Glass Fiber
Glass Fiber
Glass Fiber
Glass fiber
Glass fiber (or glass fibre) is a material consisting of
numerous extremely fine fibers of glass.
Fiber formation
Glass fiber is formed when thin strands of silica-based or other formulation glass are extruded into
many fibers with small diameters suitable for textile processing. The technique of heating and
drawing glass into fine fibers has been known for millennia, and was practiced in Egypt and
Venice.[3] Before the recent use of these fibers for textile applications, all glass fiber had been
manufactured as staple (that is, clusters of short lengths of fiber).
The modern method for producing glass wool is the invention of Games Slayter working at the
Owens-Illinois Glass Company (Toledo, Ohio). He first applied for a patent for a new process to
make glass wool in 1933. The first commercial production of glass fiber was in 1936. In 1938
Owens-Illinois Glass Company and Corning Glass Works joined to form the Owens-Corning
Fiberglas Corporation. When the two companies joined to produce and promote glass fiber, they
introduced continuous filament glass fibers.[4] Owens-Corning is still the major glass-fiber
producer in the market today.[5]
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The most common type of glass fiber used in fiberglass is E-glass, which is alumino-borosilicate
glass with less than 1% w/w alkali oxides, mainly used for glass-reinforced plastics. Other types of
glass used are A-glass (Alkali-lime glass with little or no boron oxide), E-CR-glass
(Electrical/Chemical Resistance; alumino-lime silicate with less than 1% w/w alkali oxides, with
high acid resistance), C-glass (alkali-lime glass with high boron oxide content, used for glass staple
fibers and insulation), D-glass (borosilicate glass, named for its low dielectric constant), R-glass
(alumino silicate glass without MgO and CaO with high mechanical requirements as
reinforcement), and S-glass (alumino silicate glass without CaO but with high MgO content with
high tensile strength).[6]
Pure silica (silicon dioxide), when cooled as fused quartz into a glass with no true melting point,
can be used as a glass fiber for fiberglass, but has the drawback that it must be worked at very high
temperatures. In order to lower the necessary work temperature, other materials are introduced as
"fluxing agents" (i.e., components to lower the melting point). Ordinary A-glass ("A" for "alkali-
lime") or soda lime glass, crushed and ready to be remelted, as so-called cullet glass, was the first
type of glass used for fiberglass. E-glass ("E" because of initial electrical application), is alkali free,
and was the first glass formulation used for continuous filament formation. It now makes up most
of the fiberglass production in the world, and also is the single largest consumer of boron minerals
globally. It is susceptible to chloride ion attack and is a poor choice for marine applications. S-glass
("S" for "Strength") is used when high tensile strength (modulus) is important, and is thus
important in composites for building and aircraft construction. The same substance is known as R-
glass ("R" for "reinforcement") in Europe. C-glass ("C" for "chemical resistance") and T-glass ("T"
is for "thermal insulator" – a North American variant of C-glass) are resistant to chemical attack;
both are often found in insulation-grades of blown fiberglass.[7]
Special Purpose
ECR Long term acid resistance and short term alkali resistance
Chemistry
The basis of textile-grade glass fibers is silica, SiO2. In its pure form it exists as a polymer, (SiO2)n.
It has no true melting point but softens up to 1200 °C, where it starts to degrade. At 1713 °C, most
of the molecules can move about freely. If the glass is extruded and cooled quickly at this
temperature, it will be unable to form an ordered structure.[9] In the polymer it forms SiO4 groups
which are configured as a tetrahedron with the silicon atom at the center, and four oxygen atoms at
the corners. These atoms then form a network bonded at the corners by sharing the oxygen atoms.
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The vitreous and crystalline states of silica (glass and quartz) have similar energy levels on a
molecular basis, also implying that the glassy form is extremely stable. In order to induce
crystallization, it must be heated to temperatures above 1200 °C for long periods of time.[4]
Although pure silica is a perfectly viable glass and glass fiber, it must be worked with at very high
temperatures, which is a drawback unless its specific chemical properties are needed. It is usual to
introduce impurities into the glass in the form of other materials to lower its working temperature.
These materials also impart various other properties to the glass that may be beneficial in different
applications. The first type of glass used for fiber was soda lime glass or A-glass ("A" for the alkali it
contains). It is not very resistant to alkali. A newer, alkali-free (<2%) type, E-glass, is an alumino-
borosilicate glass.[10] C-glass was developed to resist attack from chemicals, mostly acids that
destroy E-glass.[10] T-glass is a North American variant of C-glass. AR-glass is alkali-resistant
glass. Most glass fibers have limited solubility in water but are very dependent on pH. Chloride
ions will also attack and dissolve E-glass surfaces.
