Glass compositions and fibers made therefrom
View Patent ↗Embodiments of the present invention provides fiberizable glass compositions formed from batch compositions comprising significant amounts of one or more glassy minerals, including perlite and/or pumice.
1. A fiberizable glass composition comprising:
53-64 weight percent SiO 2 ;
9 to less than 12 weight percent Al 2 O 3 ;
0-3 weight percent ZrO 2 ;
0-3 weight percent La 2 O 3 ;
from greater than 0 to 3 weight percent MnO 2 ;
10.5-18 weight percent alkali oxide component (R 2 O), wherein the alkali oxide component comprises Na 2 O in an amount ranging from 8.5 to 16 weight percent and K 2 O in an amount ranging from 2 to 4 weight percent; and
a metal oxide (RO) component selected from the group consisting of MgO, CaO, BaO, and ZnO,
wherein the metal oxide component is present in an amount to provide a ratio of R 2 O/RO ranging from about 0.15 to about 1.5, wherein the glass composition comprises less than 1 weight percent of Fe 2 O 3 and is substantially free of B 2 O 3 and SrO.
2. The glass composition of claim 1 , wherein the RO component is present in an amount ranging from 7 weight percent to 31 weight percent.
3. The glass composition of claim 1 , wherein the RO component comprises a mixture of metal oxides.
4. The glass composition of claim 3 , wherein the RO component comprises a mixture of CaO and MgO.
5. The glass composition of claim 1 , wherein the RO component comprises CaO in an amount ranging from 7 to 26 weight percent.
6. The glass composition of claim 1 , wherein the RO component comprises MgO in an amount up to 5 weight percent.
7. The glass composition of claim 1 , wherein R 2 O further comprises Li 2 O.
8. The glass composition of claim 1 , wherein Na 2 O is present in an amount ranging from 9 to 16 weight percent.
9. The glass composition of claim 1 , wherein R 2 O comprises Li 2 O in an amount from greater than 0 to 2 weight percent.
10. The glass composition of claim 1 , wherein the RO component comprises ZnO in an amount from greater than 0 to 3 weight percent.
11. The glass composition of claim 1 , further comprising TiO 2 in an amount from greater than 0 to 3 weight percent.
12. The glass composition of claim 1 , wherein the glass composition has a fiber forming temperature ranging from about 1120° C. to about 1300° C.
13. The glass composition of claim 1 , wherein the difference between forming temperature and liquidus temperature of the glass composition is at least about 65° C.
14. The glass composition of claim 1 , wherein the difference between forming temperature and liquidus temperature of the glass composition ranges from about 45° C. to about 165° C.
15. A fiberizable glass composition formed from a batch composition comprising:
at least 50 weight percent of a glassy mineral, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
at least 5 weight percent of a sodium source,
wherein the glass composition comprises 8 to less than 12 weight percent Al 2 O 3 , less than 1 weight percent of Fe 2 O 3 , 8.5 to 16 weight percent Na 2 O, 2 to 4 weight percent K 2 O, 0-3 weight percent La 2 O 3 , from greater than ht percent MnO 2 , 0-3 weight percent ZrO 2 , and is substantially free of B 2 O 3 and SrO.
16. The glass composition of claim 15 , wherein the batch comprises at least 60 weight percent of the glassy mineral.
17. The glass composition of claim 15 , wherein the batch comprises at least 65 weight percent of the glassy mineral.
18. The glass composition of claim 15 , wherein the batch comprises at least 10 weight percent of the sodium source.
19. The glass composition of claim 15 , wherein the glassy mineral comprises perlite, pumice or mixtures thereof.
20. A fiberizable glass composition comprising:
56-63 weight percent SiO 2 ;
9 to less than 12 weight percent Al 2 O 3 ;
12-17 weight percent RO (CaO+MgO);
12-14 weight percent R 2 O (Na 2 O+K 2 O);
0-2 weight percent Li 2 O;
0-3 weight percent ZnO;
0-3 weight percent ZrO 2 ;
from greater than 0 to 3 weight percent MnO 2 ; and
0-3 weight percent La 2 O 3 ,
wherein the glass composition is substantially free of B 2 O 3 and SrO.
21. A fiberizable glass composition comprising:
60-64 weight percent SiO 2 ;
9 to less than 12 weight percent Al 2 O 3 ;
7-15 weight percent RO (CaO+MgO);
13-15.5 weight percent R 2 O (Na 2 O+K 2 O);
0-2 weight percent Li 2 O;
0-3 weight percent ZnO;
0-3 weight percent ZrO 2 ;
from greater than 0 to 3 weight percent MnO 2 ; and
0-3 weight percent La 2 O 3 ,
wherein the glass composition is substantially free of B 2 O 3 and SrO.
22. A fiberizable glass composition comprising:
54-63 weight percent SiO 2 ,
9 to less than 12 weight percent Al 2 O 3 ,
11-16.5 weight percent RO (CaO+MgO);
14-17 weight percent R 2 O (Na 2 O+K 2 O);
0-2 weight percent Li 2 O;
0-3 weight percent ZnO;
0-3 weight percent ZrO 2 ;
from greater than 0 to 3 weight percent MnO 2 ; and
0-3 weight percent La 2 O 3 ,
wherein the glass composition is substantially free of B 2 O 3 and SrO.
23. The glass compositions of any of claims 20 to 22 , wherein the glass composition comprises less than 0.7 weight percent Fe 2 O 3 .
24. A continuous glass fiber comprising:
53-64 weight percent SiO 2 ,
8 to less than 12 weight percent Al 2 O 3 ,
0-3 weight percent La 2 O 3 ,
from greater than 0 to 3 weight percent MnO 2 ;
8.5-18 weight percent alkali oxide (R 2 O) component, wherein the alkali oxide component comprises Na 2 O in an amount ranging from 8.5 to 16 weight percent; and
a metal oxide (RO) component selected from the group consisting of MgO, CaO, SrO, BaO, and ZnO, wherein the metal oxide component is present in an amount to provide a mass ratio of R 2 O/RO ranging from about 0.15 to about 1.5,
wherein the glass composition comprises less than 1 weight percent of Fe 2 O 3 .
25. The glass composition of claim 1 , wherein the composition was formed from a batch composition comprising perlite, pumice, or mixtures thereof.
26. A fiberizable glass composition comprising:
greater than 60 to 64 weight percent SiO 2 ;
9-14 weight percent Al 2 O 3 ;
0-3 weight percent ZrO 2 ;
0-3 weight percent La 2 O 3 ;
from greater than 0 to 3 weight percent MnO 2 ;
10.5-18 weight percent alkali oxide component (R 2 O), wherein the alkali oxide component comprises Na 2 O in an amount ranging from 8.5 to 16 weight percent and K 2 O in an amount ranging from 2 to 4 weight percent; and
a metal oxide (RO) component selected from the group consisting of MgO, CaO, BaO, and ZnO,
wherein the metal oxide component is present in an amount to provide a ratio of R 2 O/RO ranging from about 0.15 to about 1.5, wherein the glass composition comprises less than 1 weight percent of Fe 2 O 3 and is substantially free of B 2 O 3 and SrO.
27. The glass composition of claim 1 , wherein Si 2 O is present in an amount from 53 to less than 62 weight percent.
28. The glass composition of claim 1 , wherein LiO 2 , SO 3 , or ZnO is present in the glass composition.