Premix for preparing basalt fibre, basalt fibre, use of the basalt fibre, premix for preparing a composite, method for preparing the composite, and composite

Abstract

The present invention relates to the fields of materials engineering, chemistry and mechanical engineering. More specifically, the present invention describes a basalt fibre composition, a process for preparing basalt fibre, use thereof and a composite comprising basalt fibre. In one embodiment, the invention provides a basalt fibre comprising a combination of three different rock samples. The invention also relates to a method for preparing basalt fibre by melting the rock combinations, generating a continuous fibre by forming the molten material and a composite comprising basalt fibre. Said basalt fibre is also an alternative to glass fibre and carbon fibre. Glass fibre involves known occupational risks and therefore the present invention allows the elimination of waste related to glass fibre use and production, complying with ESG (environmental, social and governance) best practices. The basalt fibre of the present invention allows performance which is unattainable by glass fibre, at a much lower cost than carbon fibre.

Description

Descriptive Report of Invention Patent PREMIX FOR THE PREPARATION OF BASALT FIBER, BASALT FIBER, USE OF BASALT FIBER, PREMIX FOR THE PREPARATION OF COMPOSITE, PROCESS FOR PREPARING COMPOSITE AND COMPOSITE Field of the Invention

[0001] The present invention falls within the fields of materials engineering, chemistry, and mechanical engineering. More specifically, the invention includes a premix for preparing basalt fiber, a process for preparing basalt fiber, a basalt fiber, its use, and a composite comprising basalt fiber. Basalt fiber is also an alternative to fiberglass, which presents known occupational hazards. The invention enables the elimination of waste related to the use and production of fiberglass, in compliance with ESG (Environmental and Social Governance) best practices. Furthermore, the invention provides performance improvements on a scale unattainable with fiberglass, and at a much lower cost than carbon fiber. Background of the Invention

[0002] Basalt fibers are obtained through the processing of basalt, a silicate-rich magmatic rock, and are widely used due to their mechanical and thermal properties. Despite their qualities, basalt fiber production in Brazil is limited.

[0003] Volcanic rocks containing plagioclase and pyroxene (components of basalt fiber) are found, for example, throughout the South-Central region of Brazil in the geological formation known as the Serra Geral Formation (FSG). Thus, the raw material necessary for the manufacture of basalt fibers is available in the country. However, there is still a great need. by basalt fibers with improved physical and chemical properties, which are preferably obtained from local sources.

[0004] Fiber production involves multiple parameters, and adding value to naturally extracted materials and improving their properties is a constant challenge in the technical field of materials engineering. The current high demand for materials for a wide variety of applications makes it essential to develop alternatives to the most commonly used materials. In this context, the more rational use of naturally extracted materials and the incorporation of technology add value and special functionalities to these materials.

[0005] Basalt rocks from the Serra Geral Formation (FSG), for example, are commonly used to produce cobblestones and construction materials, such as basements, sinks, and sidewalks. However, the incorporation of technology can modify properties and / or find more valuable application contexts. Thus, the development of new materials based on available resources to obtain alternative materials for high-tech applications is a constant demand in the field of materials engineering. Technologies in this technical area can significantly impact the economic development of the region, thus causing a significant positive environmental impact by promoting the more rational use of materials extracted from nature.

[0006] Among the rocks found in nature, there are some that are not considered suitable for certain applications due to their chemical composition. One example is "BRE" (Breccia – named after the deposit itself), considered problematic because current products derived from this rock have low added value and are not considered satisfactory. BRE rock is found in abundance, but it is not used in high-performance products. Therefore, its incorporation into high-value-added products remains a technical challenge in the industry.

[0007] Fiberglass is widely used in industry, but it poses known occupational hazards. Fiberglass can cause irritation to the eyes, skin, nose, and throat of workers directly exposed to it. Therefore, continuous or frequent contact with fiberglass or its fragments can cause these and other problems, such as aggravating pre-existing bronchitis and asthma, representing a significant occupational hazard.

[0008] Fiberglass is widely used in the production of composites in industry, such as fiberglass-reinforced plastics (FRP). The FRP production process also poses other occupational hazards to workers, such as prolonged exposure to organic solvents used in FRP production, which can lead to known health problems in the medium and long term. Therefore, it is necessary to develop alternatives to fiberglass that avoid the corresponding occupational hazards and eliminate fiberglass production waste.

[0009] Carbon fiber, on the other hand, is a widely used fiber type today, boasting a wide range of high-tech material applications. However, a significant disadvantage of carbon fiber is its high cost, which limits its accessibility and / or applications in various product types. Therefore, the development of alternative fibers with advantageous properties and lower costs compared to the high cost of carbon fibers is necessary.

