The Manufacturing Technology of Continuous Glass Fibres

Transcription

1 Glass Science and Technology 6 The Manufacturing Technology of Continuous Glass Fibres {Second, completeiy revised edition) K.L. LOEWENSTEIN, B.Sc, Ph.D., F.S.G.T. Consultant and Director, Fibertech Ltd., Farnborough, Hants., England ELSEVIER Amsterdam Oxford - New York 1983

2 CONTENTS Prcfacc, v Clossary of glass fibre terms, vii Short conversion table, x Chapter I. A brief history Cha.pter II. Class and glass fibres, 5 Re ferences, 13 Chapter ITT. The produets and manufacturing processes, 15 III. 1. The produets, J5 II T. 1. I Mat, 15 III.1.2 Rovings, Roving cloth or woven rovings, II Combinati on mats, 2 3 L IT Y a rn s, 2 3 III. 1.6 Chopped Strands, 2 4 HI Millcd fibres, An outline of the manufacturing processes, Chapter I G Glass manu.facture, 32 I 1. General, 32 IV z. Glass compositions, 33 IV 3. Selcction of raw materials for F. glass manufacture, 39 IV 1. Raw materials for introducing silica [Si0 2 J, 40 IV 2. Raw materials for introducing aluniina (A1 Z 0 3 ), 40 IV Raw materials for introducing boric oxide (.BzOj), 41. IV 3 4. Raw materials for introducing magnesia (MgOJ, 42 IV Raw materials for introducing calcium oxidc (CaO) 43 IV.3 6. Raw materials for introducing fluoride (F IV. 3 7 ^ 2 ), 44 IV Ilse of sodium sulphate, 44 1 ron oxide (Fe20 I 4. 3 ), 4 5 llandling, weighing, mixing of raw materials into T 5. batcb, 4 5 Production of E glass, 47 IV. 5. 1, The charactcristics of E glass from thc point of I5.2. view of glass melting, Production of E glass by unit mclter, 48 I5.4. Design parameters of unit melter, 5] Special features, 56

3 XI I -1 I V. 5, IV. 5, 6. T I. 5.. s. I , 1 V I5.9. IV. (),. 1. TV. ().2. IV. 6,. IV.6. 3.],. IV. b.. 2 IV.6., I T I I. 7. On cxtending the campaign lifo of a unit melter Tor E glass, 00 Services and safcty, 61 Instrumentation, control and alarms, 72 \ T eiv dcvelopnient of furnaces for L' glass niamifacturc, 75 AlT-electric furnaces, 77 Mixcd electric/fossi1 fuel-fired furnaces, 82 Control of atmospheric pollution originating fron) a unit melter making F. glass, 8 2 I0. The forehearth or feeder, 85 forehearths for marhle manufacture, 89 Forehearths and proecss for rodmaking, 1)0 Torehearths for direet-mclt Operation, HO Sonic alternative configurations for forehearths 91 Sonic eonstructional details of forehearths, 9 6 Choice of refractories, 100 Fi ring system of the forehearth, 100 Instrumentation, controls, and alarms, 104 Recent developiiicnts in the deslgn and Operation of forehearths for the direct-melt proecss, 104 I' Technical control of glass manufacturc. I 1. The commissioning of the furnace for the production of T, glass, 108 I/.2. Operating the furnace, 112 I.7. 2 I T.7.2 Control of the melter, 11.3 Control of the forehearth, 115 Long-term control and historv of the Operation, 1 lt. Chapter The conversion of glass into glass fibre, TIS T. Marbles and rod; quality control. Sorting and fccding of marbles to bushings, T20 Z. The fibre-drawing furnace - the bushing, 122 V.2. 1 V _ 2 V , , The choicc of platinum mctals and allovs used, 125 The nozzles, 129 The construetion of a bushing, its assembly and niounting in a framc, 135 The design of larger bushings, 143 The Strickland-PPG ( VMicrodyne' ] and 'C processes 144 Nozzle shields and the stability of the fibre drawing proecss, 148 Bushings - heating and associated Services, temperature control, and their start-up and Operation, 154 Bushing clectrics Tempcrature control- and temperature ramps, 160 Power and control connections to the bushing, start-up and Operation, The behaviour of bushings as they age, The replacemcnt of bushings, 166

