CA2267445A1 - Mineral fiber compositions - Google Patents
Mineral fiber compositions Download PDFInfo
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- CA2267445A1 CA2267445A1 CA002267445A CA2267445A CA2267445A1 CA 2267445 A1 CA2267445 A1 CA 2267445A1 CA 002267445 A CA002267445 A CA 002267445A CA 2267445 A CA2267445 A CA 2267445A CA 2267445 A1 CA2267445 A1 CA 2267445A1
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- na2o
- mgo
- sio2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C13/00—Fibre or filament compositions
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2213/00—Glass fibres or filaments
- C03C2213/02—Biodegradable glass fibres
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- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
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Abstract
Mineral fiber compositions are disclosed which, in a first embodiment, include the following components, indicated in weight percents: about 54 to about 70 percent SiO2, about 0 to about 4 percent Al2O3, about 0 to about 6 percent Na2O, about 0 to about 6 percent K2O, about 0 to about 6 percent MgO, about 10 to about 28 percent CaO, about 6 to about 17 percent total iron as FeO, and about 0 to about 5 percent TiO2, wherein the total weight percent of SiO2 and Al2O3 ranges from about 56 percent to about 72 percent, the total weight percent of MgO and CaO ranges from about 12 percent to about 28 percent, the total weight percent of Na2O and K2O does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent. In a second embodiment, the compositions include the following components, indicated in weight percents: about 50 to about 68 percent SiO2, about 0 to about 4 percent Al2O3, about 0 to about 6 percent K2O, about 0 to about 6 percent Na2O, about 0 to about 10 percent MgO, about 10 to about 28 percent CaO, about 6 to about 16 percent total iron as FeO, about 0 to about 5 percent TiO2, and about 0.5 to about 12 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 6 percent and the total weight of all components, including trace elements, if any, is 100 percent.
Description
MINERAL FIBER COMPOSITIONS
TECHNICAL FIELD
This invention relates to mineral fiber compositions and, more particularly, to S insulation products formed from fibers made from such compositions.
BACKGROUND OF THE INVENTION
Mineral fiber insulation is well known and has been a commercial product for an extended period of time. Such insulation typically is made from a nonwoven network of intertwined fibers that have been fiberized from a melt, by one of several processes discussed below, and that are held together by a binder. The binder may be any suitable material but quite commonly is a phenol-formaldehyde resin or a ureaformaldehyde resin. A
conveyor typically collects the binder-coated fibers in the form of a blanket and the blanket is heat cured to produce the final insulation product. Insulation materials of various densities can be produced by varying the conveyor speed and the thickness of the cured insulation.
Glass wools are generally prepared by a rotary process, whereby a glass melt is dropped into a "spinner" having a peripheral wall having a multitude of holes therein, through which the glass is forced by centrifugal force to form fibers, which process gives excellent fiber yields, i.e., low "shot" contents and excellent insulating properties. However, the glasses used to produce these fibers have low softening temperatures so that their use is generally limited to only moderately high service temperatures.
Mineral woofs, on the other hand, have higher softening and use temperatures and thus can typically be used in higher temperature environments. However, these compositions generally have forming temperatures which are too high for rotary fiberizing. Mineral woofs are usually formed by external centrifuge processes that produce a lower fiber yield and a higher shot content than the rotary process. An example of a mineral wool intended to be fiberized by an external centrifuge process is disclosed in WO 96/00196.
Previously in the art mineral wool compositions have been reported which allegedly can be formed into fiber by a rotary process. (See International Patent Application Publications WO 95/01941 and WO 93I02977, U.S. Patent No. S,SS4,324, and European 3 0 Patent Application EP S 83 792). However, these compositions a11 contain high amounts of Na20, K20, and B203, which can negatively affect the high temperature performance of the fiber, or high amounts of A120, which can decrease the biosolubility of the fiber.
Although mineral fibers have not been linked to disease in humans, it has become desirable to increase the biosolubility of mineral fibers. One would expect that increasing the solubility of mineral fibers would further decrease the time the fibers remain in a lung, if they were to be inhaled, and thus that the dissolution rate of mineral fibers in a saline solution having a composition similar to that existing in a human lung would be a good indicator of the biosolubility of such fibers. This dissolution rate can be improved by altering the chemical composition of a fiber. Previously in the art, it was thought that these alterations could not be made without impairing other properties of the fibers necessary for commercial purposes.
Accordingly, it is an object of the present invention to provide an improved mineral fiber composition and an improved mineral fiber formed from such composition.
Another object of the present invention is to provide a mineral fiber useable in relatively high temperature environments.
A further object of the present invention is to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process.
Yet another object of the present invention is to provide a mineral fiber that is relatively biosoluble, yet sufficiently durable.
More preferably, it is an object of the present invention to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process, which fiber is usable in high temperature environments and is sufficiently durable.
More preferably, it is an object of the present invention to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process, which fiber is usable in high temperature environments and is relatively biosoluble, yet suffciently durable.
SUMMARY OF THE INVENTION
The above objects as well as other objects not specifically enumerated are accomplished by a mineral fiber composition according to a first embodiment of the present invention, which includes the following components, indicated in weight percents: about 54 to about 70 percent Si02, about 0 to about 4 percent A1203, about 0 to about 6 percent Na20, about 0 to about 6 percent K20, about 0 to about 6 percent MgO, about 10 to about 28 percent CaO, about 6 to about 17 percent total iron as FeO, and about 0 to about 5 percent Ti02, wherein the total weight percent of Si02 and A1203 ranges from about 56 percent to about 72 percent, the total weight percent of Mg0 and Ca0 ranges from about 12 percent to about 28 percent, the total weight percent of Na20 and K20 does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
The above objects are also accomplished by a mineral fiber composition according to a second embodiment of the present invention, which includes the following components, indicated in weight percents: about 50 to about 68 percent Si02, about 0 to about 4 percent A1203, about 0 to about 6 percent K20, about 0 to about 6 percent Na20, about 0 to about 10 percent MgO, about 10 to about 28 percent CaO, about 6 to about 16 percent total iron as FeO, about 0 to about S percent Ti02, and about 0.5 to about 12 percent Zr02, wherein the total weight of Na20 and K20 does not exceed 6 percent and the total weight of a11 components, including trace elements, if any, is 100 percent.
The above objects are further accomplished by mineral wool insulation including mineral fibers having a composition according to the first embodiment of the present invention, and by a mineral wool insulation including mineral fibers having a composition according to the second embodiment of the present invention.
DETAILED DESCRIPTION AND
PREFERRED EMBODIMENTS OF THE INVENTION
As will be discussed more filly below, mineral fiber compositions according to the present invention have relatively lower liquidus temperatures and relatively higher viscosities than a standard rockwool, thus allowing rotary fiberization thereof. For these compositions, the liquidus temperatures are generally less than about 2200~F ( I 204~C), and, more preferably, less than about 2180~F ( 1 l93 ~C). These relatively lower liquidus temperatures are due at least in part to the relatively low Mg0 content of the mineral fiber compositions. The viscosity of the compositions generally falls between about 150 and about 1000 poise at 2250~F (1232~C) and, more preferably, between about 200 and 800 poise at 2250~F (1232~C). With these properties, the compositions of this invention have su~ciently low liquidus temperatures and adequate viscosity ranges to allow these compositions to be used in a typical rotary fiberizing apparatus.