[0010] Document CN107759082A (2018) describes a high-hardness basalt fiber containing the following materials: basalt ore, kaolin, quartz, nano-silica, nickel metal, and silane coupling agent, with the basalt ore comprising up to 80% of the fiber by weight. This document does not disclose or suggest the objects of the invention or a premix or a fiber as defined in the present invention.

[0011] Document CN113526874A (2021) describes a basalt-type fiber, its preparation method, and its uses. This preparation process The fiber uses the following raw materials: fly ash, red mud, residual gypsum, coal gangue, and slag; the additives include a combination of flux, dispersant, and impact modifier. The process involves the steps of initial mixing of the materials, melting, and molding. This document does not disclose or suggest the objects of the invention and does not disclose a premix or a fiber as defined in this invention.

[0012] Document CN114477756A (2022) describes a basalt fiber and its production method. Said fiber has specific properties, including melt viscosity rate; and size of the basalt particles used to compose the fiber. Said production process includes the steps of a) characterizing the physical and chemical parameters of the basalt raw material; b) cleaning, drying, and grinding the basalt; c) melting and homogenizing the starting material; and d) striation to form basalt fibers. Said document does not disclose or suggest the objects of the invention and does not disclose a premix or a fiber as defined in the present invention.

[0013] Document CN102690063A (2012) describes a basalt composite material and its production method. This document discloses the use of 10% to 20% by weight of sepiolite, and the basalt fiber production process comprising the fusion and modulation steps. The basalt fibers presented in this document have improved chemical durability, flexibility, alkaline and acid resistance, and thermal resistance. This document does not disclose or suggest the objects of the invention and does not disclose a premix or a fiber as defined in the present invention.

[0014] The present invention solves several problems in the prior art. In one aspect, the basalt fiber of the invention provides performance unattainable by fiberglass and at a much lower cost than carbon fiber.

[0015] From what can be inferred from the literature researched, no documents were found anticipating or suggesting the teachings of the present invention, so that the solution proposed here has, in the eyes of the inventors, novelty and inventive step compared to the state of the art. Summary of the Invention

[0016] The present invention addresses the problems of the prior art by developing a premix for the preparation of basalt fiber. This premix comprises a composition of different rock samples for the production of basalt fibers, providing high chemical resistance and high tensile strength. The mineral composition of the basalt fiber comes from rocks found in Brazil, solving the historical supply problem for the manufacture of basalt fibers in the country.

[0017] The basalt fibers of the present invention exhibit mechanical and thermal properties that enable a wide range of applications. One example is the manufacture of a composite with widespread application in the automotive, aerospace, and construction industries, to name a few. This composite offers chemical resistance, mechanical strength, and vibration resistance, while being lightweight and exhibiting good thermal stability, among other advantages.

[0018] The basalt fiber of the present invention is an advantageous alternative to carbon fiber, which has a wide range of high-tech material applications. However, carbon fibers are expensive, limiting their use. The basalt fibers of the present invention are advantageous and much cheaper alternatives (around one-tenth the price of carbon fiber).

[0019] The premix of the present invention is a technical solution that makes it possible to use BRE rock for higher-value-added products, such as basalt fiber production. Although the quantity of BRE rock found in nature is very large, its chemical composition previously precluded its use in many applications. The premix of the present invention solves this and other problems, providing a surprising solution for incorporating BRE rocks into high-value-added products.

[0020] Thus, this invention has a significant impact on the country's economic development by enabling the addition of value to a locally obtained material. An example of a local source is the Serra Geral Formation (FSG) deposits.

[0021] The invention provides an alternative to the use of fiberglass, which presents known occupational hazards, as well as the elimination of waste related to the use and production of fiberglass, in compliance with ESG (Environmental and Social Governance) best practices. Furthermore, the basalt fiber of the invention provides greater strength than fiberglass, so the usage rate is lower (e.g., mass usage can be ~20% lower) compared to fiberglass. In other words, for the same mass quantity, the use of the basalt fiber of the invention provides greater performance / properties.

[0022] The invention also provides an alternative to carbon fiber, which has a wide range of high-tech materials applications. One disadvantage of carbon fiber is its high cost, so the basalt fiber of the present invention presents itself as a much cheaper alternative (around one-tenth or less of the price of carbon fiber). The basalt fiber of the invention, when used in the same proportions as carbon fiber, provides approximately 80% of the equivalent strength of carbon fiber. Therefore, being much cheaper and providing mechanical properties comparable to those of carbon fiber, the basalt fiber of the invention is a clearly advantageous alternative and solves several technical problems in the sector.

[0023] In a first object, the present invention presents a premix for the preparation of basalt fiber with high tensile strength and high chemical resistance to extreme pH values.

[0024] In another object, the present invention presents a process for the preparation of basalt fiber comprising: at least one melting step of the said premix containing basalt fiber; shaping the molten premix into a continuous fiber; and winding the basalt fiber.

