Patent Application
20230416141
The present invention relates to a bushing and a method for producing glass fiber.
As disclosed in Patent Document 1, bushings including a base plate and a plurality of nozzles provided at a bottom surface of the base plate are used for producing glass fiber.
In the bushings as described above, from the viewpoint of reducing the amount of material used for the base plate, the base plate has been reduced in size by arranging adjacent nozzles closer to each other. However, with such small-sized bushings, molten glass that flows out from the nozzles tends to adhere between adjacent nozzles or the like. When the molten glass adheres between adjacent nozzles or the like, it becomes difficult to stably draw out the molten glass from the nozzles, and for example, glass filaments are more likely to break.
An object of the present invention is to provide a bushing that allows molten glass to be stably drawn out from nozzles provided in a small-sized base plate, and a method for producing glass fiber.
A bushing to solve the above problem includes a base plate and a nozzle group provided at a bottom surface of the base plate. The nozzle group includes a first nozzle row in which a plurality of first nozzles are aligned and a second nozzle row in which a plurality of second nozzles are aligned, the second nozzle row being arranged adjacent to the first nozzle row. The bushing is configured to satisfy the following relations (1) to (6) where, for each of the plurality of first nozzles and the plurality of second nozzles, D1 is a nozzle hole inner diameter [mm], Lt is a nozzle flow path length [mm], A1 is a nozzle hole cross-sectional area [mm2], A2 is a nozzle wall cross-sectional area [mm2], L1 is an interval [mm] between the centers of adjacent first nozzles in the first nozzle row and an interval [mm] between the centers of adjacent second nozzles in the second nozzle row, and L2 is an interval [mm] between the center of the first nozzle row in a row width direction and the center of the second nozzle row in the row width direction.
y1≤Y≤y2 (1)
y1=4/3×X+3 (2)
y2=4/3×X+8 (3)
X=D14/Lt (4)
Y=A3−(A1+A2) (5)
A3=L1×L2 (6)
According to this configuration, since Y is equal to or greater than y1, a space around the nozzle can be suitably secured in accordance with the outlet velocity of the molten glass flowing out from the nozzle. Thus, adhesion of the molten glass, flowing out from the nozzle, between adjacent nozzles or the like can be suppressed. In addition, since Y is equal to or less than y2, the space around the nozzle does not become excessively large with respect to the outlet velocity of the molten glass flowing out from the nozzle. Thus, an increase in the production cost of the bushing can be suppressed.
The bushing is preferably configured to further satisfy the following relation (7).
0.2≤X≤3.0 (7)
According to this configuration, the molten glass can be more stably drawn out from the nozzles.
In the bushing, a mean value of arithmetic mean roughnesses Ra at an inner surface of a nozzle hole of each of the plurality of first nozzles and the plurality of second nozzles is preferably 2 μm or less. According to this configuration, the outlet velocity of the molten glass flowing out from the nozzle can be made further uniform. Thus, adhesion of the molten glass, flowing out from the nozzle, between adjacent nozzles or the like can be suppressed.
A method for producing glass fiber includes supplying molten glass to a bushing, drawing out a plurality of glass filaments from the bushing, and then gathering the plurality of glass filaments into a strand. The bushing includes a base plate and a nozzle group provided at a bottom surface of the base plate. The nozzle group includes a first nozzle row in which a plurality of first nozzles are aligned and a second nozzle row in which a plurality of second nozzles are aligned, the second nozzle row being arranged adjacent to the first nozzle row. The foregoing relations (1) to (6) are satisfied where, for each of the plurality of first nozzles and the plurality of second nozzles, D1 is a nozzle hole inner diameter [mm], Lt is a nozzle flow path length [mm], A1 is a nozzle hole cross-sectional area [mm2], and A2 is a nozzle wall cross-sectional area [mm2], L1 is an interval [mm] between the centers of adjacent first nozzles in the first nozzle row and an interval [mm] between the centers of adjacent second nozzles in the second nozzle row, and L2 is an interval [mm] between the center of the first nozzle row in a row width direction and the center of the second nozzle row in the row width direction.