The compositions of the present invention are preferably resistant to high temperature degradation, such that they form wool products that can be used in relatively high temperature environments. The compositions of the present invention also preferably produce fibers which are relatively biosoluble, yet sufficiently durable to maintain a wool product's physical integrity over many years in the location at which it is installed. Such fibers preferably should not only be fairly inert to moisture attack at the installation site, but also capable of dissolving in a physiological medium, such as human lung fluid.
Like a standard rockwool composition described below, the compositions of the present invention have a relatively low Na20+K20 content to help give the rotary fiberized product relative good high temperature resistance. However, the compositions of the present invention include, relative to a standard rockwool, moderately increased amounts of Si02, greatly reduced amounts of AI20a, and an increased Fe203 content. In one embodiment of the invention, the compositions can also include an increased Zr02 content.
As discussed more fully below, these changes can be implemented in varying degrees to produce compositions that are not only fiberizable by rotary methods, but also, in varying degrees, are resistant to high temperatures, durable, and preferably, relatively biosoluble.
A mineral fiber composition according to a f rst embodiment of the present invention include the following components, in about the indicated weight percents (as is standard practice in the art, the components are reported as oxides, even though essentially no such individual crystals are present):
Component Weight Percent Si02 54-70 Na20 0-6 Mg0 0-6 Ca0 10-28 Total Iron as Fe0* 6-17 Ti02 0-5 S102+A1203 56-72 Na20+K20 0-6 Mg0+Ca0 12-28.
*Iron is present as both Fe2+ and Fe3+ or in oxide form as Fe0 and Fe203.
Since the fraction of Fe2+ and Fe3+ is unknown, the total of both iron oxides is expressed herein as FeO.
TECHNICAL FIELD
This invention relates to mineral fiber compositions and, more particularly, to S insulation products formed from fibers made from such compositions.
BACKGROUND OF THE INVENTION
Mineral fiber insulation is well known and has been a commercial product for an extended period of time. Such insulation typically is made from a nonwoven network of intertwined fibers that have been fiberized from a melt, by one of several processes discussed below, and that are held together by a binder. The binder may be any suitable material but quite commonly is a phenol-formaldehyde resin or a ureaformaldehyde resin. A
conveyor typically collects the binder-coated fibers in the form of a blanket and the blanket is heat cured to produce the final insulation product. Insulation materials of various densities can be produced by varying the conveyor speed and the thickness of the cured insulation.
Glass wools are generally prepared by a rotary process, whereby a glass melt is dropped into a "spinner" having a peripheral wall having a multitude of holes therein, through which the glass is forced by centrifugal force to form fibers, which process gives excellent fiber yields, i.e., low "shot" contents and excellent insulating properties. However, the glasses used to produce these fibers have low softening temperatures so that their use is generally limited to only moderately high service temperatures.
Mineral woofs, on the other hand, have higher softening and use temperatures and thus can typically be used in higher temperature environments. However, these compositions generally have forming temperatures which are too high for rotary fiberizing. Mineral woofs are usually formed by external centrifuge processes that produce a lower fiber yield and a higher shot content than the rotary process. An example of a mineral wool intended to be fiberized by an external centrifuge process is disclosed in WO 96/00196.
Previously in the art mineral wool compositions have been reported which allegedly can be formed into fiber by a rotary process. (See International Patent Application Publications WO 95/01941 and WO 93I02977, U.S. Patent No. S,SS4,324, and European 3 0 Patent Application EP S 83 792). However, these compositions a11 contain high amounts of Na20, K20, and B203, which can negatively affect the high temperature performance of the fiber, or high amounts of A120, which can decrease the biosolubility of the fiber.
Although mineral fibers have not been linked to disease in humans, it has become desirable to increase the biosolubility of mineral fibers. One would expect that increasing the solubility of mineral fibers would further decrease the time the fibers remain in a lung, if they were to be inhaled, and thus that the dissolution rate of mineral fibers in a saline solution having a composition similar to that existing in a human lung would be a good indicator of the biosolubility of such fibers. This dissolution rate can be improved by altering the chemical composition of a fiber. Previously in the art, it was thought that these alterations could not be made without impairing other properties of the fibers necessary for commercial purposes.
Accordingly, it is an object of the present invention to provide an improved mineral fiber composition and an improved mineral fiber formed from such composition.
Another object of the present invention is to provide a mineral fiber useable in relatively high temperature environments.
A further object of the present invention is to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process.
Yet another object of the present invention is to provide a mineral fiber that is relatively biosoluble, yet sufficiently durable.
More preferably, it is an object of the present invention to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process, which fiber is usable in high temperature environments and is sufficiently durable.
More preferably, it is an object of the present invention to provide a mineral fiber composition that may be formed into a mineral fiber in a rotary fiberizing process, which fiber is usable in high temperature environments and is relatively biosoluble, yet suffciently durable.
SUMMARY OF THE INVENTION
The above objects as well as other objects not specifically enumerated are accomplished by a mineral fiber composition according to a first embodiment of the present invention, which includes the following components, indicated in weight percents: about 54 to about 70 percent Si02, about 0 to about 4 percent A1203, about 0 to about 6 percent Na20, about 0 to about 6 percent K20, about 0 to about 6 percent MgO, about 10 to about 28 percent CaO, about 6 to about 17 percent total iron as FeO, and about 0 to about 5 percent Ti02, wherein the total weight percent of Si02 and A1203 ranges from about 56 percent to about 72 percent, the total weight percent of Mg0 and Ca0 ranges from about 12 percent to about 28 percent, the total weight percent of Na20 and K20 does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
The above objects are also accomplished by a mineral fiber composition according to a second embodiment of the present invention, which includes the following components, indicated in weight percents: about 50 to about 68 percent Si02, about 0 to about 4 percent A1203, about 0 to about 6 percent K20, about 0 to about 6 percent Na20, about 0 to about 10 percent MgO, about 10 to about 28 percent CaO, about 6 to about 16 percent total iron as FeO, about 0 to about S percent Ti02, and about 0.5 to about 12 percent Zr02, wherein the total weight of Na20 and K20 does not exceed 6 percent and the total weight of a11 components, including trace elements, if any, is 100 percent.
The above objects are further accomplished by mineral wool insulation including mineral fibers having a composition according to the first embodiment of the present invention, and by a mineral wool insulation including mineral fibers having a composition according to the second embodiment of the present invention.
