WO2017063167A1 - 一种高性能玻璃纤维组合物及其玻璃纤维和复合材料 - Google Patents

一种高性能玻璃纤维组合物及其玻璃纤维和复合材料 Download PDF

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WO2017063167A1
WO2017063167A1 PCT/CN2015/091987 CN2015091987W WO2017063167A1 WO 2017063167 A1 WO2017063167 A1 WO 2017063167A1 CN 2015091987 W CN2015091987 W CN 2015091987W WO 2017063167 A1 WO2017063167 A1 WO 2017063167A1
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Prior art keywords
glass
glass fiber
cao
ratio
weight percentage
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PCT/CN2015/091987
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English (en)
French (fr)
Inventor
章林
曹国荣
邢文忠
顾桂江
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巨石集团有限公司
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Priority to HUE15906052A priority Critical patent/HUE054124T2/hu
Priority to JP2017557047A priority patent/JP6633651B2/ja
Application filed by 巨石集团有限公司 filed Critical 巨石集团有限公司
Priority to DK15906052.4T priority patent/DK3275847T3/da
Priority to EP15906052.4A priority patent/EP3275847B1/en
Priority to PL15906052T priority patent/PL3275847T3/pl
Priority to RU2017137765A priority patent/RU2017137765A/ru
Priority to ES15906052T priority patent/ES2859646T3/es
Priority to CN201580078767.9A priority patent/CN107531552B/zh
Priority to MA41018A priority patent/MA41018B2/fr
Priority to KR1020177035232A priority patent/KR102038087B1/ko
Priority to BR112017023548-0A priority patent/BR112017023548B1/pt
Priority to PT159060524T priority patent/PT3275847T/pt
Priority to MX2017013635A priority patent/MX2017013635A/es
Priority to CA2984174A priority patent/CA2984174C/en
Priority to AU2015411780A priority patent/AU2015411780B2/en
Priority to PCT/CN2015/091987 priority patent/WO2017063167A1/zh
Publication of WO2017063167A1 publication Critical patent/WO2017063167A1/zh
Priority to SA517390253A priority patent/SA517390253B1/ar
Priority to US15/805,159 priority patent/US10189742B2/en
Priority to ZA2017/08661A priority patent/ZA201708661B/en

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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C3/00—Glass compositions
    • C03C3/04—Glass compositions containing silica
    • C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
    • C03C3/11—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen
    • C03C3/112—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen containing fluorine
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/04—Fibre optics, e.g. core and clad fibre compositions
    • C03C13/045—Silica-containing oxide glass compositions
    • C03C13/046—Multicomponent glass compositions
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C3/00—Glass compositions
    • C03C3/04—Glass compositions containing silica
    • C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
    • C03C3/083—Glass compositions containing silica with 40% to 90% silica, by weight containing aluminium oxide or an iron compound
    • C03C3/085—Glass compositions containing silica with 40% to 90% silica, by weight containing aluminium oxide or an iron compound containing an oxide of a divalent metal
    • C03C3/087—Glass compositions containing silica with 40% to 90% silica, by weight containing aluminium oxide or an iron compound containing an oxide of a divalent metal containing calcium oxide, e.g. common sheet or container glass
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C3/00—Glass compositions
    • C03C3/04—Glass compositions containing silica
    • C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
    • C03C3/089—Glass compositions containing silica with 40% to 90% silica, by weight containing boron
    • C03C3/091—Glass compositions containing silica with 40% to 90% silica, by weight containing boron containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C3/00—Glass compositions
    • C03C3/04—Glass compositions containing silica
    • C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
    • C03C3/11—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen
    • C03C3/112—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen containing fluorine
    • C03C3/115—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen containing fluorine containing boron
    • C03C3/118—Glass compositions containing silica with 40% to 90% silica, by weight containing halogen or nitrogen containing fluorine containing boron containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2213/00—Glass fibres or filaments

Definitions

  • the present invention relates to a glass fiber composition, and more particularly to a high performance glass fiber composition capable of reinforcing a substrate as an advanced composite material, and glass fibers and composite materials thereof.
  • Glass fiber is an inorganic fiber material, and it can be used to reinforce a resin to obtain a composite material with excellent properties.
  • high-performance glass fiber was originally used in the defense, military and other fields of defense, military and other fields. With the advancement of technology and economic development, high-performance glass fiber has been widely used in civil and industrial fields such as motors, wind blades, pressure vessels, offshore oil pipelines, sports equipment, and the automotive industry.
  • R glass fiber which has slightly lower mechanical properties than conventional R glass fibers. Its melting and forming properties are significantly better than conventional R glass, but it is matched with the ratio of calcium to calcium. Unreasonable, the crystallization risk of the glass is still large, and too much Li 2 O is introduced, which not only affects the chemical stability of the glass, but also increases the cost of raw materials, and is also disadvantageous for large-scale industrial production.
  • the main components of Gaoqiang 2# glass fiber also include SiO 2 , Al 2 O 3 , MgO, and also introduce some parts of Li 2 O, B 2 O 3 , CeO 2 and Fe 2 O 3 , which also have high strength and Modulus, and its molding temperature is only about 1245 ° C, the liquidus temperature is 1320 ° C, the temperature of both is much lower than S glass fiber, but its molding temperature is lower than the liquidus temperature, but it is not good for glass fiber. Drawing, the drawing temperature must be increased, and a special form of the leaking nozzle is used to prevent the glass from devitrifying during the drawing process, which causes difficulty in temperature control and is difficult to achieve large-scale industrial production.
