OXYNITRIDE GLASS AND FIBERS THEREOF

Abstract: An oxynitride glass which has Si-M₁-M₂-O-N system and contains SiO₂, Si₃N₄ and M₁O in a mole% satisfying the following equations (a) and (b): (SiO₂+3Si₃N₄+M₁O)x100 / (100+2Si₃N₄) = 65 to less than 100 mole% (a) (SiO₂+3Si₃N₄ / M₁O = 0.7 to 2.3 (b) wherein M₁ is Ca, or Ca and Mg; M₂ is a metal except Ca and Mg, a process for preparing thereof and a fiber thereof. The oxynitride glass has excellent hardness and elastic modulus so that it is adapted to a reinforcing material.

Description: The present invention relates to an oxynitride glass composition, a process for its production, and fibers thereof. An oxynitride glass has a structure formed by the replacement of oxygen in an oxide glass by trivalent nitrogen. It is considered that the replacement leads to a tightening of the glass network by means of the formation of more bonds than those of an oxide glass. Therefore, an oxynitride glass has a high elastic modulus in comparison with a conventional glass. The compositions of known oxynitride glasses include Ca-Si-Al-O-N, Na-Ca-Si-O-N, La-Si-Al-O-N, Na-B-Si-O-N, Mg-Si-Al-O-N, Si-Al-O-N, Y-Al-Si-O-N and Na-B-Al-P-O-N. These oxynitride glasses have been produced by, for example, melting, sol-gel, or N₂-blowing methods, and by treatment of a porous glass with NH₃ gas. According to the melting method, a metal nitride is incorporated into a metal oxide and melted at a high temperature. Examples of such a metal oxide include SiO₂, Na₂O, K₂O, La₂O₃, Y₂O₃, ZrO₂, TiO₂, Na₂O, K₂O and B₂O₃ (boron may be considered as a metal, in context). Examples of such a metal nitride include Si₃N₄ and AlN. According to the sol-gel method, an oxide glass precursor having -OH or -OR groups is reacted with NH₃. Examples of such an oxide glass precursor are silicon and titanium tetraalkoxides. Known oxynitride glass compositions have a nitrogen content of less than 15 atomic percent (9% by weight). The nitrogen in the raw materials is not all retained in the glass system during the preparation of an oxynitride glass, so that oxynitride glass having a low nitrogen content (5-6% by weight) is usually obtained. Glass fibers are useful as a reinforcing material, e.g. for a material for moulding such as plastics or cement. Fibers generally used in conventional composite materials are E-glass fibers or S-glass fibers. E-glass has a maximum elastic modulus of 7,500 kg/mm². Imperial N-672 has perhaps the highest elastic modulus, 12,110 kg/mm². Known oxynitride glass fiber obtained by the sol-gel method has an elastic modulus of about 8,000 kg/mm² which is insufficient for use as reinforcing glass fibers of composite materials. US-A-4609631 discloses oxynitride glass fiber produced by remelting of a bulk oxynitride glass having the maximum nitrogen content of 15 at % and a high elastic modulus of 140-180 GPa, but such a fiber is very expensive because it contains 42.6-45.4% by weight (wt%) of yttrium. A novel oxynitride glass composition has a Si-M₁-M₂-O-N system and contains SiO₂, Si₃N₄ or a metal nitride and M₁O in amounts, as mole%, satisfying the following equations (a) and (b): (SiO₂+3Si₃N₄+M₁O)x100/(100+2Si₃N₄) = 0.65 to less than 1 (a) (SiO₂+3Si₃N₄/M₁O = 0.7 to 2.3 (b) wherein M₁ is Ca, or Ca and Mg; M₂ is an oxide-forming metal except Ca and Mg. A process for preparing such an oxynitride glass composition comprises heating to a melt, at 1400-1900°C under an inert atmosphere, a mixture of SiO₂; Si₃N₄ or a metal nitride; an oxide of M₂ (or a compound which gives the oxide by thermal decomposition); and M₁O (or a compound which gives M₁O by thermal decomposition), wherein M₁ is Ca, or Ca and Mg; M₂ is a metal except Ca and Mg. That is, the oxynitride glass can contain a large amount of nitrogen by incorporating a large amount of CaO, or CaO and MgO so that the glass has a remarkably high elastic modulus and hardness. A process for preparing the improved oxynitride glass having high elastic modulus comprises the following steps: (i) mixing of SiO₂, a nitride selected from the group consisting of Si₃N₄ and a metal nitride, a compound selected from the group consisting of a metal oxide except CaO and MgO; and a compound which leads a metal oxide by thermal decomposition, a compound selected from the group of CaO CaO + MgO, and a compound which leads CaO or MgO by thermal decomposition, in a mole% satisfying the following equations (a) and (b): (SiO₂ + 3Si₃N₄ +CaO+MgO)×100 / (100+2Si₃N₄) = 65 to less than 100 mole% (a) (SiO₂+3Si₃N₄) / CaO+MgO = 0.7 to 2.3 (b) in which equations CaO is mole% of CaO or mole% of a compound converted to CaO basis; MgO is mole % of MgO or mole% of a compound converted to MgO basis. (ii) heating the mixture to melt at a temperature of 1400 - 1900 °C under an inert atmosphere. The present oxynitride glass fiber is a fiber made of the above-mentioned glass. Fig. 1 is a schematic cross-sectional view of a spinning apparatus used for producing the oxynitride glass fiber of the present invention. Fig.2 shows the relationship between Vickers hardnesses and nitrogen contents of the glasses obtained in Examples, from which it is understood that hardness increases with increasing nitrogen content. Fig. 3 shows the relationship between elastic moduli and nitrogen contents of the resultant glass fibers in Examples. In Fig. 3, the abscissa indicates nitrogen content (at%) in the fibers, and the ordinate indicates elastic modulus. Fig. 4 shows a process for production of a fishing rod using a reinforcing glass fiber (Example 65). Fig. 5 is a cross-sectional view of a pressure unit of an optical fiber cable (Example 67). Fig. 6 is a cross-sectional view of a refractory electric wire which employs the oxynitride glass of the present invention (Example 69). Fig. 7 shows time-change of bending strength of moldings which employ reinforcing glass fibers (Example 70). Fig. 8 is a cross-sectional view of a bumper using the oxynitride glass fiber (Example 71). Fig. 9 is a schematic perspective view of an apparatus for preparing the oxynitride glass fiber which is used in a flywheel (Example 72). Fig. 10(a) is a perspective view of a racket frame using the oxynitride glass fiber, Fig. 10(b) is a cross-sectional view taken along line A - A' of Fig. 10(a), and Fig. 10(c) is a perspective view partly broken of the racket frame of Fig. 10(a) (Example 73). Fig. 11(a) is an elevational view of a protective cloth using the oxynitride glass fiber, and Fig. 11(b) is a cross-sectional view of Fig. 11(a) (Example 74). Fig. 12 is a perspective view of an air filter using the oxynitride glass fiber (Example 75). Fig. 13 is a cross-sectional view of a golf club shaft using the oxynitride glass fiber (Example 76) . Fig. 14(a) is a cross-sectional view of a pressure cylinder using the oxynitride glass fiber, and Fig. 14(b) is a cross-sectional view taken along line A - A of Fig 14(a) (Example 77). The oxynitride glass of the present invention preferably contains a large amount of nitrogen, 15 at% or more, and hence, it has a close bridge formation based on Si-N bonds. Accordingly, the glass of the present invention has a tighter glass network in comparison with a known glass, and this leads to hardness of the surface and a high elastic modulus of the glass. The invention provides a glass fiber which has a nitrogen content of 15 - 30 at% and an elastic modulus of not less than 12,500 kg/mm² by melting a cheap raw material and spinning. According to the invention, there can be obtained a high elastic modulus which cannot be obtained by a known glass fiber. The oxynitride glass of the present invention has Si-M₁-M₂-O-N glass system, in which M₁ is Ca or Ca + Mg. That is, the oxynitride glass has a Si-Ca-M₂-O-N or Si-Ca-Mg-M₂-O-N glass system. Suitable examples of the metal M₂ are Al, Sr, La, Ba, Y, Ti, Zr, Na, K, Sb and B. These metals may be in combination of two or more thereof. Therefore, the typical compositions of the oxynitride glass are Ca-Si-Al-O-N, Na-Ca-Si-O-N, La-Ca-Si-Al-O-N, Na-B-Ca-Si-O-N, Mg-Ca-Si-Al-O-N, Si-Ca-Al-O-N, Y-Al-Ca-Si-O-N, Na-B-Ca-Si-Al-P-O-N, Ca-Mg-Si-Al-O-N, Sr-Ca-Mg-Si-Al-O-N, Ba-Ca-Mg-Si-Al-O-N and Y-Ca-Mg-Si-Al-O-N. Further, the oxynitride glass has a composition wherein the oxide system is in a mole% satisfying the following relationships (a) and (b): (SiO₂+3Si₃N₄+CaO+MgO)×100 / (100+2Si₃N₄) = 65 to less than 100 mole% (a) (SiO₂+3Si₃N₄) / CaO+MgO = 0.7 to 2.3 (b) in which equations CaO is mole% of CaO or mole% of a compound converted to CaO basis; MgO is mole% of MgO or mole% of a compound converted to MgO basis. The oxynitride glass of the present invention contains a large amount of Ca and Mg in comparison with a known oxynitride glass. When (SiO₂+3Si₃N₄+CaO+MgO)×100 / (100+2Si₃N₄) is smaller than 65 mole%, there is obtained a glass having a crystal. When (SiO₂+3Si₃N₄) / CaO+MgO is smaller than 0.7, or over than 2.3, a resultant glass has a nitrogen content of less than 15 at%, so that the glass does not have a high elastic modulus. To obtain the oxynitride glass of the present invention, it is preferable to mix (i) SiO₂; (ii) Si₃N₄ or another metal nitride; (iii) a metal oxide except CaO and MgO; and (iv) CaO, or CaO + MgO. Suitable examples of the metal oxide in (iii) are Al₂O₃, BaO, Sb₂O₃, SrO, Na₂O, K₂O, La₂O₃, CeO₂, Y₂O₃, ZrO₂, TiO₂, Na₂O, K₂O and B₂O₃. Instead of these metal oxides, there may be used a compound which gives the metal oxide by thermal decomposition, such as a carbonate, hydroxide or oxalate. These metal oxides and the compounds which lead to metal oxides may be used in combinations of two or more thereof. Suitable examples of the metal nitride other than Si₃N₄ are AlN and BN. It is preferable to use AlN with Al₂O₃, and BN with B₂O₃. These nitrides and Si₃N₄ may be also used in combinations thereof. The oxynitride glass contains CaO as an essential conponent. The oxynitride glass may contain CaO with MgO. Further, instead of CaO and MgO, there may be used a compound which gives CaO or MgO by thermal decomposition, such as a carbonate, hydrate or oxalate. These raw materials are mixed in such mole% as satisfying the following equations (a) and (b): (SiO₂+3Si₃N₄+CaO+MgO)×100 / (100+2Si₃N₄) = 65 to less than 100 mole% (a) (SiO₂+3Si₃N₄) / CaO+MgO = 0.7 to 2.3 (b) in which equations CaO is mole% of CaO or of a compound converted to CaO and calculated as CaO; MgO is mole% of MgO or of a compound converted to MgO and calculated as MgO. The oxides and the nitrides are mixed and heated to give the oxynitride glass. Melting of the mixture is preferably carried out at a temperature of 1400 - 1950 °C , for 1 minute to 3 hours at a heating rate of 10 - 800 °C/min, under an inert or a nitrogen atmosphere. The inert atmosphere may be at ordinary pressure. Melting is carried out in a heating furnace such as an electric furnance or an image furnace. Alternatively, a mixture of only the oxides may be melted in a crucible in air and ground to give a powder. Then, the powder of the oxides is mixed with a nitride, and melted in a high temperature under an inert atmosphere to give the oxynitride glass. Then, the resultant oxynitride glass is subjected to rapid or slow cooling. The cooled oxynitride glass is removed to a spinning apparatus heated at a temperature of 1100 - 1600 °C, and it is spun under an inert atmosphere to give a continuous fiber at the spinning rate of 20 - 3000 m/min. Alternatively, spinning of the oxynitride glass may be carried out by cooling the melted glass at from the melting temperature to 1100 -1600 °C in a heating furnace of spinning apparatus and spinning under an inert atmosphere. In this method, a feeder supplies raw materials of the oxynitride glass continuously into a furnace in a spinning apparatus continuously, where direct spinning can be carried out. The resultant glass preferably has a nitrogen content of 15 - 30 at%, an elastic modulus of 12,500 - 25,000 kg/mm² and a tensile strength of 70 - 500 kg/mm². When the nitrogen content is smaller than 15 at%, the glass does not show a high elastic modulus. On the other hand, if the nitrogen content is over 30 at%, the glass is crystallized. Adjustment of the nitrogen content is carried out by the amount of a nitride in an additive raw material. It is preferable that the diameter of the glass fiber is 3 - 50 µm. When the diameter is smaller than such range, the handling of the spinning becomes difficult. On the other hand, when the diameter is over that range, the strength is remarkably decreased. Referring now to the drawing by numerals of reference, a spinning furnace used for producing the oxynitride glass fibers is illustrated in Fig. 1. The spinning furnace 1 for the glass fibers is provided with a boron nitride crucible 2 having a fine outlet opening (3 mm ⊘) for the fiber at lower part thereof; a long graphite heating element 3 surrounding the side surface of said crucible 2; and a casing 6 which contains said crucible 2 and heating element 3, and is provided with a nitrogen gas chamber 5 where the glass fiber 4 passes through. The crucible 2 is on a crucible stand 9 which stands on a cylindrical graphite tube 8 placed on a boron nitride insulator 7 having a central opening where the fiber passes through. Casing 6 has a heat