DETAILED DESCRIPTION AND
PREFERRED EMBODIMENTS OF THE INVENTION
As will be discussed more filly below, mineral fiber compositions according to the present invention have relatively lower liquidus temperatures and relatively higher viscosities than a standard rockwool, thus allowing rotary fiberization thereof. For these compositions, the liquidus temperatures are generally less than about 2200~F ( I 204~C), and, more preferably, less than about 2180~F ( 1 l93 ~C). These relatively lower liquidus temperatures are due at least in part to the relatively low Mg0 content of the mineral fiber compositions. The viscosity of the compositions generally falls between about 150 and about 1000 poise at 2250~F (1232~C) and, more preferably, between about 200 and 800 poise at 2250~F (1232~C). With these properties, the compositions of this invention have su~ciently low liquidus temperatures and adequate viscosity ranges to allow these compositions to be used in a typical rotary fiberizing apparatus.
The compositions of the present invention are preferably resistant to high temperature degradation, such that they form wool products that can be used in relatively high temperature environments. The compositions of the present invention also preferably produce fibers which are relatively biosoluble, yet sufficiently durable to maintain a wool product's physical integrity over many years in the location at which it is installed. Such fibers preferably should not only be fairly inert to moisture attack at the installation site, but also capable of dissolving in a physiological medium, such as human lung fluid.
Like a standard rockwool composition described below, the compositions of the present invention have a relatively low Na20+K20 content to help give the rotary fiberized product relative good high temperature resistance. However, the compositions of the present invention include, relative to a standard rockwool, moderately increased amounts of Si02, greatly reduced amounts of AI20a, and an increased Fe203 content. In one embodiment of the invention, the compositions can also include an increased Zr02 content.
As discussed more fully below, these changes can be implemented in varying degrees to produce compositions that are not only fiberizable by rotary methods, but also, in varying degrees, are resistant to high temperatures, durable, and preferably, relatively biosoluble.
A mineral fiber composition according to a f rst embodiment of the present invention include the following components, in about the indicated weight percents (as is standard practice in the art, the components are reported as oxides, even though essentially no such individual crystals are present):
Component Weight Percent Si02 54-70 Na20 0-6 Mg0 0-6 Ca0 10-28 Total Iron as Fe0* 6-17 Ti02 0-5 S102+A1203 56-72 Na20+K20 0-6 Mg0+Ca0 12-28.
*Iron is present as both Fe2+ and Fe3+ or in oxide form as Fe0 and Fe203.
Since the fraction of Fe2+ and Fe3+ is unknown, the total of both iron oxides is expressed herein as FeO.
Preferred ranges for components of the composition according to the first embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 56-68 Na20 0-5 Mg0 1-6 Ca0 10-25 Total Iron as Fe0 8-16 Ti02 0-4 StO2+A1203 58-71 K20+Na20 0-5 Mg0+Ca0 14-26.
More preferred ranges for components of the composition according to the first embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 58-65 Na20 0-4 Mg0 2-5 Ca0 11-20 Total Iron as Fe0 9-13 2 S Ti02 0-3 Si02+A1203 60-68 Na20+K20 0-4 Mg0+Ca0 17-22.
-S-Comparative Example 1 The table below shows the approximate weight percent composition and some properties as well of a commercial as rockwool, the i.e., Composition same A, for seven mineral through ing to the wool compositions, H, first i.e., Compositions accord B
embodiment invention.
of the present Component A B C D E F G H
Si02 4S.4 62.00 63.0 62.0 62.0 64.0 63.0 62.0 AI2O3 13.7 3.00 2.0 3.0 3.0 1.0 2.0 3.0 Na20 2.2 2.60 2.S 2.S S.S 2.S 2.S 2.5 K20 O.S 0.90 O.S O.S 0.5 O.S O.S O.S
Mg0 11.3 4.S0 3.S 2.S 3.0 2.S 2.S 3.S2 Ca0 19.6 13.35 18.S 19.S 16.0 19.5 19.5 18.48 Ti02 1.4 1.90 0.2 0.2 0.2 0.2 0.2 0.2 Total Iron 11.75 9.8 9.8 9.8 9.8 9.8 9.8 As Fe0 5.4 Liquidus 22S 1 2171 2160 2158 2101 -- 2196 2180 (F) Liquidus (C) 1231 1188 1182 1181 1149 -- 1202 1193 Viscosity' 104 442 328 344 -- -- --Shrinkz 6 3 -- 4 -- 11 4 Dissol. Rate31 S 42 -- 42 -- 107 94 'Measured in poise at 22S0~F (1230~C).
ZMeasured at 930~C.
3Measured as ng/cm2-hr in a model physiological saline solution at 37~C with a flow rate of 0.2 mL per minute 2S A standard rockwool's lack of suitability for fiberizing by a rotary process is evidenced from the values given for Composition A. Specifically, Composition A
has a liquidus temperature of 22S 1 ~F ( 1231 ~C), which is generally too high to achieve economical results from the typical rotary process now used. Also, Composition A has a viscosity of 104 poise at 2250~F (1230~C), which is generally too low to achieve good quality fibers with low shot content. In addition, the dissolution rate of Composition A, 15 ng/cm2-hr, is much lower than desired.
In contrast, Composition B has a liquidus temperature of 2171~F (1 l88~C) and a viscosity of 442 poise at 2250~C, Composition C has a liquidus temperature of 2160~F ( 1182~C) and a viscosity of 328 poise, and Composition D has a liquidus temperature of 2158~F ( 1181 ~C) and a viscosity of 344 poise, which indicates that Compositions B, C and D should be economically fiberizable, with fairly good fiber quality, using relatively standard rotary fiberization methods. In addition, the high temperature resistances of Compositions B and D compare well with that of Composition A, i.e., 3 and 4 percent linear shrink, respectively, vs. 6 percent linear shrink at 930~C. The percent linear shrink is a measure of fire resistance determined from a standard fire test, with less shrinkage indicating better fire performance. Further, Compositions B and D each has an improved dissolution rate of 42 ng/cmz-hr with respect to Composition A.
It is believed that the temperature resistances of compositions according to the first embodiment of the invention are due to the relatively low alkali, i.e., NazO + KzO, contents thereof, and that the relatively low liquidus temperatures thereof are due at least in part to their relatively low Mg0 contents. In addition, it is believed that the relatively improved dissolution rates of the compositions are due to the low alumina levels thereof. As can be seen from Compositions F and G, these improved dissolution rates can be quite high, i.e., 107 ng/cmz-hr for Composition F, although potentially at some sacrifice of other properties for certain compositions, i.e., the higher liquidus temperature of Composition G.
Accordingly, alternative compositions according to a second embodiment of the present invention are desirable in some instances to produce certain combinations of liquidus, viscosity and dissolution rate, while retaining temperature resistance.
