WO2023127220A1 - ガラス長繊維の製造方法、及びガラス長繊維 - Google Patents
ガラス長繊維の製造方法、及びガラス長繊維 Download PDFInfo
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- WO2023127220A1 WO2023127220A1 PCT/JP2022/037176 JP2022037176W WO2023127220A1 WO 2023127220 A1 WO2023127220 A1 WO 2023127220A1 JP 2022037176 W JP2022037176 W JP 2022037176W WO 2023127220 A1 WO2023127220 A1 WO 2023127220A1
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- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 1
- RMTGISUVUCWJIT-UHFFFAOYSA-N n-[3-[3-aminopropoxy(dimethoxy)silyl]propyl]-1-phenylprop-2-en-1-amine;hydrochloride Chemical compound Cl.NCCCO[Si](OC)(OC)CCCNC(C=C)C1=CC=CC=C1 RMTGISUVUCWJIT-UHFFFAOYSA-N 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- WGOROJDSDNILMB-UHFFFAOYSA-N octatriacontanediamide Chemical compound NC(=O)CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC(N)=O WGOROJDSDNILMB-UHFFFAOYSA-N 0.000 description 1
- PQQKPALAQIIWST-UHFFFAOYSA-N oxomolybdenum Chemical compound [Mo]=O PQQKPALAQIIWST-UHFFFAOYSA-N 0.000 description 1
- 125000005702 oxyalkylene group Chemical group 0.000 description 1
- 239000002540 palm oil Substances 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 238000005191 phase separation Methods 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- WVDDGKGOMKODPV-ZQBYOMGUSA-N phenyl(114C)methanol Chemical compound O[14CH2]C1=CC=CC=C1 WVDDGKGOMKODPV-ZQBYOMGUSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000088 plastic resin Substances 0.000 description 1
- 229920001432 poly(L-lactide) Polymers 0.000 description 1
- 229920006110 poly(m-benzoyl4,4'-methylenebis(cyclohexylamine)) Polymers 0.000 description 1
- 229920000052 poly(p-xylylene) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920006396 polyamide 1012 Polymers 0.000 description 1
- 229920006394 polyamide 410 Polymers 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920001748 polybutylene Polymers 0.000 description 1
- 125000003367 polycyclic group Chemical group 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920000223 polyglycerol Polymers 0.000 description 1
- 229920006123 polyhexamethylene isophthalamide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920001228 polyisocyanate Polymers 0.000 description 1
- 239000005056 polyisocyanate Substances 0.000 description 1
- 229920000582 polyisocyanurate Polymers 0.000 description 1
- 239000011495 polyisocyanurate Substances 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 239000001205 polyphosphate Substances 0.000 description 1
- 235000011176 polyphosphates Nutrition 0.000 description 1
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- XAEFZNCEHLXOMS-UHFFFAOYSA-M potassium benzoate Chemical compound [K+].[O-]C(=O)C1=CC=CC=C1 XAEFZNCEHLXOMS-UHFFFAOYSA-M 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- YGSDEFSMJLZEOE-UHFFFAOYSA-M salicylate Chemical compound OC1=CC=CC=C1C([O-])=O YGSDEFSMJLZEOE-UHFFFAOYSA-M 0.000 description 1
- 229960001860 salicylate Drugs 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 235000017550 sodium carbonate Nutrition 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 235000012424 soybean oil Nutrition 0.000 description 1
- 239000003549 soybean oil Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 description 1
- 229920001909 styrene-acrylic polymer Polymers 0.000 description 1
- 239000005720 sucrose Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 150000003457 sulfones Chemical class 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 238000010558 suspension polymerization method Methods 0.000 description 1
- 239000003760 tallow Substances 0.000 description 1
- MHSKRLJMQQNJNC-UHFFFAOYSA-N terephthalamide Chemical compound NC(=O)C1=CC=C(C(N)=O)C=C1 MHSKRLJMQQNJNC-UHFFFAOYSA-N 0.000 description 1
- TUNFSRHWOTWDNC-HKGQFRNVSA-N tetradecanoic acid Chemical compound CCCCCCCCCCCCC[14C](O)=O TUNFSRHWOTWDNC-HKGQFRNVSA-N 0.000 description 1
- FAGUFWYHJQFNRV-UHFFFAOYSA-N tetraethylenepentamine Chemical compound NCCNCCNCCNCCN FAGUFWYHJQFNRV-UHFFFAOYSA-N 0.000 description 1
- DLYUQMMRRRQYAE-UHFFFAOYSA-N tetraphosphorus decaoxide Chemical compound O1P(O2)(=O)OP3(=O)OP1(=O)OP2(=O)O3 DLYUQMMRRRQYAE-UHFFFAOYSA-N 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- CVNKFOIOZXAFBO-UHFFFAOYSA-J tin(4+);tetrahydroxide Chemical compound [OH-].[OH-].[OH-].[OH-].[Sn+4] CVNKFOIOZXAFBO-UHFFFAOYSA-J 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- DQZNLOXENNXVAD-UHFFFAOYSA-N trimethoxy-[2-(7-oxabicyclo[4.1.0]heptan-4-yl)ethyl]silane Chemical compound C1C(CC[Si](OC)(OC)OC)CCC2OC21 DQZNLOXENNXVAD-UHFFFAOYSA-N 0.000 description 1
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 1
- 229920000785 ultra high molecular weight polyethylene Polymers 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
-
- 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
- C03C3/097—Glass compositions containing silica with 40% to 90% silica, by weight containing phosphorus, niobium or tantalum
-
- 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
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
- C03B37/01—Manufacture of glass fibres or filaments
- C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
-
- 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
- C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
- C03C1/002—Use of waste materials, e.g. slags
-
- 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
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/28—Macromolecular compounds or prepolymers obtained by reactions involving only carbon-to-carbon unsaturated bonds
-
- 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
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/28—Macromolecular compounds or prepolymers obtained by reactions involving only carbon-to-carbon unsaturated bonds
- C03C25/285—Acrylic resins
-
- 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
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/28—Macromolecular compounds or prepolymers obtained by reactions involving only carbon-to-carbon unsaturated bonds
- C03C25/30—Polyolefins
-
- 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
- C03C3/093—Glass compositions containing silica with 40% to 90% silica, by weight containing boron containing aluminium containing zinc or zirconium
-
- 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
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/60—Glass recycling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- the present invention relates to a method for producing long glass fibers and long glass fibers.
- Patent Document 1 a glass fiber reinforced plastic sheet is produced by reusing glass fibers recovered by dissolving the resin from a glass fiber reinforced resin molded product (hereinafter sometimes referred to as "recovered glass fibers"). method is described.
- the present inventor melted the glass fiber recovered from the glass fiber reinforced resin molded product and mixed it with a glass fiber mineral material, which is a material refined from a plurality of types of ores or ores, as a raw material, and spun to form a long fiber.
- a glass fiber mineral material which is a material refined from a plurality of types of ores or ores, as a raw material, and spun to form a long fiber.
- Patent Document 2 From the viewpoint of reducing the amount of waste, it is expected to increase the amount of recovered glass fiber used (hereinafter sometimes referred to as "recycling rate") relative to the total amount of glass raw material.
- the production method of long glass fiber using recovered glass fiber since the content of components other than glass fiber increases in the production method with a high recycling rate, the production of long glass fiber using only glass fiber mineral material Compared to the method, the liquidus temperature of the molten glass obtained by melting the frit is increased, the operating temperature range of the molten glass is narrowed, and the spinnability of the molten glass is reduced. In addition, depending on the glass composition of the glass fiber to be produced, the spinning temperature (1000 poise temperature) rises, and a large amount of energy is required to keep the furnace at a high temperature. There is an inconvenience that it will end up.
- JP-A-2003-55475 Japanese Patent Application No. 2021-107957
- the spinning temperature is low while increasing the recycling rate and suppressing an increase in the liquidus temperature of the molten glass and a narrowing of the working temperature range of the molten glass.
- a method for producing such long glass fibers has not been provided.
- the problem to be solved by the present invention is to increase the recycling rate, suppress the rise in the liquidus temperature of the molten glass and the narrowing of the working temperature range of the molten glass, and produce long glass fibers with a low spinning temperature. It is an object of the present invention to provide a method for manufacturing long glass fibers using recovered glass fibers.
- the present inventors have conducted repeated studies, and found that when the glass composition of the recovered glass fiber and the glass fiber mineral material are not the same and a predetermined relationship is satisfied, the recycling rate is increased and the liquidus temperature of the molten glass is increased. and that the spinning temperature can be lowered while suppressing the narrowing of the working temperature range of the molten glass.
- the present invention has been completed based on these findings.
- the present invention comprises a glass melting step to obtain molten glass by melting glass raw materials containing glass fibers and glass fiber mineral materials recovered from glass fiber reinforced resin molded articles; A spinning step of spinning the molten glass into long glass fibers,
- the content of the glass fibers recovered from the glass fiber reinforced resin molded product in the glass raw material is in the range of 11 to 75% by mass, and the following formula (1) is satisfied.
- S, A, B and C are as follows.
- the following formula (2) is preferably satisfied. 10.8 ⁇ S+ABC ⁇ 34.3 (2) where S, A, B and C are as described above.
- S, A, B, and C satisfy the above formula (2), the spinning temperature of the molten glass can be lowered to produce long glass fibers in which the elastic modulus of the glass fibers is suppressed from decreasing.
- the content of the glass fiber recovered from the glass fiber reinforced resin molded article in the glass raw material is preferably in the range of 15 to 75% by mass, more preferably in the range of 15 to 60% by mass. When the content is within this range, the liquidus temperature of the molten glass can be lowered to produce long glass fibers.
- the following formula (3) is more preferably satisfied. 14.9 ⁇ S+ABC ⁇ 32.4 (3) where S, A, B and C are as described above.
- S, A, B, and C satisfy the above formula (3), it is possible to further suppress the increase in the liquidus temperature of the molten glass and the narrowing of the working temperature range to produce long glass fibers.
- the following formula (4) is more preferably satisfied. 21.9 ⁇ S+ABC ⁇ 30.4 (4) where S, A, B and C are as described above.
- S, A, B and C satisfy the above formula (4), the spinning temperature of the molten glass can be particularly lowered to produce long glass fibers.
- the present invention is obtained by melting and spinning glass raw materials containing glass fibers and glass fiber mineral materials recovered from glass fiber reinforced resin molded products, and recovering from the glass fiber reinforced resin molded products in the glass raw materials.
- the glass fiber content is in the range of 11 to 75% by mass, the above formula (1) is satisfied, and the total amount of long glass fibers is 48.00 to 62.00% by mass.
- the long glass fiber of the present invention has a high recycling rate of the raw material, the spinning temperature of the molten glass is reduced, and the rise in the liquidus temperature of the molten glass and the narrowing of the working temperature range of the molten glass are suppressed. It is a long glass fiber.