insulator 10 on a whole inner side wall thereof, cooling jackets 11, 12 on lower and upper parts thereof to give an inner chamber which contains said crucible 2 and heating element 3. Lower cooling jacket 11 contacts said heating element 3 to provide an electrode. Upper cooling jacket 12 has a central opening, wherein there is provided a radiation thermometer 14 having a protective quartz glass plate 13 on the lower side thereof. Futher, on the side wall of casing 6, there is provided a gas inlet 15, which supplies nitrogen into nitrogen gas chamber 5 containing the crucible. A fiber outlet 16, which can open and shut, is below said lower cooling jacket 11, to maintain a nitrogen gas atmosphere contacting the glass. A removable auxiliary chamber 17 is provided immediately below the fibre outlet 16, in order to assist spinning in a complete nitrogen atmosphere. The resultant glass fibre 4 is wound onto a winder 18. The following Examples 1 to 55 illustrate glass compositions of the present inventions. Examples 56 to 64 illustrate comparative compositions. Conditions and results are summarised in Table 1. The nitrogen content of the glass fibres was measured by the Kjeldahl method and X-ray photoelectron analysis. Example 1 SiO₂ (22.8 mol%), CaO (40.8 mol%), MgO (12.0 mol%) and Al₂O₃ (14.4 mol%) were mixed together to melt at a temperature of 1500 °C for 2 hours in the air. After cooling the mixture, it was ground into a particle size of about 10 µm by a ball mill. Then, it was mixed with Si₃N₄ (10 mol%), and was put into a boron nitride crucible 2 placed in the spinning apparatus shown in Fig. 1. The mixture was melted at a temperature of 1750 °C for 30 minutes under a nitrogen atmosphere by a cylindrical carbon heating element 3, which was kept warm by a surrounding heat insulator 10. The temperature was reduced until 1500 °C, and thereafter the mixture was spun and wound onto a winder 18. Spinning was carried out at the spinning rate of 1,000 m/min to give a continuous fiber having a diameter of 20 µm. The physical properties of the oxynitride glass fiber are shown in Table 1. Example 2 In the same manner as described in Example 1 but changing the amounts of the raw materials and conditions as reported in Table 1, there was prepared the oxynitride glass fiber. In Example 2, the oxides were mixed to melt at a temperature of 1500 °C for 40 minutes in the air, and the mixture of the oxides with the nitride were melted at a temperature of 1790 °C for 20 mintutes under a nitrogen atmosphere. Spinning was carried out at the spinning rate of 1,200 m/min to give a continuous fiber having a diameter of 18 µm and a length of 3 km. The physical properties of the oxynitride glass fiber are shown in Table 1. Example 3 SiO₂ (22.8 mol%), Si₃N₄ (10.0 mol%), CaO (40.8 mol%), MgO (12.0 mol%) and Al₂O₃ (14.4 mol%) were mixed together before grinding into a particle size of about 10 µm by a ball mill. Then, the mixture was put into a boron nitride crucible 2 shown in Fig. 1, and melted at a temperature of 1750 °C for 30 minutes under a nitrogen atmospher. The temperature of the oxynitride glass was reduced until a spinning temperature of 1,500 °C and spun at the spinning rate of 1500 m/min to give a fiber having a diameter of 15 µm. The physical properties of the oxynitride glass fiber are shown in Table 1. Example 4 In the same manner as described in Example 3, but chainging the amounts of the raw materials and conditions as in Table 1, there was prepared the oxynitride glass fiber. In Example 4, the mixture of the oxides and nitride was melted at a temperature of 1790 °C for 30 minutes. The temperature was reduced until a spinning temperature of 1490 °C, and spun at the spinning rate of 1350 m/min to give a fiber having a diameter of 15 µm and a length of 4.5 km. Example 5 The raw oxides listed in Table 1 were mixted and melted at a temperature of 1500 °C for 2 hours in the air. After cooling the mixture, it was ground into a particle size of about 10 µm by a ball mill. Then, it was mixed with Si₃N₄ and was put into a boron nitride crucible. The mixture was melted at a temperature of 1750 °C for 30 minutes under a nitrogen atmosphere to give an oxynitride glass. The resultant oxynitride glass was put into a boron nitride crucible 2 placed in the spinning apparatus shown in Fig. 1. The glass was heated until 1380 °C under a nitrogen atmosphere, and was spun and wound