  • the liquidus temperature of the mainstream E glass is generally lower than 1200 ° C
  • the molding temperature is lower than 1300 ° C
  • the liquidus temperature of the above high performance glass is generally higher than 1300 ° C
  • the molding temperature is higher than 1350 ° C
  • the present invention is directed to solving the problems described above. It is an object of the present invention to provide a high performance glass fiber composition.
  • a high performance glass fiber composition comprising the following components, the content of each component being expressed in weight percent as follows:
  • the content of F 2 may preferably be 0.01% by weight or more and less than 0.3% by weight.
  • the content of Li 2 O may preferably be 0.01% by weight or less and 0.1% by weight or less.
  • B 2 O 3 in an amount of more than 0% by weight and less than 0.1% by weight.
  • a glass fiber made of the above glass fiber composition.
  • a composite material comprising the glass fibers described above.
  • the ratio range of CaO/MgO and SiO 2 /CaO is strictly controlled by rationally arranging the content ranges of SiO 2 , CaO, MgO, Li 2 O and F 2 , and K 2 O, Na is utilized.
  • the 2 O and Li 2 O ternary mixed alkali effect, and a small amount of B 2 O 3 can also be selectively introduced.
  • the above design can overcome the high temperature of the liquidus in the high performance glass, the crystallization rate is too fast, the molding temperature is high, and it is not easy to cool. The surface tension of the glass liquid is too large and it is difficult to clarify.
  • the present invention also has exceptionally excellent heat resistance when a high content of TiO 2 is introduced.
  • the high performance glass fiber composition according to the present invention contains the following components, and the content of each component is expressed by weight percentage as follows:
  • the functions and contents of the components in the glass fiber composition are as follows:
  • SiO 2 is the main oxide forming the glass skeleton and functions to stabilize the components.
  • the content of SiO 2 is limited to a range of 58-62%, and if the content is too low, the mechanical properties of the glass are affected; if the content is too high, the viscosity of the glass is too high. It is difficult to melt and clarify.
  • the content of SiO 2 may be limited to 58.5 to 61%. More preferably, the content of SiO 2 may be limited to 58.5 to 60.4%.
  • Al 2 O 3 is also an oxide forming a glass skeleton. When combined with SiO 2 , it can play a substantial role in the mechanical properties of the glass and plays an important role in preventing phase separation and water resistance of the glass.
  • the content of Al 2 O 3 is limited to a range of 14-18%, and if it is low, a sufficiently high glass mechanical property cannot be obtained; if the content is too high, the glass is made. Too high a viscosity results in difficulty in melting and clarification.
  • the content of Al 2 O 3 may be limited to 14.5-1%. More preferably, the content of Al 2 O 3 may be limited to 14.5-16.5%.
  • CaO is an important network excipient oxide which is particularly effective in lowering the high temperature viscosity of glass.
  • the content is too high, the crystallization tendency of the glass is increased, and the crystals such as anorthite and wollastonite are precipitated from the glass.
  • the role of MgO in glass is similar to that of CaO, but the field strength of Mg 2+ is higher, which plays an important role in increasing the modulus of the glass.
  • the disadvantage is that if the MgO content is too high, the crystallization tendency and the crystallization rate of the glass are increased, and there is a risk that crystals such as diopside are precipitated from the glass.
  • the glass fiber composition of the invention introduces anorthite (CaAl 2 Si 2 O8), diopside (CaMgSi 2 O 6 ) or wollastonite (CaSiO 3 ) by rationally designing the content ratio of CaO, MgO and SiO 2 .
  • the competitive growth between crystals thus delaying the growth of these three crystals, to achieve the purpose of reducing the risk of glass devitrification.
  • the crystallization state of the glass is controlled by the contention of the anion group in the glass by means of Mg 2+ ions, Ca 2+ ions and Si 4+ ions, thereby lowering the liquidus temperature and the degree of crystallization.
  • Mg 2+ ions there are too many Mg 2+ ions, and diopside crystallization will become strong; when CaO/MgO is too high, Ca 2+ ions are too much, and anorthite crystallization will become strong; when SiO When 2 / CaO is too high, the viscosity of the glass is too large; when SiO 2 /CaO is too low, the wollastonite crystallization will become strong.
  • Both K 2 O and Na 2 O can reduce the viscosity of the glass, and are good fluxes, which can lower the viscosity of the glass and improve the crystallization property of the glass.
  • the amount of introduction should not be much to avoid reducing the strength of the glass.
  • the weight percentage of Na 2 O + K 2 O is limited to less than 2%.
  • TiO 2 not only reduces the viscosity of the glass at high temperatures, but also has a certain fluxing effect. At the same time, high content of TiO 2 can greatly improve the heat resistance of the glass. Accordingly, in the glass fiber composition of the present invention, the content of TiO 2 is limited to a content of less than 3.5% by weight. The inventors have found that the glass of the present invention has exceptionally excellent heat resistance when the content of TiO 2 is in the range of more than 2% and less than 3.5%.
  • Fe 2 O 3 is advantageous for the melting of glass and also for improving the crystallization properties of glass. However, since iron ions and ferrous ions have a coloring effect, the amount of introduction is not preferable. Thus, in the glass fiber composition of the present invention, the weight percentage of Fe 2 O 3 is limited to less than 1%.