- the method for producing long glass fibers of the present embodiment includes a glass melting step of melting glass raw materials containing recovered glass fibers and glass fiber mineral materials to form molten glass, and spinning the molten glass to form long glass fibers. Including the spinning process.
- the long glass fiber of the present embodiment is obtained by melting and spinning the glass raw material containing the recovered glass fiber and the glass fiber mineral material.
- the glass fiber reinforced resin molded article is obtained, for example, by kneading chopped strands of glass fiber glass filaments having a predetermined length and a thermoplastic resin with a twin-screw kneader to obtain resin pellets. It is obtained by performing injection molding using the obtained resin pellets.
- the glass fiber reinforced resin molded product can be produced by injection compression molding, two-color molding, blow molding, foam molding (including supercritical fluid foam molding), insert molding, in-mold coating molding, extrusion.
- Molding method sheet molding method, thermoforming method, rotational molding method, laminate molding method, press molding method, blow molding method, stamping molding method, infusion method, hand lay-up method, spray-up method, resin transfer molding method, sheet It may be obtained by a known molding method such as a molding compound method, a bulk molding compound method, a pultrusion method, a filament winding method, or the like.
- the glass composition of the glass forming the glass fiber of the glass fiber reinforced resin molded product is not particularly limited.
- the glass composition that the glass fiber can take include, for example, the most general E-glass composition, an acid-resistant glass composition, a high-strength and high-modulus glass composition, a high-modulus and easily manufacturable glass composition, and a low dielectric constant and low dielectric loss tangent. glass composition and the like.
- the glass composition of the glass forming the glass fiber of the glass fiber reinforced resin molded article is preferably an E glass composition or an acid resistant glass composition.
- the glass composition of the glass forming the glass fiber of the glass fiber reinforced resin molded article is more preferably an E glass composition, because it has a large distribution volume and is highly effective in reducing the environmental load.
- the E-glass composition includes SiO 2 in the range of 52.0 to 56.0% by mass and Al 2 O 3 in the range of 12.0 to 16.0% by mass with respect to the total amount of the glass fiber, for a total of 20.
- the composition contains MgO and CaO in the range of 0 to 25.0% by mass and B 2 O 3 in the range of 0.0 to 10.0% by mass.
- the acid-resistant glass composition includes SiO 2 in the range of 52.0 to 62.0% by mass and Al 2 O 3 in the range of 12.0 to 16.0% by mass, for a total of 16 .0 to 30.0% by mass of MgO and CaO.
- the high-strength, high-modulus glass composition includes SiO 2 in the range of 60.0 to 70.0% by mass, Al 2 O 3 in the range of 20.0 to 30.0% by mass, and MgO in the range of 5.0 to 15.0% by mass, Fe 2 O 3 in the range of 0 to 1.5% by mass, and Na 2 O and K 2 O in the range of 0 to 0.2% by mass in total. and Li 2 O.
- the high elastic modulus easily manufacturable glass composition contains SiO 2 in the range of 57.0 to 60.0% by mass and Al 2 O 3 in the range of 17.5 to 20.0% by mass with respect to the total amount of glass fibers. , containing MgO in the range of 8.5-12.0% by weight, CaO in the range of 10.0-13.0% by weight, and B 2 O 3 in the range of 0.5-1.5% by weight and SiO 2 , Al 2 O 3 , MgO and CaO in a total amount of 98.0% by mass or more.
- the low dielectric constant low dielectric loss tangent glass composition includes SiO 2 in the range of 48.0 to 62.0% by mass, B 2 O 3 in the range of 17.0 to 26.0% by mass, and Al 2 O 3 in the range of 9.0 to 18.0% by mass, CaO in the range of 0.1 to 9.0% by mass, MgO in the range of 0 to 6.0% by mass, and a total of 0.5% by mass.
- Na 2 O, K 2 O and Li 2 O in the range of 05-0.5% by weight TiO 2 in the range of 0-5.0% by weight; SrO in the range of 0-6.0% by weight; A composition containing a total of F 2 and Cl 2 in the range of 0 to 3.0 mass % and P 2 O 5 in the range of 0 to 6.0 mass %.
- thermoplastic resins examples include thermoplastic resins and thermosetting resins, but thermoplastic resins are preferable from the viewpoint of recyclability of the resin itself.
- Thermoplastic resins forming the glass fiber reinforced resin molded article include polyethylene, polypropylene, polystyrene, styrene/maleic anhydride resin, styrene/maleimide resin, polyacrylonitrile, acrylonitrile/styrene (AS) resin, acrylonitrile/butadiene/styrene ( ABS) resin, chlorinated polyethylene/acrylonitrile/styrene (ACS) resin, acrylonitrile/ethylene/styrene (AES) resin, acrylonitrile/styrene/methyl acrylate (ASA) resin, styrene/acrylonitrile (SAN) resin, methacrylic resin, poly Vinyl chloride (PVC), polyvinylidene chloride (PVC), polyvinylidene chloride (P
- polyethylene examples include high density polyethylene (HDPE), medium density polyethylene, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and ultra high molecular weight polyethylene.
- HDPE high density polyethylene
- LDPE low density polyethylene
- LLDPE linear low density polyethylene
- ultra high molecular weight polyethylene examples include high density polyethylene (HDPE), medium density polyethylene, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and ultra high molecular weight polyethylene.
- polypropylene examples include isotactic polypropylene, atactic polypropylene, and syndiotactic polypropylene.
- polystyrene examples include general-purpose polystyrene (GPPS), which is atactic polystyrene having an atactic structure, high-impact polystyrene (HIPS) obtained by adding a rubber component to GPPS, and syndiotactic polystyrene having a syndiotactic structure.
- GPPS general-purpose polystyrene
- HIPS high-impact polystyrene
- methacrylic resin a polymer obtained by homopolymerizing one of acrylic acid, methacrylic acid, styrene, methyl acrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, and fatty acid vinyl ester, or two Examples thereof include polymers obtained by copolymerizing more than one species.
- polyvinyl chloride examples include vinyl chloride homopolymers polymerized by conventionally known emulsion polymerization methods, suspension polymerization methods, microsuspension polymerization methods, bulk polymerization methods, and monomers copolymerizable with vinyl chloride monomers. and a graft copolymer obtained by graft-polymerizing a vinyl chloride monomer to the polymer.
- polyamide examples include polycaproamide (polyamide 6), polyhexamethylene adipamide (polyamide 66), polytetramethylene adipamide (polyamide 46), polytetramethylene sebacamide (polyamide 410), polypentamethylene adipamide Pamide (Polyamide 56), Polypentamethylene Sebacamide (Polyamide 510), Polyhexamethylene Sebacamide (Polyamide 610), Polyhexamethylene Dodecamide (Polyamide 612), Polydecamethylene Adipamide (Polyamide 106), polydecamethylene sebacamide (polyamide 1010), polydecamethylene dodecamide (polyamide 1012), polyundecaneamide (polyamide 11), polyundecanamide (polyamide 116), polydodecanamide (polyamide 12), poly xylene adipamide (polyamide XD6), polyxylene sebacamide (polyamide XD10), polymetaxylylene adipamide (polyamide M
- polyacetal examples include homopolymers having oxymethylene units as main repeating units, and copolymers containing oxyalkylene units mainly consisting of oxymethylene units and having 2 to 8 adjacent carbon atoms in the main chain. A coalescence etc. are mentioned.
- polyethylene terephthalate examples include polymers obtained by polycondensation of terephthalic acid or derivatives thereof and ethylene glycol.
- polybutylene terephthalate examples include polymers obtained by polycondensation of terephthalic acid or derivatives thereof and 1,4-butanediol.
- polytrimethylene terephthalate examples include polymers obtained by polycondensation of terephthalic acid or derivatives thereof and 1,3-propanediol.
- polycarbonate examples include a polymer obtained by a transesterification method in which a dihydroxydiaryl compound and a carbonate ester such as diphenyl carbonate are reacted in a molten state, and a polymer obtained by a phosgene method in which a dihydroxyaryl compound and phosgene are reacted. mentioned.
- polyarylene sulfide examples include linear polyphenylene sulfide, crosslinked polyphenylene sulfide whose molecular weight is increased by performing a curing reaction after polymerization, polyphenylene sulfide sulfone, polyphenylene sulfide ether, and polyphenylene sulfide ketone.
- modified polyphenylene ether examples include a polymer alloy of poly(2,6-dimethyl-1,4-phenylene) ether and polystyrene, a copolymer of poly(2,6-dimethyl-1,4-phenylene) ether and styrene/butadiene.
- polymer alloy with coalescence polymer alloy of poly(2,6-dimethyl-1,4-phenylene) ether and styrene/maleic anhydride copolymer, poly(2,6-dimethyl-1,4-phenylene) ether and polyamide, and polymer alloys of poly(2,6-dimethyl-1,4-phenylene) ether and styrene/butadiene/acrylonitrile copolymer.
- polyaryletherketone examples include polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and polyetheretherketoneketone (PEEKK).
- liquid crystal polymer at least one selected from aromatic hydroxycarbonyl units, aromatic dihydroxy units, aromatic dicarbonyl units, aliphatic dihydroxy units, and aliphatic dicarbonyl units, which are thermotropic liquid crystal polyesters. and a (co)polymer consisting of a structural unit of
- fluororesin examples include polytetrafluoroethylene (PTFE), perfluoroalkoxy resin (PFA), fluoroethylene propylene resin (FEP), fluoroethylene tetrafluoroethylene resin (ETFE), polyvinyl fluoride (PVF), polyfluoride. vinylidene chloride (PVDF), polychlorotrifluoroethylene (PCTFE), ethylene/chlorotrifluoroethylene resin (ECTFE), and the like.
- PTFE polytetrafluoroethylene
- PFA perfluoroalkoxy resin
- FEP fluoroethylene propylene resin
- ETFE fluoroethylene tetrafluoroethylene resin
- PVDF polyvinyl fluoride
- PVDF vinylidene chloride
- PCTFE polychlorotrifluoroethylene
- ECTFE ethylene/chlorotrifluoroethylene resin
- ionomer (IO) resin examples include copolymers of olefins or styrene and unsaturated carboxylic acids, in which some of the carboxyl groups are neutralized with metal ions.
- olefin/vinyl alcohol resin examples include ethylene/vinyl alcohol copolymer, propylene/vinyl alcohol copolymer, saponified ethylene/vinyl acetate copolymer, and saponified propylene/vinyl acetate copolymer.
- cyclic olefin resin examples include monocyclic compounds such as cyclohexene, polycyclic compounds such as tetracyclopentadiene, and polymers of cyclic olefin monomers.
- polylactic acid examples include poly-L-lactic acid that is a homopolymer of L-lactic acid, poly-D-lactic acid that is a homopolymer of D-lactic acid, and stereocomplex-type polylactic acid that is a mixture thereof.
- cellulose resin examples include methylcellulose, ethylcellulose, hydroxycellulose, hydroxymethylcellulose, hydroxyethylcellulose, hydroxyethylmethylcellulose, hydroxypropylmethylcellulose, cellulose acetate, cellulose propionate, and cellulose butyrate.
