EP0946356A4 - Mineral fiber compositions - Google Patents
Mineral fiber compositionsInfo
- Publication number
- EP0946356A4 EP0946356A4 EP97932411A EP97932411A EP0946356A4 EP 0946356 A4 EP0946356 A4 EP 0946356A4 EP 97932411 A EP97932411 A EP 97932411A EP 97932411 A EP97932411 A EP 97932411A EP 0946356 A4 EP0946356 A4 EP 0946356A4
- Authority
- EP
- European Patent Office
- Prior art keywords
- percent
- mgo
- cao
- sio
- feo
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- 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
-
- 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
- C03C2213/00—Glass fibres or filaments
- C03C2213/02—Biodegradable glass fibres
Definitions
- This invention relates to mineral fiber compositions and, more particularly, to insulation products formed from fibers made from such compositions.
- 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.
- 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 wools 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 wools 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.
- 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.
- 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 SiO 2 , about 0 to about 4 percent Al 2 O 3 , about 0 to about 6 percent Na 2 0, about 0 to about 6 percent K 2 O, 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 TiO 2 , wherein the total weight percent of SiO 2 and Al 2 O 3 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 Na 2 O and K 2 O does not exceed 6 percent, and the total weight percent of all components, including trace elements, if any, is 100 percent.
- 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 SiO 2 , about 0 to about 4 percent Al 2 O 3 , about 0 to about 6 percent K 2 O, about 0 to about 6 percent Na 2 O, 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 TiO 2 , and about 0.5 to about 12 percent ZrO 2 , wherein the total weight of Na 2 O and K 2 O does not exceed 6 percent and the total weight of all components, including trace elements, if any, is 100 percent.
- 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.
- the liquidus temperatures are generally less than about 2200°F (1204°C), and, more preferably, less than about 2180°F (1193°C). These relatively lower liquidus temperatures are due at least in part to the relatively low MgO 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).
- compositions of this invention have sufficiently 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.
- compositions of the present invention have a relatively low Na 2 O+K 2 O content to help give the rotary fiberized product relative good high temperature resistance.
- the compositions of the present invention include, relative to a standard rockwool, moderately increased amounts of SiO 2 , greatly reduced amounts of Al O 3 , and an increased Fe 2 O 3 content.
- the compositions can also include an increased ZrO 2 content.
- 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 first 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):
- Comparative Example 1 The table below shows the approximate weight percent composition and some properties of a commercial rockwool, i.e., Composition A, as well as the same for seven mineral wool compositions, i.e., Compositions B through H, according to the first embodiment of the present invention.
- Composition A has a liquidus temperature of 2251 °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/cm 2 -hr, is much lower than desired.
- Composition B has a liquidus temperature of 2171°F (1188°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
- 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.
- 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.
- Compositions B and D each has an improved dissolution rate of 42 ng/cm 2 -hr with respect to Composition A.
- compositions according to the first embodiment of the invention are due to the relatively low alkali, i.e., Na 2 O + K 2 O, contents thereof, and that the relatively low liquidus temperatures thereof are due at least in part to their relatively low MgO contents.
- relatively improved dissolution rates of the compositions are due to the low alumina levels thereof.
- these improved dissolution rates can be quite high, i.e., 107 ng/cm 2 -hr for Composition F, although potentially at some sacrifice of other properties for certain compositions, i.e., the higher liquidus temperature of Composition G.
- 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:
- compositions according to the second embodiment of the invention are as follows, in about the indicated weight percents:
- 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.
- compositions are very similar, with Composition J having 3 percent ZrO 2 substituted for 2 percent SiO 2 and 1 percent CaO in Composition D.
- this addition of ZrO 2 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.
- 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%.
- the high rate of linear shrinkage of Composition I can be attributed to both its SiO 2 concentration and its ZrO 2 concentration.
- the formulation of Composition I includes 2% less SiO 2 and 1.5% more ZrO 2 than Composition D. Also, Composition I has the same percentage of SiO 2 but 1.5% less ZrO 2 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% ZrO 2 does not sufficiently make up for the high temperature resistance which is lost when 2% of SiO 2 is removed from the composition. However, as can be seen from comparing Composition D with Composition J, the addition of 3% of ZrO 2 substituted for the 2% loss of SiO 2 does adequately make up for the high temperature resistance which is lost when the SiO 2 is removed.
