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2010 | Buch

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Fiberglass and Glass Technology

Energy-Friendly Compositions and Applications

herausgegeben von: Frederick T. Wallenberger, Paul A. Bingham

Verlag: Springer US

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

Fiberglass and Glass Technology: Energy-Friendly Compositions and Applications provides a detailed overview of fiber, float and container glass technology with special emphasis on energy- and environmentally-friendly compositions, applications and manufacturing practices which have recently become available and continue to emerge. Energy-friendly compositions are variants of incumbent fiberglass and glass compositions that are obtained by the reformulation of incumbent compositions to reduce the viscosity and thereby the energy demand. Environmentally-friendly compositions are variants of incumbent fiber, float and container glass compositions that are obtained by the reformulation of incumbent compositions to reduce environmentally harmful emissions from their melts. Energy- and environmentally-friendly compositions are expected to become a key factor in the future for the fiberglass and glass industries.

This book consists of two complementary sections: continuous glass fiber technology and soda-lime-silica glass technology. Important topics covered include:

o Commercial and experimental compositions and products

o Design of energy- and environmentally-friendly compositions

o Emerging glass melting technologies including plasma melting

o Fiberglass composite design and engineering

o Emerging fiberglass applications and markets

Fiberglass and Glass Technology: Energy-Friendly Compositions and Applications is written for researchers and engineers seeking a modern understanding of glass technology and the development of future products that are more energy- and environmentally-friendly than current products.

Inhaltsverzeichnis

Frontmatter

Continuous Glass Fibers

Frontmatter

Chapter 1. Commercial and Experimental Glass Fibers

Abstract

Continuous glass fibers can be formed from melts with a wide range of compositions and viscosities. This chapter reviews pure silica fibers which are formed from highly viscous melts, silicate glass fibers with 50–70% SiO₂ which are formed from moderately viscous melts, aluminate glass fibers with 50–80% Al₂O₃, as well as yttria-alumina-garnet (YAG) glass fibers which are formed from inviscid (literally non-viscous) melts. Commercial glass fibers are made for a variety of applications from pure silica rods and from silicate melts containing 50–70% SiO₂ and 10–25% Al₂O₃. Boron-free, essentially boron-free, and borosilicate E-glass are general-purpose fibers. ERC-glass offers high corrosion resistance, HS-glass offers high-strength composites, D-glass offers a low dielectric constant, and A-glass offers the possibility of using waste container glass for less demanding applications.

Frederick T. Wallenberger

Chapter 2. Design of Energy-Friendly Glass Fibers

Abstract

Incumbent fiberglass compositions rely on decades of commercial experience. From a compositional point of view, many of these melts require more energy than needed in their production, or emit toxic effluents into the environment. This chapter reviews the design of energy- and/or environmentally friendly E-glass, HT-glass, ECR-glass, A-glass, and C-glass compositions, which have lower viscosities or fiber-forming temperatures and therefore require less energy in a commercial furnace than the respective incumbent compositions and/or do not contain ingredients which are of environmental concern.

Frederick T. Wallenberger

Chapter 3. Composite Design and Engineering

Abstract

Fiberglass is a versatile and cost-effective reinforcement for composites. Many processes, resins, and forms of fiberglass facilitate this versatility. The design, engineering, manufacture, and properties of fiberglass-reinforced composite products from diverse thermoset and thermoplastic resins are described. The attributes of fiberglass-reinforced composites include its mechanical and chemical properties, lightweight, corrosion resistance, longevity, low total system cost, and Class A surface properties. Specific examples illustrate the importance of the form of the fiberglass reinforcement and of the interfacial bond between the glass fibers and the matrix resin in optimizing composite properties. In addition, recent advances are described with regard to the fabrication of fiberglass-reinforced wind turbine blades.

J.H.A. van der Woude, E.L. Lawton

Chapter 4. Glass Fibers for Printed Circuit Boards

Abstract

Fiberglass imparts numerous positive benefits to modern printed circuit boards. Reinforced laminate composites have an excellent cost–performance relationship that makes sense for most applications. At the leading edge of the technology, new glass fibers with improved properties, in combination with the best resin systems available, are able to meet very challenging performance, cost, and regulatory demands while remaining manufacturable.

Anthony V. Longobardo

Chapter 5. High-Strength Glass Fibers and Markets

Abstract

High-strength glass fibers play a crucial role in composite applications requiring combinations of strength, modulus, and high-temperature stability. Compositions in the high-strength glass group include S-glass and R-glass, which are used for applications requiring physical properties that cannot be satisfied by conventional E-glass. Additional compositions are also available for specialized applications requiring extreme performance in any one area. The main competition for high-strength glasses in the marketplace comes from carbon and polymer fibers. Ultimately, the product of choice is based on a compromise between cost and performance and will vary depending on the application.

