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I Soda ash improves the quality of both the brick and the itself for plants where slight or no actual losses occur If. &.' I hollow tile. Experience at thU plant has emphasized an even more interesting point, namely, the property of soda ash of de pressing the maturing temperature is firing. The material used has as extremely narrow firing range; about six courses of brick is the bottom of every kiln were formerly so light colored and soft as to be practically unsalable. With soda ash, two different percentages of treatment are used; the heavier treatment b tfsed on the required pro portion of the production to set six courses in each kiln, and through underfired bride in the lower portions of the kilns If the maturing temperature of ware in selected portions of the kiln may be reduced by similar differential soda a.-h treatment, over-all firing time may be reduced. Less heat and consequently less time will be required to mature the lower courses of brick which carry the heavier soda a>i; treatment. Time saved at the last end of a firing leads to worth-while fuel saving, and any saving of firing time i* automatically an increase in firing capacity. There are t* j a textile j subdivided in 1' used most get i coancr form i batteries, and tko in air-cot ! starting point j Textile fibers i the ccmimiou.- certain Isnsels in the drier are reserved for these brick. '^..Conclusion building up a These brick are also identified by a scratch mark on the back. Instead of the capacity of each kiln being cut ap-' proxixnately 4500 brick, the kilns now turn out their full capacity of fully fired brick;"' the brick' from the lower courses are as dark and hard as those from the higher The foregoing-examples are typical results obtained by tbe use of soda ash in the Barker-Truog process and repre sent a wide variation of raw materials and plant proce dure as .well as of geographical location. Development I threads that a a&Sty. Both filers. ; AS of the b; courses. The shrinkage, furthermore, is as uniform as the color. The probable usefulness of such a procedure m along the lines discussed was ocver of greater important t than at the present time when high-quality production a; f molten glass jJgUssmdtieg other plants, in regard to production as well as cost and minimum cost b urgently needed. i. . ad staple tex quality, b interesting. Soxvay Process Cokmnt Another application of thb same procedure suggests Sykaccsv. KiwYm < loch-pressure j . tfrou fibers i ^.a,^cra* FIBERGLAS: SOME PROPERTIES AND NEW APPLICATIONS' Bv F. V. Toolky " J the*pad .`ff^Snatnre and Abstract *jyf5 of produt Fiberglas b produced in two basic forms, namely, as a woo! and as a textile. There JnbjSemtion, the are three varieties of wool: (1) thermal-insulation wool, the starting point for a large .jjgjTtq desired number of insulation products; (2) bonded mat wool, used m the form of a retainer ^^application mat in electric storage batteries; and (3) air-filter wool, used in the deaning and condi tioning of air. Textile fibers are of two types, continuous and staple. These two types fi&Ute hand!.1 tjifproducts ax represent starting points in the construction of numerous yams, tapes, and fabrics used f lai^eoeveyer. for electrical insulation and chemical filtration purposes. Other applications range - | and It from use as wicking for oil lamps and stoves to use as a pipe lagging material. The ? products versatility and utility of Fiberglas are a consequence of the chemical and physical proper i The wool proc ties of the original basic fibers and the high adaptability of the fibers for predetermined ***.** which II orderly organized arrangement. Fiberglas can be used profitably wherever (1) elec- { <V*oeead of th tridty b generated, transmitted, or used, (2) air is cleaned or conditioned, (3) .heat is | * the other. J conserved, controlled, or excluded, and (4) fabrics are needed to withstand brat. rot. i.jSSjLfront lbe 1 j dampness, decay, or chemical attack. Xew and future applications of Fiberglas indude f Gct in Pits use or development as (1) a wicking in combination with peat moss to feed 2?fJ*cdca solutions, through controlled capillarity, to the roots of growing plants; (2) a i *ur?s combination insulant and surface finish in the form of a new strong, rigid, lightweight board; (3) a new low-temperature insulating medium in the form of an asphalt-en f Fibe, closed rigid bat; (4) a surgical suture and tracer yarn in surgical sponges; and (5) a dec orative fabric. Used as an effective replacement material for cork, nooferrous asbestos, aluminum, and mica, Fiberglas is becoming increasingly important as a strategic mate rial. f fibers* ; T5?