SnO2 and CeO2 are present in a total amount of up to about 8 wt. %. (Section 30) 22. The glass composition according to item 21, which is substantially free of B2O3. (Section 31) Item 32. The glass composition according to item 21, further comprising Nb2O5 in an amount of up to about 5 wt.%. SiO260~68wt%; Al2O314~19wt%; CaO 5% by weight or less; MgO 10~16% by weight; Na2O 0~1% by weight; K2O 0~1% by weight; Li2O 0.4~2wt%; TiO20~2% by weight; B2O30~3% by weight; Fe2O30~1wt%; SnO20~4% by weight; ZnO 0~4% by weight; at least one rare earth oxide in an amount between about 1 and about 8 weight percent; and Other components: 0 to 11% by weight in total 1. A glass composition suitable for fiber formation comprising: (Section 33) 33. The glass composition according to claim 32, wherein the at least one rare earth oxide is present in an amount of at least 3 wt. %. (Section 34) 33. The glass composition of claim 32, wherein the at least one rare earth oxide is present in an amount of up to about 5 wt. %. (Section 35) 33. The glass composition according to claim 32, wherein the at least one rare earth oxide comprises at least one of La2O3, Y2O3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. (Section 36) 33. The glass composition according to claim 32, wherein ZnO is present in an amount of up to about 4 wt. %. (Section 37) 33. The glass composition of claim 32, wherein SnO2 is present in an amount of up to about 4 wt. %. (Section 38) 33. The glass composition according to claim 32, wherein CeO2 is present in an amount of up to about 4 wt. %. (Section 39) 33. The glass composition of claim 32, wherein both SnO2 and CeO2 are present in a total amount of up to about 8 wt.%. (Section 40) 33. The glass composition according to item 32, which is substantially free of B2O3. (Section 41) Item 42. The glass composition according to item 32, further comprising Nb2O5 in an amount of up to about 5 wt.%. SiO259~62wt%; Al2O314~19wt%; CaO 4~8% by weight; MgO 6~11% by weight; Na2O 0~1% by weight; K2O 0~1% by weight; Li2O 0~2wt%; TiO20~3% by weight; B2O30~3% by weight; Fe2O30~1wt%; Cu2O 0~2wt%; SrO 0~3% by weight; at least one rare earth oxide in an amount of 3% by weight or greater; and Other components: 0 to 11% by weight in total 1. A glass composition suitable for fiber formation, comprising: (Section 43) 43. The glass composition of claim 42, wherein the at least one rare earth oxide is present in an amount of at least 4 wt. %. (Section 44) 43. The glass composition of claim 42, wherein the at least one rare earth oxide is present in an amount of up to about 8 wt. %. (Section 45) 43. The glass composition of claim 42, wherein the at least one rare earth oxide is present in an amount of up to about 5 wt. %. (Section 46) 43. The glass composition according to claim 42, wherein the at least one rare earth oxide comprises at least one of La2O3, Y2O3, Sc2O3, Nd2O3, CeO2, Sm2O3, and Gd2O3. (Section 47) 43. The glass composition according to paragraph 42, wherein SrO is present in an amount of up to about 3 wt. %. (Section 48) 43. The glass composition according to claim 42, wherein Cu2O is present in an amount of up to about 2 wt%. (Section 49) 43. The glass composition of claim 42, wherein Y2O3 is present in an amount of up to about 5 wt. %. (Section 50) 43. The glass composition of claim 42, wherein both Cu2O and SrO are present in a total amount of up to about 5 wt. %. (Section 51) 43. The glass composition according to item 42, which is substantially free of B2O3.

Claims

1. SiO ２ 56–68% by weight; Al ２ O ３ 11 to less than 18% by weight; CaO 0-5% by weight; MgO 10-16% by weight; Na ２ 0-1% by weight; K ２ O 0% to 1% by weight; Li ２ 0.5% by weight; TiO ２ 0-2% by weight; B ２ O ３ 0-3% by weight; Fe ２ O ３ 0-1% by weight; SnO ２ 0–4% by weight; ZnO is present in an amount of up to 4 wt.%; at least one rare earth oxide in an amount of 0.05 wt. % or greater; and Other components: 0 to 11% by weight in total 1. A glass composition suitable for fiber formation comprising: wherein said composition is substantially free of B 2 O 3 .

2. Al ２ O ３ The glass composition of claim 1 , wherein is present in an amount of 14 to less than 18 wt %.

3. Na ２ O+K ２ O + Li ２ 2. The glass composition according to claim 1, wherein the O content is greater than 1 wt. %.

4. Na ２ O+K ２ 2. The glass composition of claim 1, wherein the O content is less than 0.5 wt. %.

5. Li ２ 2. The glass composition according to claim 1, wherein the O content is 0.4 to 2 wt. %.

6. SiO ２ 2. The glass composition of claim 1, wherein the content of is at least 60% by weight.

7. 10. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of at least 1 wt. %.

8. 10. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of at least 3 wt. %.

9. 10. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of up to 8 wt.%.

10. 10. The glass composition of claim 1, wherein the at least one rare earth oxide is present in an amount of up to 5 wt.%.

11. The at least one rare earth oxide is La ２ O ３ , Y ２ O ３ , Sc ２ O ３ , Nd ２ O ３ , CeO ２ , Sm ２ O ３ and Gd ２ O ３ The glass composition of claim 1 , comprising at least one of:

12. SnO ２ The glass composition of claim 1 , wherein is present in an amount of up to 4 wt. %.

13. CeO ２ The glass composition of claim 1 , wherein is present in an amount of up to 4 wt. %.

14. SnO ２ and CeO ２ 2. The glass composition of claim 1, wherein both of said components are present in a total amount of up to 8 wt. %.

15. Nb in an amount of up to 5 wt.% ２ O ５ The glass composition of claim 1 further comprising:

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