- thermoplastic resins At least one of these thermoplastic resins is used.
- thermosetting resin examples include unsaturated polyester resin, vinyl ester resin, epoxy (EP) resin, melamine (MF) resin, phenol resin (PF), urethane resin (PU), polyisocyanate, polyisocyanurate, polyimide ( PI), urea (UF) resin, silicone (SI) resin, furan (FR) resin, benzoguanamine (BR) resin, alkyd resin, xylene resin, bismaleidotriazine (BT) resin, and diallyl phthalate resin (PDAP). mentioned.
- the glass fiber reinforced resin molded product may contain various additives in addition to the glass fiber and the resin.
- various additives include flame retardants, colorants, release agents, antioxidants, ultraviolet absorbers, antistatic agents, nucleating agents, plasticizer fillers, modifiers, and the like.
- the flame retardant examples include phosphorus-based flame retardants such as non-halogen phosphates, halogen-containing phosphates, non-halogen condensed phosphates, halogen-containing condensed phosphates, polyphosphates, red phosphorus, and brominated flame retardants.
- TBA tetrabromobisphenol A
- DBDPO decabromodiphenyl ether
- OCTA octabromodiphenyl oxide
- TBP tribromophenol
- coloring agent examples include titanium oxide, zinc oxide, zinc sulfide, and carbon black.
- Examples of the releasing agent include talc stearate, metallic soap, polyethylene wax, ethylenebisstearamide, EDA (ethylenediamine), EBA (ethylenebisstearicamide), higher fatty acid sodium salt, and higher fatty acid potassium salt. .
- antioxidants examples include phenol antioxidants, amine antioxidants, sulfur antioxidants, phosphorus antioxidants, and the like.
- ultraviolet absorber examples include salicylate-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, benzotriador-based ultraviolet absorbers, cyanoacrylate-based ultraviolet absorbers, nickel chelate-based ultraviolet absorbers, and hindered amine-based ultraviolet absorbers. be done.
- antistatic agent examples include anionic surfactants, cationic surfactants, nonionic surfactants, and amphoteric surfactants.
- nucleating agent examples include talc, dibenzylidene sorbitol, and ⁇ crystal nucleating agent.
- plasticizer examples include phthalic acid plasticizers such as DOP (dioctyl phthalate), DBP (dibutyl phthalate), DHP (diheptyl phthalate), DIDP (diisodecyl phthalate), DINP (diisononyl phthalate), fatty acid plasticizers, and TCP.
- phthalic acid plasticizers such as DOP (dioctyl phthalate), DBP (dibutyl phthalate), DHP (diheptyl phthalate), DIDP (diisodecyl phthalate), DINP (diisononyl phthalate), fatty acid plasticizers, and TCP.
- Examples of the filler include talc, mica, glass flakes, glass beads, calcium carbonate, and the like.
- the modifier include polybutadiene, styrene-butadiene copolymer, styrene-butadiene-styrene block copolymer, acrylonitrile-butadiene-styrene copolymer, methyl methacrylate-butadiene-styrene copolymer, methyl methacrylate-acrylonitrile- Butadiene-styrene copolymer, methyl methacrylate-butadiene copolymer, acrylonitrile-styrene-acrylic rubber copolymer, acrylonitrile-ethylene propylene rubber-styrene copolymer, methyl methacrylate-acrylic rubber copolymer, methyl methacrylate-acrylic rubber -Styrene copolymer, methyl methacrylate-acrylic-buta
- the recovery of the glass fiber from the glass fiber reinforced resin molded product is performed by, for example, heating the glass fiber reinforced resin molded product at 450 to 800 ° C. for 0.5 to 8 hours
- the heat contained in the glass fiber reinforced resin molded product It is carried out by incineration of the plastic resin, dissolution of the resin contained in the glass fiber reinforced thermal resin molding in a solvent such as benzyl alcohol, and the like.
- the collected glass fiber collected as described above contains organic matter derived from the glass fiber reinforced resin molded article and a small amount of organic matter used when collecting the glass fiber from the glass fiber reinforced resin molded article remaining on the surface. are doing.
- the ignition loss of the recovered glass fiber is, for example, in the range of 0.001 to 0.500% by mass, preferably in the range of 0.002 to 0.400% by mass, and 0.003 to 0.300% by mass. %, more preferably 0.004 to 0.200% by mass, even more preferably 0.005 to 0.115% by mass, and 0.010% by mass. -0.100% by weight is particularly preferred, 0.015 to 0.075% by weight is particularly preferred, and 0.020 to 0.060% by weight is most preferred.
- the ignition loss is an index showing the amount of organic matter remaining on the surface of the recovered glass fiber in trace amounts, and is measured in accordance with JIS R 3420:2013.
- the number average fiber length of the recovered glass fibers is, for example, in the range of 5 to 5000 ⁇ m.
- the number average fiber length of the recovered glass fibers is preferably in the range of 10 to 500 ⁇ m, more preferably in the range of 15 to 500 ⁇ m, and more preferably 20 to 500 ⁇ m. It is more preferably in the range of 450 ⁇ m, even more preferably in the range of 25 to 400 ⁇ m, particularly preferably in the range of 30 to 350 ⁇ m, even more preferably in the range of 35 to 330 ⁇ m, even more preferably 40 to 300 ⁇ m.
- the recovered glass fiber may be pulverized to a predetermined length in a pulverizer such as a ball mill after being recovered from the glass fiber reinforced resin molded product.
- the number average fiber length of the recovered glass fibers means the number average fiber length of the recovered glass fibers after pulverization.
- the number average fiber length of the recovered glass fibers can be calculated by the following method. First, the recovered glass fibers are transferred to a glass petri dish, and acetone is used to disperse the recovered glass fibers on the surface of the petri dish. Next, for 1000 or more of the collected glass fibers dispersed on the petri dish surface, the fiber length is measured using a stereoscopic microscope, the average value is calculated, and the average value is taken as the number average fiber length of the collected glass fibers.
- components other than glass fibers include metal oxides such as zinc oxide and titanium oxide, non-metal oxides such as diphosphorus pentoxide, and organic substances.
- the metal oxides and non-metal oxides affect the spinnability of the molten glass.
- the glass raw material contains the recovered glass fibers in a range of 11 to 75% by mass. If the content of the recovered glass fibers in the glass raw material is less than 11% by mass, the recycling rate in the method for producing long glass fibers is too low. On the other hand, when the content of the recovered glass fibers in the frit is more than 75% by mass, the liquidus temperature of the molten glass becomes high and the spinnability of the molten glass deteriorates.
- the frit preferably contains 15 to 75 mass %, more preferably 15 to 60 mass % of the recovered glass fibers. When the content of the recovered glass fibers is within this range, the liquidus temperature of the glass fibers of the present embodiment can be 1250° C.
- the glass raw material more preferably contains 17 to 50% by mass of the recovered glass fiber, more preferably 20 to 45% by mass of the recovered glass fiber, and particularly preferably 26 to 42% by mass. range of said recovered glass fibers, most preferably in the range of 30-40% by weight of said recovered glass fibers.
- the glass fiber mineral material is composed of at least one of multiple types of ores and materials refined from these ores (hereinafter sometimes referred to as "ore-derived refined materials"). Each ore and these ore-derived materials so that a desired glass composition as a whole (hereinafter sometimes referred to as a "design glass composition”) is obtained based on the components contained in the ore and these ore-derived refined materials The type of each refining material and the content ratio of each ore and each refining material derived from these ores can be determined.
- Examples of the ore include silica sand, feldspar, clay, and limestone.
- Examples of the mineral-derived refined material include silica powder, dolomite, talc, clay, alumina, and soda ash.
- S SiO 2 content (% by mass) relative to the total amount of the glass fiber mineral material - SiO 2 content (% by mass) relative to the total amount of glass fibers recovered from the glass fiber reinforced resin molded product
- A Al 2 O 3 content (% by mass) relative to the total amount of the glass fiber mineral material - Al 2 O 3 content (% by mass) relative to the total amount of glass fibers recovered from the glass fiber reinforced resin molded product
- B B 2 O 3 content (% by mass) relative to the total amount of the glass fiber mineral material - B 2 O 3 content (% by mass) relative to the total amount of glass fibers recovered from the glass fiber reinforced resin molded article
- C CaO content (% by mass) relative to the total amount of the glass fiber mineral material - CaO content (% by mass) relative to the total amount of glass fibers recovered from the glass fiber reinforced resin molded product, 5.2 ⁇ S+ABC ⁇ 46.9 (1) becomes.
- the content of each of the components described above in the recovered glass fiber and the glass fiber mineral material can be measured using an ICP emission spectrometer for Li, which is a light element, and for other elements, the wavelength dispersive type Measurement can be performed using a fluorescent X-ray analyzer.
- a measurement method first, glass batch (mixed and prepared glass raw materials), or glass fiber (when organic matter adheres to the surface of glass fiber, or when glass fiber is mainly reinforced in organic matter (resin) If it is contained as a material, it is used after removing the organic matter, for example, by heating in a muffle furnace at 300 to 650 ° C. for about 0.5 to 24 hours) is placed in a platinum crucible and placed in an electric furnace.
- the glass batch is held at 1550° C. for 4 hours and 1650° C. for 2 hours and melted while stirring, and the glass fiber is held at a temperature of 1550° C. for 6 hours and melted while stirring. , to obtain a homogeneous molten glass.
- the obtained molten glass is poured onto a carbon plate to prepare glass cullet, which is then pulverized into powder to obtain glass powder.
- the obtained glass powder is thermally decomposed with an acid, and then quantitatively analyzed using an ICP emission spectrometer.
- Other elements are quantitatively analyzed using a wavelength dispersive X-ray fluorescence spectrometer after molding the glass powder into a disc shape with a press.
- each of SiO 2 and Al 2 O 3 in the glass fiber mineral material strengthens the glass network, it contributes to increasing the spinning temperature of the molten glass and improving the elastic modulus of the long glass fiber.
- each of B2O3 and CaO of the glass fiber mineral material tends to reduce the viscosity of the molten glass. Furthermore, when the difference in glass composition between the glass fiber mineral material and the recovered glass fibers is small, the influence of trace amounts of organic substances and inorganic substances remaining in the recovered glass fibers becomes relatively large, and the liquidus temperature and Spinning temperature rises.
- the spinning temperature can be set to 1400° C.
- the degree of liquidus temperature deterioration indicates the liquidus temperature increased by mixing the recovered glass fiber with the glass raw material made of the glass fiber mineral material.
- the working temperature range deterioration degree indicates the working temperature range narrowed by mixing the recovered glass fiber with the glass raw material made of the glass fiber mineral material.
- the following working temperature range of the molten glass melted from the glass raw material prepared without mixing the recovered glass fiber, and the glass raw material made of the glass fiber mineral material prepared by mixing the recovered glass fiber It is a difference in the following working temperature ranges of molten glass in the method for producing long glass fibers. Said working temperature range is the difference between the spinning temperature and the liquidus temperature.