  • Li 2 O Compared with Na 2 O and K 2 O, Li 2 O not only can significantly reduce the viscosity of the glass, thereby improving the glass melting performance, and is obviously helpful for improving the mechanical properties of the glass. At the same time, a small amount of Li 2 O can provide considerable free oxygen, which facilitates the formation of tetrahedral coordination of more aluminum ions, enhances the network structure of the glass system, and further reduces the crystallization ability of the glass. However, the content of Li 2 O should not be too high, too much Li + will exhibit a significant net-breaking effect, which will destroy the stability of the glass structure, and will accelerate the crystallization tendency of the glass.
  • the content of Li 2 O is limited to a content ranging from 0.01 to 0.5% by weight.
  • the inventors have found that even if the content of Li 2 O is controlled to a lower range such as 0.01% or more and less than 0.1%, the technical effect is excellent.
  • F 2 fluorine
  • a large number of studies have shown that a small amount of fluorine is difficult to treat exhaust gas, but it has a significant effect on glass fluxing, lowering molding temperature and liquidus temperature. For example, 0.2% F 2 can reduce the molding of 4-6 ° C. Temperature and liquidus temperature, which is advantageous for wire drawing of high performance glass.
  • the content of F 2 is limited to a content of less than 1% by weight. Considering that the technical effect of low content of F 2 is still excellent, the content of F2 is generally controlled to be 0.01% or more and less than 0.3%.
  • a small amount of B 2 O 3 can be selectively introduced into the glass fiber composition of the present invention to provide a good fluxing action and also reduce the viscosity and crystallization risk of the glass.
  • the inventors have unexpectedly discovered that in the high performance glass system of the present invention, when a small amount of B 2 O 3 and Li 2 O are introduced, B 2 O 3 can further increase the strength, modulus and other physics of the glass in addition to the above effects. performance. We believe that it is possible that a small amount of B 2 O 3 actively enters the glass structure, which in turn helps to reinforce the properties of the glass.
  • the weight percentage of B 2 O 3 is defined to be in the range of more than 0% and less than 0.1%.
  • the glass fiber composition of the present invention is also allowed to contain a small amount of impurities, and the content by weight is generally not more than 1%.
  • the high performance glass fiber composition according to the present invention contains the following components, and the content of each component is expressed by weight percentage as follows:
  • the glass fiber composition according to the present invention contains the following components, and the content of each component is expressed by weight percentage as follows:
  • the glass fiber composition according to the present invention contains the following components, and the content of each component is expressed by weight percentage as follows:
  • the high-performance glass fiber composition of the invention and the glass fiber and the composite material thereof can overcome the high temperature of the liquidus of the traditional high-performance glass, the crystallization rate is fast, and the molding temperature is high on the basis of ensuring high mechanical properties.
  • the surface tension of the glass liquid is too large, it is difficult to clarify, and it is difficult to carry out large-scale and high-efficiency production, which significantly reduces the molding temperature, liquidus temperature and surface tension of the high-performance glass, and reduces the difficulty of forming the glass under the same conditions.
  • the degree of crystallization and the bubble rate, while the glass fiber has excellent mechanical strength.
  • the basic idea of the present invention is that the content of each component of the glass fiber composition is expressed by weight percentage: SiO 2 is 58-62%, Al 2 O 3 is 14-18%, CaO+MgO is 20-24.5%, CaO More than 14%, Li 2 O is 0.01-0.4%, Na 2 O+K 2 O is less than 2%, TiO 2 is less than 3.5%, Fe 2 O 3 is less than 1%, F 2 is less than 1%, weight
  • the glass fiber composition according to the present invention can overcome the high temperature of the liquidus of the traditional high performance glass, the crystallization rate is too fast, the molding temperature is high, and the cooling is difficult, and the surface tension of the glass liquid is biased on the basis of ensuring high mechanical properties. Large, difficult to clarify, difficult to carry out large-scale high-efficiency production, significantly reducing the molding temperature, liquidus temperature and surface tension of high-performance glass, under the same conditions, reducing the forming difficulty, crystallization degree and bubble rate of glass. At the same time, the glass fiber has excellent mechanical strength. Further, the present invention also has exceptionally excellent heat resistance when a high content of TiO 2 is introduced.
  • the specific content values of SiO 2 , Al 2 O 3 , CaO, MgO, Na 2 O, K 2 O, Fe 2 O 3 , Li 2 O, TiO 2 and B 2 O 3 in the glass fiber composition of the present invention are selected as The examples are compared to the performance parameters of conventional E glass, conventional R glass and modified R glass. In performance comparison, six performance parameters are selected:
  • the molding temperature corresponds to the temperature at which the glass melt has a viscosity of 10 3 poise.
  • the liquidus temperature corresponds to the temperature at which the crystal nucleus begins to form when the glass melt is cooled, that is, the upper limit temperature of the glass crystallization.
  • the temperature of the crystallization peak which corresponds to the temperature of the strongest peak of glass crystallization during the DTA test.
  • the higher the temperature the more energy is required to grow the crystal nucleus, and the crystallization tendency of the glass is smaller.
  • the strength of the monofilament, the tensile strength of the glass fiber strand unit can withstand the fineness.
  • each component can be obtained from a suitable raw material, and various raw materials are mixed in proportion to achieve the final expected weight percentage of each component, and the mixed batch material is melted and clarified, and then the glass liquid
  • the glass fiber is formed by the leaking nozzle on the drain plate being pulled out, and the glass fiber is drawn around the rotating head of the wire drawing machine to form a raw silk cake or a yarn group.
  • these glass fibers can be further processed in a conventional manner to meet the expected requirements.
