A chemically resistant e-glass composition

Abstract

The invention relates to a chemically resistant E-glass composition. The E-glass comprises 52-62% SiO2, 9-18% AI2O3, 18-27% CaO, 0,1-2% MgO, and 0,5-4% B2O3 by weight.

Description

[0001] A CHEMICALLY RESISTANT E-GLASS COMPOSITION

[0002] TECHNICAL FIELD

[0003] The present invention relates to glass compositions, and more particularly to glass compositions for forming fibers.

[0004] BACKGROUND OF THE INVENTION

[0005] Glass fiber is an inorganic fiber material that can be used to reinforce resins to produce high- performance composite materials. E-glass is the most common glass composition used to produce continuous glass fibers. As science and technology advance, there is a growing need to enhance the performance of glass fiber reinforced composites. Traditional E-glass fiber, which contains a high proportion of boron, cannot meet the performance demands in certain application areas such as wind turbine blades, high-performance pipes, and automotive parts due to its relatively loose structure, low mechanical strength, and poor corrosion resistance.

[0006] EP4172120A1 discloses to an E-glass composition, disclosing glass compositions suitable for fiber formation, specifically for glass fibers with rare earth oxides (RE2O3) and high modulus. The glass composition may contain approximately 44,5 to 64% by weight of SiO2, approximately 12 to 32% by weight of AI2O3, approximately 0,1 to 15,5% by weight of CaO, and approximately 5 to 22% by weight of MgO. It also contains less than 1 % by weight of Fe2O3, less than 2% by weight of TiO2, less than 3% by weight of Na2O, up to 12% by weight of Y2O3, up to 6% by weight of CeO2, up to 4% by weight of ZnO, and less than 4,5% by weight of B2O3. These glass compositions can be used to form glass fibers and can be incorporated into various composites.

[0007] BRIEF DESCRIPTION

[0008] The object of the invention is to provide an E-glass with high chemical resistance.

[0009] In order to achieve above objective, the invention relates to a chemically resistant E-glass composition. The E-glass comprises, by weight percentage: 52-62% SiO2, 9-18% AI2O3, 18- 27% CaO, 0,1-2% MgO, and 0,5-4% B2O3. The use of boron lowers the melting and forming temperatures, thereby enabling a much more controlled and easier fiber production process. Furthermore, it has been determined that its acidic corrosion resistance is comparable to that of boron-free E-glasses, also known as ECR glass.

[0010] In a preferred embodiment of the invention, the weight percentage of SiO2 is in the range of 54% to 58%. This provides the main glass-forming component in which other components are dissolved.

[0011] In a preferred embodiment of the invention, the weight percentage of AI2O3 is in the range of 12% to 16%. This increases the structural and chemical durability of the E-glass and improves its mechanical properties.

[0012] In a preferred embodiment of the invention, the weight percentage of CaO is in the range of 20% to 24%. This improves the melting and physical properties of the E-glass.

[0013] In a preferred embodiment of the invention, the weight percentage of MgO is in the range of 1% to 2%. This increases the tensile strength of the glass. Additionally, MgO within the specified range in the E-glass determines the glass viscosity and forming behavior.

[0014] In a preferred embodiment of the invention, the weight percentage of B2O3 is in the range of 2% to 4%. The use of boron lowers the melting and forming temperatures, thereby enabling a much more controlled and easier fiber production process.

[0015] In a preferred embodiment of the invention, the weight percentage of Na2O is in the range of 0% to 2%. Na2O lowers the melting temperature, allowing for a more controlled production and forming process.

[0016] In a preferred embodiment of the invention, the weight percentage of K2O is in the range of 0% to 2%. K2O will lower the melting temperature, allowing for a more controlled production and forming process.

[0017] In a preferred embodiment of the invention, the weight loss after a 24-hour HCI corrosion test is in the range of 0,3% to 0,4%. This demonstrates that the E-glass exhibits high acidic corrosion resistance, particularly for use in pipes, resulting in a long-lasting E-glass. In a preferred embodiment of the invention, the weight loss after a 100-hour HCI corrosion test is in the range of 0% to 0,4%. This shows the E-glass has high acidic corrosion resistance, especially for pipe applications, leading to a durable product.

[0018] In a preferred embodiment of the invention, the weight loss after a 24-hour HCI corrosion test at 96°C is in the range of 0% to 0,7%. This confirms the material's suitability for long-term use in acidic environments, such as in pipes.

[0019] In a preferred embodiment of the invention, the weight loss after a 24-hour H2SO4 corrosion test is 0%. This indicates excellent resistance to sulfuric acid, ensuring the longevity of the E- glass, especially in pipe applications.

[0020] In a preferred embodiment of the invention, the weight loss after a 100-hour H2SO4 corrosion test is 0%. This further confirms the material's high acidic corrosion resistance for long-lasting performance.

[0021] In a preferred embodiment of the invention, the weight loss after an 8-hour H2SO4 corrosion test at 96°C is in the range of 0% to 2,8%. This result again points to the high acidic corrosion resistance of the E-glass, making it a durable choice for applications like pipes. In a preferred application, such as for use in pipes, it increases the mechanical and acidic corrosion resistance of the pipes.

[0022] DETAILED DESCRIPTION OF THE INVENTION

[0023] In this detailed description, the subject matter of the invention is explained with examples and references for better understanding, without any limitation.

[0024] An E-glass composition provided for use in a composite, particularly as a composite coating inside a pipe, contains the following by weight percentage: 52% - 62% SiO2; 9% - 18% AI2 03; 18% - 27% CaO; 0,1 % - 2% MgO; 0,5% - 4% B2O3 and other additives.