- S+ABC satisfies the following formula (2). 10.8 ⁇ S+ABC ⁇ 34.3 (2)
- the spinning temperature of the molten glass can be lowered to produce long glass fibers in which the decrease in the elastic modulus of the glass fibers is further suppressed.
- the elastic modulus of the long glass fibers obtained by the method for producing long fibers of the present embodiment can be made equal to or higher than the elastic modulus of standard E glass (88 GPa).
- a fiber-reinforced resin molded article containing long glass fibers having an elastic modulus of 88 GPa or more is a fiber-reinforced resin molded article in which the reinforcing effect of the long glass fibers is sufficiently obtained.
- the spinning temperature can be set to 1350° C. or lower.
- the elastic modulus of long glass fibers means the Young's modulus measured by the following method. First, long glass fibers are held at a temperature of 1550° C. for 6 hours and melted with stirring to obtain homogeneous molten glass. Next, the obtained molten glass is poured onto a carbon plate and cooled to produce glass cullet. Next, the obtained glass cullet is processed into a test piece of 25 mm ⁇ 25 mm ⁇ 5 mm using a cutting machine such as a diamond cutter and a grinder, and an index of elastic modulus is measured by an ultrasonic pulse method according to JIS R1602: 1995.
- the value of the Young's modulus is the glass raw material that is a mixture of the recovered glass fiber and the glass fiber mineral material used to produce the long glass fiber, or the raw glass fiber that has the same composition as the long glass fiber.
- the value of Young's modulus measured using glass cullet obtained by the following method instead of glass cullet obtained by melting the glass long fibers can be regarded as the same value.
- frit is placed in a platinum crucible, the platinum crucible is held in an electric furnace at a temperature in the range of 1400 to 1650 ° C. for 4 hours, and the frit is stirred. Melt to obtain homogeneous molten glass. Next, the molten glass is poured onto a carbon plate and cooled to obtain glass cullet.
- S+ABC satisfies the following formula (3). 14.9 ⁇ S+ABC ⁇ 32.4 (3)
- the liquidus temperature deterioration degree can be set to 10° C. or less, and the working temperature range deterioration degree can be set to 30° C. or less.
- the spinning temperature can be set to 1320° C. or lower.
- the S is preferably 0.5 or more from the viewpoint of contributing to the improvement of the elastic modulus of the long glass fibers, and is preferably 12.4 or less from the viewpoint of contributing to the reduction of the spinning temperature.
- the S is more preferably in the range of 1.9 to 9.4, still more preferably in the range of 2.4 to 8.0, particularly preferably in the range of 2.7 to 7.7, and 5.1 to 7.5. is most preferred.
- the above A is preferably -3.4 or more from the viewpoint of contributing to the improvement of the elastic modulus of the long glass fibers, and is preferably 13.9 or less from the viewpoint of contributing to the reduction of the spinning temperature.
- the A is more preferably in the range of -1.4 to 9.6, still more preferably in the range of 0.3 to 8.3, particularly preferably in the range of 0.9 to 7.5, and 3.0 to 7.5. A range of 0 is most preferred.
- the B is preferably -9.9 or more from the viewpoint of contributing to the reduction of the spinning temperature, and preferably 17.4 or less from the viewpoint of contributing to the improvement of the elastic modulus of the long glass fiber. .
- the B is more preferably in the range of -8.9 to 14.9, more preferably in the range of -7.9 to 9.9, particularly preferably in the range of -6.9 to 8.4, -5.5 A range of ⁇ 0.0 is most preferred.
- the C is preferably -20.0 or more from the viewpoint of contributing to a reduction in the spinning temperature, and preferably 6.9 or less from the viewpoint of contributing to the improvement of the elastic modulus of the long glass fibers.
- the C is more preferably in the range of -14.9 to 4.9, more preferably in the range of -13.4 to 5.4, particularly preferably in the range of -12.5 to 2.5, -9.8 A range of ⁇ -4.3 is most preferred.
- the long glass fiber of the present embodiment contains SiO 2 in the range of 48.00 to 62.00% by mass, Al 2 O 3 in the range of 12.00 to 21.40% by mass, and B 2 O 3 in the range of 0.10 to 15.00% by weight, CaO in the range of 10.00 to 22.50% by weight, and MgO in the range of 1.30 to 10.00% by weight, in total It is spun to contain P 2 O 5 , TiO 2 and ZnO in the range of 0.01-10.00% by weight. Furthermore, the long glass fiber of the present embodiment may contain less than 5.00% by mass of other components, or may contain no other components.
- the glass composition of the long glass fibers is within the above range, when E-glass fibers, which are general-purpose recovered glass fibers, and recovered glass fibers with acid-resistant glass fibers are used, the glass fiber mineral material and the recovered glass fibers When the composition difference does not become too small and the raw material recycling rate is increased, the spinning temperature of the molten glass is low, and the rise in the liquidus temperature of the molten glass and the narrowing of the working temperature range of the molten glass are suppressed. be.
- the long glass fiber of the present embodiment preferably contains SiO 2 in the range of 50.00 to 60.00% by mass and Al 2 O 3 in the range of 13.00 to 19.00% by mass with respect to the total amount of the long glass fiber.
- B 2 O 3 in the range of 0.30 to 5.00% by weight, CaO in the range of 12.00 to 20.00% by weight, and MgO in the range of 2.50 to 9.00% by weight;
- the total content of P 2 O 5 , TiO 2 and ZnO in the range of 0.01 to 9.50% by weight and other components in the range of 0 to 4.00% by weight are spun.
- the long glass fiber of the present embodiment preferably contains SiO 2 in the range of 51.00 to 59.00% by mass and Al 2 O in the range of 14.00 to 18.50% by mass with respect to the total amount of the long glass fiber.
- B 2 O 3 in the range of 1.00-4.50% by weight, CaO in the range of 12.50-19.00% by weight, and MgO in the range of 3.00-8.50% by weight.
- a total of P 2 O 5 , TiO 2 and ZnO in the range of 0.01 to 9.00% by weight, and other components in the range of 0 to 3.00% by weight.
- the long glass fiber of the present embodiment preferably contains SiO 2 in the range of 52.00 to 58.00% by mass and Al 2 O in the range of 14.50 to 18.00% by mass with respect to the total amount of the long glass fiber.
- B 2 O 3 in the range of 1.50-4.00% by weight, CaO in the range of 13.00-18.00% by weight, and MgO in the range of 3.50-8.00% by weight.
- a total of P 2 O 5 , TiO 2 and ZnO in the range of 0.01 to 8.50% by weight, and other components in the range of 0 to 2.00% by weight.
- P 2 O 5 , TiO 2 , and ZnO are components contained in additives contained in the glass fiber reinforced resin molded product.
- the sum of the absolute values of S, A, B and C is 10.6 or more from the viewpoint of contributing to the improvement of the spinnability of molten glass even if the recycling rate is increased. It is preferably 46.9 or less from the viewpoint of preventing phase separation of the molten glass.
- the sum of the absolute values of S, A, B and C is more preferably in the range of 12.8 to 31.1, still more preferably in the range of 17.1 to 29.9, and particularly preferably in the range of 18.9. 1 to 29.4, most preferably 22.9 to 28.9.
- the frit is supplied to a melting furnace and melted at a temperature in the range of 1400 to 1650°C, for example.
- the molten glass is pulled out from 1 to 30,000 nozzle tips of platinum bushings controlled to a predetermined temperature, and rapidly cooled to form glass filaments.
- a sizing agent or a binder is applied to the formed glass filaments using an applicator that is an applicator, and a sizing shoe is used to bundle 1 to 30,000 glass filaments while the winding machine is operated.
- a long glass fiber is obtained by winding the tube at high speed.
- a nozzle tip having a non-circular shape and at least one of a protrusion and a notch for quenching the molten glass is used, and the temperature conditions are controlled to form a glass having a flat cross-sectional shape.
- Long glass fibers composed of filaments may be obtained.
- the long glass fiber obtained by the production method of this embodiment has a length of at least 1000 m.
- the converted fiber diameter of the glass filaments constituting the long glass fibers of the present embodiment is, for example, in the range of 3.0 to 100.0 ⁇ m, preferably in the range of 4.0 to 70.0 ⁇ m, more preferably 5.0 ⁇ m. It is in the range of 0 to 50.0 ⁇ m, more preferably in the range of 6.5 ⁇ m to 40.0 ⁇ m, particularly preferably in the range of 7.0 to 30.0 ⁇ m.
- the converted fiber diameter of the glass filament means the diameter of a perfect circle having the same area as the cross-sectional area of the glass filament.
- the cross section of the glass filament means a cross section perpendicular to the fiber length direction of the glass fiber.
- the cross-sectional shape of the glass filaments constituting the long glass fibers of the present embodiment is usually circular.
- the shapes include, for example, oval, elliptical, and rectangular.
- an elliptical shape means a shape in which the short sides of a rectangle are replaced with semicircles having diameters corresponding to the short sides.
- the ratio of the long diameter to the short diameter (long diameter/short diameter) in the cross section is, for example, in the range of 2.0 to 10.0. , preferably in the range of 3.0 to 8.0.
- the long glass fiber of this embodiment can be processed into various forms.
- a chopped strand is mentioned as a form which the long glass fiber of this embodiment can be processed.
- the number of glass filaments (bundle number) constituting the chopped strands is preferably 1 to 20,000, more preferably 50 to 10,000, still more preferably 200 to 8,000.
- the length of the long glass fibers constituting the chopped strands is preferably 1.0 to 100.0 mm, more preferably 1.2 to 51.0 mm, still more preferably 1.5 to 30.0 mm, particularly preferably 2 .0-15.0 mm, most preferably 2.3-7.8 mm.
- the forms that the long glass fibers of the present embodiment can be processed include, for example, rovings that do not cut glass long fibers composed of 10 to 30,000 glass filaments, and 1 to 20,000 glass filaments.
- a cut fiber obtained by pulverizing the constituent long glass fiber to a length of 0.001 to 0.900 mm by a known device such as a ball mill or a Henschel mixer can be mentioned.
- the long glass fibers of the present embodiment are processed into, for example, chopped strands, the chopped strands and a thermoplastic resin are kneaded with a twin-screw kneader, and the resulting resin pellets are used for injection molding to form a glass fiber reinforced resin. you can get the goods.
- the glass fiber reinforced resin molded product can be produced by injection compression molding, two-color molding, hollow molding, foam molding (including supercritical fluid foam molding), insert molding, in-mold coating molding, and extrusion molding.
- sheet molding method sheet molding method, thermoforming method, rotational molding method, laminate molding method, press molding method, blow molding method, stamping molding method, infusion method, hand lay-up method, spray-up method, resin transfer molding method, sheet molding
- molding methods such as the compound method, the bulk molding compound method, the pultrusion method, and the filament winding method.