  • the content of the glass fiber composition is Expressed as a percentage by weight. It should be noted that the total content of the components of the examples is slightly less than 100%, and it can be understood that the residual amount is a trace impurity or a small component which cannot be analyzed.
  • the glass fiber composition of the present invention has the following advantages as compared with the conventional R glass and the modified R glass: (1) having a much lower liquidus temperature, which is advantageous for lowering the glass. Crystallization risk, increase fiber The drawing efficiency; (2) has a higher crystallization peak temperature, which indicates that the formation and growth of the nucleus during the crystallization process requires more energy, that is, the crystallization risk of the glass of the invention under the same conditions. smaller. (3) It has a lower molding temperature. At the same time, the glass fibers obtained by the present invention have higher monofilament strength and softening point temperature than the modified R glass.
  • the glass fiber composition of the present invention has made a breakthrough in crystallization property, filament strength and heat resistance compared with the current mainstream modified R glass, and the crystallization risk of the glass is greatly increased under the same conditions.
  • the drop, monofilament strength and softening point temperature are significantly improved, and the overall technical solution is more cost-effective, making it easy to achieve large-scale industrial production.
  • the glass fiber composition according to the present invention can be made into a glass fiber having the above excellent properties.
  • the glass fiber composition according to the present invention can be combined with one or more organic and/or inorganic materials to produce a composite material having excellent properties, for example, a glass fiber reinforced substrate.
  • the high-performance glass fiber composition of the invention and the glass fiber and the composite material thereof can overcome the high liquidus temperature and the crystallization rate of the conventional high-performance glass on the basis of ensuring high mechanical properties. It is too fast, the molding temperature is too high, it is not easy to cool, the surface tension of the glass liquid is too large, it is difficult to clarify, and it is difficult to carry out large-scale and high-efficiency production, which significantly reduces the molding temperature, liquidus temperature and surface tension of high-performance glass. Under the condition, the forming difficulty, the degree of crystallization and the bubble rate of the glass are lowered, and the glass fiber has excellent mechanical strength.
