Patent EA-004869-B1 (EA)
Title: Mineral wool composition and method
Inventor: BERNARD JEAN-LUC
IPC: C03C25/00
Filed: 2001-03-16
Abstract: 1. A thermally stable mineral wool capable of dissolving in a physiological medium, and comprising fibres whereof the constituents, given in weigh percentages, are as follows: SiO2	35-60 %, preferably 39-55 %; Al2O3	12-27 %, preferably 16-25 %; CaO	0-35 %, preferably 3-25 %; MgO	0-30 %, preferably 0-15 %; Na2O	0-17 %, preferably 6-12 %; K2O	0-17 %, preferably 3-12 %; R2O(Na2O + K2O)	10-17 %, preferably 12-17 %; P2O5	0-5 %, preferably 0-2 % Fe2O3	0-20 %; B2O3	0-8 %, preferably 0-4 %; TiO2	0-3 %, and it also comprises a phosphorus compound whereof the phosphorus content, expressed in the form P2O5, varies by 0.2, particularly more than 0.5 % to 5 %, in particular less than 2 % of the total volume of fibres, capable of reacting as from 100 degree C with the fibres to form a coating at the surface of the fibres. 2. The mineral wool as claimed in 1, characterized in that comprising fibres whereof the constituents, given in weigh percentages, are as follows: SiO2	35-55 %, preferably 40-52%; Al2O3	16-27 %, preferably 16-25 %; CaO	3-35 %, preferably 10-25 %; MgO	0-15 %, preferably 0-10 %; Na2O	0-15 %, preferably 6-12 %; K2O	0-15 %, preferably 3-12 %; R2O (Na2O + K2O)	10-17 %, preferably 12-17 %; P2O5	0-5 %, preferably 0-2 % Fe2O3	0-15 %; B2O3	0-8 %, preferably 0-4 %; TiO2	0-3 %, and MgO content is 0 and 5 %, preferably 0-2 %, when R2O <=13.0%. 4. The mineral wool as claimed in one of claims 1 to 3, characterized in that the alkali content (Na2O+K2O) of the fibers is such that: 13.0%<=R2O<=15%, especially 13.3%<=R2O<=14.5%. 5. The mineral wool as claimed in one of the preceding claims, characterized in that the Fe2O3 (total iron) contents of the fibers are such that: 0%<=Fe2O3<=5%, preferably 0%<=Fe2O3<=3%, especially 0.5%<=Fe2O3<=2.5%. 6. The mineral wool as claimed in one of claims 1 to 4, characterized in that the Fe2O3 (total iron) contents of the fibers are such that: 5%<=Fe2O3<=15%, especially 5%<=Fe2O3<=8%. 7. The mineral wool as claimed in one of the preceding claims, characterized in that the compositions of the fibers satisfy the relationship: (Na2O+K2O)/Al2O3>=0.5. 8. The mineral wool as claimed in one of the preceding claims, characterized in that the constituents of the fibers satisfy the relationship: (Na2O+K2O)/Al2O3>=0.6, especially (Na2O+K2O)/Al2O3>=0.7. 9. The mineral wool as claimed in one of the preceding claims, characterized in that the lime and magnesia contents of the fibers are such that: 10%<=CaO<=25%, especially 15%<=CaO<=25% and 0%<=MgO<=5% with preferably 0%<=MgO<=2%, especially 0%<=MgO<=1%. 10. The mineral wool as claimed in one of claims 1 to 8, characterized in that the lime and magnesia contents of the fibers are such that: 5%<=MgO<=10% and 5%<=CaO<=15%, preferably with 5%<=CaO<=10%. 11. The mineral wool as claimed in one of the preceding claims, characterized in that the fibers have a dissolution rate of at least 30 ng/cm<2> per hour measured at a pH of 4.5. 12. The mineral wool as claimed in one of the preceding claims, characterized in that the glass corresponding to the fibers may be fiberized by internal centrifuging. 13. The mineral wool as claimed in one of the preceding claims, characterized in that the coating capable of forming on the surface of the fibers essentially consists of an alkaline-earth phosphate. 14. The mineral wool as claimed in claim 13, characterized in that the alkaline-earth phosphate is a calcium phosphate. 15. The mineral wool as claimed in one of the preceding claims, characterized in that the phosphorus compound capable of reacting with the fibers is a compound which decomposes above 100 degree C, releasing phosphoric acid or phosphoric anhydride. 16. The mineral wool as claimed in claim 15, characterized in that the phosphorus compound is chosen from: ammonium phosphates, phosphoric acid and ammonium hydrogenophosphates. 17. A process for manufacturing mineral wool, characterized in that fibers are essentially formed from molten oxides whose constituents are mentioned below in the following percentages by weight: SiO2	35-60 %, preferably 39-55 %; Al2O3	12-27 %, preferably 16-25 %; CaO	0-35 %, preferably 3-25 %; MgO	0-30 %, preferably 0-15 %; Na2O	0-17 %, preferably 6-12 %; K2O	0-17 %, preferably 3-12 %; R2O(Na2O + K2O)	10-17 %, preferably 12-17 %; P2O5	0-5 %, preferably 0-2 % Fe2O3	0-20 %; B2O3	0-8 %, preferably 0-4 %; TiO2	0-3 %, and in that a phosphorus compound, capable of reacting with the fibers in order to form a coating on the surface of the fibers, is then applied, especially by spraying or impregnating with a solution. 18. Use of the mineral wool as claimed in any one of claims 1 to 16 in fire-resistant structural systems.