* fibers, on : r gather 5^r). Stapl L Introduction Knowledge of new materials, of the jobs they will do, and how they will do them is an all-important factor in making the most effective use of research, engineering, and designing time. There are many materials lor which such information could profitably be summarized at the present time. This is particularly desirable in the cae of Presented at the Forty-Fourth Annual Meeting. The American Ceramic Society. Inc.. Cincinnati. Ohio, April 22. 1942 (Glass Division). Received May 12. 19-52. r r -,tBOt corutn Fiberglas because of the rapidly expanding scope of i;- f More application and the attendant difficulty of keeping t1* r** Pecdcc technical man informed as to what thb unique matoial css ; AsJiK do or b doing technologically. In 1931. there was but or* ; Fiberglas product; today, 330 separate Fiberglas product- : are manufactured, and large quantities of basic fibers sr. - yams are contributing to the value of a wide variety " independently manufactured articles. G>3SS is an old and faithful servant of mankind, and ~ pvrat;o0 t0 *=><. All, f-om tl rj\ r ' Urf','nuout f ^"`^"vous Cb this fibrous form, relatively new on the industrial scene. *' continues to fulfill its traditional role. am ga Vol. 22. No ' warn. Fiberglas: Some Properties end A eu: Appliealioits, 61 are two basic forms of Fibulas, viz., a wool fora , t,,tne fiber form. The wool form may be further abdivided into three elemental fibers: (1) a fine form vrd most generally for thermal insulation, (2) a slightly emriet fora used as a retainer mat in electrical storage Wttcrics and (3) a much coarser form used for air filuaUoa in air-conditioning systems. The first of these the starting point for a Urge variety of insulation products. Textile fibers likewise east in two elemental forms, via. the continuous fiber and the staple fiber, which are used in up Urge number and variety of yams and ,breads that are subsequently woven into fabrics of wide wtffity. Both fibers are much finer than the thermal wool "ttt* w *vea WgW. Length* * ^4 filaments are *** only by packaging requirements. The individual Gasaeats " the most commonly made continuous strand .* 0.00022 in in diameter, although here again this diame. ter can be varied considerably on cither side according to lbc characteristics desired in the final product. Small amounts lubricants and coatings arc used on *** **** fibers and continuous filament strands. The* materials, usually starch or vegetable and mineral the forming operations and keep the mdl- *idu*l **** filaments from rubbing together. This apP&cation is important, for the strength of glass fibers is redaced U saH*ces of the fibers become scratched, then. AH of the basic fibers are produced by the attenuation (4) J noltes glass as it issues from small orifices at the bottom The yarns that go into the manufacture of fabrics are ct gUssmelting tanks or furnaces. In all varieties of wool built up from the original staple slivers and continuous ad staple textile fibers, the attenuation is produced by filament strands on standard textile machinery, the latter high-pressure jets of steam or air; the attenuation of con- requiring but slight modification. Original continuous "tmocus bers is produced by mechanical drawing-at high strands are twisted and plied together to give any desired ifmtdi. yarn construction, the latter depending on the service fane- jvr*tionto be fulfilled. Ordinarily, yarns will consist of from Wool fibers two to twenty original strands, and the heavier construe- a; Wool fibers are collected on a traveling conveyer which tiocs commonly involve as many as ten separate twisting the pack through a series of automatic operations, asd plying operations. d>tmtare and number of which depend on the particular The original staple sliver h converted into yarn by a type f product to be made. These processes include drafting and twisting process patterned after wonted hdAution. the application of a binding agent, comptcs- yarn methods. Yams of various degrees of fineness are -Sjo desired density, the curing of the binding agent, produced; the degree of- drafting b governed by the de- ifa'application of special adhesives and coverings to bri&tatc handling, and cutting to desired size. Some of rtit products are complete for use