onto a winder. Spinning was carried out at the spinning rate of 1,500 m/min to give a continuous fiber having a diameter of 15 µm. Example 6 In the same manner as described in Example 5 but chainging the amounts of the raw materials and conditions as in Table 1, there were prepared the oxynitride glass fiber. Spinning was carried out at a spinning rate of 80 m/min to give a continuous fiber having a diameter of 25 µm. Examples 7-11, 16-18, 20, 24-34, 37-52 and 55 In the same manner as described in Example 1 but changing the amounts of the raw materials and conditions as in Table 1, there were prepared the oxynitride glass fibers. In these Examples, the oxides were melted at a temperature of 1500 °C for 1 hour in the air. The physical properties of the oxynitride glass fibers are also shown in Table 1. As the results, the oxynitride glass fibers obtained in Examples 7 - 9 have low nitrogen contents and low elastic moduli. Example 12 SiO₂ (8.6 mol%), Si₃N₄ (19.4 mol%), CaO (59.8 mol%), MgO (6.9 mol%) and Al₂O₃ (5.2 mol%) were mixed and compressed under a pressure of 1500 kg/cm² for 30 seconds by a rolling mill. The mixture was subjected to heating up to 1780 °C in an image furnace under a nitrogen atmosphere for 3 minutes and melted. Then, the mixture was quickly quenched by a double roller to give an oxynitride glass. The resulting glass was a flake having a thickness of about 25 µm. The resultant glass was put into a crucible 2 in the spinning apparatus shown in Fig. 1. It was heated at a temperature of 1570 °C under a nitrogen atmosphere, and then was spun to give a continuous fiber. Example 13 SiO₂ (8.6 mol%), Si₃N₄ (19.4 mol%), CaO (58.3 mol%), MgO (6.9 mol%), Al₂O₃ (5.2 mol%) and Y₂O₃ (1,5 mol%) were compressed and formed under a pressure of 1500 kg/cm² for 30 seconds. The mixture was subjected to heating up to 1770 °C in an image furnace under a nitrogen atmosphere and melted. The mixture was dropped onto an iron plate placed under the furnace to give an oxynitride glass. Then, the resultant glass was spun in the same manner as described in Example 12 to give a fiber. Examples 14 and 54 In the same manner as described in Example 13, but changing the amounts of the raw materials and conditions as in Table 1, there was prepared the oxynitride glass fibers. Examples 15, 19 and 21 In the same manner as described in Example 5 but changing the amounts of the raw materials and conditions as in Table 1, there were prepared the oxynitride glass fibers. Examples 22, 35 and 36 In the same manner as described in Example 3, but changing the amounts of the raw materials and conditions as in Table 1, there was prepared the oxynitride glass fibers. Example 23 The raw materials (oxides and nitride) listed in Table 1 were mixed before grinding into a particle size of about 10 µm by a ball mill. The mixture was put into a boron nitride crucible and melted at a temperature of 1730 °C under a nitrogen atmosphere to give an oxynitride glass. The resultant oxynitride glass was put into a boron nitride crucible 2 placed in the spinning apparatus shown in Fig. 1. The glass was heated under a nitrogen atmosphere and was spun at a temperature of 1530 °C to give a continuous fiber. Example 53 In the same manner as described in Example 12, but changing the amounts of the raw materials and conditions as in Table 1, there was prepared the oxynitride glass fiber. Examples 56 - 61 In the same manner as described in Example 7, the oxides and nitride listed in Table 1 were treated, but there were not obtained oxynitride glasses. In Examples 56 and 57, (SiO₂ + 3Si₃N₄ + M₁O) × 100 / (100 + 2SiO₂) is less than 65 mole%, and there were obtained incomplete glasses having part of a crystal phase. In Examples 58 and 59, (SiO₂ + 3Si₃N₄) / M₁O is less than 0.7, and the mixtures were not melted completely and gave crystals. In Examples 60 and 61, (SiO₂ + 3Si₃N₄) / M₁O is over 2.3, and the mixtures could be melted and were contained a crystal phase. Examples 62 -64 In the same manner as described in Example 7 but changing the amounts of the raw materials and conditions as in Table 1, there were prepared the oxynitride glass fibers. The physical properties of the oxynitride glass fibers are also shown in Table 1. As the results, it is understood that the oxynitride glass fibers have a low Vickers hardness and elastic modulus. The physical properties of the oxynitride glasses are shown in the