E-glass does not actually melt, but softens instead, the softening point being "the temperature at
which a 0.55–0.77 mm diameter fiber 235 mm long, elongates under its own weight at 1 mm/min
when suspended vertically and heated at the rate of 5 °C per minute".[11] The strain point is
reached when the glass has a viscosity of 1014.5 poise. The annealing point, which is the
temperature where the internal stresses are reduced to an acceptable commercial limit in 15
minutes, is marked by a viscosity of 1013 poise.[11]
Properties
Thermal
Fabrics of woven glass fibers are useful thermal insulators because of their high ratio of surface
area to weight. However, the increased surface area makes them much more susceptible to
chemical attack. By trapping air within them, blocks of glass fiber make good thermal insulation,
with a thermal conductivity of the order of 0.05 W/(m·K).[12]
Selected properties
C-
3300 -- 69.0 2.49 7.2 -- --
glass[14]
S-2
4890 1600 85.5 2.46 2.9 1056 ~20
glass
Mechanical properties
The strength of glass is usually tested and reported for "virgin" or pristine fibers—those that have
just been manufactured. The freshest, thinnest fibers are the strongest because the thinner fibers
are more ductile. The more the surface is scratched, the less the resulting tenacity.[10] Because
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glass has an amorphous structure, its properties are the same along the fiber and across the
fiber.[9] Humidity is an important factor in the tensile strength. Moisture is easily adsorbed and
can worsen microscopic cracks and surface defects, and lessen tenacity.
In contrast to carbon fiber, glass can undergo more elongation before it breaks.[9] Thinner
filaments can bend further before they break.[15] The viscosity of the molten glass is very important
for manufacturing success. During drawing, the process where the hot glass is pulled to reduce the
diameter of the fiber, the viscosity must be relatively low. If it is too high, the fiber will break
during drawing. However, if it is too low, the glass will form droplets instead of being drawn out
into a fiber.
Manufacturing processes
Melting
There are two main types of glass fiber manufacture and two main types of glass fiber product.
First, fiber is made either from a direct melt process or a marble remelt process. Both start with the
raw materials in solid form. The materials are mixed together and melted in a furnace. Then, for
the marble process, the molten material is sheared and rolled into marbles which are cooled and
packaged. The marbles are taken to the fiber manufacturing facility where they are inserted into a
can and remelted. The molten glass is extruded to the bushing to be formed into fiber. In the direct
melt process, the molten glass in the furnace goes directly to the bushing for formation.[11]
Formation
The bushing plate is the most important part of the machinery for making the fiber. This is a small
metal furnace containing nozzles for the fiber to be formed through. It is almost always made of
platinum alloyed with rhodium for durability. Platinum is used because the glass melt has a
natural affinity for wetting it. When bushings were first used they were 100% platinum, and the
glass wetted the bushing so easily that it ran under the plate after exiting the nozzle and
accumulated on the underside. Also, due to its cost and the tendency to wear, the platinum was
alloyed with rhodium. In the direct melt process, the bushing serves as a collector for the molten
glass. It is heated slightly to keep the glass at the correct temperature for fiber formation. In the
marble melt process, the bushing acts more like a furnace as it melts more of the material.[16]
Bushings are the major expense in fiber glass production. The nozzle design is also critical. The
number of nozzles ranges from 200 to 4000 in multiples of 200. The important part of the nozzle
in continuous filament manufacture is the thickness of its walls in the exit region. It was found that
inserting a counterbore here reduced wetting. Today, the nozzles are designed to have a minimum
thickness at the exit. As glass flows through the nozzle, it forms a drop which is suspended from
the end. As it falls, it leaves a thread attached by the meniscus to the nozzle as long as the viscosity
is in the correct range for fiber formation. The smaller the annular ring of the nozzle and the
thinner the wall at exit, the faster the drop will form and fall away, and the lower its tendency to
wet the vertical part of the nozzle.[17] The surface tension of the glass is what influences the
formation of the meniscus. For E-glass it should be around 400 mN/m.[10]
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The attenuation (drawing) speed is important in the nozzle design. Although slowing this speed
down can make coarser fiber, it is uneconomic to run at speeds for which the nozzles were not
designed.[4]
Safety
Glass fiber has increased in popularity since the discovery that asbestos causes cancer and its
subsequent removal from most products. However, the safety of glass fiber is also being called into
question, as research shows that the composition of this material (asbestos and glass fiber are both
silicate fibers) can cause similar toxicity as asbestos.[19][20][21][22]
1970s studies on rats found that fibrous glass of less than 3 μm in diameter and greater than 20 μm
in length is a "potent carcinogen".[19] Likewise, the International Agency for Research on Cancer
found it "may reasonably be anticipated to be a carcinogen" in 1990. The American Conference of
Governmental Industrial Hygienists, on the other hand, says that there is insufficient evidence,
and that glass fiber is in group A4: "Not classifiable as a human carcinogen".
