Organic-inorganic composite fibers and methods thereof

Patent metadata

Field	Value
Publication number	US-10875806-B2
Application number	US-201816013006-A
Country	US
Kind code	B2
Filing date	Jun 20, 2018
Priority date	Jul 19, 2017
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

An organic-inorganic composite, including: a discontinuous phase having a plurality of adjacent and similarly oriented fibers of an inorganic material; and a continuous organic phase having a thermoplastic polymer, such that the continuous organic phase surrounds the plurality of adjacent and similarly oriented fibers of the inorganic material, and the organic-inorganic composite is a plurality of adjacent and similarly oriented fibers of inorganic material contained within a similarly oriented host fiber of the thermoplastic polymer. Also disclosed are methods of making and using the composite.

First claim

What is claimed is:

1. A method of making an organic-inorganic composite, comprising:
a first melting at a suitable temperature, a batch of suitable proportions of sources or precursors comprising:
15 to 20% zinc oxide;
8 to 12% lithium phosphate;
4 to 8% zinc pyrophosphate;
12 to 16% potassium monophosphate;
12 to 16% sodium hexametaphosphate;
0.1 to 2% calcium carbonate;
0.1 to 2% strontium carbonate;
4 to 10% aluminum metaphosphate; and
20 to 40% zinc sulfate heptahydrate, based on a 100 weight percent total of the inorganic portion of the composite to produce a product of the first melting; and
a second melting of the product of the first melting.

2. The method of claim 1 , further comprising: pouring or extruding the product of the first melt into a rod and annealing the rod at to form an annealed zinc sulfophosphate (ZSP) glass rod.

3. The method of claim 1 , further comprising: extruding the annealed ZSP glass rod form an extruded and annealed ZSP glass rod.

4. The method of claim 2 , further comprising: wrapping the extruded and annealed ZSP glass rod in a thermoplastic polymer film selected from a polyetherimide (PEI), a polyethersulfone (PS), or mixtures thereof, to form a polymer wrapped glass rod, the thermoplastic polymer film having a thickness of from 0.1 to 2.0 mm.

5. The method of claim 4 , further comprising: heating the polymer wrapped glass rod to form a glass and polymer rod preform.

6. The method of claim 5 , further comprising: drawing the glass and polymer rod preform to produce a drawn fiber having a diameter of from 10 microns to 500 microns.

7. The method of claim 6 , further comprising: making a fiber bundle preform comprising:
heating the drawn fiber;
stacking the heated and drawn fiber into a fiber bundle of from 100 to 2,000 fibers; and
wrapping and heat sealing the fiber bundle with a thermoplastic film.

8. The method of claim 7 , further comprising: drawing the fiber bundle preform into a first fine fiber wherein continuous individual glass filaments in the composite have diameters from 2 to 10 microns, and the first fine fiber having an exterior diameter of about 100 to 300 microns.

9. The method of claim 8 , further comprising: drawing the resulting first fine fiber into a second fine fiber, and the second fine fiber having an exterior diameter of from 10 to 150 microns.

Assignees

• Corning Inc

Inventors

• Decker Heather Bossard
• Hart Shandon Dee
• Kim Jenny
• Li Yanfei
• Mccarthy Joseph Edward
• Smith Nicholas James
• Zimmermann James William

Classifications

• C03C25/32

  obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds · CPC title

• G02B6/04

  formed by bundles of fibres (G02B6/24 takes precedence) · CPC title

• C03B19/02

  by casting {molten glass, e.g. injection moulding} · CPC title

• C03C3/17

  containing aluminium or beryllium · CPC title

• C09D179/08

  Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors · CPC title