[0025] Table 1 : Weight Percentage Values of Materials Used for the E-Glass Composition

[0026] The Reference-1 glass composition shown in Table 1 contains by weight percentage. According to the Table 1 above the glass composition comprises by weight 54,01 % SiO2, 14,35% AI2O3, 22,33% CaO, 1 ,5% MgO, 6% B2O3, 0,83% Na2O, and 0,07% K2O. When the acidic corrosion resistance of the E-glass prepared with this composition was tested, the weight loss was found to be 7,35% in HCI at room temperature for 24 hours, 8,59% in HCI at room temperature for 72 hours, 21 ,3% in HCI at room temperature for 100 hours, and 82,9% in HCI at 96°C for 24 hours. For the same glass composition, the weight loss was 6,91% in H2SO4 at room temperature for 24 hours, 12,9% in H2SO4 at room temperature for 72 hours, 19% in H2SO4 at room temperature for 100 hours, and approximately 67,9% in H2SO4 at 96°C for 8 hours. The Reference-2 glass composition shown in Table 1 contains by weight percentage: 60,13% SiO2, 12,80% AI2O3, 22,25% CaO, 3,15% MgO, 0% B2O3, 0,75% Na2O, and 0,12% K2O. The E-glass from this composition showed a weight loss of 0,81% in HCI at room temperature for 24 hours, with no weight loss observed at 72 and 100 hours in HCI at room temperature, nor after 24 hours in HCI at 96°C. For this composition, no weight loss was observed after 24 hours in H2SO4 at room temperature, a 0,54% weight loss after 72 hours in H2SO4 at room temperature, and no weight loss after 100 hours in H2SO4 at room temperature or after 8 hours in H2SO4 at 96°C.

[0027] The Sample-1 glass composition shown in Table 1 contains by weight percentage: 56,33% SiO2, 13,45% AI2O3, 22,40% CaO, 2% MgO, 4% B2O3, 0,83% Na2O, and 0,07% K2O. The E-glass from this composition showed a weight loss of 0,33% in HCI at room temperature for 24 hours, 0,25% after 72 hours, and no loss after 100 hours. The weight loss was 0,68% after 24 hours in HCI at 96°C. For this same composition, no weight loss was observed in H2 SO4 at room temperature for 24, 72, and 100 hours, nor after 8 hours in H2SO4 at 96°C.

[0028] The Sample-2 glass composition shown in Table 1 contains by weight percentage: 56,52% SiO2, 13,27% AI2O3, 22,40% CaO, 2% MgO, 4% B2O3, 0,83% Na2O, and 0,07% K2O. The E-glass from this composition showed a weight loss of 0,37% in HCI at room temperature for 24 hours, 0,24% after 72 hours, and 0,39% after 100 hours. No weight loss was found after 24 hours in HCI at 96°C. For this composition, no weight loss was observed in H2SO4 at room temperature for 24, 72, and 100 hours, while the weight loss was 2,67% after 8 hours in H2SO4 at 96°C.

[0029] The Sample-3 glass composition shown in Table 1 contains by weight percentage: 56,85% SiO2, 12,95% AI2O3, 22,40% CaO, 2% MgO, 4% B2O3, 0,83% Na2O, and 0,07% K2O. The E-glass from this composition showed a weight loss of 0,42% in HCI at room temperature for 24 hours, 0,45% after 72 hours, and 0,38% after 100 hours. The weight loss was 0,70% after 24 hours in HCI at 96°C. For this composition, no weight loss was observed in H2SO4 at room temperature for 24 and 72 hours, or after 100 hours. The weight loss was 2,82% after 8 hours in H2SO4 at 96°C.

[0030] The Sample-4 glass composition shown in Table 1 contains by weight percentage: 56,01% SiO2, 14,35% AI2O3, 22,33% CaO, 1 ,5% MgO, 4% B2O3, 0,83% Na2O, and 0,07% K2O. The E-glass from this composition showed a weight loss of 0,26% in HCI at room temperature for 24 hours, with no weight loss observed after 72 and 100 hours, nor after 24 hours in HCI at 96°C. For this composition, no weight loss was observed in H2SO4 at room temperature for 24, 72, and 100 hours, nor after 8 hours in H2SO4 at 96°C.

Claims

CLAIMS1. A chemically resistant E-glass composition comprising 52-62% SiO2, 9-18% AI2O3, 18-27% CaO, 0,1-2% MgO, 0,5-4% B2O3 by weight.

2. An E-glass composition according to Claim 1 , wherein the weight percentage of SiO2 is in the range of 54% to 58%.

3. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of AI2O3 is in the range of 12% to 16%.

4. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of CaO is in the range of 20% to 24%.

5. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of MgO is in the range of 1 % to 2%.

6. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of B2O3 is in the range of 2% to 4,5%.

7. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of Na2O is in the range of 0% to 2%.

8. An E-glass composition according to any of the preceding claims, wherein that the weight percentage of K2O is in the range of 0% to 1 %.

9. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after a 24-hour HCI corrosion test is in the range of 0,3% to 0,4%.

10. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after a 100-hour HCI corrosion test is in the range of 0% to 0,4%.

11. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after a 24-hour HCI corrosion test at 96°C is in the range of 0% to 0,7%.

12. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after a 24-hour H2SO4 corrosion test is 0%.

13. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after a 100-hour H2SO4 corrosion test is 0%.

14. An E-glass produced from a composition according to any of the preceding claims, wherein that the weight loss after an 8-hour H2SO4 corrosion test at 96°C is in the range of 0 to 2,8%.

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