The North American Insulation Manufacturers Association (NAIMA) claims that glass fiber is
fundamentally different from asbestos, since it is man-made instead of naturally occurring.[23]
They claim that glass fiber "dissolves in the lungs", while asbestos remains in the body for life.
Although both glass fiber and asbestos are made from silica filaments, NAIMA claims that asbestos
is more dangerous because of its crystalline structure, which causes it to cleave into smaller, more
dangerous pieces, citing the U.S. Department of Health and Human Services:
Synthetic vitreous fibers [fiber glass] differ from asbestos in two ways that may provide at
least partial explanations for their lower toxicity. Because most synthetic vitreous fibers
are not crystalline like asbestos, they do not split longitudinally to form thinner fibers.
They also generally have markedly less biopersistence in biological tissues than asbestos
fibers because they can undergo dissolution and transverse breakage.[24]
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A 1998 study using rats found that the biopersistence of synthetic fibers after one year was 0.04–
13%, but 27% for amosite asbestos. Fibers that persisted longer were found to be more
carcinogenic.[25]
As with many other composite materials (such as reinforced concrete), the two materials act
together, each overcoming the deficits of the other. Whereas the plastic resins are strong in
compressive loading and relatively weak in tensile strength, the glass fibers are very strong in
tension but tend not to resist compression. By combining the two materials, GRP becomes a
material that resists both compressive and tensile forces well.[27] The two materials may be used
uniformly or the glass may be specifically placed in those portions of the structure that will
experience tensile loads.[6][26]
Uses
Uses for regular glass fiber include mats and fabrics for thermal insulation, electrical insulation,
sound insulation, high-strength fabrics or heat- and corrosion-resistant fabrics. It is also used to
reinforce various materials, such as tent poles, pole vault poles, arrows, bows and crossbows,
translucent roofing panels, automobile bodies, hockey sticks, surfboards, boat hulls, and paper
honeycomb. It has been used for medical purposes in casts. Glass fiber is extensively used for
making FRP tanks and vessels.[6][26]
Open-weave glass fiber grids are used to reinforce asphalt pavement.[28] Non-woven glass
fiber/polymer blend mats are used saturated with asphalt emulsion and overlaid with asphalt,
producing a waterproof, crack-resistant membrane. Use of glass-fiber reinforced polymer rebar
instead of steel rebar shows promise in areas where avoidance of steel corrosion is desired.[29]
Potential uses
Glass fiber use has recently seen use in biomedical applications in the assistance of joint
replacement[30] where the electric field orientation of short phosphate glass fibers can improve
osteogenic qualities through the proliferation of osteoblasts and with improved surface chemistry.
Another potential use is within electronic applications[31] as sodium based glass fibers assist or
replace lithium in lithium-ion batteries due to its improved electronic properties.
See also
Basalt fiber
Carbon fiber
BS4994
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Composite materials
Fiberglass
Fiberglass molding
Filament tape
Gelcoat
Glass cloth
Glass fiber reinforced concrete (GFRC or GRC)
Glass microsphere
Glass Poling
Glass wool
Optical fiber
Pele's hair, naturally occurring glass fibre.
Quartz fiber
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13. Frederick T. Wallenberger; Paul A. Bingham (October 2009). Fiberglass and Glass Technology:
Energy-Friendly Compositions and Applications (https://books.google.com/books?id=REYTVy3
OCWgC&pg=PA211). Springer. pp. 211–. ISBN 978-1-4419-0735-6. Retrieved 29 April 2011.
14. Hull, D.; Clyne, T. W., eds. (1996), "Fibres and matrices" (https://www.cambridge.org/core/book
s/an-introduction-to-composite-materials/fibres-and-matrices/062E64AB1E04EC499473B26ED
A5A3C27), An Introduction to Composite Materials, Cambridge Solid State Science Series
(2 ed.), Cambridge: Cambridge University Press, p. 15, doi:10.1017/cbo9781139170130.004 (h
ttps://doi.org/10.1017%2Fcbo9781139170130.004), ISBN 978-1-139-17013-0, retrieved
2020-11-07
15. Hillermeier KH, Melliand Textilberichte 1/1969, Dortmund-Mengede, pp. 26–28, "Glass fiber—
its properties related to the filament fiber diameter".