  • the glass fiber composition of the invention Compared with the current mainstream modified R glass, the glass fiber composition of the invention has made a breakthrough in crystallization property, monofilament strength and heat resistance, and the risk of crystallization of glass is greatly reduced under the same conditions, monofilament The strength and softening point temperature are significantly improved, and the overall technical solution is more cost-effective, making it easy to achieve large-scale industrial production.

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Abstract

一种高性能玻璃纤维组合物及其玻璃纤维和复合材料，该玻璃纤维组合物各组分的含量以重量百分比表示为:：SiO2 58-62%，Al2O3 14-18%，CaO+MgO 20-24.5%，CaO大于14%，Li2O 0.01-0.4%，Na2O+K2O小于2%，TiO2小于3.5%，Fe2O3小于1%，F2小于1%，重量百分比的比值C1=CaO/MgO的范围为C1大于2且小于等于2.6，重量百分比的比值C2=SiO2/CaO的范围为3.3-4.3。该组合物能显著提高玻璃纤维的机械强度和软化点温度，降低玻璃的高温粘度，并能有效抑制玻璃的析晶倾向、降低玻璃的液相线温度，适于大规模池窑生产。

Description

一种高性能玻璃纤维组合物及其玻璃纤维和复合材料 技术领域
本发明涉及一种玻璃纤维组合物，尤其涉及一种能作为先进复合材料增强基材的高性能玻璃纤维组合物及其玻璃纤维和复合材料。
背景技术
玻璃纤维属于无机纤维材料，用它增强树脂可制得性能优良的复合材料。高性能玻璃纤维作为先进复合材料的增强基材，最初主要应用于航空、航天、兵器等国防军工领域。随着科技的进步及经济的发展，高性能玻璃纤维在民用、工业领域如电机、风力叶片、压力容器、海上石油管道、体育器材、汽车行业得到了广泛应用。
自从美国欧文斯科宁公司(简称OC公司)开发出S-2玻璃纤维后，各国竞相开发生产各种成分的高性能玻璃纤维，如法国圣戈班公司开发的R玻璃纤维、美国OC公司开发的HiPer-tex玻璃纤维、中国南京玻璃纤维研究设计院开发的高强2#玻璃纤维等。最初的高性能玻璃成分以MgO-Al2O3-SiO2系统为主体，典型方案如美国OC公司的S-2玻璃，不过它的生产难度过大，成型温度高达1571℃左右，液相线温度达到1470℃，难于实现大规模工业化生产。OC公司主动放弃了生产S-2玻璃纤维，将其专利权转让给了美国AGY公司，后者一直致力于小规模生产S型玻璃纤维及其改进产品。
随后，为了降低玻璃的熔化温度及成型温度使其能更好地满足规模化池窑生产的要求，国外各大公司陆续开发了以MgO-CaO-Al2O3-SiO2系统为主体的高性能玻璃，典型方案如法国圣戈班公司的R玻璃和美国OC公司的HiPer-tex玻璃，这是一种以牺牲部分玻璃性能换取生产规模的折衷策略，不过由于设计方案过于保守，尤其是将Al2O3含量保持在20％以上，优选25％，造成生产难度依然很高，虽然实现了小规模的池窑化生产，但生产效率低下、产品性价比不高。因此，OC公司也放弃了生产HiPer-tex玻璃纤维，将其专利权转让给了欧洲3B公司。2007年前后，由于OC公司和圣戈班公司的玻纤业务合并成立OCV公司，R玻璃纤维的核心技术也相应转让给了OCV公司。传统R玻璃的钙镁比例太低，造成成型困难、析晶风险高，同时玻璃液的表面张力大、澄清难度较高，成型温度达到1410℃，液相线温度达到1330℃，这都造成玻璃纤维拉制上的困难，同样难于实现大规模工业化生产。
此外，PPG工业公司公布了另一种R玻璃纤维，这种玻璃纤维的机械性能略低于传统R 玻璃纤维，熔化和成型性能明显优于传统R玻璃，但由于硅钙比例与钙镁比例搭配不合理，该玻璃的析晶风险依然较大，同时引入了过多的Li2O，不仅影响玻璃的化学稳定性，而且提高了原料成本，也不利于大规模工业化生产。
高强2#玻璃纤维的主要成分也包括SiO2、Al2O3、MgO，同时还引入了部分Li2O、B2O3、CeO2和Fe2O3，它也具有较高的强度及模量，且其成型温度只有1245℃左右，液相线温度为1320℃，两者的温度均比S玻璃纤维低得多，但其成型温度比液相线温度低却不利于玻璃纤维的良好拉制，必须提高拉丝温度，采用特殊形式的漏嘴，以防止拉丝过程中发生玻璃失透现象，这造成温度控制上的困难，也难于实现大规模工业化生产。
综上所述，我们发现，现阶段的各类高性能玻璃纤维在实际生产中均存在普遍的问题，即玻璃的液相线温度偏高、析晶风险较大，成型温度偏高、表面张力偏大、澄清难度较高。目前，主流E玻璃的液相线温度一般低于1200℃，成型温度低于1300℃，而上述高性能玻璃的液相线温度普遍高于1300℃，成型温度高于1350℃，这些因素极易造成在生产过程中发生玻璃析晶现象、玻璃液粘度不均及澄清不良等现象，从而大大降低玻璃纤维的生产效率、产品质量以及耐火材料、铂金漏板的使用寿命。
发明内容
本发明旨在解决上面描述的问题。本发明的目的是提供一种高性能玻璃纤维组合物。
根据本发明的一个方面，提供一种高性能玻璃纤维组合物，所述玻璃纤维组合物含有下述组分，各组分的含量以重量百分比表示如下：
Figure PCTCN2015091987-appb-000001
并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.6，重量百分比的比值C2＝SiO2/CaO的范围为3.3-4.3。
其中，可优选F2的含量以重量百分比表示为大于等于0.01％且小于0.3％。
其中，可优选Li2O的含量以重量百分比表示为大于等于0.01％且小于0.1％。
此外，还可以进一步含有B2O3，其含量以重量百分比表示为大于0％且小于0.1％。
根据本发明的另一个方面，提供一种玻璃纤维，所述玻璃纤维由上述的玻璃纤维组合物制成。
根据本发明的另一个方面，提供一种复合材料，所述复合材料包括上述的玻璃纤维。
