Glass Fiber Composition for High Modulus and Fine Fiber Forming
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Solution Overview
Problem
Existing glass fibers face challenges in achieving high elastic modulus, satisfactory productivity, and the ability to produce fine-count fibers due to limitations in forming temperature and temperature difference, leading to issues like nozzle creep, clogging, and reduced facility lifetime.
Innovation Solution
A glass composition with specific oxide ratios of SiO2, Al2O3, MgO, CaO, and B2O3, along with controlled temperature differences, enables high elastic modulus and stable production of fine-count fibers, reducing forming temperatures and extending facility life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the forming temperature Tx is increased to achieve high elastic modulus glass fiber, then the elastic modulus is improved, but the production cost increases due to higher energy consumption and the lifetime of the bushing apparatus is shortened
Solution Approach 1:
The patent changes the chemical composition parameters of the glass, specifically increasing SiO2 content to 70-77 mass% and Al2O3 to 12-20 mass%, which fundamentally alters the glass properties to achieve high elastic modulus at lower forming temperatures, thereby resolving the contradiction between strength and energy consumption
2Strength
If the forming temperature Tx is increased to achieve high elastic modulus glass fiber, then the elastic modulus is improved, but the lifetime of the bushing apparatus is shortened
Solution Approach 1:
By changing the glass composition parameters (SiO2: 70-77 mass%, Al2O3: 12-20 mass%), the patent enables formation of high-modulus glass fiber at reduced temperatures, which lessens thermal stress on the bushing apparatus and extends its operational lifetime
3Productivity
If the temperature difference ΔTxy is increased to improve productivity, then the productivity is improved, but the forming temperature Tx must be increased which leads to higher energy consumption
Solution Approach 1:
The patent changes the glass composition to achieve a liquidus temperature Ty of 1150-1250°C while maintaining forming temperature Tx of 1250-1350°C, creating an optimal temperature difference ΔTxy of 100-150°C that improves productivity without requiring excessive temperature increases
4Manufacturing precision
If the nozzle diameter is made smaller to produce fine-count glass fiber, then the fiber fineness is improved, but the nozzle is prone to creep deformation and the base plate lifetime is shortened
Solution Approach 1:
By changing the forming temperature parameter to a lower range (1250-1350°C) through glass composition optimization, the patent reduces thermal stress on small-diameter nozzles, preventing creep deformation and extending base plate lifetime while maintaining fine-count fiber production capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition allows for high-modulus glass fibers with improved productivity and thermal stability, facilitating the production of fine-count fibers while reducing production costs and enhancing the performance of glass-fiber-containing composite materials.
Implementation Method 1
the temperature at which its viscosity at high temperature corresponds to 10^3 poise
Data Source
AI summary
Provided is a composition for a glass fiber which has a high elastic modulus and satisfactory productivity, and can facilitate the production of a fine-count glass fiber. The composition for a glass fiber of the present invention includes, as a glass composition expressed as a mass percent in terms of oxide, 50% to 70% of SiO2, 21% to 25% of Al2O3, 3% to 13% of MgO, 3% to 15% of CaO, and 0.5% to 5% of B2O3, wherein the composition has a temperature difference ΔTxy between a forming temperature Tx and a liquidus temperature Ty of 90°C or more.