- 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 Al 2 O 3 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 Al 2 O 3 replaced with roughly 1.5 percent CaO 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/cm 2 -hr, respectively, as compared with 42 and 44.3 ng/cm 2 -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.
- 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.
- the compositions of this invention can be formed into mineral wool fibers by a rotary fiberizing apparatus.
- 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.
- the fibers are coated as they are attenuated from the fiberizing apparatus.
- 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.
- compositions of this invention have been described above as being primarily useful in mineral wool insulation products, one skilled in the art will understand that the compositions of this invention can be used to form mineral fibers useful in other applications than insulation.
- fibers formed from the compositions of this invention can also be used to form air handling ducts, ceiling panels and acoustical panels.
Landscapes
- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Glass Compositions (AREA)
- Agricultural Chemicals And Associated Chemicals (AREA)
Abstract
Description
Claims
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US74184996A | 1996-10-31 | 1996-10-31 | |
US741849 | 1996-10-31 | ||
US08/778,419 US5932347A (en) | 1996-10-31 | 1996-12-31 | Mineral fiber compositions |
US778419 | 1996-12-31 | ||
PCT/US1997/011432 WO1998018618A1 (en) | 1996-10-31 | 1997-07-08 | Mineral fiber compositions |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0946356A1 EP0946356A1 (en) | 1999-10-06 |
EP0946356A4 true EP0946356A4 (en) | 2000-06-21 |
Family
ID=27113932
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP97932411A Withdrawn EP0946356A4 (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) | NO991990L (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 |
WO2011006875A2 (en) * | 2009-07-13 | 2011-01-20 | Rockwool International A/S | Mineral fibres and their use |
CN116568473A (en) * | 2020-12-15 | 2023-08-08 | 日本板硝子株式会社 | Glass fiber for reinforcement, 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 |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SU249577A (en) * | ||||
WO1993022251A1 (en) * | 1992-04-23 | 1993-11-11 | Isover Saint-Gobain | Mineral fibres capable of dissolving in a physiological medium |
WO1996000196A1 (en) * | 1994-06-23 | 1996-01-04 | Rockwool International A/S | Thermostable and biologically soluble fibre compositions |
WO1996016913A1 (en) * | 1994-12-02 | 1996-06-06 | Isover Saint-Gobain | A mineral fiber composition |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
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 |
DE69502149T2 (en) * | 1994-02-11 | 1998-08-13 | Rockwool Int | SYNTHETIC GLASS FIBERS |
-
1997
- 1997-07-08 WO PCT/US1997/011432 patent/WO1998018618A1/en not_active Application Discontinuation
- 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 AU AU35873/97A patent/AU728381B2/en not_active Ceased
- 1997-07-08 JP JP52043298A patent/JP2001524063A/en active Pending
- 1997-07-08 KR KR1019990703448A patent/KR20000052666A/en not_active Application Discontinuation
- 1997-07-11 TW TW086109815A patent/TW397872B/en not_active IP Right Cessation
-
1999
- 1999-04-27 NO NO991990A patent/NO991990L/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SU249577A (en) * | ||||
WO1993022251A1 (en) * | 1992-04-23 | 1993-11-11 | Isover Saint-Gobain | Mineral fibres capable of dissolving in a physiological medium |
WO1996000196A1 (en) * | 1994-06-23 | 1996-01-04 | Rockwool International A/S | Thermostable and biologically soluble fibre compositions |
WO1996016913A1 (en) * | 1994-12-02 | 1996-06-06 | Isover Saint-Gobain | A mineral fiber composition |
Non-Patent Citations (1)
Title |
---|
See also references of WO9818618A1 * |
Also Published As
Publication number | Publication date |
---|---|
WO1998018618A1 (en) | 1998-05-07 |
AU728381B2 (en) | 2001-01-11 |
NO991990D0 (en) | 1999-04-27 |
TW397872B (en) | 2000-07-11 |
CA2267445A1 (en) | 1998-05-07 |
JP2001524063A (en) | 2001-11-27 |
AU3587397A (en) | 1998-05-22 |
NO991990L (en) | 1999-04-27 |
EP0946356A1 (en) | 1999-10-06 |
KR20000052666A (en) | 2000-08-25 |
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Legal Events
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