根据本发明的玻璃纤维组合物，通过合理配置SiO2、CaO、MgO、Li2O和F2的含量范围，严格控制CaO/MgO和SiO2/CaO的比值范围，以及利用K2O、Na2O和Li2O三元混合碱效应，并且还可以选择性地引入少量B2O3。上述设计方案在保证较高力学性能的基础上，能够克服传统高性能玻璃液相线温度偏高、析晶速率偏快，成型温度偏高、不易冷却，玻璃液表面张力偏大、不易澄清，难于进行大规模高效率生产的问题，显著降低了高性能玻璃的成型温度、液相线温度和表面张力，同等条件下降低了玻璃的成型难度、析晶程度和气泡率，同时玻璃纤维具有优异的机械强度。此外，当引入高含量的TiO2时，本发明还拥有异常优秀的耐热性能。
具体来说，根据本发明的高性能玻璃纤维组合物含有下述组分，且各组分的含量以重量百分比表示如下：
Figure PCTCN2015091987-appb-000002
并且，重量百分比的比值C1＝CaO/MgO的范围为C1大于2且小于等于2.6，重量百分比的比值C2＝SiO2/CaO的范围为3.3-4.3。
该玻璃纤维组合物中各组分的作用及含量说明如下：
SiO2是形成玻璃骨架的主要氧化物，并且起稳定各组分的作用。在本发明的玻璃纤维组合物中，限定SiO2的重量百分比含量范围为58-62％，若其含量太低会影响玻璃的机械性能；若其含量太高则会使玻璃的粘度过高导致熔化、澄清困难。优选地，SiO2的含量范围可以限定为58.5-61％。更优选地，SiO2的含量范围可以限定为58.5-60.4％。
Al2O3也是形成玻璃骨架的氧化物，与SiO2结合时可对玻璃的机械性能起到实质性的作用，并且在阻止玻璃分相和抗水性方面起着重要作用。在本发明的玻璃纤维组合物中，限定Al2O3的重量百分比含量范围为14-18％，若其含量较低会无法获得足够高的玻璃机械性能；若其含量太高则会使玻璃的粘度过高导致熔化、澄清困难。优选地，Al2O3的含量范围可以限定为14.5-17％。更优选地，Al2O3的含量范围可以限定为14.5-16.5％。
CaO作为重要的网络外体氧化物在降低玻璃的高温粘度方面特别有效，但其含量过高会增大玻璃的析晶倾向，造成从玻璃中析出钙长石、硅灰石等晶体的危险。MgO在玻璃中的作用与CaO大体类似，但Mg2+的场强更高，对提高玻璃的模量起很重要的作用。不利之处在于MgO含量过高会增大玻璃的析晶倾向和析晶速率，存在从玻璃中析出透辉石等晶体的危险。本发明的玻璃纤维组合物通过合理设计CaO、MgO、SiO2的含量比例，引入了钙长石(CaAl2Si2O8)、透辉石(CaMgSi2O6)或者硅灰石(CaSiO3)晶体之间的竞争生长，从而延缓这三种晶体的生长，达到降低玻璃失透危险的目的。本发明限定CaO+MgO的重量百分比总含量范围为20-24.5％，并且规定C1＝CaO/MgO的比例范围为大于2且小于等于2.6，C2＝SiO2/CaO的比例范围为3.3-4.3。以借助Mg2+离子、Ca2+离子和Si4+离子在玻璃中对阴离子团的争夺作用调节、控制玻璃的析晶状态，从而降低液相线温度和析晶程度。显然，当CaO/MgO太低时，Mg2+离子太多，透辉石析晶会变得强势；当CaO/MgO太高时，Ca2+离子太多，钙长石析晶会变得强势；当SiO2/CaO太高时，玻璃粘度太大；当SiO2/CaO太低时，硅灰石析晶会变得强势。优选地，C1＝CaO/MgO的比值范围可以限定为大于2且小于等于2.4，C2＝SiO2/CaO的比例范围为3.4-4.2。更优选地，C2＝SiO2/CaO的比例范围为3.5-4.0。
K2O和Na2O均能降低玻璃粘度，是良好的助熔剂，能降低玻璃粘度，改善玻璃的析晶性能。但引入量不宜多，以避免降低玻璃的强度。在本发明的玻璃纤维组合物中，限定Na2O+K2O的重量百分比含量范围为小于2％。
TiO2不仅可以降低高温时的玻璃粘度，还具有一定的助熔作用。同时，高含量的TiO2还能大大提升玻璃的耐热性能。因此，本发明的玻璃纤维组合物中，限定TiO2的重量百分比含量范围为小于3.5％。发明人发现，当TiO2的含量范围为大于2％且小于3.5％时，本发明的玻璃拥有异常优秀的耐热性能。
Fe2O3有利于玻璃的熔制，也能改善玻璃的析晶性能。但由于铁离子和亚铁离子具有着色作用，故引入量不宜多。因此，在本发明的玻璃纤维组合物中，限定Fe2O3的重量百分比含量范围为小于1％。
同Na2O和K2O相比，Li2O不仅能显著地降低玻璃粘度，从而改善玻璃熔制性能，并且对提高玻璃的力学性能有明显帮助。同时，少量Li2O就能提供可观的游离氧，有利于更多的铝离 子形成四面体配位，增强玻璃体系的网络结构，可进一步降低玻璃的析晶能力。但是Li2O的含量也不宜过高，太多的Li+会表现出显著的断网作用，会破坏玻璃结构的稳定性，反而会加速玻璃的析晶倾向。因此，在本发明的玻璃纤维组合物中，限定Li2O的重量百分比含量范围为0.01-0.5％。发明人发现，即使将Li2O的含量控制在较低范围如大于等于0.01％且小于0.1％时，其技术效果依然优异。
本发明的玻璃纤维组合物中还允许含有少量氟(F2)。大量研究表明，少量的氟对废气治理的难度很小，但在玻璃助熔、降低成型温度和液相线温度方面却有显著作用，比如0.2％的F2就能降低4-6℃的成型温度和液相线温度，这对于高性能玻璃的拉丝成型是很有利的。因此，在本发明的玻璃纤维组合物中，限定F2的重量百分比含量范围为小于1％。考虑到低含量F2的技术效果依然出色，一般情况下控制F2的含量范围为大于等于0.01％且小于0.3％。
此外，本发明的玻璃纤维组合物中还可以选择性地引入少量B2O3，可起较好的助熔作用，还能降低玻璃的粘度和析晶危险。发明人意外发现，在本发明的高性能玻璃体系中，当引入少量B2O3与Li2O共存时，B2O3除了上述作用，还能进一步提高玻璃的强度、模量及其他物理性能。我们认为，可能是少量的B2O3都积极地进入玻璃结构，反而有利于补强玻璃的各项性能。因此，在本发明的玻璃纤维组合物中，限定B2O3的重量百分比含量范围为大于0％且小于0.1％。
此外，本发明的玻璃纤维组合物中还允许含有少量杂质，重量百分比含量一般不超过1％。
本发明的玻璃纤维组合物中，选择各组分含量的上述范围的有益效果在后面会通过实施例给出具体实验数据来说明。
下面是根据本发明的玻璃纤维组合物中所包括的各组分的优选取值范围示例。
优选示例一
根据本发明的高性能玻璃纤维组合物含有下述组分，且各组分的含量以重量百分比表示如下：
Figure PCTCN2015091987-appb-000003
并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.4，重量百分比的比值C2＝SiO2/CaO的范围为3.4-4.2。
优选示例二
根据本发明的玻璃纤维组合物含有下述组分，且各组分的含量以重量百分比表示如下：
Figure PCTCN2015091987-appb-000004
并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.4，重量百分比的比值C2＝SiO2/CaO的范围为3.5-4.0。
