Methods to Make Glass Compositions and Fibers Made Therefrom

Abstract

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.

That which is claimed: 
     
         1 . A glass composition comprising:
 53-64 weight percent SiO 2 ;   8-12 weight percent Al 2 O 3 ;   8.5-18 weight percent alkali oxide component (R 2 O); and   a metal oxide (RO) component,   
       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. 
     
     
         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 the R 2 O comprises Na 2 O, K 2 O or Li 2 O or mixtures thereof. 
     
     
         8 . The glass composition of claim of  claim 1 , wherein R 2 O comprises Na 2 O in an amount ranging from 6.5 to 16 weight percent 
     
     
         9 . The glass composition of claim of  claim 1 , wherein R 2 O comprises K 2 O in an amount ranging from 2 to 4 weight percent. 
     
     
         10 . The glass composition of claim of  claim 1 , wherein R 2 O comprises Li 2 O in an amount up to 2 weight percent. 
     
     
         11 . The glass composition of  claim 1  further comprising ZrO 2  in an amount up to 8 weight percent. 
     
     
         12 . The glass composition of  claim 1 , wherein the RO component comprises ZnO in an amount up to 3 weight percent. 
     
     
         13 . The glass composition of  claim 1  further comprising MnO 2  in an amount up to 3 weight percent. 
     
     
         14 . The glass composition of  claim 1  further comprising TiO 2  in an amount up to 3 weight percent. 
     
     
         15 . The glass composition of  claim 1  further comprising La 2 O 3  in an amount up to 3 weight percent. 
     
     
         16 . The glass composition of  claim 1  having a fiber forming temperature ranging from about 1120° C. to about 1300° C. 
     
     
         17 . 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. 
     
     
         18 . 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. 
     
     
         19 . A 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.   
     
     
         20 . The glass composition of  claim 19 , wherein the batch comprises at least 60 weight percent of the glassy mineral. 
     
     
         21 . The glass composition of  claim 19 , wherein the batch comprises at least 65 weight percent of the glassy mineral. 
     
     
         22 . The glass composition of  claim 19 , wherein the batch comprises at least 10 weight percent of the sodium source. 
     
     
         23 . The glass composition of  claim 19 , wherein the glassy mineral comprises perlite, pumice or mixtures thereof. 
     
     
         24 . A method of producing a glass composition comprising:
 providing a batch composition comprising at least 50 weight percent of a glassy mineral and at least 5 weight percent of a sodium source, the glassy 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.   
     
     
         25 . The method of  claim 24 , wherein the batch composition is heated to a fiber forming temperature ranging from about 1120° C. to about 1300° C. 
     
     
         26 . The method of  claim 25  further comprising fiberizing the glass composition. 
     
     
         27 . A glass composition comprising:
 56-63 weight percent SiO 2 ;   9-12 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 ;   0-3 weight percent MnO 2 ; and   0-3 weight percent La 2 O 3 .   
     
     
         28 . A glass composition comprising:
 60-64 weight percent SiO 2 ;   9-12 weight percent Al 2 O 3 ;   7-15 weight percent RO (CaO+MgO); and   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 ;   0-3 weight percent MnO 2 ; and   0-3 weight percent La 2 O 3 .   
     
     
         29 . A glass composition comprising:
 54-63 weight percent SiO 2 ;   9-14 weight percent Al 2 O 3 ;   11-16.5 weight percent RO (CaO+MgO); and   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 ;   0-3 weight percent MnO 2 ; and   0-3 weight percent La 2 O 3 .   
     
     
         30 . The glass compositions of any of  claims 27  to  29 , wherein the glass composition comprises less than 0.7 weight percent Fe 2 O 3 . 
     
     
         31 . A glass fiber comprising:
 53-64 weight percent SiO 2 ;   8-12 weight percent Al 2 O 3 ;   
     
     
         8 . 5-18 weight percent alkali oxide (R 2 O) component; and
 a metal oxide (RO) component, 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.   
     
     
         32 . A polymeric composite comprising:
 a polymeric material; and   at least one glass fiber in the polymeric material, the at least one glass fiber comprising:   53-64 weight percent SiO 2 ;   8-12 weight percent Al 2 O 3 ;   
     
     
         8 . 5-18 weight percent alkali oxide (R 2 O) component; and
 a metal oxide (RO) component, 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.   
     
     
         1 - 32 . (canceled) 
     
     
         33 . A method of producing a glass composition comprising:
 providing a batch composition comprising at least 50 weight percent of a glassy mineral, at least 5 weight percent of a sodium source, and at least one additional component selected from the group consisting of Li 2 O, La 2 O 3 , MnO 2 , TiO 2 , ZnO, and ZrO 2 , wherein the glassy mineral comprises 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.   
     
     
         34 . 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 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 ;   8-12 weight percent Al 2 O 3 ;   8.5-18 weight percent alkali oxide (R 2 O) component; and   a metal oxide (RO) component, 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.