Mineral fiber compositions according to a second embodiment of the invention include the following components, in about the indicated weight percents:
Component Weight Percent SiOz 50-68 Na20 0-6 Mg0 0-10 Ca0 10-28 Total Iron as Fe0 6-16 _7_ Ti02 0-5 Zr02 0. 5-12 Na20+K20 0-6 Preferred ranges for components of the composition according to the second embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 52-66 Ai203 0-3.5 Na20 0-5 Mg0 1-8 Ca0 11-25 Total Iron as Fe0 7-15 1 S Ti02 0-4 Zr02 1-11 Na20+K20 0-5 More preferred ranges for components of the composition according to the second embodiment are as follows, in about the indicated weight percents:
Component Weight Percent Si02 54-64 A123 0-3 . S
K20 0-4.5 Na20 0-4.5 Mg0 1-4 Ca0 12-23 Total Iron as Fe0 7-14 Ti02 0-3 3 0 Zr02 1-9 Na20+K20 0-4.5 _g_ More preferred ranges for components of the compositions according to the second embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 57-62 S A123 0. S-2 Na20 0-3 Mg0 2-4 Ca0 16-22 Total Iron as Fe0 7-12 Ti02 0-2 Zr02 1-S
Na20+K20 0-4.5 Example 2 Specific examples of compositions according to the second embodiment of this invention are shown in the following table with quantities being presented by approximate weight percent of total composition.
Component I J K L M N 0 P
Q R S p Si02 60 60 60 56 60 62 62 60 60.5 60.06 60 A120a 3 3 2 3 3 3 3 2 0.5 1.5 1.34 Na20 2.5 2.5 0.25 2. 2.5 2.5 2.5 0.25 4 2.5 2.5 S
K20 0.5 0.5 2.75 0.5 0.5 0.5 0.5 2.75 0.16 0.38 0.35 Mg0 2.S7 2.4 2.5 2.17 2.05 3.2 2.88 2 3.14 3.07 3.07 Ca0 19.94 18.6 19.5 16.83 l 5.95 l 6.8 15.12 18 19.86 l9.43 19.43 c~
Ba0 0 0 0 0 3.0 0 0 0 N
Ti02 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.06 0.06 0.06 r 0 10 Total Iron As Fe0 8 9 8 9 8 9 9 11 . . . . . . . . .
Zr02 1.5 3 3 9 3 2 4 3 . .
Liquidus (F) 2110 2137 213S 2151 2091 2121 2137 2117 Liquidus (C) 1154 1169 1168 1l77 1144 1161 1169 11S8 N
Viscosity) 366 % Shrink2 41.7 12.2 5.5 7.1 16.3 Dissol. Rate3 44.3 'Measured in poise at n 2250F (1232C).
Measured at 930C.
3Measured as ng/cm2-hr a model with .2 in physiological a flow mL
saline rate per solution of minute.
at 37C 0 .-w N
As can be seen by comparing Composition D with Composition J, the compositions are very similar, with Composition J having 3 percent ZrOz substituted for 2 percent SiOz and 1 percent Ca0 in Composition D. As can further be seen, this addition of ZrOz in Composition J produces a moderate reduction in the liquidus temperature of that composition as compared to Composition D, and a moderate increase in viscosity at 2250~F
(1232~C). Both changes are desirable, to improve the economics and fiber quality of rotary fiberization, respectively. As can also be seen, Composition J has a dissolution rate which is comparable to that of Composition D, and a temperature resistance that is relatively good.
The percent linear shrink of Composition I was measured and was determined to be 41.7%. This is a high rate of linear shrinkage when compared with the linear shrinkages for Compositions D and J. The high rate of linear shrinkage of Composition I can be attributed to both its SiOz concentration and its ZrOz concentration.
The formulation of Composition I includes 2% less SiOz and 1.5% more ZrOz than Composition D. Also, Composition I has the same percentage of SiOz but 1.5%
less ZrOz than Composition J. The relatively high linear shrinkage for Composition I
indicates that, for that particular composition, while maintaining the other components relatively constant, the addition of only 1.5% ZrOz does not suffciently make up for the high temperature resistance which is lost when 2% of SiOz is removed from the composition.
However, as can be seen from comparing Composition D with Composition J, the addition of 3% of ZrOz substituted for the 2% loss of SiOz does adequately make up for the high temperature resistance which is lost when the SiOz is removed.
The biosolubility of Composition J, while much improved relative to a standard rockwool such as Composition A, is still lower than achieved by a more preferred embodiment of the invention. An increase in such biosolubility as a result of a decrease in 2S AI2O3 content can be seen by comparing Composition J with Compositions R
and S.
Compositions R and S are similar to Composition J, with roughly 1.5 percent A1z03 replaced with roughly 1.5 percent Ca0 and MgO, collectively. Compositions R and S have dissolution rates in a model physiological saline solution, at 37~C with a flow rate of 0.2 mL
per minute, of 74 and 80 ng/cmz-hr, respectively, as compared with 42 and 44.3 ng/cmz-hr, respectively, for Compositions D and J. Compositions R and S also have relatively good high temperature resistance, and liquidus temperatures similar to that of Composition D.
The viscosity of Composition S also is in a range that should allow for relatively good fiber quality in a rotary fiberizing process (the viscosity of Composition R has not been tested, but is expected to also be within an acceptable range). For these reasons, Compositions R and S
are at this time the most preferred embodiments of the present invention.
As stated above, the compositions of this invention can be formed into mineral wool fibers by a rotary fiberizing apparatus. If used to create an insulation product, the fibers can be coated with a binder to hold the insulation product together. The fibers can also be coated with lubricating agents, wetting agents, antistatic agents and extenders or stabilizers. Typically, the fibers are coated as they are attenuated from the fiberizing apparatus. However, one skilled in the art will appreciate that the fibers can be coated at any time in the insulation formation process. Once the fibers have been attenuated from the fiberizing apparatus, the fibers are typically collected on a porous conveyor belt or other collection apparatus to be formed into an insulation product.
Although the compositions of this invention have been described above as being primarily useful in mineral wool insulation products, one skilled in the art will I S understand that the compositions of this invention can be used to form mineral fibers useful in other applications than insulation. For example, fibers formed from the compositions of this invention can also be used to form air handling ducts, ceiling panels and acoustical panels.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those of skill in the art that various changes and modifications can be made to the compositions of this invention without departing from the scope of the invention, which is defined in the appended claims.
Component Weight Percent Si02 56-68 Na20 0-5 Mg0 1-6 Ca0 10-25 Total Iron as Fe0 8-16 Ti02 0-4 StO2+A1203 58-71 K20+Na20 0-5 Mg0+Ca0 14-26.
More preferred ranges for components of the composition according to the first embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 58-65 Na20 0-4 Mg0 2-5 Ca0 11-20 Total Iron as Fe0 9-13 2 S Ti02 0-3 Si02+A1203 60-68 Na20+K20 0-4 Mg0+Ca0 17-22.