as they are taken from 4e*conveyer. The material often is but scmiprocessed, Wiiiu, and it serves as a raw material in the building of dir products (see Sections III and iV). The wool process consists of a standard glass-tank operala which the batch is charged in a conventional way * one end of the tank and glass wool fibers arc produced X the other. Both the staple and continuous processes Ader from the wool process in that each involves the use V glut cuQct in the form of marbles. The glass marbles ^gfcty.i.tcd carefully before they are reiuclied is special *^*tric furnaces. -Supir fibers are collected in the form of a web of interfibers, on a traveling belt from which they are subgathered without twist, as a sliver (pronounced Staple fibers average 8 to 15 in. in length; m^**88****1* are madc by a different process. The Zj. '** ^k^ents, 102 or more, are continuous in length. **7 fairr#e gatheredj *in.to. a strandi, .they arc d. rawn me>KI) sired fineness. The coarsest staple yams are made without drafting. 1IL Properties, Produets, end Applications (1) Properties The great utility and versatility of Fiberglas arise from two fundamental sources, viz.. (1) the physical and-chemi cal properties of the glass from which the basic fibers are made and (2) the adaptability of the fibers to organized formation and arrangement which makes possible the building up of derivative products of prescribed and exact ing specifications. Reduced to fibers, the properties that characterize glass in general are retained, although tome properties are modified considerably. Brittleness disappears as a prac tical consideration and is replaced by flexibility and re siliency. The tensile strength of glass increases extra ordinarily as the size cf the unit or, in this case, fiber is decreased. Fibers with calculated tensile strengths as high as 2,000,000 Ib./sq. in. have been produced in the labora tory. Fibers of a size used in regular continuous-filament production show tensile strengths of around 300,000 to 500.000 fb./sq. in., a value considerably more than the tensile strength of hard-drawn steel piano wire. Glass fibers are incombustible, a property which is of extreme importance in practically all applications from the safety standpoint. High-heat and electrical resistance are responsible for the wide applicability of Fiberglas in the electrical field. Tapes, yams, and fabrics used in tbe electrical industry can safely withstand temperatures up to ioo:*f. 02 Bulletin of The American Ceramic Society--Toaley The electrical properties of glass arc retained in filler form and are augmented by the use c-f glasses substantially free of Group 1 alkalis. Filjerglas electrical taj>cs combine high dielectric strength and electrical insulation resist ance with extremely love moisture absorption. profitably used wherever (!' electricity is generated, tram- mitted. or used, (2) air is cleaned or conditioned. (3 beat is Density, degree conserved, controlled, or excluded, or (-T- fabrics a;- I surface conditio needed to withstand heat. rot. dampnos. decay. I Thus the mate chemical attack. j purposes not ot { * IV* lb. P*r cu. I sheets, metal-m * of predetermine solating all typ iturn ranges fro " product. Siam I . Insulation are a [ ^cud-insulating \ FlC. 1.--Basic fibers used in the production of Fiberglas products. Top row {UJt tc ri^hJ): continuous filament strand and staple sliver; bottom row \lrft to right): insu lation wool, bonded mat fiber, and air filter wool. Fie. 3.--Continuous filament yams on various typo of packages * Fie. 2.--Carefully inspected marbles u>cd in the manu facture of textile fibers Chemical durability Iveeomes of increasing i:n|>ortance when the glass surface is increased by fiberizing. A de gree of attack which would be negligible in a large article is a serious matter with a small fiber, so special glasses must be employed according to the service condition*- to Ik: cncounttied. The thermal and air-filtering properties of Fiberglas result from its general fiber form and adaptability to form* ability and organized arrangement. In the ease of ther mal-insulation wool, this adaptability make- possible the formation of s fiber mass with a iiia\iaiuiii of dead air spaces. In the ease of air filter wod. a structure with adequate strength having an extended surface for the application of the dust-catching adhe-ive. low resistance to the passage of air, and high-heat resi-tanoc is ntade possible. The properties of incombo-iibility ar.d dutabiiity art here