According to the present invention, molten glass can be stably drawn out from nozzles provided in a small-sized base plate.
An embodiment of a bushing and a method for producing glass fiber will be described below with reference to the accompanying drawings.
As illustrated in
The bushing 11 includes a bushing body 11a to which molten glass MG is supplied, and a base plate 11b provided at a bottom of the bushing body 11a. Although not illustrated, the bushing body 11a includes a supply port through which the molten glass MG is supplied, a screen for suppressing deposition of foreign matter on the base plate 11b, and a terminal for resistance heating.
The bushing 11 includes a nozzle group provided at a bottom surface 11b1 of the base plate 11b. The molten glass MG is supplied to the nozzles N, and glass filaments GF are drawn out from the nozzles N. The number of nozzles is preferably 800 to 10000, and more preferably 2000 to 8000. In the figure, the nozzle group of the bushing 11 is illustrated in a simplified manner.
As illustrated in
As illustrated in
As illustrated in
The bushing 11 is configured to satisfy the following relations (1) to (6).
y1≤Y≤y2 (1)
y1=4/3×X+3 (2)
y2=4/3×X+8 (3)
X=D14/Lt (4)
Y=A3−(A1+A2) (5)
A3=L1×L2 (6)
Here, L1 represents an interval [mm] between the centers of adjacent first nozzles N1 in the first nozzle row R1 and an interval [mm] between the centers of adjacent second nozzles N2 in the second nozzle row R2. L2 represents an interval [mm] between the center of the first nozzle row R1 in a row width direction and the center of the second nozzle row R2 in the row width direction. In other words, L2 represents an interval [mm] between the center of one of the first nozzles N1 and the center of the second nozzle N2 located closest to this nozzle N1, that is, the interval [mm] between the centers of the first nozzle N1 and the second nozzle N2 adjacent to each other. A straight line passing through the center of the first nozzle row R1 in the row width direction and a straight line passing through the center of the second nozzle row R2 in the row width direction are parallel. The row width direction of the first nozzle row R1 is a direction parallel to the bottom surface 11b1 of the base plate 11b and orthogonal to the alignment direction of the first nozzles N1, and coincides with the X-axis direction, for example, in
The relation (4) above is an equation for obtaining a numerical value representing the degree of outlet velocity of the molten glass MG flowing out from the nozzle N. The larger the nozzle hole inner diameter D1, the faster the outlet velocity of the molten glass MG. On the other hand, the shorter the nozzle flow path length Lt, the faster the outlet velocity of the molten glass MG.
The relation (5) above is an equation for obtaining a value representing a size of a space around one nozzle N. Specifically, each nozzle arrangement area A3 indicated by the dotted pattern in
The nozzle hole inner diameter D1 [mm] is, for example, preferably in a range of 0.5 mm or more and 3.0 mm or less, and more preferably in a range of 0.8 mm or more and 2.0 mm or less. The nozzle flow path length Lt [mm] is preferably in a range of 1.5 mm or more and 8.0 mm or less, and more preferably in a range of 2.5 mm or more and 6.0 mm or less. The nozzle hole cross-sectional area A1 [mm2] is preferably in a range of 0.2 mm2 or more and 7.0 mm2 or less, and more preferably in a range of 0.5 mm2 or more and 5.0 mm2 or less. The nozzle wall cross-sectional area A2 [mm2] is preferably in a range of 0.6 mm2 or more and 4.9 mm2 or less, and more preferably in a range of 0.8 mm2 or more and 3.5 mm2 or less.
The bushing 11 is preferably configured to further satisfy the following relation (7), for example, from the viewpoint of more stably drawing out the molten glass MG from the nozzles N.
0.2≤X≤3.0 (7)
A mean value of arithmetic mean roughnesses Ra at an inner surface Ns of the nozzle hole of each of the first nozzles N1 and the second nozzles N2 is preferably 2 μm or less. This mean value of the arithmetic mean roughnesses Ra is more preferably 0.1 μm or more, and still more preferably in a range of 0.3 μm or more and 1.5 μm or less.