-S-Comparative Example 1 The table below shows the approximate weight percent composition and some properties as well of a commercial as rockwool, the i.e., Composition same A, for seven mineral through ing to the wool compositions, H, first i.e., Compositions accord B
embodiment invention.
of the present Component A B C D E F G H
Si02 4S.4 62.00 63.0 62.0 62.0 64.0 63.0 62.0 AI2O3 13.7 3.00 2.0 3.0 3.0 1.0 2.0 3.0 Na20 2.2 2.60 2.S 2.S S.S 2.S 2.S 2.5 K20 O.S 0.90 O.S O.S 0.5 O.S O.S O.S
Mg0 11.3 4.S0 3.S 2.S 3.0 2.S 2.S 3.S2 Ca0 19.6 13.35 18.S 19.S 16.0 19.5 19.5 18.48 Ti02 1.4 1.90 0.2 0.2 0.2 0.2 0.2 0.2 Total Iron 11.75 9.8 9.8 9.8 9.8 9.8 9.8 As Fe0 5.4 Liquidus 22S 1 2171 2160 2158 2101 -- 2196 2180 (F) Liquidus (C) 1231 1188 1182 1181 1149 -- 1202 1193 Viscosity' 104 442 328 344 -- -- --Shrinkz 6 3 -- 4 -- 11 4 Dissol. Rate31 S 42 -- 42 -- 107 94 'Measured in poise at 22S0~F (1230~C).
ZMeasured at 930~C.
3Measured as ng/cm2-hr in a model physiological saline solution at 37~C with a flow rate of 0.2 mL per minute 2S A standard rockwool's lack of suitability for fiberizing by a rotary process is evidenced from the values given for Composition A. Specifically, Composition A
has a liquidus temperature of 22S 1 ~F ( 1231 ~C), which is generally too high to achieve economical results from the typical rotary process now used. Also, Composition A has a viscosity of 104 poise at 2250~F (1230~C), which is generally too low to achieve good quality fibers with low shot content. In addition, the dissolution rate of Composition A, 15 ng/cm2-hr, is much lower than desired.
In contrast, Composition B has a liquidus temperature of 2171~F (1 l88~C) and a viscosity of 442 poise at 2250~C, Composition C has a liquidus temperature of 2160~F ( 1182~C) and a viscosity of 328 poise, and Composition D has a liquidus temperature of 2158~F ( 1181 ~C) and a viscosity of 344 poise, which indicates that Compositions B, C and D should be economically fiberizable, with fairly good fiber quality, using relatively standard rotary fiberization methods. In addition, the high temperature resistances of Compositions B and D compare well with that of Composition A, i.e., 3 and 4 percent linear shrink, respectively, vs. 6 percent linear shrink at 930~C. The percent linear shrink is a measure of fire resistance determined from a standard fire test, with less shrinkage indicating better fire performance. Further, Compositions B and D each has an improved dissolution rate of 42 ng/cmz-hr with respect to Composition A.
It is believed that the temperature resistances of compositions according to the first embodiment of the invention are due to the relatively low alkali, i.e., NazO + KzO, contents thereof, and that the relatively low liquidus temperatures thereof are due at least in part to their relatively low Mg0 contents. In addition, it is believed that the relatively improved dissolution rates of the compositions are due to the low alumina levels thereof. As can be seen from Compositions F and G, these improved dissolution rates can be quite high, i.e., 107 ng/cmz-hr for Composition F, although potentially at some sacrifice of other properties for certain compositions, i.e., the higher liquidus temperature of Composition G.
Accordingly, alternative compositions according to a second embodiment of the present invention are desirable in some instances to produce certain combinations of liquidus, viscosity and dissolution rate, while retaining temperature resistance.
Mineral fiber compositions according to a second embodiment of the invention include the following components, in about the indicated weight percents:
Component Weight Percent SiOz 50-68 Na20 0-6 Mg0 0-10 Ca0 10-28 Total Iron as Fe0 6-16 _7_ Ti02 0-5 Zr02 0. 5-12 Na20+K20 0-6 Preferred ranges for components of the composition according to the second embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 52-66 Ai203 0-3.5 Na20 0-5 Mg0 1-8 Ca0 11-25 Total Iron as Fe0 7-15 1 S Ti02 0-4 Zr02 1-11 Na20+K20 0-5 More preferred ranges for components of the composition according to the second embodiment are as follows, in about the indicated weight percents:
Component Weight Percent Si02 54-64 A123 0-3 . S
K20 0-4.5 Na20 0-4.5 Mg0 1-4 Ca0 12-23 Total Iron as Fe0 7-14 Ti02 0-3 3 0 Zr02 1-9 Na20+K20 0-4.5 _g_ More preferred ranges for components of the compositions according to the second embodiment of the invention are as follows, in about the indicated weight percents:
Component Weight Percent Si02 57-62 S A123 0. S-2 Na20 0-3 Mg0 2-4 Ca0 16-22 Total Iron as Fe0 7-12 Ti02 0-2 Zr02 1-S
Na20+K20 0-4.5 Example 2 Specific examples of compositions according to the second embodiment of this invention are shown in the following table with quantities being presented by approximate weight percent of total composition.
Component I J K L M N 0 P
Q R S p Si02 60 60 60 56 60 62 62 60 60.5 60.06 60 A120a 3 3 2 3 3 3 3 2 0.5 1.5 1.34 Na20 2.5 2.5 0.25 2. 2.5 2.5 2.5 0.25 4 2.5 2.5 S
K20 0.5 0.5 2.75 0.5 0.5 0.5 0.5 2.75 0.16 0.38 0.35 Mg0 2.S7 2.4 2.5 2.17 2.05 3.2 2.88 2 3.14 3.07 3.07 Ca0 19.94 18.6 19.5 16.83 l 5.95 l 6.8 15.12 18 19.86 l9.43 19.43 c~
Ba0 0 0 0 0 3.0 0 0 0 N
Ti02 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.06 0.06 0.06 r 0 10 Total Iron As Fe0 8 9 8 9 8 9 9 11 . . . . . . . . .
Zr02 1.5 3 3 9 3 2 4 3 . .
Liquidus (F) 2110 2137 213S 2151 2091 2121 2137 2117 Liquidus (C) 1154 1169 1168 1l77 1144 1161 1169 11S8 N
Viscosity) 366 % Shrink2 41.7 12.2 5.5 7.1 16.3 Dissol. Rate3 44.3 'Measured in poise at n 2250F (1232C).
Measured at 930C.
3Measured as ng/cm2-hr a model with .2 in physiological a flow mL
saline rate per solution of minute.
at 37C 0 .-w N
As can be seen by comparing Composition D with Composition J, the compositions are very similar, with Composition J having 3 percent ZrOz substituted for 2 percent SiOz and 1 percent Ca0 in Composition D. As can further be seen, this addition of ZrOz in Composition J produces a moderate reduction in the liquidus temperature of that composition as compared to Composition D, and a moderate increase in viscosity at 2250~F
(1232~C). Both changes are desirable, to improve the economics and fiber quality of rotary fiberization, respectively. As can also be seen, Composition J has a dissolution rate which is comparable to that of Composition D, and a temperature resistance that is relatively good.
