Glass compositions, fiberizable glass compositions, and glass fibers and articles of manufacture made therefrom
View Patent ↗The present invention relates generally to glass compositions incorporating rare earth oxides. In one embodiment, a glass composition suitable for fiber forming comprises 51-65 weight percent SiO 2 , 12.5-19 weight percent Al 2 O 3 , 0-16 weight percent CaO, 0-12 weight percent MgO, 0-2.5 weight percent Na 2 O, 0-1 weight percent K 2 O, 0-2 weight percent Li 2 O, 0-3 weight percent TiO 2 , 0-3 weight percent ZrO 2 , 0-3 weight percent B 2 O 3 , 0-3 weight percent P 2 O 5 , 0-1 weight percent Fe 2 O 3 , at least one rare earth oxide in an amount not less than 0.05 weight percent, and 0-11 weight percent total other constituents. In some embodiments, the at least one rare earth oxide comprises at least one of La 2 O 3 , Y 2 O 3 , Sc 2 O 3 , and Nd 2 O 3 . The at least one rare earth oxide is present in an amount of at least 1 weight percent in some embodiments. The at least one rare earth oxide, in some embodiments, is present in an amount of at least 3 weight percent. The glass compositions can be used to form glass fibers which can be incorporated into a variety of other fiber glass products (e.g., strands, rovings, fabrics, etc.) and incorporated into various composites.
1. An article of manufacture comprising:
SiO 2
51-65
weight percent;
Al 2 O 3
12.5-22
weight percent;
CaO
0-16
weight percent;
MgO
0-12
weight percent;
Na 2 O
0-2.5
weight percent;
K 2 O
0-1
weight percent;
Li 2 O
0-2
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-3
weight percent;
P 2 O 5
0-3
weight percent;
Fe 2 O 3
0-1
weight percent;
at least one rare earth oxide in an amount not less than 0.05 weight percent,
wherein the Na 2 O+K 2 O+Li 2 O content is greater than 1 weight percent.
2. The article of manufacture of claim 1 , wherein the article is a roving.
3. The article of manufacture of claim 1 , wherein the article is a yarn.
4. The article of manufacture of claim 1 , wherein the article is a fabric.
5. The article of manufacture of claim 4 , wherein the fabric is woven.
6. The article of manufacture of claim 1 , wherein the article is a composite.
7. The article of manufacture of claim 6 , wherein the composite comprises a polymeric resin and a plurality of glass fibers disposed in the polymeric resin, wherein at least one of the plurality of glass fibers comprises the glass composition comprising:
SiO 2
54-64
weight percent;
Al 2 O 3
14-19
weight percent;
CaO
0.5-14.0
weight percent;
MgO
6-9
weight percent;
Na 2 O
0-1.5
weight percent;
K 2 O
0-1
weight percent;
Li 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-1
weight percent;
Fe 2 O 3
0-0.5
weight percent;
at least one rare earth oxide in an amount greater than 1 weight percent; and
Na 2 O+K 2 O+Li 2 O is greater than 1 weight percent.
8. The article of manufacture of claim 1 , wherein the article is a prepreg.
9. The article of manufacture of claim 8 , wherein the prepreg comprises a polymeric resin and a plurality of glass fibers in contact with the polymeric resin, wherein at least one of the plurality of glass fibers comprises a glass composition comprising:
SiO 2
54-64
weight percent;
Al 2 O 3
14-19
weight percent;
CaO
0.5-14.0
weight percent;
MgO
6-9
weight percent;
Na 2 O
0-1.5
weight percent;
K 2 O
0-1
weight percent;
Li 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-1
weight percent;
Fe 2 O 3
0-0.5
weight percent;
at least one rare earth oxide in an amount greater than 1 weight percent; and
Na 2 O+K 2 O+Li 2 O is greater than 1 weight percent.
10. The article of manufacture of claim 8 , wherein the article is a printed circuit board.
11. A glass composition suitable for fiber forming comprising:
SiO 2
51-65
weight percent;
Al 2 O 3
12.5-19
weight percent;
CaO
0-20
weight percent;
MgO
0-12
weight percent;
Na 2 O
0-2.5
weight percent;
K 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-3
weight percent;
P 2 O 5
0-3
weight percent;
Fe 2 O 3
0-1
weight percent;
Li 2 O in an amount greater than 0 weight percent and up to 2 weight percent; and
at least one rare earth oxide in an amount not less than 0.05 weight percent,
wherein the glass composition is substantially free of CeO 2 ; and
wherein the glass composition is substantially free of Y 2 O 3 , the MgO content is greater than four times the CaO content, or the CaO content is greater than the MgO content.
12. The glass composition of claim 11 , wherein MgO is present in an amount up to about 9 weight percent.
13. The glass composition of claim 11 , wherein the CaO content is between about 0.5 and about 15 weight percent.
14. The glass composition of claim 11 , wherein the Na 2 O+K 2 O+Li 2 O content is greater than 1 weight percent.
15. The glass composition of claim 11 , wherein the SiO 2 content is at least 60 weight percent.
16. The glass composition of claim 11 , wherein the at least one rare earth oxide is present in an amount of at least 1 weight percent.