优选示例三
根据本发明的玻璃纤维组合物含有下述组分，且各组分的含量以重量百分比表示如下：
Figure PCTCN2015091987-appb-000005
并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.6，重量百分比的比值C2＝SiO2/CaO的范围为3.3-4.3。
本发明的一种高性能玻璃纤维组合物及其玻璃纤维和复合材料，在保证较高力学性能的基础上，能够克服传统高性能玻璃液相线温度偏高、析晶速率偏快，成型温度偏高、不易冷 却，玻璃液表面张力偏大、不易澄清，难于进行大规模高效率生产的问题，显著降低了高性能玻璃的成型温度、液相线温度和表面张力，同等条件下降低了玻璃的成型难度、析晶程度和气泡率，同时玻璃纤维具有优异的机械强度。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互任意组合。
本发明的基本思想是，玻璃纤维组合物的各组分含量以重量百分比表示为：SiO2为58-62％，Al2O3为14-18％，CaO+MgO为20-24.5％，CaO为大于14％，Li2O为0.01-0.4％，Na2O+K2O为小于2％，TiO2为小于3.5％，Fe2O3为小于1％，F2为小于1％，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.6，重量百分比的比值C2＝SiO2/CaO的范围为3.3-4.3。此外，还可以进一步含有B2O3，其含量以重量百分比表示为大于0％且小于0.1％。根据本发明的玻璃纤维组合物在保证较高力学性能的基础上，能够克服传统高性能玻璃液相线温度偏高、析晶速率偏快，成型温度偏高、不易冷却，玻璃液表面张力偏大、不易澄清，难于进行大规模高效率生产的问题，显著降低了高性能玻璃的成型温度、液相线温度和表面张力，同等条件下降低了玻璃的成型难度、析晶程度和气泡率，同时玻璃纤维具有优异的机械强度。此外，当引入高含量的TiO2时，本发明还拥有异常优秀的耐热性能。
选取本发明的玻璃纤维组合物中SiO2、Al2O3、CaO、MgO、Na2O、K2O、Fe2O3、Li2O、TiO2、B2O3的具体含量值作为实施例，与传统E玻璃、传统R玻璃和改良R玻璃的性能参数进行对比。在性能对比时，选用六个性能参数：
(1)成型温度，对应于玻璃熔体在粘度为103泊时的温度。
(2)液相线温度，对应于玻璃熔体冷却时晶核开始形成的温度，即玻璃析晶的上限温度。
(3)△T值，成型温度与液相线温度之差，表示拉丝成型的温度范围。
(4)析晶峰温度，DTA测试过程中对应于玻璃析晶最强峰的温度。一般情况下，该温度越高，表明晶核长大所需能量越多，玻璃的析晶倾向越小。
(5)单丝强度，玻璃纤维原丝单位细度能承受的拉伸力。
(6)软化点温度，表征玻璃抵抗高温变形的能力。
上述六个参数及其测定方法是本领域技术人员所熟知的，因此采用上述参数能够有力地说明本发明的玻璃纤维组合物的性能。
实验的具体过程为：各组分可从适当的原料中获取，按比例将各种原料进行混合，使各组分达到最终的预期重量百分比，混合后的配合料进行熔化并澄清，然后玻璃液通过漏板上的漏嘴被拉出从而形成玻璃纤维，玻璃纤维被牵引绕到拉丝机旋转机头上形成原丝饼或纱团。当然，这些玻璃纤维可用常规方法进行深加工以符合预期要求。
下面给出根据本发明的玻璃纤维组合物的具体实施例。
实施例1
Figure PCTCN2015091987-appb-000006
并且，重量百分比的比值C1＝CaO/MgO为2.04，重量百分比的比值C2＝SiO2/CaO为4.11。
在实施例1中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000007
实施例2
Figure PCTCN2015091987-appb-000008
Figure PCTCN2015091987-appb-000009
并且，重量百分比的比值C1＝CaO/MgO为2.60，重量百分比的比值C2＝SiO2/CaO为3.97。在实施例2中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000010
实施例3
Figure PCTCN2015091987-appb-000011
并且，重量百分比的比值C1＝CaO/MgO为2.4，重量百分比的比值C2＝SiO2/CaO为3.60。在实施例3中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000012
Figure PCTCN2015091987-appb-000013
实施例4
Figure PCTCN2015091987-appb-000014
并且，重量百分比的比值C1＝CaO/MgO为2.45，重量百分比的比值C2＝SiO2/CaO为4.30。在实施例4中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000015
实施例5
Figure PCTCN2015091987-appb-000016
Figure PCTCN2015091987-appb-000017
并且，重量百分比的比值C1＝CaO/MgO为2.07，重量百分比的比值C2＝SiO2/CaO为4.03。在实施例5中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000018
实施例6
Figure PCTCN2015091987-appb-000019
并且，重量百分比的比值C1＝CaO/MgO为2.16，重量百分比的比值C2＝SiO2/CaO为3.50。在实施例6中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000020
实施例7
Figure PCTCN2015091987-appb-000021
Figure PCTCN2015091987-appb-000022
并且，重量百分比的比值C1＝CaO/MgO为2.42，重量百分比的比值C2＝SiO2/CaO为4.00。在实施例7中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000023
实施例8
Figure PCTCN2015091987-appb-000024
并且，重量百分比的比值C1＝CaO/MgO为2.29，重量百分比的比值C2＝SiO2/CaO为3.40。在实施例8中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000025
Figure PCTCN2015091987-appb-000026
