Glass composition for producing high strength and high modulus fibers

Patent metadata

Field	Value
Publication number	US-9352999-B2
Application number	US-201113719508-A
Country	US
Kind code	B2
Filing date	Jun 30, 2011
Priority date	Jun 30, 2010
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

A glass composition including SiO 2 in an amount from about 69.5 to about 80.0% by weight, Al 2 O 3 in an amount from about 5.0 to about 18.5% by weight, MgO in an amount from about 5.0 to about 14.75% by weight, CaO in an amount from 0.0 to about 3.0% by weight, Li 2 O in an amount from about 3.25 to about 4.0% by weight, and Na20 in an amount from 0.0 to about 2.0% by weight is provided. Glass fibers formed from the inventive composition may be used in applications that require high strength, high stiffness, and low weight. Such applications include, but are not limited to, woven fabrics for use in forming wind blades, armor plating, and aerospace structures.

First claim

Having thus described the invention, what is claimed is:

1. A composition for preparing high strength, light weight glass fibers comprising:
SiO 2 in an amount from about 69.5 to about 80.0%% by weight of the total composition,
Al 2 O 3 in an amount from about 5.0 to about 18.5% by weight of the total composition,
CaO in an amount from 0.0 to about 3.0% by weight of the total composition,
MgO in an amount from 5.0 to about 14.75% by weight of the total composition,
Li 2 O in an amount from 3.25 to about 4.0% by weight of the total composition, and
Na 2 O in an amount from 0.0 to about 2.0% by weight of the total composition, wherein said composition comprises less than 1.0% by weight of B 2 O 3 and wherein said composition is capable of producing glass fibers having a specific modulus of about 33.9 MJ/kg to about 35 MJ/kg.

2. The glass composition of claim 1 , wherein
Al 2 O 3 is present in an amount from about 9.0 to about 15.4% by weight of the total composition, and
MgO is present in an amount from 5.0 to about 10.2% by weight of the total composition.

3. The glass composition of claim 2 , wherein
Al 2 O 3 is present in an amount from about 9.5 to about 15.3% by weight of the total composition, and
MgO is present in an amount from 6.9 to about 10.2% by weight of the total composition.

4. The glass composition of claim 1 , wherein
SiO 2 is present in an amount from about 69.5 to about 74.5% by weight of the total composition, and
Al 2 O 3 is present in an amount from about 10.30 to about 18.5% by weight of the total composition.

5. The glass composition of claim 1 , wherein
SiO 2 is present in an amount from about 69.5 to about 76.5% by weight of the total composition, and
Al 2 O 3 is present in an amount from about 5.0 to about 15.4% by weight of the total composition.

6. The composition of claim 1 , wherein said composition is free of B 2 O 3 and fluorine.

7. The composition of claim 1 , wherein said composition has a ΔT up to about 250° C.

8. The composition of claim 1 , wherein said composition has a ΔT of from about 100° C. to about 250° C.

9. The composition of claim 1 , wherein said composition has a log 3 temperature from about 1255° C. to about 1550° C.

10. The composition of claim 1 , wherein said composition has a liquidus temperature no greater than about 1510° C.

11. The composition of claim 1 , wherein components of said composition are melted in a refractory tank melter.

12. A continuous high strength, light weight glass fiber produced from a composition according to claim 1 .

13. The glass fiber of claim 12 , wherein said glass fiber has a specific strength from about 1.74 MJ/kg to about 2.09 MJ/kg.

14. The glass fiber of claim 12 , wherein said glass fiber has a pristine fiber tensile strength between about 4200 and about 5000 MPa, a modulus between about 80 and about 86 GPa, and a density between about 2.35 and about 2.46 g/cc.

15. A method of preparing a reinforced composite product comprising combining at least one polymer matrix material and a plurality of glass fibers according to claim 12 .

16. The glass fiber of claim 13 , wherein said glass fiber has a specific strength of greater than 2.01 MJ/Kg and less than or equal to about 2.09 MJ/kg.

17. The glass fiber of claim 1 , wherein said glass fiber has a specific modulus of greater than 34.1 MJ/Kg and less than or equal to about 35.0 MJ/kg.

18. A method of forming a continuous high performance glass fiber comprising:
providing a molten glass composition including a composition according to claim 1 ; and
drawing said molten glass composition through orifices in a bushing to form a continuous glass fiber.

19. The method of claim 18 , wherein said glass fiber has a specific strength from about 1.74 MJ/kg to about 2.09 MJ/kg.

20. The method of claim 18 , wherein said glass fiber has a specific modulus of greater than 34.1 MJ/Kg and less than or equal to about 35.0 MJ/kg.

21. The method of claim 19 , wherein said glass fiber has a specific strength of greater than 2.01 MJ/Kg and less than or equal to about 2.09 MJ/kg.

22. The method of claim 18 , wherein said glass fiber has a pristine fiber tensile strength between about 4200 and about 5000 MPa, a modulus between about 80 and about 86 GPa, and a density between about 2.35 and about 2.46 g/cc.

23. A method of preparing a reinforced composite product comprising:
preparing a plurality of glass fibers according to the method of claim 18 and combining said plurality of glass fibers with at least one polymer matrix material.

24. A reinforced composite product comprising:
a polymer matrix; and
a plurality of glass fibers, said glass fibers being produced from a composition comprising:
SiO 2 in an amount from about 69.5 to about 80.0%% by weight of the total composition,
Al 2 O 3 in an amount from about 5.0 to about 18.5% by weight of the total composition,
CaO in an amount from 0.0 to about 1.8% by weight of the total composition,
MgO in an amount from 5.0 to about 14.75% by weight of the total composition,
Li 2 O in an amount from 3.25 to about 4.0% by weight of the total composition, and
Na 2 O in an amount from 0.0 to about 2.0% by weight of the total composition, wherein said composition has less than 1.0% by weight of B 2 O 3 .

25. The composite product of claim 24 , wherein said polymer matrix is a thermoplastic polymer selected from polyesters, polypropylene, polyamide, polyethylene terephtalate, polybutylene and combinations thereof.

26. The composite product of claim 24 , wherein said polymer matrix is a thermoset polymer selected from epoxy resins, unsaturated polyesters, phenolics, vinylesters and combinations thereof.

Assignees

• Hofmann Douglas A
• Mcginnis Peter Bernard
• Ocv Intellectual Capital Llc

Inventors

• Hofmann Douglas A
• Mcginnis Peter Bernard

Classifications

• C03C13/00 Primary

  Fibre or filament compositions (manufacture of fibres or filaments C03B37/00) · CPC title

• C03C3/085

  containing an oxide of a divalent metal · CPC title

• Y10T442/2951

  Coating or impregnation contains epoxy polymer or copolymer or polyether · CPC title

• Y10T442/2934

  Coating or impregnation contains vinyl polymer or copolymer · CPC title

• B29K2309/08

  Glass · CPC title