Methods to make 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 method of producing a glass composition comprising:
providing a batch composition comprising dolomite, at least 50 weight percent of a glassy mineral, and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
heating the batch to form a melt of the glass composition,
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 0 to 3 weight percent MnO 2 ; and
0-3 weight percent ZrO 2 ;
wherein the glass composition is substantially free of B 2 O 3 and SrO.
2. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature ranging from about 1120° C. to about 1300° C.
3. The method of claim 2 , further comprising fiberizing the glass composition.
4. The method of claim 1 , wherein the batch composition comprises at least 65 weight percent of a glassy mineral.
5. The method of claim 1 , wherein the glassy mineral comprises perlite, pumice, or mixtures thereof.
6. The method of claim 1 , wherein the batch composition comprises at least 10 weight percent of a sodium source.
7. The method of claim 1 , wherein the sodium source comprises sodium carbonate (soda).
8. The method of claim 1 , wherein the batch composition comprises limestone in an amount up to 17 weight percent.
9. The method of claim 1 , wherein the batch composition comprises dolomite in an amount up to 13 weight percent.
10. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature ranging from about 1400° C. to about 1450° C.
11. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature which differs from the liquidus temperature of a glass composition from about 45° C. to about 165° C.
12. The method of claim 1 , wherein the batch composition is heated to a fiber forming temperature which differs from the liquidus temperature by at least 65° C.
13. A method of producing a glass composition comprising:
providing a batch composition comprising dolomite, at least 50 weight percent of a glassy mineral, and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
heating the batch to form a melt of the glass composition, wherein the glass composition comprises:
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 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.
14. A method of producing a glass composition comprising:
providing a batch composition comprising dolomite, at least 50 weight percent of a glassy mineral, and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
heating the batch to form a melt of the glass composition, wherein the glass composition comprises:
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 B 2 O 3 and SrO.
15. A method of producing a glass composition comprising:
providing a batch composition comprising dolomite, at least 50 weight percent of a glassy mineral, and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
heating the batch to form a melt of the glass composition, wherein the glass composition comprises:
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.
16. A method of producing a glass composition comprising:
providing a batch composition comprising dolomite, at least 50 weight percent of a glassy mineral, and at least 5 weight percent of a sodium source, the glassy mineral comprising a combination of SiO 2 and Al 2 O 3 in an amount of at least 80 weight percent; and
heating the batch to form a melt of the glass composition, wherein the glass composition comprises:
from 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 ;
less than 1 weight percent of Fe 2 O 3 ;
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 is substantially free of B 2 O 3 and SrO.