The mean value of the arithmetic mean roughnesses Ra at the inner surface Ns of the nozzle hole can be adjusted by a shape of a drill used for drilling the nozzle hole or vibration of the drill. The mean value of the arithmetic mean roughnesses Ra at the inner surface Ns of the nozzle hole can also be adjusted by bringing a drill into contact with the inner surface Ns of the nozzle hole or annealing the inner surface Ns of the nozzle hole.
The mean value of the arithmetic mean roughnesses Ra is a value in an unused state before the molten glass MG is caused to flow. The mean value of the arithmetic mean roughnesses Ra can be measured as follows.
First, a plurality of nozzles N are manufactured under the same manufacturing conditions, and then a nozzle N to be measured is extracted as a sample from the plurality of nozzles N. Subsequently, the extracted sample is cut along a direction in which a hole axis of the nozzle hole extends (the direction corresponding to the Z-axis direction in the bushing 11). Subsequently, the arithmetic mean roughness Ra of the inner surface Ns of the nozzle hole is measured along the direction in which the hole axis extends in accordance with JIS B 0601:2001.
For the measurement of the arithmetic mean roughness Ra, Surfcoder (manufactured by Kosaka Laboratory Ltd., product name: ET4000) is used. The measurement distance is 1 mm. The arithmetic mean roughness Ra is measured at six different positions.
Subsequently, a mean value of the arithmetic mean roughnesses Ra measured at the six positions is taken as the mean value of the arithmetic mean roughnesses Ra of the inner surface Ns. The nozzles N other than the sample for which the arithmetic mean roughnesses Ra were measured are regarded as having the same mean value as the mean value of the arithmetic mean roughnesses Ra in the sample.
The bushing 11 of the present embodiment further includes a plurality of cooling members 15 provided at the bottom surface 11b1 of the base plate 11b. The cooling members 15 cool the molten glass MG drawn out from the nozzles N. Examples of the cooling member 15 include a cooling fin and a cooling pipe having a flow path through which a cooling medium flows.
Each cooling member 15 has a longitudinal direction and is arranged extending along the first nozzle row R1 and the second nozzle row R2. The plurality of cooling members 15 are arranged at predetermined intervals. In the bushing 11 of the present embodiment, two nozzle rows, the first nozzle row R1 and the second nozzle row R2, are arranged between the adjacent cooling members 15. But three or more nozzle rows may be arranged between the adjacent cooling members 15.
Examples of materials for the bushing body 11a, the base plate 11b, the nozzles N, and the cooling members 15 include noble metals and noble metal alloys. The noble metal is gold, silver, platinum, palladium, rhodium, iridium, ruthenium, or osmium. The materials for the bushing body 11a, the base plate 11b, the nozzles N, and the cooling members 15 are preferably platinum or a platinum alloy from the viewpoint of enhancing durability. Examples of the platinum alloy include a platinum-rhodium alloy.
Next, a method for producing glass fiber will be described.
In the method for producing glass fiber, the glass strand GS is produced by supplying the molten glass MG to the bushing 11 described above, drawing out the plurality of glass filaments GF from the bushing 11, and then gathering the plurality of glass filaments GF into a strand.
The viscosity of the molten glass MG at the forming temperature at which the glass filaments GF are formed is preferably in a range of from 102.0 to 103.5 dPa·s, and more preferably in a range of from 102.5 to 103.3 dPa·s. Here, the viscosity of the molten glass MG refers to the viscosity of the molten glass at a position where the molten glass flows into the nozzles N.
Examples of the form of the glass fiber include the cake CA in which the glass strand GS is wound. The glass strand GS can be used as, for example, chopped strands cut to a predetermined length, milled fibers, rovings, yarns, mats, fabrics, tapes, or braided fabrics. Examples of applications of the glass fiber include vehicle applications, electronic material applications, building material applications, civil engineering applications, aircraft-related applications, shipbuilding applications, logistics applications, industrial machinery applications, and daily necessities applications.
Next, the actions and effects of the present embodiment will be described.