again of great advantage. {2) Products end Applications As a general statement concerning the applicability of Fiberglas, it may be said that this wr-atilc material can 1>e * wool fulfills lh. . trial insulation safety, enduri: -- lightness in t\c: Bouded mat The electrical industry is the chief user of Fiberglas i: storage batt its textile form. Tl L used widely as tapes, cloths, braido* *" ^hle by keeping slewing?, and tying coru> for the insulation of clectii. | P^les. They motors, generators. transformers, and other typo o' l operating and distributing equipment. Because relatives j employed in th sad hns good e) thin layers of glass tape will insulate well and berau * : * -^1. aut products 1 remarkable resistance to heat will allow motors to op**'-*- t sis. Effusing medit: at much higher temperatures than when alternate in-*-'- t ^coating for um lion material:- arc used, Fiberglas offers the advania*.:v * j* -- codon. weight and space savings. higher operating efliciv~* i- ~r. la the field c and lower equipment maintenance costs when used * *. <l*s to organic suitable varnishes and impregnants and in accordance / .... uni:> for sound engineering techniques. " V. `'"ttlar rtuisam In the chemical field, gin*-*; fabrics arc Uing use d a* : [ thcr mats v chemicai filtration cloths. especially under condition's s' . ^onsimetion. volving corrosive liquids or ga-cs at high unperatfl' , patching adht and (2; anode bags for electroplating proces-cs. Mi"''* ` surface lancous tnda>:rial u-cs of Fiberglas fabric rangv f-oni !''' l`vly low res: lagging and facing; for insulation block to v\i- k< for kit- - kioed propert: sene or oil lamps a^d stows. rleaeiug air. Fiberglas thermal-insulation wool is processed t:;'* miny forms to make it more adaptable for particular u-' j Vol. 22. S* IV tflecti Fibcrglas: Some Properties and Xcic Applications 03 knMty. degree of flexibility or rigidity, external form. and ^-rfjee condition can ail be varied to suit tfcr application. 71:u* the material is prepared for home and industrial purposes not only in the form of a fleecy white wool of 1`. i lb. per cu. ft. density, but also in -xib!e-to-rigid sheets, metal-mesh and sewn blankets, blocks, and boards oi predetermined specifications, which are used for in- plating all types of industrial equipment in all tempera ture ranges from subxero to l2CO'F,, according to the product. -Standard sixes and thicknesses of sectional pipe insulation are also fabricated from the original basic thcrcul-in-ulating wool fiber. gradually finding their way into industry and others will soon appear. Some of the new developments are improvements on old products, and in general these depend on the impor tant Fibcrglas property of adaptability to orderly, predeter mined arrangement. Such a development is the rein forced staple sliver. The incorporation of a continuous strand in the staple sliver during forming or twisting pre vents further drafting and yields a product which is an effective filler for electrical cables. Other new developments have grown out of newer methods of processing and application which take fuller advantage of certain desirable properties. Fjc. 5.--Fibcrglas slervings. tying cords, _ electrical issulkting tapes and cloths, and chemical filtration dotht. These illustrate only a few of the end products bufft from the original textile fibers by a succession of twisting, plying, weaving, and braiding processes. In these different products. Fiberglas thermal-insulating wool fulfills the necessary requirements for a good indus trial insulation, namely, low thermal conductivity, fire ufety, enduring resistance to vibrations and settling, lightness in weight, cleanliness, and durability. Bonded mat filter finds its greatest use as retainer mats in stonge butteries. These mats greatly extend battery He by keeping active material is place on the battery pula. They can serve this purpose because the glass employed in them is resistant to attack by the battery add and has good electrical insulation characteristics. Bonded *t products have been used less extensively as a lightduMng medium, as an inorganic faring material, and as a rting lor underground pipes to combat electrolytic corrwinn. la the field of air conditioning, the adaptability of Fibcrt*a to organized arrangement is again recognized. The titer units for removing dirt, lint, soot, plant pollens, and ""Ur nuisance dusts from the air arc built up of a scries ^ filto mats which differ in the sues of fibers used in their ^tt'truction. The individual fibers are coated with a dustetching adhesive. This orderly arrangement allows a surface coatact in a limited space and offers rela|^xly low resistance to the passage of air. These cotn- Pfopertics mean, oil integration, a high capacity for ng nir. IV. New end Future AppUcetion* '"'c* effective Fibcrglas products and applications are '1*3) Fie. 6.