[0025] In another object, the present invention presents a basalt fiber comprising high tensile strength and high chemical resistance to extreme pH values.

[0026] In another object, the present invention presents the use of basalt fiber, as defined in any of the previous objects, for preparing a structural, functional and / or finishing composite.

[0027] In another object, the present invention presents a premix for the preparation of a composite comprising an amount of basalt fiber as defined above.

[0028] In another object, the present invention presents a composite preparation process comprising at least one step of incorporating the premix for the composite preparation as defined above.

[0029] In another object, the present invention presents a composite comprising an amount of basalt fiber as defined above dispersed in a matrix.

[0030] These and other objects of the invention will be immediately appreciated by those skilled in the art and will be described in detail below. Brief Description of the Figures

[0031] The following figures are presented:

[0032] Figure 1 shows a diffractogram of the mineralogical composition of the BAS sample, where the X axis indicates the count; and Y indicates position [*2θ] (copper (Cu)).

[0033] Figure 2 shows a diffractogram of the mineralogical composition of the BRE sample, in which the X axis indicates the count; and Y indicates position [*2θ] (copper (Cu)).

[0034] Figure 3 shows a diffractogram of the mineralogical composition of the DAC sample, in which the X axis indicates the count; and Y indicates position [*2θ] (copper (Cu)).

[0035] Figure 4 shows micrographs of the glass obtained for the composition formed in an example of the present invention after an increase in temperature to 1460°C (4 hours after cessation of outgassing), at a magnification of 750-1000x. In the top images, a homogeneous region (left), a segregation region (right) are shown; and below are shown a region with single, transparent crystalline inclusions (left) and a region with unfused inclusion (right).

[0036] Figure 5 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after an elevation in temperature to 1460°C for 4 hours (2 hours after cessation of gas emission), at a magnification of 750-1000x. In the top images, a homogeneous region (left), a segregation region (right) are shown, and below is shown a region with crystalline inclusions (translucent).

[0037] Figure 6 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after an elevation in temperature to 1460°C for 7 hours (5 hours after cessation of gas emission), at a magnification of 750-1000x. The image on the left shows a homogeneous region, while the image on the right shows a region of segregation.

[0038] Figure 7 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after a rise in temperature to 1450°C (with a short rise time to the temperature of 1460°C), 4 hours, at a magnification of 750-1000x. In the top images are shown homogeneous regions (left) and a segregation region (right); below are shown regions with translucent crystalline inclusions, in the form of needles.

[0039] Figure 8 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after an elevation in temperature to 1450°C (with a short rise time to 1460°C), 4 hours. The top images show homogeneous regions (left), segregation regions (right); and the bottom images show regions with unmelted inclusion (left) and regions with crystalline (translucent) inclusions.

[0040] Figure 9 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after a temperature rise to 1460°C, 6 h, at 750-1000x magnification. In the top images, homogeneous regions (left) and aggregation regions (left) are shown; and below is shown a region of unmelted inclusion.

[0041] Figure 10 shows a micrograph of the glass obtained for the composition formed in an example of the present invention after an elevation in temperature to 1450°C, 5 h at 750-1000x magnification, at a magnification of 750-1000x. In the top images, homogeneous regions (left), regions with aggregations (right) are shown; and in the bottom images are shown regions with translucent crystalline inclusions (left), regions with translucent crystalline needle-like inclusions (middle), and regions with unfused inclusions (right).

[0042] Figure 11 shows a schematic of an embodiment of an apparatus for the production of continuous fibers.

[0043] Figure 12 shows the results of thermogravimetric analysis (TGA) for the basalt fiber of the present invention.

[0044] Figure 13 shows the appearance of the mixture after 1 minute with the tank rotating (without intensifier).

[0045] Figure 14 shows the appearance of the mixture after 30 seconds with the intensifier on.

[0046] Figure 15 shows the appearance of the mixture after 60 seconds with the intensifier on.

[0047] Figure 16 shows the composite obtained through the premix of sample V18 after pressing.

[0048] Figure 17 shows the appearance of mixture V18 comprising 5% basalt fiber by volume using the SEMCO mixer. Detailed Description of the Invention

[0049] Basalt fibers are obtained by processing basalt containing plagioclase and pyroxene. These fibers, and the composites generated from them, have a wide range of applications, including in the automotive, construction, and aerospace industries, among others.

[0050] Without wishing to be limited by theory, high-performance composites generally have a saturation limit for the reinforcing load, making the use of certain low-performance fibers unfeasible. The basalt fiber of the present invention solves this problem and provides high performance levels unattainable with glass fiber, all at a much lower cost than carbon fiber.

[0051] In the context of the present invention, the acronym “BAS” should be understood as a rock classified as BASALT within the range defined by the TAS diagram (Total-Alkali vs. Silica diagram) which is known to a person skilled in the art.