Robert L. Hausrath, Anthony V. Longobardo

Soda-Lime-Silica Glasses

Frontmatter

Chapter 6. Compositions of Industrial Glasses

Abstract

The principles behind commercial glass manufacture are discussed in terms of production-related considerations: meltability, workability, refining, and economics. Examples of the implementation of these principles are given to explain their importance and their technical impact. The historical development of the key commercial glasses are charted over the centuries up to the present day, providing insight into how and why we have arrived at today’s commercial glass compositions and detailing their strengths, weaknesses, and variations.

Antonín Smrček

Chapter 7. Design of New Energy-Friendly Compositions

Abstract

In order to be energy efficient, environmentally friendly and sustainable, commercial glass production in the 21st century must evolve and some of the technologies and methodologies that will make this possible are discussed. Development and implementation of energy-efficient and environmentally friendly soda–lime–silica glass compositions are discussed in terms of environmental and legislative requirements; the reduction of melting energies and atmospheric emissions; glass properties and the effects of individual glass components and raw materials; and technologies that can help glassmakers to meet new requirements. This in-depth treatment provides detailed step-by-step analysis, with appropriate examples, of the opportunities for compositional reformulation, new raw materials, new melting and abatement technologies, and some of the practical and economic effects that such changes will provide.

Paul A. Bingham

Glass Melting Technology

Frontmatter

Chapter 8. Basics of Melting and Glass Formation

Abstract

The energy/enthalpy functions of solids and melts are investigated as a function of temperature. Several thermal effects can be understood on an atomic scale surprisingly well by energy levels and wave functions of the bonding electrons and their interaction with the oscillating atoms. Among these effects are the melting transition, the glass transformation, the thermal expansion, structural phase transitions, and relaxation effects occurring near the glass transition temperature, Tg. Glass formation is favored if sufficient strong directed bonds are present between the constituents and the melting entropy per particle is sufficiently small.

Hans-Jürgen Hoffmann

Chapter 9. Thermodynamics of Glass Melting

Abstract

First, a model based on linear algebra is described by which the thermodynamic properties of industrial multi-component glasses and glass melts can be accurately predicted from their chemical composition. The model is applied to calculate the heat content of glass melts at high temperatures, the standard heat of formation of glasses from the elements, and the vapor pressures of individual oxides above the melt. An E-fiber glass composition is depicted as an example. Second, the role of individual raw materials in the melting process of E-glass is addressed, with a special focus on the decomposition kinetics and energetic situation of alkaline earth carriers. Finally, the heat of the batch-to-melt conversion is calculated. A simplified reaction path model comprising heat turnover, content of residual solid matter, and an approach to batch viscosity is outlined.

Reinhard Conradt

Chapter 10. Glass Melt Stability

Abstract

The employment of sensors during glass melting represents a major prerequisite for an improved process control leading to higher production yields. In situ sensoring techniques can be divided into two groups: on the one hand, techniques which extract information of glass melt properties, e.g., oxidation state and concentrations of relevant polyvalent species (such as iron, sulfur, chromium) and on the other hand, techniques which monitor the furnace atmosphere with respect to toxic emissions (e.g., SO₂, NO_x) and combustion species (e.g., CO, CO₂, H₂O). Nowadays it is feasible not only to install early warning systems indicating deviations from target glass properties, but also to implement process control systems which enforce a stable and reproducible glass melting. Examples are given for the redox control of green glass melting utilizing high portions of recycled cullet and the redox control of amber glass melting.

Helmut A. Schaeffer, Hayo Müller-Simon

Chapter 11. Plasma Melting Technology and Applications

Abstract

A plasma arc melter is a modular high-intensity skull melter capable of rapidly melting a wide variety of materials, both conductive and nonconductive. Although its commercial use to melt and process metals is well known, the method is less well known as a method of melting glass. Extensive research has been conducted by several organizations into the use of skull melting of glass using plasma arcs. This research has shown plasma melting to be a promising technology that can achieve high efficiencies, high temperatures, extreme flexibility, low capital cost, rapid changeovers of glass formulas, and minimal scrap. Plasma melting lends itself to modular melting in which each step of the glass melting process is partitioned into functional modules, which can greatly improve melting efficiency and throughput. Also, plasma arc melting has been shown to be a promising technology for rapidly and inexpensively producing “synthetic minerals” melted from common commercial oxides.

J. Ronald Gonterman, M. A. Weinstein

Backmatter

Titel: Fiberglass and Glass Technology
herausgegeben von: Frederick T. Wallenberger
Paul A. Bingham
Verlag: Springer US
Electronic ISBN: 978-1-4419-0736-3
Print ISBN: 978-1-4419-0735-6
DOI: https://doi.org/10.1007/978-1-4419-0736-3

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