The percent linear shrink of Composition I was measured and was determined to be 41.7%. This is a high rate of linear shrinkage when compared with the linear shrinkages for Compositions D and J. The high rate of linear shrinkage of Composition I can be attributed to both its SiOz concentration and its ZrOz concentration.
The formulation of Composition I includes 2% less SiOz and 1.5% more ZrOz than Composition D. Also, Composition I has the same percentage of SiOz but 1.5%
less ZrOz than Composition J. The relatively high linear shrinkage for Composition I
indicates that, for that particular composition, while maintaining the other components relatively constant, the addition of only 1.5% ZrOz does not suffciently make up for the high temperature resistance which is lost when 2% of SiOz is removed from the composition.
However, as can be seen from comparing Composition D with Composition J, the addition of 3% of ZrOz substituted for the 2% loss of SiOz does adequately make up for the high temperature resistance which is lost when the SiOz is removed.
The biosolubility of Composition J, while much improved relative to a standard rockwool such as Composition A, is still lower than achieved by a more preferred embodiment of the invention. An increase in such biosolubility as a result of a decrease in 2S AI2O3 content can be seen by comparing Composition J with Compositions R
and S.
Compositions R and S are similar to Composition J, with roughly 1.5 percent A1z03 replaced with roughly 1.5 percent Ca0 and MgO, collectively. Compositions R and S have dissolution rates in a model physiological saline solution, at 37~C with a flow rate of 0.2 mL
per minute, of 74 and 80 ng/cmz-hr, respectively, as compared with 42 and 44.3 ng/cmz-hr, respectively, for Compositions D and J. Compositions R and S also have relatively good high temperature resistance, and liquidus temperatures similar to that of Composition D.
The viscosity of Composition S also is in a range that should allow for relatively good fiber quality in a rotary fiberizing process (the viscosity of Composition R has not been tested, but is expected to also be within an acceptable range). For these reasons, Compositions R and S
are at this time the most preferred embodiments of the present invention.
As stated above, the compositions of this invention can be formed into mineral wool fibers by a rotary fiberizing apparatus. If used to create an insulation product, the fibers can be coated with a binder to hold the insulation product together. The fibers can also be coated with lubricating agents, wetting agents, antistatic agents and extenders or stabilizers. Typically, the fibers are coated as they are attenuated from the fiberizing apparatus. However, one skilled in the art will appreciate that the fibers can be coated at any time in the insulation formation process. Once the fibers have been attenuated from the fiberizing apparatus, the fibers are typically collected on a porous conveyor belt or other collection apparatus to be formed into an insulation product.
Although the compositions of this invention have been described above as being primarily useful in mineral wool insulation products, one skilled in the art will I S understand that the compositions of this invention can be used to form mineral fibers useful in other applications than insulation. For example, fibers formed from the compositions of this invention can also be used to form air handling ducts, ceiling panels and acoustical panels.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those of skill in the art that various changes and modifications can be made to the compositions of this invention without departing from the scope of the invention, which is defined in the appended claims.
Claims (27)
1. A mineral fiber composition comprising the following components, indicated in weight percents:
about 54 to about 70 percent SiO2, about 0 to about 4 percent A12O3, about 0 to about 6 percent Na20, about 0 to about 6 percent K2O, about 0 to about 6 percent MgO, about 10 to about 28 percent CaO, about 6 to about 17 percent total iron as FeO, and about 0 to about 5 percent TiO2, wherein the total weight percent of SiO2 and A12O3 ranges from about 56 percent to about 72 percent, the total weight percent of MgO and CaO ranges from about 12 percent to about 28 percent, the total weight percent of Na2O and K2O does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
about 54 to about 70 percent SiO2, about 0 to about 4 percent A12O3, about 0 to about 6 percent Na20, about 0 to about 6 percent K2O, about 0 to about 6 percent MgO, about 10 to about 28 percent CaO, about 6 to about 17 percent total iron as FeO, and about 0 to about 5 percent TiO2, wherein the total weight percent of SiO2 and A12O3 ranges from about 56 percent to about 72 percent, the total weight percent of MgO and CaO ranges from about 12 percent to about 28 percent, the total weight percent of Na2O and K2O does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
2. The mineral fiber composition according to claim 1, comprising the following components indicated in weight percents:
about 56 to about 68 percent SiO2, about 0 to about 3 percent A12O3, about 0 to about 5 percent Na2O, about 0 to about 5 percent K2O, about 1 to about 6 percent MgO, about 10 to about 25 percent CaO, about 8 to about 16 percent total iron as FeO, and about 0 to about 4 percent TiO2, wherein the total weight percent of SiO2 and AlzO3 ranges from about 58 percent to about 71 percent, the total weight percent of MgO and CaO ranges from about 14 percent to about 26 percent, the total weight percent of Na2O and K2O does not exceed 5 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
about 56 to about 68 percent SiO2, about 0 to about 3 percent A12O3, about 0 to about 5 percent Na2O, about 0 to about 5 percent K2O, about 1 to about 6 percent MgO, about 10 to about 25 percent CaO, about 8 to about 16 percent total iron as FeO, and about 0 to about 4 percent TiO2, wherein the total weight percent of SiO2 and AlzO3 ranges from about 58 percent to about 71 percent, the total weight percent of MgO and CaO ranges from about 14 percent to about 26 percent, the total weight percent of Na2O and K2O does not exceed 5 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
3. The mineral fiber composition according to claim 1, comprising the following components indicated in weight percents:
about 58 to about 65 percent SiO2, about 0 to about 3 percent A12O3, about 0 to about 4 percent K2O, about 0 to about 4 percent Na2O, about 2 to about percent MgO, about 11 to about 20 percent CaO, about 9 to about 13 percent total iron as FeO, and about 0 to about 3 percent TiO2, wherein the total weight percent of SiO2 and A12O3 ranges from about 60 percent to about 68 percent, the total weight percent of MgO and CaO ranges from about 17 percent to about 22 percent, the total weight percent of Na2O and K2O does not exceed 4 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
about 58 to about 65 percent SiO2, about 0 to about 3 percent A12O3, about 0 to about 4 percent K2O, about 0 to about 4 percent Na2O, about 2 to about percent MgO, about 11 to about 20 percent CaO, about 9 to about 13 percent total iron as FeO, and about 0 to about 3 percent TiO2, wherein the total weight percent of SiO2 and A12O3 ranges from about 60 percent to about 68 percent, the total weight percent of MgO and CaO ranges from about 17 percent to about 22 percent, the total weight percent of Na2O and K2O does not exceed 4 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
4. The mineral fiber composition according to claim 1, comprising the following components in the indicated weight percents:
about 62 percent SiO2, about 3 percent A12O3, about 2.6 percent K2O, about 0.9 percent NazO, about 4.5 percent MgO, about 13.4 percent CaO, about 1.9 percent TiO2, and about 11.7 percent total iron as FeO.
about 62 percent SiO2, about 3 percent A12O3, about 2.6 percent K2O, about 0.9 percent NazO, about 4.5 percent MgO, about 13.4 percent CaO, about 1.9 percent TiO2, and about 11.7 percent total iron as FeO.