--Some products derived from insulation wool and a roll of bonded mat fiber frequently used as a facing material. An interesting new application of Fibergtas is in the field of hydroponics, where effective use is made of its hereto fore relatively obscure property of controlled capillarity. Glass-tape -wicking in combination with peat moss feeds chemical solutions to the plant roots at a fixed rate. Fibcrglas thermal-insulation wool is the raw material used in the production of a new strong, rigid lightweight insulation board by a newly developed process that com bines pressure and a carefully controlled heating cycle to increase the density of the material without loss of resili ency. This board, -used largely as a combination insula tion and surface finish, releases for other purposes large quantities of aluminum formerly used as a faring mate rial over Fibcrglas insulation wool. Developed to replace cork for low-lcrapcrature insula tion, Filscrglas AE board, a rigid bat of insulation wool enclosed in asphalt, is being widely used in domestic food-storage lockers and in other large-scale refrigeration units. In the field of medicine, Fibcrglas is undergoing thor ough investigation as a surgical suture*1 and as a tracer yarn in surgical sponges.* In addition, Filerglas tape is l>eing used tc filter blood plasma in army field kits.* Both bonded mat of the type used in batteries and chemical filter cloth have been used quite successfully in 1 Roy P. Scbolz and Philip S. Moumjoy, "Fiberglas Suture Material." Amer. Jour. Surgery, 56 (3) G19-21 (19-12). : Edward F. Lcwi-on, "Rayahle Gauze as a Factor of Safctv in Surgical Operations." Bull. .-1 mer. Coll. Surgeons. 21 [ij 39-10 (19-12). 1 "Xew-Type Plasma Filler Will Aid in Prevention'! Fatal Wound Shock." Surgical Business. June. 1942. 64 Bulletin of The American Ceramic Society--Ernst laboratories as Altering pads in Buchner funnels when the solutions being Altered were destructive to ordinary papers. Many decorative applications of Fiberglas have been developed in the past, and this development undoubtedly will proceed at some more appropriate future time. Vari ous colored damasks, brocades,,satins, taffetas, and secs have been veil established, and products made from these include overdrapes, glass curtains, shower curtains, bedspreads, tablecloths, and lamp shades. V. Rote of Fibergtss in the War Emergency Used as an effective replacement material for cork. noaferrous asbestos, aluminum, and mica. Fiberglas is becoming important as a strategic material in the war program. Electrical manufacturers and design engineers have achieved savings in both space and weight in newelectrical equipment through the use of Fiberglas electrical tapes and cloths. Fiberglas is taking the place of cork in certain types of low-temperature insulation. It is also combined Vith mica Is tbe manufacture of ground insula tion for electrical equipment, thereby reducing consider ably the quantity of mica required. JUkascw Laou>tokix* OvtxvCounsc Ficici.as Coirounox N'lVits, Omo MODELING SHEET GLASS IN A POTTERV'KILN* Bv Doiav.M.'Eknst Abs4tlact A method is docribed for obtaining relief pattern in sheet glass while bending it into decorative and usable forms. The fact that sheets of glass may be bent in a ceramic are worked out in high relief. This explains the pebbled mold in a pottery kiln has been discovered in the Ceramic texture of some of the pieces. The porosity of tbe biscuit Laboratory- of the University of Cincinnati. When tbe causes the kilo wash to dry with a pebbled surface. glass is cooled, it has an appearance quite different from The type of modeling also affects the success of the im the crisp perfection of glass bent is the smooth metal pression. Tbe heavy creeping mass of heated glass has a molds used commercially. It is more like old hand-roGed tendency to slide over the crevices. Definition is given glass. by a calculated change in form that checks this viscous Tbe tendency of tbe heated glass, asit bends to tbe shape flow; an instant, giving an accent where it is needed; other- of the mold, to pick up impressions of each minute raised ^w-be, the