4 AI Tbc repair and construction of bushings on plant. site, ] l'ibrc size applicators, Types o applicators, 169.S. Gathering shoes or combs, water sprays and pull-down rollers, Water sprays, Gathering shoes and combs, 178 S. Pull-down rollers, The mechanical attenuation of fibrös; winders and othet equipment, tbcir principles of Operation and construction, , 6.1.3, Winders t'o makc cakes, 182 The collet, 182 The traverse, 186 Changes oecuring during tbe winding of a cake, ,4 Automatic windexs for manu.racturing glass J ihre cakes, The direct-roving winder, 196 The di rect-wet-c.hopper, 198 i Geometry of a single bushing position 7, ,7.2.1,7.2.2 V,, V,7.2.5 V V V.7. V.8, V. 9. V.9.1. V. 10. V V V.10, V ll. Principles of bushing position geometry, 201 Services requ:i red in a fibre-drawing department, 208 Soft or distilled wuter, 208 Public water supply, 210 Electricity,211 Air condi t ion.ing and working conditions, 212 Fibre size supply and return fi f any), 214 Compressed air, 216 Waste disposai, 216 Layout of a r ibre-draivi ng department, 218 Tbc handling of fibre cakes, 222 The drying of glass fibre cakes, 226 RefVrences, 242 Dielcctric drying, 22 8 Control of tbe fibre-drawing process, 230 l'ibre size - correct type and quantity deposited, 2 30 Kater content, 231 Splitting efficiency, 2.^2 Control of t.cx (or count), 232 The commissi oning of a direct-mcit. furriace and assoeiated fibre-drawing department, 237 Chapter VI. Fibre sizes for conti nuous glass f ihres, 2-13 Vl.l. Fibre sizes for yarns and glass fibre producta derived froin yarns, 2 44

5 VT.2. VT. VI. 3,1. VT. 2. Fibre size for yarns and cords Tor the reinforceinent of rubber and elastoiners, 252 J-ibre sizes for glass fibre products for thc direct reinf orceinent of therniosetting and thermop]astic polymers, 2 54 Properties imparted by the fibre sizc wh i ch forms a nccessary part of the manufacturing process and/or properties of the products, 255 The naturc of glass surfaees and the probler:) of linki.ng glass fibres to polymers, 258 VT. Polymers for composit.es, 259 VT. 4. Keying agcnts, 2 60 VT. 5. The fiimformcr and adhcsivc, 269 VT. 6. Plasticiscrs, VT. 7. Lubricants or softcners, 2 76 VT.8. hmulsifying agcnts, 2 76 VI. 9. Antistatic agcnts, 2 76 VT. 10. MisccI 1 aacous otlicr materials, 2 79 VT Formulation of fibre sizes for the reinforcement of plastics etc., 280 VI. 12. Mixing equipment, 28 7 VI. 1.3, Examples of fibre sizc f ornmlat i ons for glass Tibi'es that require chopping, 28 8 VT. 14. Fxamples of fibre sizes for glass fibres which arc uscd in continuous lengths, 2 91 VT.15. Thixotropic fibre sizes, 2 93 Referenc.es, 295 Chaptcr VII, The conversion of glass fibre Strand into salcablc products, Vli.l. The manufacture of chopped Strand raat, 297 VII.1.1. Thc forming section, 2 99 VII The binder appli.cator section, 306 VII.T. The oven, 30 8 VT Ancillary equipment, 310 VII.1.5. Chopped Strand mat - some general operational procedures, 311 VII. 2. Thc manufacture of continuous Strand mat, 312 VT 1. The manufacture of tissue or roofing mat, 315 VII. 4. The manufacture of rovi.ngs, 317 VII Rovings for chopping, 32.3 VI Rovings for weaving, 325 VIT. 4. Rovings for winding and. pultrus Ion, 327 VTI.4.4. The di rectly-wound roving, 328 VII. 5. Thc manufacture of roving cloth, 329 VI1.6. The manufacture of chopped Strands from cakes, 323 VTT.7. Thc manufacture of yarns, 333 VII.8. Rc fcrences, 339 Thc disposal of waste glass fibre Strands and products, 339 Author and Name Index, 340 Subiect Index, 545