16. Loewenstein, K.L. (1973). The Manufacturing Technology of Continuous Glass Fibers. New
York: Elsevier Scientific. p. 91. ISBN 978-0-444-41109-9.
17. Loewenstein, K.L. (1973). The Manufacturing Technology of Continuous Glass Fibers. New
York: Elsevier Scientific. p. 94. ISBN 978-0-444-41109-9.
18. Mohr, J.G.; W.P. Rowe (1978). Fiberglass. Atlanta: Van Nostrand Reindhold. p. 13. ISBN 978-
0-442-25447-6.
19. "Fiber Glass: A Carcinogen That's Everywhere" (http://www.ejnet.org/rachel/rehw444.htm).
Rachel's News. Environmental Research Foundation. 1995-05-31. Retrieved 2008-10-30.
20. John Fuller (2008-03-24). "Fiberglass and Asbestos" (http://home.howstuffworks.com/home-im
provement/household-safety/tips/dangerous-insulation1.htm). Is insulation dangerous?.
Retrieved 27 August 2010.
21. "Fiberglass" (https://web.archive.org/web/20110720122709/http://www.einstein.yu.edu/ehs/Ind
ustrial%20Hygiene/Fs_Fibergls.htm). Yeshiva University. Archived from the original (http://www.
einstein.yu.edu/ehs/Industrial%20Hygiene/Fs_Fibergls.htm) on 20 July 2011. Retrieved
27 August 2010.
22. Infante, PF; Schuman, LD; Huff, J (1996). "Fibrous glass insulation and cancer: response and
rebuttal". American Journal of Industrial Medicine. 30 (1): 113–20. doi:10.1002/(sici)1097-
0274(199607)30:1<113::aid-ajim21>3.3.co;2-n (https://doi.org/10.1002%2F%28sici%291097-0
274%28199607%2930%3A1%3C113%3A%3Aaid-ajim21%3E3.3.co%3B2-n). PMID 16374937
(https://pubmed.ncbi.nlm.nih.gov/16374937).
23. "What does the research show about the health and safety of fiber glass?" (https://web.archive.
org/web/20100613074803/http://naima.org/pages/resources/faq/faq_fiber.html). FAQs About
Fiber Glass Insulation. NAIMA. Archived from the original (http://www.naima.org/pages/resourc
es/faq/faq_fiber.html#Anchor-What-32744) on 13 June 2010. Retrieved 27 August 2010.
24. Toxicological Profile for Synthetic Vitreous Fibers (https://www.atsdr.cdc.gov/toxprofiles/tp161-
p.pdf) (U.S. Department of Health and Human Services, Public Health Services, Agency for
Toxic Substances and Disease Registry), September 2004, p. 17.
25. T. W. Hesterberga, G. Chaseb, C. Axtenc, 1, W. C. Millera, R. P. Musselmand, O. Kamstrupe,
J. Hadleyf, C. Morscheidtg, D. M. Bernsteinh and P. Thevenaz (2 August 1998).
"Biopersistence of Synthetic Vitreous Fibers and Amosite Asbestos in the Rat Lung Following
Inhalation". Toxicology and Applied Pharmacology. 151 (2): 262–275.
doi:10.1006/taap.1998.8472 (https://doi.org/10.1006%2Ftaap.1998.8472). PMID 9707503 (http
s://pubmed.ncbi.nlm.nih.gov/9707503).
26. Ilschner, B; et al. (2000). "Composite Materials". Ullmann's Encyclopedia of Industrial
Chemistry. Weinheim, Germany: Wiley-VCH Verlag GmbH & Co. KGaA.
doi:10.1002/14356007.a07_369 (https://doi.org/10.1002%2F14356007.a07_369). ISBN 978-
3527306732.
27. Erhard, Gunter. Designing with Plastics (https://books.google.com/books?id=mesU4WbE5CIC
&q=Designing+with+Plastics). Trans. Martin Thompson. Munich: Hanser Publishers, 2006.
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External links
CDC – Fibrous Glass – NIOSH Workplace Safety and Health Topic (https://www.cdc.gov/niosh/
topics/fibrousglass/)
Fiberglass and health (https://www.einstein.yu.edu/administration/environmental-health-safety/i
ndustrial-hygiene/fiberglass.aspx) Archived (https://web.archive.org/web/20171103085831/htt
p://www.einstein.yu.edu/administration/environmental-health-safety/industrial-hygiene/fiberglas
s.aspx) 2017-11-03 at the Wayback Machine
International Geosynthetics Society (http://www.geosyntheticssociety.org), information on
geotextiles and geosynthetics in general.
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