초록

Fiberizable basalt compositions are disclosed. The fibers are produced from natural basalt rock modified with alkaline earth metal oxides. The fibers can be used to make low density composites for ceiling tile or boards.

대표청구항 ▼

1. High softening basalt fibers produced from 95 to 60% by weight natural basalt rock modified with 5.0 to 40.0 weight percent of an additive consisting essentially of only at least one alkaline earth metal oxide wherein the basalt fibers have a composition containing at least 12 weight percent CaO

1. High softening basalt fibers produced from 95 to 60% by weight natural basalt rock modified with 5.0 to 40.0 weight percent of an additive consisting essentially of only at least one alkaline earth metal oxide wherein the basalt fibers have a composition containing at least 12 weight percent CaO and 15 weight percent or less of MgO, wherein the composition has a viscosity of log n=1.0 at a temperature of 2950° F. or less. 2. Basalt fibers according to claim 1 having a composition containing 12 to 40 weight percent CaO and 2 to 15 weight percent MgO. 3. Basalt fibers according to claim 1 having a composition containing 14 to 30 weight percent CaO and 3 to 12 weight percent MgO. 4. Basalt fibers according to claim 1 having a composition containing 15 to 25 weight percent CaO and 4 to 11 weight percent MgO. 5. Basalt fibers according to claim 1 modified with 10.0 to 30.0 weight percent alkaline earth metal oxides. 6. Basalt fibers according to claim 1 modified with 15.0 to 25.0 weight percent alkaline earth metal oxides. 7. Basalt fibers according to claim 1 modified with 20.0 weight percent alkaline earth metal oxides. 8. Basalt fibers according to claim 1 wherein the alkaline earth metal oxides are MgO and CaO. 9. Basalt fibers according to claim 1 wherein the alkaline earth metal oxides are CaO. 10. Basalt fibers according to claim 1 wherein the natural basalt is a low alkali basalt. 11. Basalt fibers according to claim 1 wherein the natural basalt rock is Oregon Yakima basalt. 12. Basalt fibers according to claim 1 where said basalt is Yakima basalt in an amount of about 83.7% and said additive consists essentially of only CaO in an amount of about 17.7%. 13. Basalt fibers produced from Oregon Yakima basalt rock modified with 10.0 to 30.0 weight percent of an additive which is substantially only CaO or MgO and CaO, wherein the basalt fibers have a composition containing 12 to 40 weight percent CaO and 2 to 15 weight percent MgO, wherein the composition has a viscosity of log n=1.0 at a temperature of 2950° F. or less. 14. Basalt fibers produced from Oregon Yakima basalt rock modified with 15.0 to 25.0 weight percent of an additive which is substantially only CaO or MgO and CaO, wherein the basalt fibers have a composition containing 14 to 30 weight percent CaO and 3 to 12 weight percent MgO, wherein the composition has a viscosity of log n=1.0 at a temperature of 2950° or less. 15. Basalt fibers of claim 14 wherein said additive is only CaO, wherein the resulting composition has a viscosity of log n=1.0 at a temperature of 2950° or less, and wherein the fibers have a high softening temperature as indicated by a viscosity of log n=11.0. 16. Ceiling tile or boards produced from the fibers of claim 1. 17. Ceiling tile or boards according to claim 16 wherein the additive is CaO or a mixture of MgO and CaO. 18. Ceiling tile or boards according to claim 16 wherein the basalt rock is Oregon Yakima basalt. 19. Ceiling tile according to claim 16 wherein the alkaline earth metal oxide is CaO. 20. Ceiling tile according to claim 16 wherein the basalt fibers have a composition containing 14 to 30 weight percent CaO and 3 to 12 weight percent MgO. 21. Ceiling tile according to claim 16 wherein the basalt fibers have a composition containing 15 to 25 weight percent CaO and 4 to 11 weight percent MgO. 22. A method of producing mineral wool comprising the steps of: a. providing a raw material consisting essentially of 60-95% by weight natural basalt rock modified with 5 to 40 weight percent of an additive consisting essentially of only at least one alkaline earth metal oxide wherein the basalt fibers have a composition containing at least 12 weight percent CaO and 15 weight percent or less of MgO; b. melting the raw material; c. forming the molten raw material into fibers; d. cooling the fibers; and e. collecting the cooled fibers wherein the composition has a viscosity of log n=1.0 at a temperature of 2950° F. or less, and wherein the fibers have a high softening temperature as indicated by a viscosity of log n=11.0. 23. A method according to claim 22 wherein the alkaline earth metal oxides are CaO or a mixture of MgO and CaO. 24. A method according to claim 22 wherein the basalt rock is Oregon Yakima basalt. 25. A method according to claim 22 wherein the alkaline earth metal is CaO.