实施例9
Figure PCTCN2015091987-appb-000027
并且，重量百分比的比值C1＝CaO/MgO为2.50，重量百分比的比值C2＝SiO2/CaO为3.40。在实施例9中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000028
实施例10
Figure PCTCN2015091987-appb-000029
Figure PCTCN2015091987-appb-000030
并且，重量百分比的比值C1＝CaO/MgO为2.05，重量百分比的比值C2＝SiO2/CaO为4.20。
在实施例10中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000031
实施例11
Figure PCTCN2015091987-appb-000032
并且，重量百分比的比值C1＝CaO/MgO为2.02，重量百分比的比值C2＝SiO2/CaO为3.99。
在实施例11中测定的六个参数的数值分别是：
Figure PCTCN2015091987-appb-000033
下面进一步通过列表的方式，给出本发明玻璃纤维组合物的上述实施例以及其他实施例与传统E玻璃、传统R玻璃和改良R玻璃的性能参数的对比。其中，玻璃纤维组合物的含量以 重量百分比表示。需要说明的是，实施例组分总含量略微小于100％，可以理解为残余量是微量杂质或不能分析出的少量组分。
表1
Figure PCTCN2015091987-appb-000034
表2
Figure PCTCN2015091987-appb-000035
由上述表中的具体数值可知，与传统R玻璃和改良R玻璃相比，本发明的玻璃纤维组合物拥有以下优势：(一)具有低得多的液相线温度，这有利于降低玻璃的析晶风险、提高纤维 的拉丝效率；(二)具有较高的析晶峰温度，这表明玻璃在析晶过程中晶核的形成和长大需要更多的能量，也就是说同等条件下本发明玻璃的析晶风险更小。(三)具有较低的成型温度。同时，与改良R玻璃相比，本发明所得的玻璃纤维还拥有更高的单丝强度和软化点温度。由此可见，与目前主流的改良R玻璃相比，本发明的玻璃纤维组合物在析晶性能、单丝强度和耐热性能方面取得了突破性的进展，同等条件下玻璃的析晶风险大幅下降、单丝强度和软化点温度明显提高，而且整体技术方案的性价比更高，易于实现大规模工业化生产。
根据本发明的玻璃纤维组合物可制成具有上述优良性能的玻璃纤维。
根据本发明的玻璃纤维组合物与一种或多种有机和/或无机材料结合可制备得到性能优良的复合材料，例如，玻纤增强基材。
综上所述，本发明的一种高性能玻璃纤维组合物及其玻璃纤维和复合材料，在保证较高力学性能的基础上，能够克服传统高性能玻璃液相线温度偏高、析晶速率偏快，成型温度偏高、不易冷却，玻璃液表面张力偏大、不易澄清，难于进行大规模高效率生产的问题，显著降低了高性能玻璃的成型温度、液相线温度和表面张力，同等条件下降低了玻璃的成型难度、析晶程度和气泡率，同时玻璃纤维具有优异的机械强度。
最后应说明的是：在本文中，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包含一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下，由语句“包括一个…”限定的要素，并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案，而非对其限制。尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
工业实用性
与目前主流的改良R玻璃相比，本发明的玻璃纤维组合物在析晶性能、单丝强度和耐热性能方面取得了突破性的进展，同等条件下玻璃的析晶风险大幅下降、单丝强度和软化点温度明显提高，而且整体技术方案的性价比更高，易于实现大规模工业化生产。

Claims (10)

  1. 一种高性能玻璃纤维组合物，其特征在于，所述玻璃纤维组合物含有下述组分，各组分的含量以重量百分比表示如下：
    Figure PCTCN2015091987-appb-100001
    并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.6，重量百分比的比值C2＝SiO2/CaO的范围为3.3-4.3。
  2. 根据权利要求1所述的高性能玻璃纤维组合物，其特征在于，还可以进一步含有B2O3，其含量以重量百分比表示为大于0％且小于0.1％。
  3. 根据权利要求1或2所述的高性能玻璃纤维组合物，其特征在于，F2的含量以重量百分比表示为大于等于0.01％且小于0.3％。
  4. 根据权利要求1或2所述的高性能玻璃纤维组合物，其特征在于，Li2O的含量以重量百分比表示为大于等于0.01％且小于0.1％。
  5. 根据权利要求1所述的高性能玻璃纤维组合物，其特征在于，重量百分比的比值C2＝SiO2/CaO的范围为3.4-4.2。
  6. 根据权利要求1所述的高性能玻璃纤维组合物，其特征在于，各组分的含量以重量百分比表示如下：
    Figure PCTCN2015091987-appb-100002
    Figure PCTCN2015091987-appb-100003
    并且，重量百分比的比值C1＝CaO/MgO的范围为大于2且小于等于2.4，重量百分比的比值C2＝SiO2/CaO的范围为3.4-4.2。
  7. 根据权利要求1所述的高性能玻璃纤维组合物，其特征在于，各组分的含量以重量百分比表示如下：
    Figure PCTCN2015091987-appb-100004
    并且，重量百分比的比值C1＝CaO/MgO的范围为C1大于2且小于等于2.4，重量百分比的比值C2＝SiO2/CaO的范围为3.5-4.0。
  8. 根据权利要求1或7所述的高性能玻璃纤维组合物，其特征在于，TiO2的含量以重量百分比表示为大于2％且小于3.5％。
  9. 一种玻璃纤维，其特征在于，所述玻璃纤维由如权利要求1-8中任一项所述的玻璃纤维组合物制成。
  10. 一种复合材料，其特征在于，所述复合材料包括如权利要求9所述的玻璃纤维。
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BR112017023548A2 (zh) 2018-08-07
RU2017137765A (ru) 2019-07-16
EP3275847A4 (en) 2018-10-03

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