- the glass fiber reinforced resin molded product includes, for example, parts such as the housing and frame of mobile electronic devices typified by smartphones, battery tray covers, sensors, automotive electrical parts such as coil bobbins, electronic device parts other than mobile electronic devices, electric Used for connection terminal parts, etc.
- the surface of the long glass fiber of the present embodiment is coated with an organic substance for the purpose of improving the adhesiveness between the glass fiber and the resin, improving the uniform dispersibility of the glass fiber in the mixture of the glass fiber and the resin, and the like.
- organic substances include urethane resins, epoxy resins, vinyl acetate resins, acrylic resins, modified polypropylenes, especially carboxylic acid-modified polypropylenes, (poly)carboxylic acids, especially maleic acid and unsaturated monomer copolymers. and silane coupling agents.
- the long glass fiber of the present embodiment may be coated with a composition containing a lubricant, a surfactant, etc. in addition to the resin or silane coupling agent.
- the composition covers the long glass fibers of the present embodiment at a rate of 0.1 to 2.0% by mass based on the mass of the long glass fibers not coated with the composition.
- the coating of the long glass fibers with an organic substance is carried out, for example, by applying the sizing agent or binder to the long glass fibers using a known method such as a roller applicator in the manufacturing process of the long glass fibers.
- the sizing agent or binder includes a solution of the resin, the silane coupling agent, or the composition.
- the coating of the long glass fibers is then completed by drying the long glass fibers coated with the solution of the resin, the silane coupling agent, or the composition.
- examples of the silane coupling agent include aminosilane, chlorosilane, epoxysilane, mercaptosilane, vinylsilane, acrylsilane, and cationic silane.
- One of these compounds may be used as the silane coupling agent, or two or more of these compounds may be used in combination.
- aminosilane examples include ⁇ -aminopropyltriethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropyltrimethoxysilane, N- ⁇ -(aminoethyl)-N'- ⁇ -(aminoethyl)- ⁇ -aminopropyltrimethoxysilane, ⁇ -anilinopropyltrimethoxysilane, and the like.
- chlorosilane examples include ⁇ -chloropropyltrimethoxysilane.
- epoxysilane examples include ⁇ -glycidoxypropyltrimethoxysilane and ⁇ -(3,4-epoxycyclohexyl)ethyltrimethoxysilane.
- mercaptosilane examples include ⁇ -mercaptotrimethoxysilane.
- Examples of the vinylsilane include vinyltrimethoxysilane and N- ⁇ -(N-vinylbenzylaminoethyl)- ⁇ -aminopropyltrimethoxysilane.
- Examples of the acrylsilane include ⁇ -methacryloxypropyltrimethoxysilane.
- Examples of the cationic silane include N-(vinylbenzyl)-2-aminoethyl-3-aminopropyltrimethoxysilane hydrochloride and N-phenyl-3-aminopropyltrimethoxysilane hydrochloride.
- lubricant examples include modified silicone oils, animal oils, hydrogenated animal oils, vegetable oils, hydrogenated vegetable oils, animal waxes, vegetable waxes, mineral waxes, condensates of higher saturated fatty acids and higher saturated alcohols, Examples include polyethyleneimine, polyalkylpolyamine alkylamide derivatives, fatty acid amides, and quaternary ammonium salts. One of these lubricants may be used, or two or more of them may be used in combination.
- Examples of the animal oil include beef tallow.
- Examples of the vegetable oils include soybean oil, coconut oil, rapeseed oil, palm oil, and castor oil.
- Examples of the animal waxes include beeswax and lanolin.
- Examples of the vegetable wax include candelilla wax and carnauba wax.
- Examples of the mineral wax include paraffin wax and montan wax.
- Examples of the condensates of higher saturated fatty acids and higher saturated alcohols include stearic acid esters such as lauryl stearate.
- fatty acid amide examples include dehydration condensates of polyethylene polyamines such as diethylenetriamine, triethylenetetramine and tetraethylenepentamine and fatty acids such as lauric acid, myristic acid, palmitic acid and stearic acid.
- quaternary ammonium salts include alkyltrimethylammonium salts such as lauryltrimethylammonium chloride.
- surfactant examples include nonionic surfactants, cationic surfactants, anionic surfactants, and amphoteric surfactants. One of these surfactants may be used, or two or more of them may be used in combination.
- nonionic surfactant examples include ethylene oxide propylene oxide alkyl ether, polyoxyethylene alkyl ether, polyoxyethylene-polyoxypropylene-block copolymer, alkylpolyoxyethylene-polyoxypropylene-block copolymer, polyoxyethylene fatty acid.
- Ester polyoxyethylene fatty acid monoester, polyoxyethylene fatty acid diester, polyoxyethylene sorbitan fatty acid ester, glycerol fatty acid ester ethylene oxide adduct, polyoxyethylene castor oil ether, hydrogenated castor oil ethylene oxide adduct, alkylamine ethylene oxide adduct fatty acid amide ethylene oxide adduct, glycerol fatty acid ester, polyglycerol fatty acid ester, pentaerythritol fatty acid ester, sorbitol fatty acid ester, sorbitan fatty acid ester, sucrose fatty acid ester, polyhydric alcohol alkyl ether, fatty acid alkanolamide, acetylene glycol, acetylene Examples include alcohols, ethylene oxide adducts of acetylene glycol, and ethylene oxide adducts of acetylene alcohol.
- cationic surfactant examples include alkyldimethylbenzylammonium chloride, alkyltrimethylammonium chloride, alkyldimethylethylammonium ethylsulfate, higher alkylamine salts (acetates, hydrochlorides, etc.), ethylene oxide adducts of higher alkylamines. , condensates of higher fatty acids and polyalkylenepolyamines, salts of esters of higher fatty acids and alkanolamines, salts of higher fatty acid amides, imidazoline-type cationic surfactants, and alkylpyridinium salts.
- anionic surfactant examples include higher alcohol sulfates, higher alkyl ether sulfates, ⁇ -olefin sulfates, alkylbenzenesulfonates, ⁇ -olefinsulfonates, fatty acid halides and N-methyltaurine.
- sulfosuccinic acid dialkyl ester salts higher alcohol phosphate ester salts, and higher alcohol ethylene oxide adduct phosphate ester salts.
- amphoteric surfactants examples include amino acid type amphoteric surfactants such as alkylaminopropionate alkali metal salts, betaine type such as alkyldimethylbetaine, and imidazoline type amphoteric surfactants.
- Glass composition A glass raw material, which is a mixture of the recovered glass fiber and the glass fiber mineral material of each example or comparative example, is placed in a platinum crucible, and the platinum crucible is held in an electric furnace at a temperature in the range of 1400 to 1650 ° C. for 4 hours, The frit was melted with stirring to obtain homogeneous molten glass. Next, the molten glass was poured onto a carbon plate and cooled to obtain lumpy glass cullet, which was pulverized into powder to obtain glass powder. After molding the glass powder into a disc shape with a press, quantitative analysis was performed using a wavelength dispersive X-ray fluorescence spectrometer. These quantitative analysis results were converted to oxides to calculate the content and total amount of each component, and the content of each component was obtained from these numerical values.
- ⁇ Spinning temperature> Using a high-temperature electric furnace with a rotating Brookfield viscometer (manufactured by Shibaura Systems Co., Ltd.), the glass cullet of each example or comparative example obtained by the above method is melted in a platinum crucible, and the melting temperature is changed. The viscosity of the molten glass was continuously measured using a viscometer provided in the electric furnace while the spinning was being carried out, and the temperature corresponding to the rotational viscosity of 1000 poise was measured as the spinning temperature.
- the working temperature range was calculated as the difference between the spinning temperature and the liquidus temperature.
- ⁇ Elastic modulus> The glass cullet of each example or comparative example obtained by the above-described method was processed into a 25 mm ⁇ 25 mm ⁇ 5 mm test piece using a cutting machine such as a diamond cutter and a grinder, and was subjected to ultra-thickness according to JIS R1602: 1995. Young's modulus was measured as an index of elastic modulus by the sound pulse method.
- ⁇ Liquidus temperature deterioration degree and working range temperature deterioration degree> The glass fiber mineral material used in each example or comparative example was blended without mixing the recovered glass fiber to prepare a glass raw material, the glass raw material was placed in a platinum crucible, and the platinum crucible was heated to 1400 to 1650 ° C. It was held in an electric furnace at a temperature within the range for 4 hours, and the frit was melted with stirring to obtain a homogeneous molten glass. Next, the molten glass was poured onto a carbon plate and cooled to obtain massive glass cullet, which was used as reference glass.
- the degree of liquidus temperature deterioration was calculated by subtracting the liquidus temperature of the molten glass obtained by melting the reference glass from the liquidus temperature of the molten glass in the manufacturing method of the long glass fiber of each example or comparative example. Further, a value obtained by subtracting the working range temperature of the molten glass in the manufacturing method of the long glass fiber of each example or comparative example from the working range temperature of the molten glass obtained by melting the reference glass was calculated as the working range temperature deterioration degree.
- Example 1 The glass fiber-reinforced thermoplastic resin molded article was heated at 625° C. for 4 hours to incinerate the thermoplastic resin, and then the remaining glass fibers A were collected.
- the glass composition of the recovered glass fiber A was as shown in Table 1 below, and the number average fiber length of the recovered glass fiber A was 320 ⁇ m.
- Glass raw material was obtained by mixing 33 parts by mass of recovered glass fiber A with 67 parts by mass of glass fiber mineral material D having composition D shown in Table 2 below. Next, the frit is placed in a platinum crucible, the platinum crucible is held in an electric furnace at a temperature in the range of 1400 to 1650° C.
- Example 2 The same operation as in Example 1 was performed except that 20 parts by mass of recovered glass fiber A was mixed with 80 parts by mass of glass fiber mineral material D to obtain a glass raw material. The results are shown in Table 3 below.
- Example 3 The same operation as in Example 1 was performed except that 50 parts by mass of glass fiber mineral material D was mixed with 50 parts by mass of recovered glass fiber A to obtain a glass raw material. The results are shown in Table 3 below.
- Example 4 The same operation as in Example 1 was performed, except that the recovered glass fiber C having the glass composition shown in Table 1 below was recovered. The results are shown in Table 3 below.
- Example 5 The same operation as in Example 1 was performed, except that the recovered glass fiber B having the glass composition shown in Table 1 below was recovered. The results are shown in Table 3 below.
- Example 6 The same operation as in Example 1 was performed, except that 50 parts by mass of the glass fiber mineral material D was mixed with 50 parts by mass of the recovered glass fiber B to obtain a glass raw material. The results are shown in Table 3 below.
- Example 7 The same procedure as in Example 1 was carried out, except that a glass fiber mineral material E having a composition E shown in Table 2 below was used. The results are shown in Table 3 below.
- Example 8 The same operation as in Example 1 was performed except that 50 parts by mass of glass fiber mineral material E was mixed with 50 parts by mass of recovered glass fiber A to obtain a glass raw material. The results are shown in Table 3 below.