following Table 1. The applications of the oxynitride fibers of the present invention are illustrated more specifically by the following Examples. Example 65 (fishing rod) A fishing rod was produced by using the oxynitride glass fibers of the present invention. Fig 4 shows a process for production of a fishing rod. Into a woven fabric (size: 20 - 100 cm × 200 - 5000 cm, fineness of a glass fiber: 15 µm, yarn numbar count: 670 g/km) of the oxynitride glass obtained in Example 5, an unsaturated polyester resin was impregnated (fiber content : 55 wt%) to give a prepreg 21. The prepreg 21 was then wound onto a metal core 22 (size: diameter 3 - 12 mm × length 300 cm ), and fixed by an adhesive plastic tape 23. Thereafter, it was cured by heating. The resulting fishing rod has higher strength than that of a conventional product, and has the same elastic modulus. Example 66 (insulating material for a connector) An insulating material for a connector was produced by using a powder obtained from the oxynitride glass fiber of the present invention. An oxynitride glass fiber bundle (average fiber diameter: 5µm) obtained in Example 5 was crushed for 10 minutes in a ball mill (vibration ball mill with alumina balls; 1200 rpm). The resulting powdered fibers (4.5 kg) were dry-mixed with crushed pellets of a polybutylene terephthalate resin, thereafter the mixture was kneaded by means of a single-screw kneading-extruding machine. The resulting mixture was formed into a rectangular test piece (1.5 × 8 cm) of an insulating material for a connector by an injection molding machine. The test piece has no warp. The heat-deforming temperature of the test piece is 225 °C. Example 67 (tensile member for an optical fiber) A tension member for an optical fiber was produced by using the oxynitride glass fiber in Example 5 and epoxy resin as a matrix by means of pultrusion method. Fig. 5 is a cross-sectional view of a pressure unit of an optical fiber cable. Fig. 5 shows a fiber unit 26 having a tensile member 27 of the oxynitride glass, and several coaxial optical fiber wires 28. The tensile menber 27 and wires 28 are surrounded by an elastomer 29. A nylon layer 30 is provided around the elastomer 29. Example 68 (radome membrane) Into a woven fabric (size: 500 × 1000 cm, glass fiber diameter: 13 µm, yarn number count: 500 g/km) of the oxynitride glass obtained in Example 5, an unsaturated polyester resin (200 g) was impregnated (fiber content : 55 wt%) to give a sheet material. The resultant membrane shows excellent properties for a radome as follows: tensile strength: 85 kg/cm width or more, elongation: 3.5 % or less, radio wave transmission coefficient: 96 % or more. Example 69 (refractory electric wire) Fig. 6 is a cross-sectional view of a refractory electric wire 31 which employs the oxynitride glass of the present invention. About a mono-core conductor 33 ( 3 × 8 mm² ) was wound a refractory layer 34 of glass cloth (width of cloth: 20 - 100 cm, length of cloth: 2000 - 5000 cm, diameter of fiber: 10 - 15 µm) made of the oxynitride glass fibers. Futher, onto the refractory layer 34 there was disposed a coating layer 36 of a vinyl chloride resin. The fire resistance of the resultant wire succeeded in the test based on the standard (No.7, dated October 16, 1978) of Japanese Fire Defence Board. Example 70 (glass fiber reinforcing cement molding) Into a composition for cement mortar was added a foaming agent (0.2 wt%) to give a foaming mortar. Then, into the foaming mortar was added the oxynitride glass (10 vol%) obtained in Example 5, and mixed to give a foaming premixture. The resultant premixture was dried to a water content to 15 %. The resultant formed material was cut into a cube (30 cm) and press-formed (150 kg) to give a test piece, which was aged and cured for 15 days. Fig. 7 shows time-change of bending strength of the resultant molding (mark ○). In the same manner as described above except that an alkali-resistant oxide glass ( MINERON-M #801, diameter of fiber: 20 µm, length of fiber: 25 mm, number of bundle: 160, manufactured by Asahi fiber glass company) was used as a reinforcing fiber, there was obtained a test piece. The results are also shown in Fig. 7 (mark ). Example 71 (bumper) Fig. 8 is a cross-sectional view of a bumper made by curing of a prepreg in a mould. The prepreg was obtained by impregnating of a synthetic resin into the glass fiber in Example 5. In