5. The mineral fiber composition according to claim 1, the following components in the indicated weight percents:
about 63 percent SiO2, about 2 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 3.5 percent MgO, about 18.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
about 63 percent SiO2, about 2 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 3.5 percent MgO, about 18.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
6. The mineral fiber composition according to claim 1, comprising the following components in the indicated weight percents:
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
7. The mineral fiber composition according to claim 1, comprising the following components in the indicated weight percents:
about 63 percent SiO2, about 3 percent A12O3, about 5.5 percent Na2O, about 0.5 percent K2O, about 3 percent MgO, about 16 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
about 63 percent SiO2, about 3 percent A12O3, about 5.5 percent Na2O, about 0.5 percent K2O, about 3 percent MgO, about 16 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
8. The mineral fiber composition according to claim 1, comprising the following components in the indicated weight percents:
about 64 percent SiO2, about 1 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
about 64 percent SiO2, about 1 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
9. The mineral fiber composition of claim 1, comprising the following components in the indicated weight percents:
about 63 percent SiO2, about 2 percent A12O3, about 2.5 percent NazO, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
about 63 percent SiO2, about 2 percent A12O3, about 2.5 percent NazO, about 0.5 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2 , and about 9.8 percent total iron as FeO.
10. The mineral fiber composition according to claim 1, wherein the composition has a liquidus temperature below about 2200~F (1204~C) and a viscosity which ranges between about 100 and about 1000 poise at 2250~F (1232~C).
11. Mineral wool insulation comprising mineral fibers having the composition of claim 1.
12. A mineral fiber composition comprising the following components, indicated in weight percents:
about 50 to about 68 percent SiO2, about 0 to about 4 percent A12O3, about 0 to about 6 percent K2O, about 0 to about 6 percent Na2O, about 0 to about percent MgO, about 10 to about 28 percent CaO, about 6 to about 16 percent total iron as FeO, about 0 to about 5 percent TiO2, and about 0.5 to about 12 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 6 percent and the total weight of all components, including trace elements, if any, is percent.
about 50 to about 68 percent SiO2, about 0 to about 4 percent A12O3, about 0 to about 6 percent K2O, about 0 to about 6 percent Na2O, about 0 to about percent MgO, about 10 to about 28 percent CaO, about 6 to about 16 percent total iron as FeO, about 0 to about 5 percent TiO2, and about 0.5 to about 12 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 6 percent and the total weight of all components, including trace elements, if any, is percent.
13. The mineral fiber composition according to claim 12 comprising the following components indicated in weight percents:
about 52 to about 66 percent SiO2, about 0 to about 3.5 percent A12O3, about 0 to about 5 percent K2O, about 0 to about 5 percent Na2O, about 1 to about 8 percent MgO, about 11 to about 25 percent CaO, about 7 to about 15 percent total iron as FeO, about 0 to about 4 percent TiO2, and about 1 to about 11 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 5 percent and the total weight of all components, including trace elements, if any, is percent.
about 52 to about 66 percent SiO2, about 0 to about 3.5 percent A12O3, about 0 to about 5 percent K2O, about 0 to about 5 percent Na2O, about 1 to about 8 percent MgO, about 11 to about 25 percent CaO, about 7 to about 15 percent total iron as FeO, about 0 to about 4 percent TiO2, and about 1 to about 11 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 5 percent and the total weight of all components, including trace elements, if any, is percent.
14. The mineral fiber composition according to claim 12 comprising the following components indicated in weight percents:
about 54 to about 64 percent SiO2, about 0 to about 3.5 percent A12O3, about 0 to about 4.5 percent K2O, about 0 to about 4.5 percent Na2O, about 1 to about 4 percent MgO, about 12 to about 23 percent CaO, about 7 to about percent total iron as FeO, about 0 to about 3 percent TiO2, and about 1 to about 9 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 4.5 percent and the total weight of all components, including trace elements, if any, is l00 percent.
about 54 to about 64 percent SiO2, about 0 to about 3.5 percent A12O3, about 0 to about 4.5 percent K2O, about 0 to about 4.5 percent Na2O, about 1 to about 4 percent MgO, about 12 to about 23 percent CaO, about 7 to about percent total iron as FeO, about 0 to about 3 percent TiO2, and about 1 to about 9 percent ZrO2, wherein the total weight of Na2O and K2O does not exceed 4.5 percent and the total weight of all components, including trace elements, if any, is l00 percent.
15. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 57 to about 62 percent SiO2, about 0.5 to about 2.0 percent A12O3, about 0 to about 4 percent K2O, about 0 to about 3 percent Na2O, about 2 to about 4 percent MgO, about 16 to about 22 percent CaO, about 7 to about 12 percent total iron as FeO, about 0 to about 2 percent TiO2, about 1 to about 5 percent ZrO2, wherein the total weight of Na2O+K2O does not exceed 4.5 percent and the total weight of all components, including trace elements, if any, is percent.
about 57 to about 62 percent SiO2, about 0.5 to about 2.0 percent A12O3, about 0 to about 4 percent K2O, about 0 to about 3 percent Na2O, about 2 to about 4 percent MgO, about 16 to about 22 percent CaO, about 7 to about 12 percent total iron as FeO, about 0 to about 2 percent TiO2, about 1 to about 5 percent ZrO2, wherein the total weight of Na2O+K2O does not exceed 4.5 percent and the total weight of all components, including trace elements, if any, is percent.
16. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.6 percent MgO, about 19.9 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 1.5 percent ZrO2.
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.6 percent MgO, about 19.9 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 1.5 percent ZrO2.
17. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.4 percent MgO, about 18.6 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.4 percent MgO, about 18.6 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
18. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 2 percent A12O3, about 0.25 percent Na2O, about 2.75 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
about 60 percent SiO2, about 2 percent A12O3, about 0.25 percent Na2O, about 2.75 percent K2O, about 2.5 percent MgO, about 19.5 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
19. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 56 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.2 percent MgO, about 16.8 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 9 percent ZrO2.
about 56 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.2 percent MgO, about 16.8 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 9 percent ZrO2.
20. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.1 percent MgO, about 16 percent CaO, about 3 percent BaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
about 60 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.1 percent MgO, about 16 percent CaO, about 3 percent BaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 3 percent ZrO2.
21. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 3.2 percent MgO, about 16.8 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 2 percent ZrO2.
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 3.2 percent MgO, about 16.8 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 2 percent ZrO2.
22. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.9 percent MgO, about 15.1 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 4 percent ZrO2.
about 62 percent SiO2, about 3 percent A12O3, about 2.5 percent Na2O, about 0.5 percent K2O, about 2.9 percent MgO, about 15.1 percent CaO, about 0.2 percent TiO2, about 9.8 percent total iron as FeO and about 4 percent ZrO2.
23. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 2 percent A12O3, about 0.25 percent Na2O, about 2.75 percent K2O, about 2 percent MgO, about 18 percent CaO, about 0.2 percent TiO2, about 11.8 percent total iron as FeO and about 3 percent ZrO2.
about 60 percent SiO2, about 2 percent A12O3, about 0.25 percent Na2O, about 2.75 percent K2O, about 2 percent MgO, about 18 percent CaO, about 0.2 percent TiO2, about 11.8 percent total iron as FeO and about 3 percent ZrO2.
24. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60.5 percent SiO2, about 0.5 percent A12O3, about 4 percent Na2O, about 0.2 percent K2O, about 3.1 percent MgO, about 19.9 percent CaO, about 0.06 percent TiO2, about 9.75 percent total iron as FeO and about 2 percent ZrO2.
about 60.5 percent SiO2, about 0.5 percent A12O3, about 4 percent Na2O, about 0.2 percent K2O, about 3.1 percent MgO, about 19.9 percent CaO, about 0.06 percent TiO2, about 9.75 percent total iron as FeO and about 2 percent ZrO2.
25. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 1.5 percent A12O3, about 2.5 percent Na2O, about 0.4 percent K2O, about 3.1 percent MgO, about 19.4 percent CaO, about 0.06 percent TiO2, about 10 percent total iron as FeO and about 3.0 percent ZrO2.
about 60 percent SiO2, about 1.5 percent A12O3, about 2.5 percent Na2O, about 0.4 percent K2O, about 3.1 percent MgO, about 19.4 percent CaO, about 0.06 percent TiO2, about 10 percent total iron as FeO and about 3.0 percent ZrO2.
26. The mineral fiber composition according to claim 12, comprising the following components indicated in weight percents:
about 60 percent SiO2, about 1.3 percent A12O3, about 2.5 percent Na2O, about 0.4 percent K2O, about 3.1 percent MgO, about 19.4 percent CaO, about 0.06 percent TiO2, about 10 percent total iron as FeO and about 3.3 percent ZrO2.
about 60 percent SiO2, about 1.3 percent A12O3, about 2.5 percent Na2O, about 0.4 percent K2O, about 3.1 percent MgO, about 19.4 percent CaO, about 0.06 percent TiO2, about 10 percent total iron as FeO and about 3.3 percent ZrO2.
27. Mineral wool insulation comprising mineral fibers having the composition of claim 12.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US74184996A | 1996-10-31 | 1996-10-31 | |
| US08/741,849 | 1996-10-31 | ||
| US08/778,419 | 1996-12-31 | ||
| US08/778,419 US5932347A (en) | 1996-10-31 | 1996-12-31 | Mineral fiber compositions |
| PCT/US1997/011432 WO1998018618A1 (en) | 1996-10-31 | 1997-07-08 | Mineral fiber compositions |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2267445A1 true CA2267445A1 (en) | 1998-05-07 |
Family
ID=27113932
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002267445A Abandoned CA2267445A1 (en) | 1996-10-31 | 1997-07-08 | Mineral fiber compositions |
Country Status (8)
| Country | Link |
|---|---|
| EP (1) | EP0946356A4 (en) |
| JP (1) | JP2001524063A (en) |
| KR (1) | KR20000052666A (en) |
| AU (1) | AU728381B2 (en) |
| CA (1) | CA2267445A1 (en) |
| NO (1) | NO991990D0 (en) |
| TW (1) | TW397872B (en) |
| WO (1) | WO1998018618A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4859415B2 (en) | 2005-08-31 | 2012-01-25 | ニチアス株式会社 | Inorganic fiber and method for producing the same |
| US7803731B2 (en) | 2007-08-15 | 2010-09-28 | Johns Manville | Fire resistant glass fiber |
| CA2767739A1 (en) * | 2009-07-13 | 2011-01-20 | Rockwool International A/S | Mineral fibres and their use |
| AU2021400610B2 (en) * | 2020-12-15 | 2023-10-05 | Nippon Sheet Glass Company, Limited | Reinforcing glass fiber, chopped strand, fiber sheet, and rod |
| WO2024034546A1 (en) * | 2022-08-08 | 2024-02-15 | 日本板硝子株式会社 | Glass composition, glass fiber, glass filler, glass fiber manufacturing method, and glass filler manufacturing method |
| WO2024034545A1 (en) * | 2022-08-08 | 2024-02-15 | 日本板硝子株式会社 | Glass composition, glass fibers, glass filler, production method for glass fibers, and production method for glass filler |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| SU249577A (en) * | ||||
| US2882173A (en) * | 1955-06-20 | 1959-04-14 | Owens Corning Fiberglass Corp | Glass composition |
| NL111147C (en) * | 1955-11-25 | |||
| FI93346C (en) * | 1990-11-23 | 1998-03-07 | Partek Ab | Mineral Fiber Composition |
| FR2690438A1 (en) * | 1992-04-23 | 1993-10-29 | Saint Gobain Isover | Mineral fibers capable of dissolving in a physiological medium. |
| AU704367B2 (en) * | 1994-02-11 | 1999-04-22 | Rockwool International A/S | Man-made vitreous fibres |
| ES2126293T3 (en) * | 1994-06-23 | 1999-03-16 | Rockwool Int | COMPOSITIONS OF THERMO-STABLE AND BIOLOGICALLY SOLUBLE FIBERS. |
| DE4443022C2 (en) * | 1994-12-02 | 1996-12-12 | Gruenzweig & Hartmann | Mineral fiber composition |
-
1997
- 1997-07-08 KR KR1019990703448A patent/KR20000052666A/en not_active Application Discontinuation
- 1997-07-08 WO PCT/US1997/011432 patent/WO1998018618A1/en not_active Application Discontinuation
- 1997-07-08 AU AU35873/97A patent/AU728381B2/en not_active Ceased
- 1997-07-08 EP EP97932411A patent/EP0946356A4/en not_active Withdrawn
- 1997-07-08 CA CA002267445A patent/CA2267445A1/en not_active Abandoned
- 1997-07-08 JP JP52043298A patent/JP2001524063A/en active Pending
- 1997-07-11 TW TW086109815A patent/TW397872B/en not_active IP Right Cessation
-
1999
- 1999-04-27 NO NO991990A patent/NO991990D0/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| JP2001524063A (en) | 2001-11-27 |
| KR20000052666A (en) | 2000-08-25 |
| AU3587397A (en) | 1998-05-22 |
| EP0946356A1 (en) | 1999-10-06 |
| AU728381B2 (en) | 2001-01-11 |
| WO1998018618A1 (en) | 1998-05-07 |
| NO991990L (en) | 1999-04-27 |
| TW397872B (en) | 2000-07-11 |
| NO991990D0 (en) | 1999-04-27 |
| EP0946356A4 (en) | 2000-06-21 |
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