- Example 9 The same operation as in Example 1 was performed except that 70 parts by mass of recovered glass fiber A was mixed with 30 parts by mass of glass fiber mineral material D to obtain a glass raw material. The results are shown in Table 4 below.
- Example 10 The same procedure as in Example 1 was carried out, except that a glass fiber mineral material F having a composition F shown in Table 2 below was used. The results are shown in Table 4 below.
- Example 11 The same operation as in Example 1 was carried out, except that a glass fiber mineral material G having a composition G shown in Table 2 below was used. The results are shown in Table 4 below.
- Example 1 The same procedure as in Example 1 was carried out, except that a glass fiber mineral material H having a composition H shown in Table 2 below was used. The results are shown in Table 4 below.
- Example 2 The same operation as in Example 1 was performed except that 20 parts by mass of recovered glass fiber A was mixed with 80 parts by mass of glass fiber mineral material H to obtain a glass raw material. The results are shown in Table 4 below.
- Example 3 The same procedure as in Example 1 was carried out, except that a glass fiber mineral material I having a composition I shown in Table 2 below was used. The results are shown in Table 4 below.
- the unit of a component is mass %.
- the unit of a component is mass %. Also shown in Table 2 are the liquidus temperatures, spinning temperatures, and working temperature ranges of the molten glasses obtained by melting each of the glass fiber mineral materials D-I having compositions D-I, respectively.
- the unit of a component is mass %.
- the unit of a component is mass %.
- liquidus temperature and spinning temperature of the molten glass in the method for producing long glass fibers of Examples 1 to 11 in which S+ABC is within a predetermined range are low, the working temperature range is wide, and the degree of liquidus temperature deterioration and working temperature Range deterioration was small.
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Abstract
Description
近年、環境問題に対する関心の高まりに伴い、廃棄物の量を削減するため、使用済みのガラス繊維強化樹脂成形品からガラス繊維を回収し、再利用することが期待されている。特許文献1には、ガラス繊維強化樹脂成形品から樹脂を溶解させて回収したガラス繊維(以下、「回収ガラス繊維」と称する場合がある)を再利用して、ガラス繊維強化プラスチックシートを作製する方法が記載されている。
廃棄物の量を削減するという観点から、ガラス原料全量に対する回収ガラス繊維の使用量(以下、「リサイクル率」と称する場合がある)を大きくすることが期待されている。しかしながら、回収ガラス繊維を使用するガラス長繊維の製造方法において、リサイクル率の高い製造方法では、ガラス繊維以外の成分の含有量が増加するため、ガラス繊維鉱物材料のみを使用するガラス長繊維の製造方法と比べて、ガラス原料が溶融された溶融ガラスの液相温度が上昇し、当該溶融ガラスの作業温度範囲が狭くなったりして、当該溶融ガラスの紡糸性が低下することがわかった。また、製造されるガラス繊維のガラス組成によっては、紡糸温度(1000ポイズ温度)が上昇し、炉を高温に保つために多量のエネルギーが必要となり、リサイクル率を向上させても、環境負荷がかかってしまうという不都合がある。
前記溶融ガラスを紡糸して、ガラス長繊維とする紡糸工程を含み、
前記ガラス原料における前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の含有量が11~75質量%の範囲であり、下記式(1)が満たされる、ガラス長繊維の製造方法である。
5.2≦S+A-B-C≦46.9 (1)
ここで、S、A、B及びCは以下の通りである。
S=前記ガラス繊維鉱物材料の全量に対するSiO2の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するSiO2の含有率(質量%)
A=前記ガラス繊維鉱物材料の全量に対するAl2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するAl2O3の含有率(質量%)
B=前記ガラス繊維鉱物材料の全量に対するB2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するB2O3の含有率(質量%)
C=前記ガラス繊維鉱物材料の全量に対するCaOの含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するCaOの含有率(質量%)
本発明のガラス長繊維の製造方法では、リサイクル率を高くし、液相温度の上昇及び前記溶融ガラスの作業温度範囲の狭小化を抑制しつつ、前記溶融ガラスの紡糸温度を低くして、ガラス長繊維を製造できる。
10.8≦S+A-B-C≦34.3 (2)
ここで、S、A、B及びCは前記される通りである。
S、A、B及びCが上記式(2)を満たすと、前記溶融ガラスの紡糸温度をより低くして、ガラス繊維の弾性率の低下が抑制されているガラス長繊維を製造できる。
14.9≦S+A-B-C≦32.4 (3)
ここで、S、A、B及びCは前記される通りである。
S、A、B及びCが上記式(3)を満たすと、前記溶融ガラスの液相温度の上昇及び作業温度範囲の狭小化を更に抑制して、ガラス長繊維を製造できる。
21.9≦S+A-B-C≦30.4 (4)
ここで、S、A、B及びCは前記される通りである。
S、A、B及びCが上記式(4)を満たすと、前記溶融ガラスの紡糸温度を特に低くして、ガラス長繊維を製造できる。
本実施形態のガラス長繊維の製造方法は、回収ガラス繊維とガラス繊維鉱物材料を含むガラス原料を溶融して溶融ガラスとするガラス溶融工程と、前記溶融ガラスを紡糸して、ガラス長繊維とする紡糸工程を含む。
本実施形態のガラス長繊維は、前記回収ガラス繊維と前記ガラス繊維鉱物材料を含む前記ガラス原料が溶融され、紡糸されてなる。
前記ガラス繊維強化樹脂成形品は、例えば、ガラス繊維のガラスフィラメントが集束され、所定の長さを備えるチョップドストランドと熱可塑性樹脂を、二軸混練機で混練して樹脂ペレットを得た後、得られた樹脂ペレットを用いて射出成形を行うことにより得られる。また、前記ガラス繊維強化樹脂成形品は、射出圧縮成形法、二色成形法、中空成形法、発泡成形法(超臨界流体発泡成形法を含む)、インサート成形法、インモールドコーティング成形法、押出成形法、シート成形法、熱成形法、回転成形法、積層成形法、プレス成形法、ブロー成形法、スタンピング成形法、インフュージョン法、ハンドレイアップ法、スプレイアップ法、レジントランスファーモールディング法、シートモールディングコンパウンド法、バルクモールディングコンパウンド法、プルトルージョン法、フィラメントワインディング法等の公知の成形方法により得られたものであってもよい。
前記ガラス繊維強化樹脂成形品の前記ガラス繊維を形成するガラスのガラス組成は特に限定されない。前記ガラス繊維が取り得るガラス組成としては、例えば最も汎用的であるEガラス組成、耐酸性ガラス組成、高強度高弾性率ガラス組成、高弾性率易製造性ガラス組成、及び低誘電率低誘電正接ガラス組成等が挙げられる。汎用性の観点からは、前記ガラス繊維強化樹脂成形品の前記ガラス繊維を形成するガラスのガラス組成は、Eガラス組成又は耐酸性ガラス組成であることが好ましい。また、流通量が多く環境負荷低減への効果が大きいことから、前記ガラス繊維強化樹脂成形品の前記ガラス繊維を形成するガラスのガラス組成は、Eガラス組成がより好ましい。
前記耐酸性ガラス組成は、ガラス繊維の全量に対し52.0~62.0質量%の範囲のSiO2と、12.0~16.0質量%の範囲のAl2O3と、合計で16.0~30.0質量%の範囲のMgO及びCaOとを含む組成である。
前記ガラス繊維強化樹脂成形品を形成する樹脂としては、熱可塑性樹脂又は熱硬化性樹脂を挙げることができるが、樹脂自体のリサイクル性の観点から、熱可塑性樹脂が好ましい。前記ガラス繊維強化樹脂成形品を形成する熱可塑性樹脂として、ポリエチレン、ポリプロピレン、ポリスチレン、スチレン/無水マレイン酸樹脂、スチレン/マレイミド樹脂、ポリアクリロニトリル、アクリロニトリル/スチレン(AS)樹脂、アクリロニトリル/ブタジエン/スチレン(ABS)樹脂、塩素化ポリエチレン/アクリロニトリル/スチレン(ACS)樹脂、アクリロニトリル/エチレン/スチレン(AES)樹脂、アクリロニトリル/スチレン/アクリル酸メチル(ASA)樹脂、スチレン/アクリロニトリル(SAN)樹脂、メタクリル樹脂、ポリ塩化ビニル(PVC)、ポリ塩化ビニリデン(PVDC)、ポリアミド、ポリアセタール、ポリエチレンテレフタレート(PET)、ポリブチレンテレフタレート(PBT)、ポリトリメチレンテレフタレート(PTT)、ポリカーボネート、ポリアリーレンサルファイド、ポリエーテルスルホン(PES)、ポリフェニルスルホン(PPSU)、ポリフェニレンエーテル(PPE)、変性ポリフェニレンエーテル(m-PPE)、ポリアリールエーテルケトン、液晶ポリマー(LCP)、フッ素樹脂、ポリエーテルイミド(PEI)、ポリアリレート(PAR)、ポリサルフォン(PSF)、ポリアミドイミド(PAI)、ポリアミノビスマレイミド(PABM)、熱可塑性ポリイミド(TPI)、ポリエチレンナフタレート(PEN)、エチレン/酢酸ビニル(EVA)樹脂、アイオノマー(IO)樹脂、ポリブタジエン、スチレン/ブタジエン樹脂、ポリブチレン、ポリメチルペンテン、オレフィン/ビニルアルコール樹脂、環状オレフィン樹脂、セルロース樹脂、ポリ乳酸等が挙げられる。