Fig. 8, holder 41 is made from a synthetic resin reinforced by the glass fiber and is U-shaped in section. As shown in Fig. 8, holder 41 has projections on main stressed parts of free ends at the upper edge 43 and lower edge 44 of the U form. Further, these parts receiving a large force may be reinforced by attached or inserted reinforcing fragments. For example, a part or all of inserted metal fragment 45 may be buried into the main stressed parts. Front surface 46 of holder 41 may be reinforced, for which a groove 47 is formed. Upper edge 43 and lower edge 44 are protected from bending forces by means of fin 48, which is formed in the inner side of holder 41. Such fin 48 fulfils a function as joint member 49 which is integrated with holder 41. Example 72 (flywheel) SiO₂ (22.8 mol%), CaO (40.8 mol%), MgO (12.0 mol%) and Al₂O₃ (14.4 mol%) were mixed and burned at a temperature of 1500 °C in air for 2 hours, thereafter the mixture was crushed into a powder (size: 1 - 10 µm), which was put into feeder 51 shown in Fig. 9. The powder in feeder 51 and the Si₃N₄ powder in feeder 52 were mixed in a continuous mixer 53 with a linear increase of the feed amount of Si₃N₄ so as to change a nitrogen content from 1 to 12 wt%, and were led into spinning furnace 54. The raw powders were melted in spinning furnace 54, and spun from a lower busing kept at 1380 °C. The surface of the fibers was treated with roller 56. Then, the fibers were formed into one strand by collecting pad 57, and wound onto winder 58. Then, the fibers were wound off with arranging the strand in one direction, and therein a resin was impregnated to form a prepreg. The nitrogen content of the glass fibers in the prepreg increases from one direction to another continuously. The prepreg was wound onto an axis from the end of less nitrogen content, and formed. Accordingly, there was obtained a flywheel in which elastic modulus increases continuously from the center to the periphery. Example 73 (racket frame) Fig. 10(a) is a perspective view of a tennis racket frame using the oxynitride glass fibers obtained in Example 5. As shown in Fig. 10(a), frame 61 is integrally composed of an elliptical head 62 with strings, racket handle 64, neck part 63 and racket handle 64. Fig. 10(b) is a cross-sectional view taken along line A - A' of Fig 10(a). The head 62 has a box-type cross-sectional structure which is composed of a core made from a foamed synthetic resin 65 and FRP reinforcing shell 66 about the core. FRP reinforcing shell 66 is, as shown in Fig 10(c), composed of robing or robing cloth 67 of the oxynitride glass fibers and oxynitride glass fibers or cabon fibers 68. That is, oxynitride glass fibers 67 are arranged along the periphery direction X of the racket frame, and the oxynitride glass fibers or carbon fibers 68 are arranged orthogonally to the oxynitride glass fibers 67 (directions Y and Z). Although the oxynitride glass fibers or carbon fibers 68 are most preferably arranged parallel to the width of the frame, these fibers may be arranged at ± 45°, preferably not more than ± 30°, to the preferred direction. Example 74 (protective cloth) Fig. 11(a) and Fig. 11(b) are respectively an elevational view and a cross-sectional view of a protective cloth using the oxynitride glass fibers in Example 5. As shown in Fig. 11, the protective cloth 71 is composed of an oxynitride glass fiber layer 72 and cover layer 73, which are sewn or jointed by an adhesive. Glass fiber layer 72 is preferably composed of plural, more preferably 3, sheets of a woven fabric of the oxynitride glass fibers, to give superior heat resistance and elastic modulus. Cover layer 73 may be any conventional cloth. The surface of the cover layer may further be coated by a sheet of a synthetic resin, to give water resistance. Example 75 (air filter) Fig. 12 is a perspective view of an air filter using the oxynitride glass fiber in Example 5. The oxynitride glass fiber 74 was laminated onto a non-woven fabric 75 (METSUKE: 80 g/m², thickness: 0.5 mm) of a polypropylene fiber (diameter of fiber: 2 - 5 µm ) to give a glass fiber filter for dust (METSUKE: 10 g/mm², thickness: 0.05 mm). The resultant filter has a low pressure loss, a high strength and an excellent collecting coefficient of dust. Example 76 (golf club shaft) Fig. 13 is a cross-sectional view of a golf club shaft using the oxynitride glass fiber in Example 5. As shown in Fig 