17. The glass composition of claim 11 , wherein the at least one rare earth oxide comprises at least one of La 2 O 3 , Y 2 O 3 , Sc 2 O 3 , and Nd 2 O 3 .
18. The glass composition of claim 11 , further comprising ZrO 2 in an amount up to about 3.0 weight percent.
19. A glass composition suitable for fiber forming comprising:
SiO 2
51-65
weight percent;
Al 2 O 3
12.5-19
weight percent;
CaO
0-20
weight percent;
MgO
0-12
weight percent;
Na 2 O
0-2.5
weight percent;
K 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-3
weight percent;
P 2 O 5
0-3
weight percent;
Fe 2 O 3
0-1
weight percent;
Li 2 O in an amount greater than 0 weight percent and up to 2 weight percent; and
at least one rare earth oxide is present in an amount greater than 1 weight percent,
wherein the glass composition is substantially free of Y 2 O 3 , the MgO content is greater than four times the CaO content, or the CaO content is greater than the MgO content.
20. The glass composition of claim 19 , wherein MgO is present in an amount up to about 9 weight percent.
21. The glass composition of claim 19 , wherein the CaO content is between about 0.5 and about 15 weight percent.
22. The glass composition of claim 19 , wherein the Na 2 O+K 2 O+Li 2 O content is greater than 1 weight percent.
23. The glass composition of claim 19 , wherein the SiO 2 content is at least 60 weight percent.
24. The glass composition of claim 19 , wherein the at least one rare earth oxide is present in an amount of at least 3 weight percent.
25. The glass composition of claim 19 , wherein the at least one rare earth oxide comprises at least one of La 2 O 3 , Y 2 O 3 , Sc 2 O 3 , and Nd 2 O 3 .
26. The glass composition of claim 19 , further comprising ZrO 2 in an amount up to about 3.0 weight percent.
27. A glass composition suitable for fiber forming comprising:
SiO 2
51-65
weight percent;
Al 2 O 3
12.5-19
weight percent;
CaO
0.5 to less than 10 weight percent;
MgO
0-12
weight percent;
Na 2 O
0-2.5
weight percent;
K 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-3
weight percent;
P 2 O 5
0-3
weight percent;
Fe 2 O 3
0-1
weight percent;
Li 2 O in an amount greater than 0 weight percent and up to 2 weight percent; and
at least one rare earth oxide in an amount not less than 0.05 weight percent,
wherein the glass composition is substantially free of Y 2 O 3 , the MgO content is greater than four times the CaO content, or the CaO content is greater than the MgO content.
28. The glass composition of claim 27 , wherein MgO is present in an amount up to about 9 weight percent.
29. The glass composition of claim 27 , wherein the Na 2 O+K 2 O+Li 2 O content is greater than 1 weight percent.
30. The glass composition of claim 27 , wherein the SiO 2 content is at least 60 weight percent.
31. The glass composition of claim 27 , wherein the at least one rare earth oxide is present in an amount of at least 1 weight percent.
32. The glass composition of claim 27 , wherein the at least one rare earth oxide comprises at least one of La 2 O 3 , Y 2 O 3 , Sc 2 O 3 , and Nd 2 O 3 .
33. The glass composition of claim 27 , further comprising ZrO 2 in an amount up to about 3.0 weight percent.
34. A glass composition suitable for fiber forming comprising:
SiO 2
54-64
weight percent;
Al 2 O 3
14-19
weight percent;
CaO
0-16
weight percent;
MgO
6-12
weight percent;
Na 2 O
0-1.5
weight percent;
K 2 O
0-1
weight percent;
Li 2 O
0-1
weight percent;
TiO 2
0-3
weight percent;
B 2 O 3
0-1
weight percent;
Fe 2 O 3
0-0.5
weight percent;
BaO
0-0.5
weight percent;
SrO
0-0.5
weight percent;
at least one rare earth oxide in an amount greater than 1 weight percent; and
Na 2 O+K 2 O+Li 2 O is greater than 1 weight percent,
wherein the sum of CaO+MgO+BaO+SrO is 8-23 weight percent.
35. The glass composition of claim 34 , wherein the MgO content is between 6 and about 9 weight percent.
36. The glass composition of claim 34 , wherein the CaO content is between about 0.5 and about 15 weight percent.
37. The glass composition of claim 34 , wherein the SiO 2 content is at least 60 weight percent.
38. The glass composition of claim 34 , wherein the at least one rare earth oxide is present in an amount of at least 3 weight percent.
39. The glass composition of claim 34 , wherein the at least one rare earth oxide comprises at least one of La 2 O 3 , Y 2 O 3 , Sc 2 O 3 , and Nd 2 O 3 .
40. The glass composition of claim 34 , further comprising ZrO 2 in an amount up to about 3.0 weight percent.