前記ポリブチレンテレフタレートとしては、テレフタル酸又はその誘導体と、1,4-ブタンジオールとの重縮合により得られる重合体等が挙げられる。
前記ポリトリメチレンテレフタレートとしては、テレフタル酸又はその誘導体と、1,3-プロパンジオールとの重縮合により得られる重合体等が挙げられる。
前記ガラス繊維強化樹脂成形品には、ガラス繊維と樹脂の他に各種添加剤を含んでもよい。各種添加剤としては、難燃剤、着色剤、離型剤、酸化防止剤、紫外線吸収剤、帯電防止剤、核剤、可塑剤充填剤、改質剤等が挙げられる。
前記核剤としては、タルク、ジベンジリデンソルビトール、及びβ晶核剤等が挙げられる。
前記改質剤としては、ポリブタジエン、スチレン-ブタジエン共重合体、スチレン-ブタジエン-スチレンブロック共重合体、アクリロニトリル-ブタジエン-スチレン共重合体、メチルメタクリレート-ブタジエン-スチレン共重合体、メチルメタクリレート-アクリロニトリル-ブタジエン-スチレン共重合体、メチルメタクリレート-ブタジエン共重合体、アクリロニトリル-スチレン-アクリルゴム共重合体、アクリロニトリル-エチレンプロピレンゴム-スチレン共重合体、メチルメタクリレート-アクリルゴム共重合体、メチルメタクリレート-アクリルゴム-スチレン共重合体、メチルメタクリレート-アクリル-ブタジエンゴム共重合体、メチルメタクリレート-アクリル-ブタジエンゴム-スチレン共重合体、メチルメタクリレート-(アクリル-シリコーンIPNゴム)共重合体、天然ゴム等を挙げることができる。
前記ガラス繊維強化樹脂成形品からの前記ガラス繊維の回収は、例えば、ガラス繊維強化樹脂成形品を450~800℃の条件で0.5~8時間加熱するガラス繊維強化樹脂成形品に含まれる熱可塑性樹脂の焼却、ガラス繊維強化熱樹脂成形品に含まれる樹脂のベンジルアルコール等の溶剤への溶解等により実施される。
ここで、強熱減量は回収ガラス繊維に表面に微量残存している有機物の量を示す指標であり、JIS R 3420:2013に準拠して測定される。
前記ガラス原料は、好ましくは15~75質量%、より好ましくは15~60質量%の範囲の前記回収ガラス繊維を含む。前記回収ガラス繊維の含有量が当該範囲であると、本実施形態のガラス繊維の液相温度を1250℃以下にできる。前記ガラス原料は、より好ましくは17~50質量%の範囲の前記回収ガラス繊維を含み、更に好ましくは20~45質量%の範囲の前記回収ガラス繊維を含み、特に好ましくは26~42質量%の範囲の前記回収ガラス繊維を含み、最も好ましくは30~40質量%の範囲の前記回収ガラス繊維を含む。
ガラス繊維鉱物材料は、複数種類の鉱石、及びこれらの鉱石から精製された材料(以下、「鉱石由来精製材料」と称する場合がある)の少なくとも1つから構成される。前記鉱石、及びこれらの鉱石由来精製材料の含有成分に基づいて、全体として所望のガラス組成(以下、「設計ガラス組成」と称する場合がある)になるように、各鉱石、及びこれらの鉱石由来各精製材料の種類、並びに、各鉱石、及びこれらの鉱石由来各精製材料の含有比率を決定できる。
前記回収ガラス繊維のガラス組成と、前記ガラス繊維鉱物材料のガラス組成とを対比した場合、SiO2、Al2O3、B2O3、及びCaOの含有率の差は下記式(1)に示される関係を満たす。すなわち、
S=前記ガラス繊維鉱物材料の全量に対するSiO2の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するSiO2の含有率(質量%)
A=前記ガラス繊維鉱物材料の全量に対するAl2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するAl2O3の含有率(質量%)
B=前記ガラス繊維鉱物材料の全量に対するB2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するB2O3の含有率(質量%)
C=前記ガラス繊維鉱物材料の全量に対するCaOの含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するCaOの含有率(質量%)とすると、
5.2≦S+A-B-C≦46.9 (1)
となる。
ここで、回収ガラス繊維およびガラス繊維鉱物材料の前述した各成分の含有率は、軽元素であるLiについてはICP発光分光分析装置を用いて測定を行うことができ、その他の元素は波長分散型蛍光X線分析装置を用いて測定を行うことができる。
測定方法としては、初めにガラスバッチ(ガラス原料を混合して調合したもの)、又はガラス繊維(ガラス繊維表面に有機物が付着している場合、又はガラス繊維が有機物(樹脂)中に主に強化材として含まれている場合には、例えば300~650℃のマッフル炉で0.5~24時間程度加熱する等して、有機物を除去してから用いる)を白金ルツボに入れ、電気炉中で、ガラスバッチにおいては1550℃で4時間、1650℃で2時間保持して撹拌を加えながら溶融させることにより、ガラス繊維においては1550℃の温度に6時間保持して撹拌を加えながら溶融させることにより、均質な溶融ガラスを得る。次に得られた溶融ガラスをカーボン板上に流し出してガラスカレットを作製した後、粉砕し粉末化してガラス粉末とする。軽元素であるLiについては得られたガラス粉末を酸で加熱分解した後、ICP発光分光分析装置を用いて定量分析する。その他の元素は前記ガラス粉末をプレス機で円盤状に成形した後、波長分散型蛍光X線分析装置を用いて定量分析する。これらの定量分析結果を酸化物換算して各成分の含有量及び全量を計算し、これらの数値から前述した各成分の含有率を求めることができる。
具体的には、S+A-B-Cが上記式(1)を満たすと、本実施形態のガラス長繊維の製造方法において、紡糸温度を1400℃以下にでき、溶融ガラスの下記液相温度悪化度を50℃以下にでき、下記作業温度範囲悪化度を80℃以下にできる。
ここで、前記液相温度悪化度は、回収ガラス繊維をガラス繊維鉱物材料からなるガラス原料に混合することで上昇した液相温度を示す。具体的には、回収ガラス繊維を混合して調製されたガラス長繊維の製造方法における溶融ガラスの液相温度と、回収ガラス繊維を混合せずに調製された、ガラス繊維鉱物材料からなるガラス原料から溶融された溶融ガラスの液相温度の差である。
さらに前記作業温度範囲悪化度は、回収ガラス繊維をガラス繊維鉱物材料からなるガラス原料に混合することで狭小化した作業温度範囲を示す。具体的には、回収ガラス繊維を混合せずに調製されたガラス原料から溶融された溶融ガラスの下記作業温度範囲と、回収ガラス繊維を混合して調製されたガラス繊維鉱物材料からなるガラス原料からガラス長繊維の製造方法における溶融ガラスの下記作業温度範囲の差である。
前記作業温度範囲は紡糸温度と液相温度との差である。
10.8≦S+A-B-C≦34.3 (2)
上記式(2)を満たすと、前記溶融ガラスの紡糸温度をより低くして、ガラス繊維の弾性率の低下がより抑制されているガラス長繊維を製造できる。具体的には、本実施形態の長繊維の製造方法により得られるガラス長繊維の弾性率を、標準的なEガラスの弾性率(88GPa)以上にできる。弾性率が88GPa以上のガラス長繊維を含む繊維強化樹脂成形品は、ガラス長繊維の補強効果が十分に得られている繊維強化樹脂成形品である。さらに、本実施形態の長繊維の製造方法において、紡糸温度を1350℃以下にできる。
ここで、ガラス長繊維の弾性率は、以下の方法で測定したヤング率を意味する。まず、ガラス長繊維を1550℃の温度に6時間保持して撹拌を加えながら溶融させることにより、均質な溶融ガラスを得る。次に、得られた溶融ガラスをカーボン板上に流し出し、冷却することでガラスカレットを作製する。次いで、得られたガラスカレットを、切削加工機、例えばダイヤモンドカッターと研磨機を用いて、25mm×25mm×5mmの試験片に加工し、JIS R1602:1995に従って超音波パルス法にて弾性率の指標としてヤング率を測定する。なお、前記ヤング率の値は、前記ガラス長繊維を製造するのに用いられる、回収ガラス繊維とガラス繊維鉱物材料との混合物であるガラス原料、又は、前記ガラス長繊維と同一の組成を備えるように調合されたガラス原料から、以下の方法で得られるガラスカレットを、前記ガラス長繊維を溶融して得られるガラスカレットに代えて用いて測定したヤング率の値と同じ値とみなすことができる。ガラス原料からガラスカレットを得る方法は、まず、ガラス原料を、白金ルツボに入れ、当該白金ルツボを1400~1650℃の範囲の温度の電気炉中に4時間保持し、当該ガラス原料を攪拌しながら溶融し、均質な溶融ガラスを得る。次に、当該溶融ガラスをカーボン板上に流し出し、冷却してガラスカレットを得る。
14.9≦S+A-B-C≦32.4 (3)
S、A、B及びCが上記式(3)を満たすと、前記溶融ガラスの液相温度の上昇及び作業温度範囲の狭小化を更に抑制して、ガラス長繊維を製造できる。具体的には、本実施形態の長繊維の製造方法において、前記液相温度悪化度を10℃以下、前記作業温度範囲悪化度を30℃以下にできる。
21.9≦S+A-B-C≦30.4 (4)
S、A、B及びCが上記式(4)を満たすと、前記溶融ガラスの紡糸温度が特に低いガラス長繊維を製造できる。具体的には、本実施形態の長繊維の製造方法において、紡糸温度を1320℃以下にできる。
前記Sは、ガラス長繊維の弾性率向上に寄与するという観点からは、0.5以上であることが好ましく、紡糸温度低減に寄与するという観点からは、12.4以下であることが好ましい。前記Sは、1.9~9.4の範囲がより好ましく、2.4~8.0の範囲が更に好ましく、2.7~7.7の範囲が特に好ましく、5.1~7.5の範囲が最も好ましい。
前記Aは、ガラス長繊維の弾性率向上に寄与するという観点からは、-3.4以上であることが好ましく、紡糸温度低減に寄与するという観点からは13.9以下であることが好ましい。前記Aは、-1.4~9.6の範囲がより好ましく、0.3~8.3の範囲が更に好ましく、0.9~7.5の範囲が特に好ましく、3.0~7.0の範囲が最も好ましい。
前記Bは、紡糸温度低減に寄与するという観点からは、-9.9以上であることが好ましく、ガラス長繊維の弾性率向上に寄与するという観点からは、17.4以下であることが好ましい。前記Bは、-8.9~14.9の範囲がより好ましく、-7.9~9.9の範囲が更に好ましく、-6.9~8.4の範囲が特に好ましく、-5.5~0.0の範囲が最も好ましい。
前記Cは、紡糸温度低減に寄与するという観点からは、-20.0以上であることが好ましく、ガラス長繊維の弾性率向上に寄与するというからは、6.9以下であることが好ましい。前記Cは、-14.9~4.9の範囲がより好ましく、-13.4~5.4の範囲が更に好ましく、-12.5~2.5の範囲が特に好ましく、-9.8~-4.3の範囲が最も好ましい。
前記ガラス長繊維のガラス組成が前記範囲であると、汎用的な回収ガラス繊維であるEガラス繊維及び耐酸性ガラス繊維を備える回収ガラス繊維を使用した際に、ガラス繊維鉱物材料と回収ガラス繊維の組成差が小さくなりすぎず、原料のリサイクル率が大きくしたときに、前記溶融ガラスの紡糸温度が低く、前記溶融ガラスの液相温度の上昇及び前記溶融ガラスの作業温度範囲の狭小化が抑制される。
本実施形態の製造方法により得られたガラス長繊維は、少なくとも1000mの長さを備える。
前記エポキシシランとしては、例えばγ-グリシドキシプロピルトリメトキシシラン、及びβ-(3,4-エポキシシクロヘキシル)エチルトリメトキシシラン等が挙げられる。
前記メルカプトシランとしては、例えばγ-メルカプトトリメトキシシラン等が挙げられる。
前記アクリルシランとしては、例えばγ-メタクリロキシプロピルトリメトキシシラン等が挙げられる。