13, carbon fibers (Torayca; T 200, manufactured by Toray Co. Ltd.) impregnated with an epoxy resin are wound onto a conical metal core ( diameter of the smaller end: 4 mm; diameter of the larger end: 14 mm; length 1300 mm ) by filament winding to form an inner layer 77 having a thickness of 3 mm. The prepreg, which was obtained by impregnating an epoxy resin into the oxynitride glass fiber in Example 5, was then wound up onto inner layer 77 to form outer layer 76 having a thickness of 1 mm. Onto outer layer 76, a film having a high mold releasing characteristic was tighten. After curing and releasing from a mold, the resulting product was cut, and then outer layer was ground to a desired size and hardness, to give a fiber reinforcing plastics shaft of a golf club. Example 77 (pressure cylinder) Fig. 14(a) is a cross-sectional view of a pressure cylinder using the oxynitride glass fiber in Example 5. Fig. 14(b) is a cross-sectional view taken along line A - A. In Fig. 14(a), pressure container 78 is composed of an inner cylinder 80 of a plastic, and a sheath 90 thereon, including a part 79 which forms an opening of pressure container 78. Inner cylinder 80 is, as shown in Fig. 14(b), made from a resin layer 82 which reinforced by fibers 81. Suitable examples of the fibers are glass fibers such as oxynitride glass fiber, E-glass fiber, S-glass fiber; metal fibers such as steel fibers; inorganic fibers such as carbon fiber, boron fiber, SiC fiber, alumina fiber; fibers of organic polymer such as aramid fiber, polyester fiber, nylon fiber; and mixtures thereof. In view of relative strength, the most preferable fiber is oxynitride glass fibers. The fibers in resin layer 82 may form a woven fabric shown in Fig. 14(b), a sheet made of fibers in one direction, a paper made of staple fibers, or any conventional form of fibers. The diameter of fibers, and the thickness of a sheet or a woven fabric may be any desired values. It is preferable to use 40 to 80 % of reinforcing fibers based on the resin layer. Sheath 90, which covers said inner cylinder 80 for reinforcing, is composed of reinforcing fiber layer 91, and protective resin layer 92 which protects layer 91. Reinforcing fiber layer 91 contains at least oxynitride glass fibers. It is preferable to wind up an oxynitride glass robing onto resin layer 82. Fiber layer 91 may further contain any other reinforcing fibers. Preferred resins for protective resin layer 92 may be any conventional resin such as a thermosetting or thermoplastic resin. Furthermore, the pressure cylinder may be comprosed of a single layer of a resin matrix containing the oxynitride glass fibers as a reinforcing material without a reinforcing fiber in a sheath. As the reinforcing materials, there may be used the oxynitride glass fiber with a suitable form of above-mentioned inorganic, organic, or metal fibers.

Claims: An oxynitride glass composition having a Si-M₁-M₂-O-N system and containing SiO₂, Si₃N₄ or a metal nitride, and M₁O, in amounts which, as mole%, satisfy the two following equations: (SiO₂+3Si₃N₄+M₁O)/(100+2Si₃N₄) = 0.65 to less than 1 (SiO₂+3Si₃N₄)/M₁O = 0.7 to 2.3 wherein M₁ is Ca, or Ca and Mg; and M₂ is an oxide-forming metal other than Ca and Mg. A composition as claimed in claim 1, wherein M₁ is Ca. A composition as claimed in claim 1, wherein M₁ is Ca and Mg. A composition as claimed in any preceding claim, which has a nitrogen content of not less than 15 at%. A composition as claimed in claim 4, which has a nitrogen content of 15-30 at%. A composition as claimed in any preceding claim, wherein M₂ is selected from Al, Sr, La, Ba, Y, Ti, Zr, Na, K, Sb and B. A process for preparing a composition as claimed in any preceding claim, which comprises heating to a melt, at 1400-1900°C under an inert atmosphere, a mixture of SiO₂; Si₃N₄ or a metal nitride; an oxide of M₂ (or a compound which gives the oxide by thermal decomposition); and M₁O (or a compound which gives M₁O by thermal decomposition). A glass fiber having a composition as claimed in any of claims 1 to 6. A glass fiber as claimed in claim 8, whose diameter is 3-50 µm. A glass fiber as claimed in claim 8 or claim 9, whose elastic modulus is not less than 12,500 kg/mm².

Inventors: KADA, KATSUHIKO, KOBAYASHI, JUNYA, MINAKUCHI, HIROYOSHI, OOTA, MASAAKI
Applicants: SHIMADZU CORPORATION
Application year: 1988
Main classification: C03C3
IPC codes: C03C13, C03B37, C03C3