(1) The faster the outlet velocity of the molten glass MG flowing out from the nozzles N and the smaller the space around the nozzle N, the easier it is for the molten glass MG flowing out from the nozzles N to adhere between the adjacent nozzles N or the like. Here, the bushing 11 of the present embodiment is configured to satisfy the foregoing relations (1) to (6). That is, in the bushing 11 of the present embodiment, since Y is equal to or greater than y1, the space around the nozzle N can be suitably secured in accordance with the outlet velocity of the molten glass MG flowing out from the nozzle N. Thus, adhesion of the molten glass MG, flowing out from the nozzle N, between the adjacent nozzles N or the like can be suppressed. In the bushing 11 of the present embodiment, since Y is equal to or less than y2, the space around the nozzle N does not become excessively large with respect to the outlet velocity of the molten glass MG flowing out from the nozzle N. Thus, an increase in the production cost of the bushing 11 can be prevented. Therefore, the molten glass MG can be stably drawn out from the nozzles N provided in the small-sized base plate 11b. This can, for example, reduce the occurrence of breakage of the glass filament GF.
(2) The bushing 11 is preferably configured to further satisfy the foregoing relation (7). In this case, the molten glass MG can be more stably drawn out from the nozzles N.
(3) In the bushing 11, the mean value of the arithmetic mean roughnesses Ra at the inner surface Ns of the nozzle hole of each of the first nozzles N1 and the second nozzles N2 is preferably 2 μm or less. In this case, the outlet velocity of the molten glass MG flowing out from the nozzle N can be made further uniform. Thus, adhesion of the molten glass MG, flowing out from the nozzle N, between the adjacent nozzles N or the like can be further suppressed. Therefore, the molten glass MG can be more stably drawn out from the nozzles N provided in the small-sized base plate 11b.
The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be implemented in combination within a technically consistent range.
y2a=4/3×X+7 (8)
y2b=4/3×X+5 (9)
Next, examples and comparative examples will be described.
In Examples 1 to 50, glass fibers were produced using bushings having the values of X and the values of Y shown in Tables 1 and 2. The number of nozzles of the bushing is 100. The mean value of the arithmetic mean roughnesses Ra at the inner surface of the nozzle hole is 1.5 μm. The viscosity of the molten glass at the forming temperature at which the glass filaments are formed is 103.0 dPa·s. The velocity at which the glass filaments are formed is in a range of 800 [m/min] or more and 3000 [m/min] or less.
In Comparative Examples 1 to 16, glass fibers were produced in the same manner as in Examples 1 to 50, except that bushings having the values of X and the values of Y shown in Table 3 were used.
Glass strands were produced continuously for 30 days using the bushings of Examples 1 to 50 and the bushings of Comparative Examples 1 to 16. For the production of glass fibers for 30 days, the productivity of the glass fiber was evaluated using the following evaluation criteria. The evaluation results are shown in Tables 1 to 3.
When the average number of times of glass filament breakage is 10 times/day or less: (A) Productivity is high.
When the average number of times of glass filament breakage is more than 10 times/day but no more than 30 times/day: (B) Productivity is slightly low.
When the average number of times of glass filament breakage exceeds 30 times/day: (C) Productivity is low.
For the bushings of all examples, the bushings in which Y represented by the relation (1) was equal to or less than y2 were evaluated as having the effect of reducing the amount of the material used for the base plate (Good), and the bushings in which Y represented by the relation (1) exceeded y2 were evaluated as having no effect of reducing the amount of the material used for the base plate (Poor). The results are shown in Tables 1 to 3.
The bushings of Examples 1 to 50 were evaluated to have high productivity of the glass fiber. On the other hand, the bushings of Comparative Examples 2, 3, 6, 8, 10, 12, 13, and 15 were evaluated to have low productivity of the glass fiber. The bushings of Comparative Examples 1, 4, 5, 7, 9, 11, 14, and 16 cannot suitably reduce the amount of the material used for the base plate because the space around the nozzle is excessively large for the outlet velocity of the molten glass flowing out from the nozzle.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-192759 | Nov 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/037804 | 10/13/2021 | WO |