前記カチオニックシランとしては、例えばN-(ビニルベンジル)-2-アミノエチル-3-アミノプロピルトリメトキシシラン塩酸塩、及びN-フェニル-3-アミノプロピルトリメトキシシラン塩酸塩等が挙げられる。
前記植物油としては、例えば大豆油、ヤシ油、ナタネ油、パーム油、及びひまし油等が挙げられる。
前記動物性ワックスとしては、例えば蜜蝋、及びラノリン等が挙げられる。
前記鉱物系ワックスとしては、例えばパラフィンワックス、及びモンタンワックス等が挙げられる。
前記高級飽和脂肪酸と高級飽和アルコールとの縮合物としては、例えばラウリルステアレート等のステアリン酸エステル等が挙げられる。
前記第4級アンモニウム塩としては、例えばラウリルトリメチルアンモニウムクロライド等のアルキルトリメチルアンモニウム塩等が挙げられる。
前記ノニオン系界面活性剤としては、例えばエチレンオキサイドプロピレンオキサイドアルキルエーテル、ポリオキシエチレンアルキルエーテル、ポリオキシエチレン-ポリオキシプロピレン-ブロックコポリマー、アルキルポリオキシエチレン-ポリオキシプロピレン-ブロックコポリマー、ポリオキシエチレン脂肪酸エステル、ポリオキシエチレン脂肪酸モノエステル、ポリオキシエチレン脂肪酸ジエステル、ポリオキシエチレンソルビタン脂肪酸エステル、グリセロール脂肪酸エステルエチレンオキサイド付加物、ポリオキシエチレンキャスターオイルエーテル、硬化ヒマシ油エチレンオキサイド付加物、アルキルアミンエチレンオキサイド付加物、脂肪酸アミドエチレンオキサイド付加物、グリセロール脂肪酸エステル、ポリグリセリン脂肪酸エステル、ペンタエリスリトール脂肪酸エステル、ソルビトール脂肪酸エステル、ソルビタン脂肪酸エステル、ショ糖脂肪酸エステル、多価アルコールアルキルエーテル、脂肪酸アルカノールアミド、アセチレングリコール、アセチレンアルコール、アセチレングリコールのエチレンオキサイド付加物、及びアセチレンアルコールのエチレンオキサイド付加物等が挙げられる。
<ガラス組成>
各実施例又は比較例の回収ガラス繊維とガラス繊維鉱物材料との混合物であるガラス原料を白金ルツボに入れ、当該白金ルツボを1400~1650℃の範囲の温度の電気炉中に4時間保持し、当該ガラス原料を攪拌しながら溶融し、均質な溶融ガラスを得た。次に、当該溶融ガラスをカーボン板上に流し出し、冷却して得た塊状のガラスカレットを粉砕し粉末化してガラス粉末とした。当該ガラス粉末をプレス機で円盤状に成形した後、波長分散型蛍光X線分析装置を用いて定量分析した。これらの定量分析結果を酸化物換算して各成分の含有量及び全量を計算し、これらの数値から各成分の含有量を求めた。
回転式ブルックフィールド型粘度計付高温電気炉(芝浦システム株式会社製)を用い、白金ルツボ中で、前述の方法で得られた各実施例又は比較例のガラスカレットを溶融し、溶融温度を変化させながら当該電気炉が備える粘度計を用いて連続的に溶融ガラスの粘度を測定し、回転粘度が1000ポイズのときに対応する温度を紡糸温度として測定した。
前述の方法で得られた各実施例又は比較例のガラスカレットを粉砕し、粒径0.5~1.5mmのガラス粒子40gを180×20×15mmの白金製ボートに入れ、1000~1500℃の温度勾配を設けた管状電気炉で8時間以上加熱した。その後、前記管状電気炉から取り出し、偏光顕微鏡で観察して、ガラス由来の結晶(失透)が析出し始めた位置を特定した。管状電気炉内の温度を、B熱電対を用いて実測し、前記結晶が析出し始めた温度を測定して液相温度とした。
紡糸温度と液相温度との差を作業温度範囲として算出した。
前述の方法で得られた各実施例又は比較例のガラスカレットを、切削加工機、例えばダイヤモンドカッターと研磨機を用いて、25mm×25mm×5mmの試験片に加工し、JIS R1602:1995に従って超音波パルス法にて弾性率の指標としてヤング率を測定した。
各実施例又は比較例で用いたガラス繊維鉱物材料を、回収ガラス繊維を混合せずに調合してガラス原料を調製し、当該ガラス原料を白金ルツボに入れ、当該白金ルツボを1400~1650℃の範囲の温度の電気炉中に4時間保持し、当該ガラス原料を攪拌しながら溶融し、均質な溶融ガラスを得た。次に、当該溶融ガラスをカーボン板上に流し出し、冷却して塊状のガラスカレットを得、基準ガラスとした。各実施例又は比較例のガラス長繊維の製造方法における溶融ガラスの液相温度から、当該基準ガラスを溶融した溶融ガラスの液相温度を減じた値を液相温度悪化度として算出した。さらに当該基準ガラスを溶融した溶融ガラスの作業範囲温度から、各実施例又は比較例のガラス長繊維の製造方法における溶融ガラスの作業範囲温度を減じた値を作業範囲温度悪化度として算出した。
ガラス繊維強化熱可塑性樹脂成形品を625℃で4時間加熱して、熱可塑性樹脂を焼却したのち、残存したガラス繊維Aを回収した。回収ガラス繊維Aのガラス組成は下記表1に示す通りであり、回収ガラス繊維Aの数平均繊維長は320μmであった。下記表2に示す組成Dを有する、67質量部のガラス繊維鉱物材料Dに、33質量部の回収ガラス繊維Aを混合して、ガラス原料を得た。次に、当該ガラス原料を白金ルツボに入れ、当該白金ルツボを1400~1650℃の範囲の温度の電気炉中に4時間保持し、当該ガラス原料を攪拌しながら溶融し、均質な溶融ガラスを得た。次に、当該溶融ガラスをカーボン板上に流し出し、冷却して塊状のガラスカレットを得、ガラス組成、紡糸温度及び液相温度を測定し、作業温度範囲、液相温度悪化度及び作業範囲温度悪化度を算出した。結果を下記表3に示す。
80質量部のガラス繊維鉱物材料Dに20質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表3に示す。
50質量部のガラス繊維鉱物材料Dに50質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表3に示す。
下記表1に示すガラス組成を有する回収ガラス繊維Cを回収する以外、実施例1と同様の操作を行った。結果を下記表3に示す。
下記表1に示すガラス組成を有する回収ガラス繊維Bを回収する以外、実施例1と同様の操作を行った。結果を下記表3に示す。
50質量部のガラス繊維鉱物材料Dに50質量部の回収ガラス繊維Bを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表3に示す。
下記表2に示す組成Eを有するガラス繊維鉱物材料Eを使用する以外、実施例1と同様の操作を行った。結果を下記表3に示す。
50質量部のガラス繊維鉱物材料Eに50質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表3に示す。
30質量部のガラス繊維鉱物材料Dに70質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表4に示す。
下記表2に示す組成Fを有するガラス繊維鉱物材料Fを使用する以外、実施例1と同様の操作を行った。結果を下記表4に示す。
下記表2に示す組成Gを有するガラス繊維鉱物材料Gを使用する以外、実施例1と同様の操作を行った。結果を下記表4に示す。
下記表2に示す組成Hを有するガラス繊維鉱物材料Hを使用する以外、実施例1と同様の操作を行った。結果を下記表4に示す。
80質量部のガラス繊維鉱物材料Hに20質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表4に示す。
下記表2に示す組成Iを有するガラス繊維鉱物材料Iを使用する以外、実施例1と同様の操作を行った。結果を下記表4に示す。
90質量部のガラス繊維鉱物材料Hに10質量部の回収ガラス繊維Aを混合してガラス原料を得た以外、実施例1と同様の操作を行った。結果を下記表4に示す。
一方、S+A-B-Cが所定範囲の実施例1~11のガラス長繊維の製造方法における溶融ガラスの液相温度及び紡糸温度は低く、作業温度範囲は広く、液相温度悪化度及び作業温度範囲悪化度は小さかった。
Claims (6)
- ガラス長繊維の製造方法であって、
ガラス繊維強化樹脂成形品から回収されたガラス繊維とガラス繊維鉱物材料を含むガラス原料を溶融して溶融ガラスとするガラス溶融工程と、
前記溶融ガラスを紡糸して、ガラス長繊維とする紡糸工程を含み、
前記ガラス原料における前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の含有量が11~75質量%の範囲であり、
下記式(1)が満たされる、ガラス長繊維の製造方法。
5.2≦S+A-B-C≦46.9 (1)
ここで、S、A、B及びCは以下の通りである。
S=前記ガラス繊維鉱物材料の全量に対するSiO2の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するSiO2の含有率(質量%)
A=前記ガラス繊維鉱物材料の全量に対するAl2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するAl2O3の含有率(質量%)
B=前記ガラス繊維鉱物材料の全量に対するB2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するB2O3の含有率(質量%)
C=前記ガラス繊維鉱物材料の全量に対するCaOの含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するCaOの含有率(質量%) - 下記式(2)が満たされる、請求項1に記載されたガラス長繊維の製造方法。
10.8≦S+A-B-C≦34.3 (2)
ここで、S、A、B及びCは前記される通りである。 - 前記ガラス原料における前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の含有量が15~60質量%の範囲である、請求項1に記載されたガラス長繊維の製造方法。
- 下記式(3)が満たされる、請求項1~3のいずれか1項に記載されたガラス長繊維の製造方法。
14.9≦S+A-B-C≦32.4 (3)
ここで、S、A、B及びCは前記される通りである。 - 下記式(4)が満たされる、請求項4に記載されたガラス長繊維の製造方法。
21.9≦S+A-B-C≦30.4 (4)
ここで、S、A、B及びCは前記される通りである。 - ガラス長繊維であって、
前記ガラス長繊維は、ガラス繊維強化樹脂成形品から回収されたガラス繊維とガラス繊維鉱物材料を含むガラス原料が溶融され、紡糸されてなり、
前記ガラス原料における前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の含有量が11~75質量%であり、下記式(1)が満たされ、
前記ガラス長繊維は、ガラス長繊維の全量に対し、48.00~62.00質量%の範囲のSiO2と、12.00~21.40質量%の範囲のAl2O3と、0.10~15.00質量%の範囲のB2O3と、10.00~22.50質量%の範囲のCaOと、1.30~10.00質量%の範囲のMgOと、合計で0.01~10.00質量%の範囲のP2O5、TiO2、及びZnOとを含有するように紡糸された、ガラス長繊維。
5.2≦S+A-B-C≦46.9 (1)
ここで、S、A、B及びCは以下の通りである。
S=前記ガラス繊維鉱物材料の全量に対するSiO2の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するSiO2の含有率(質量%)
A=前記ガラス繊維鉱物材料の全量に対するAl2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するAl2O3の含有率(質量%)
B=前記ガラス繊維鉱物材料の全量に対するB2O3の含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するB2O3の含有率(質量%)
C=前記ガラス繊維鉱物材料の全量に対するCaOの含有率(質量%)-前記ガラス繊維強化樹脂成形品から回収されたガラス繊維の全量に対するCaOの含有率(質量%)
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