pattern may show as a lot of meaningless bumps particle may be developed into impressions of definite, in the glass. The exact reproduction of designs pressed calculated relief patterns. into a mold in the traditional manner should not be ex- The process is simple. Molds are made of day. the - peeled or attempted. design is modeled thereon, and they are biseuited. A The outer contour should be controlled by designing the wash of clay and flint (25 and 75%. respectively), plus a mold so that a support for the edges of the sheet of glass little gum tragacanth, is applied to the mold to prevent is provided or warp&ge may occur if the heat of the loin is the glass from adhering to it. A dean sheet of glass cat to uneven. Small holes may be drilled in the deep crevices fit the outer contour of the mold is placed on it, and it is, if the modeling is ix< quite high relief to expel any trapped ready to be put into the kiln. The temperature is brought air that may cause a bubble in a reverse direction. up slowly to a point just sufficient to cause the heated glass A surprising amount of modeling is possiulc. A variety to move down. It sinks as a heavy film, finding the vari of different impressions may be made from the same mold ous levels of the modeled surface. by using different foreign and domestic glass compositions. The temperature required varies with different glass Single- and double-strength window glass is used for small compositions. Experimentation is necessary to find the molds; crystal and plate glass are used for large molds. temperature best suited to the type of glass being used. It All types of glass bend satisfactorily; the temperature re will probably be around cone 012, or 15W*F. Proper quired, ofcourse, varies. regulation of temperature is required because heat that is Other experiments have consisted of stacking layers of too high or that is maintained too long will cause tbe sur glass together. Glass, cut in triangles, squares, etc., and face to slip or to devitrify. placed in pattern oa flat sheet glass laid on a mold fuse to The kiln must be cooled slowly to anneal the glass, as gether as the glass bends to the mold. When various- rapid cooling to rigidity will create strain. colored glasses are combined, chipping and crazing occur if Tbe upper surface of the molded glass will be smooth the formulas are not "sympathetic." Design possibilities and will need no further attention. The under surface, are limited, owing to glass-cutting difficulties. Overglaze however, will require cleaning inasmuch as some of tbe l-fla ceramic colors applied on a fiat sheet in the same manner wash may be picked up. A mild abrasive and a wet brush as glass enamels also bend with the glass. may be used, but neither should be hard enough to snatch. Ceramic molds arc durable in a commercial, moving, A silicon carbide stick may be needed to smooth the edge if circular kilo. Glass bends satisfactorily in an undecorated the firing has been too drastic. mold, but few perfect impressions are obtained from tbe To find tbe full extent of the ups and downs that the glass decorated molds. A pottery kiln gives a better texture to will take, a coarse clay has been used for tbe forms, because the glass. tbe chance of cracking or breaking is lessened if designs The materials needed for the modeled bent glass arc in * Presented at the Forty-Fourth Annual Meeting. The American Ceramic Society. Cincinnati. Ohio, April 21, 1942 (Art Division). Received September 15. 1942. expensive. and, aside from a pottery kiln. little equipment is required. Ral Rocte 3 Lovklaso. Ohio Vol. 22. No. -1 CONVER: i , Freest con 1 siaders of pre i ctsrcd from ti : thirty year*. { - . la 1910 and ! Obso were pa- eatonl gas to * country. Gla: producer gas c j factories still c * to operate. About 1914 . *' suiter was natural gas I " Gas Com West Vtrg f ' -'.^ EVea with a Egg^tttftQoBcrr of t EsriEZeamcootingcot giggSM&icloa. rg&ty fines, 1 _ !aTO shut fpgatmrf!Ui Coajequentl; at leas' pajdodag natural ':*L POatSutd cdaL Alter tbe nev gas was obu possible to i *' fo time most of | Piping and b | v.lac with produ* r--;;.Tid op to the ; 5 ode over the v a ~ ->. CQaBtinr of & f.-.-wj*. first glass |s.|p4ana. This ? iXS***1* ** L-^st-PHtncativc fu; c cvTbia mstallatio V==L*5bP most of tl |5ELla l*ter iosta i . usually on t y Enured for this .^i_..**adged dowx .T^wbwh depended -fVmaare ,,f Uie , otrol the flow reversing op- r.-"* C- !! ' _ ^ooregencrati . * Preseated a Absecon. N `'nba- 23. (1X3) 1