Quartz Glass Fiber Sizing Agent for Fluff Suppression
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Solution Overview
Problem
Conventional sizing agents for glass fibers, particularly quartz glass fibers, fail to effectively suppress charging and fluff generation during the production and weaving processes, leading to electrical insulation failures and poor bonding properties, especially when used in high-density, thin, and multi-layered printed circuit boards.
Innovation Solution
A sizing agent comprising a cationic vinyl acetate copolymer emulsion with a weight average molecular weight of 5,000 to 500,000 and starch, applied to quartz glass fibers, which controls the charge potential between +1.5 kV to −1.0 kV and enhances pulling resistance, thereby reducing fluff generation and improving weaving stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sizing agents containing starch are used for quartz glass fibers, then the glass cloth can be manufactured, but fluff is generated on the surface due to charging of quartz glass fibers
Solution Approach 1:
The invention changes the chemical composition parameters of the sizing agent by incorporating specific antistatic agents (quaternary ammonium salts or cationic surfactants) in combination with starch and gelatinized starch. This parameter modification enables effective suppression of charging while maintaining manufacturability, resolving the contradiction between ease of manufacture and fluff generation.
Solution Approach 2:
The invention uses a composite sizing agent formulation combining multiple components: starch, gelatinized starch, and antistatic agents (quaternary ammonium salts or cationic surfactants). This composite material approach provides both coating formation capability and effective antistatic performance, eliminating fluff generation while maintaining manufacturing feasibility.
2Object-generated harmful factors
If antistatic agents are added to sizing agents for glass fibers, then charging can be suppressed, but the antistatic agents migrate and are not uniformly applied onto the surfaces of glass fibers
Solution Approach 1:
The invention uses gelatinized starch as an intermediary carrier that facilitates uniform distribution and adhesion of antistatic agents onto glass fiber surfaces. The gelatinized starch matrix prevents migration of antistatic agents while ensuring their uniform application, resolving the contradiction between charging suppression and application uniformity.
Solution Approach 2:
The invention modifies the physical state of starch by using gelatinized starch instead of ordinary starch, changing its molecular structure and bonding characteristics. This parameter change enables better retention and uniform distribution of antistatic agents, preventing migration while maintaining effective charging suppression.
3Productivity
If quartz glass fibers are spun at high speed using air jet loom, then productivity is improved, but fluff is generated on the glass cloth surface
Solution Approach 1:
The invention applies antistatic agents to the glass fibers before weaving, performing preliminary anti-action to prevent charging and fluff generation during the high-speed air jet weaving process. This preliminary treatment allows maintenance of high productivity while eliminating the harmful fluff effect.
Solution Approach 2:
The invention changes the surface properties of glass fibers by coating them with a sizing agent containing antistatic agents and gelatinized starch. This parameter modification reduces friction and charging during high-speed weaving, enabling maintained productivity without fluff generation.
4Length of moving object
If the glass cloth is made thin with thickness of 20 μm or less, then high density interconnection is achieved, but fluff damages copper foil and causes electrical insulation failure
Solution Approach 1:
The invention changes the surface properties of thin glass cloth by applying a specialized sizing agent containing antistatic agents and gelatinized starch. This parameter modification suppresses fluff generation on thin cloths, preventing damage to copper foils and maintaining electrical insulation reliability in high-density printed circuit boards.
Solution Approach 2:
The invention converts the potentially harmful effect of quartz glass fiber charging into a beneficial outcome by using antistatic agents to control charge potential. This allows thin glass cloth to be manufactured without fluff-related reliability issues, turning what would be a harmful charging effect into a controlled and useful property.
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 proposed sizing agent effectively suppresses charging and fluff formation, ensuring high-quality quartz glass cloths with improved bonding and reduced fluff, suitable for thin, high-density printed circuit boards.
Implementation Method 1
the quartz glass is liable to be charged. In actuality, while the quartz glass is spun by a known method as disclosed in Patent Documents 2-4, the quartz glass fibers are highly negatively charged at a charge potential of −2.0 kV or more at the time of spinning owing to friction with a flame stream, flow friction in the glass, and the like.
Implementation Method 2
the sizing agent has a poor antistatic effect, and hence the antistatic agent is applied onto a glass fiber bundle again after the sizing agent for glass fibers is applied onto the glass fiber bundle and dried
Data Source
AI summary
Provided are a sizing agent for quartz glass fibers capable of suppressing charging of quartz glass fibers, and suppressing generation of fluff in a production process for quartz glass fibers and a weaving process for a quartz glass cloth, a quartz glass fiber or a quartz glass yarn having applied thereonto the sizing agent, a quartz glass cloth, a prepreg for a printed circuit board, and a product using the quartz glass fiber. The sizing agent for quartz glass fibers includes an aqueous solution containing: a cationic vinyl acetate copolymer emulsion in which a cationic vinyl acetate copolymer having a weight average molecular weight of from 5,000 to 500,000 is dispersed in water; and starch, in which emulsion particles of the cationic vinyl acetate copolymer emulsion have a 50% diameter on a volume basis of from 0.1 μm to 5 μm.