[0052] In the context of the present invention, the acronym “DAC” should be understood as a rock classified as DACITE within the range defined by the TAS diagram (Total-Alkali vs. Silica diagram) which is known to a person skilled in the art.

[0053] In the context of the present invention, the acronym "BRE" should be understood as "breccia," i.e., a rock classified as DACITE within the range defined by the TAS diagram (Total-Alkali vs. Silica diagram), which is known to one skilled in the art. The "BRE" rock is found in the same region as the "DAC" rock, but "BRE" is a rock formation fault found in the same deposit. Although the "BRE" rock is within the range defined in the TAS diagram for DACITE, the chemical composition of the "BRE" rock differs from that of the "DAC" rock, and the "BRE" rock is commonly considered to be less suitable for some applications due to its different chemical composition.

[0054] Among other aspects, the premix of the present invention makes it possible to use BRE rock for higher-value-added products, such as basalt fiber production. On the one hand, the quantity of BRE rock found in nature is very large, but on the other, its chemical composition precludes its use in many applications. The premix of the present invention solves this problem and provides a surprising solution for incorporating BRE rock into high-value-added products.

[0055] One of the objects of the present invention is to provide a premix for the preparation of basalt fiber that provides high tensile strength and high chemical resistance to extreme pH values.

[0056] In one embodiment, the premix for preparing basalt fiber comprises from 0 to 100 wt % BAS; from 0 to 100 wt % BRE; from 0 to 100 wt % DAC; or combinations thereof.

[0057] In one embodiment, the premix for preparing basalt fiber comprises above 0 to 100 wt % BAS; above 0 to 100 wt % BRE; above 0 to 100 wt % DAC; or combinations thereof.

[0058] In one embodiment, the premix comprises greater than 0 to 100% by weight BAS; greater than 0 to 100% DAC; or combinations thereof.

[0059] In one embodiment, the premix comprises greater than 50 to less than 100% by weight BAS; greater than 0 to 50% DAC; or combinations thereof.

[0060] In a preferred embodiment, the premix comprises above 0 to 100% by weight a percentage by weight of BAS.

[0061] In one embodiment, the premix for preparing basalt fiber comprises above 0 to 100 wt % BAS and additionally 0 to 100 wt % BRE; and / or 0 to 100 wt % DAC.

[0062] Samples BAS, BRE, and DAC are composed primarily of plagioclase and clinopyroxene. Both samples BRE and DAC additionally contain alkali feldspar and quartz components.

[0063] In one embodiment of the present invention, the composition of the sample designated BAS is set forth in the following tables 1, 4 and 5. In one embodiment of the present invention, the composition of the sample designated BRE is set forth in the following tables 2, 4 and 5. In one embodiment of the present invention, the composition of the sample DAC is set forth in the following tables 3 and 5.

[0064] Table 1: Mineralogical composition of BAS. Mineral Legend Formula P Plagioclase (Group) 1 Na(AlSi3O8) – Ca(Al2Si2O8) C Clinopyroxene (Group) 1 CaMgSi2O6Ar Clay Mineral (Group) 1 - 1 Mineral identified by comparison with ICDD (International Centre for Diffraction Data) standards.

[0065] Table 2: Mineralogical composition of BRE. Mineral Legend Formula Q Quartz 1 SiO2P Plagioclase (Group) 1 Na(AlSi3O8) – Ca(Al2Si2O8) F Alkali Feldspar (Group) 1 KAlSi3O8C Clinopyroxene (Group) 1 CaMgSi2O6 1 Mineral identified by comparison with ICDD (International Centre for Diffraction Data) standards.

[0066] Table 3: Mineralogical composition of DAC. Legend Mineral Formula Q Quartz 1 SiO2 P Plagioclase (Group) 1 Na(AlSi3O8) – Ca(Al2Si2O8) F Alkali Feldspar (Group) 1 KAlSi3O8 C Clinopyroxene (Group) 1 CaMgSi2O6 1 Mineral identified by comparison with ICDD (International Centre for Diffraction Data) standards.

[0067] Table 4: Chemical composition Content (% by weight) Requirements d Fibers of A the raw material- Oxides indesite- basalt, raw (rocks) basalt pa commercial – BAS BREUkraine ra production of continuous fibers Chopper Stands S iO2 52.84 47.5-55.0 54.4 50.5764.93 T iO2 0.5 0.2-2.0 1.12 1.331.06 A l2O3 17.28 14.0-20.0 17.55 13.8313.47 F e2O3 8,97 7.0-13.5 9.81 13.39 7,39 F eO 1,66 M nO - - 0.15 0.20.13 M gO 6.3 3.0-8.5 4.03 6.111.46 C aO 7.1 7.0-11.0 8.12 10.133.78 N a2O 2,2 2,49 2,45 3,38 2.5-7.5 K 2O 1.6 1.61 0.73.76 P 2O5 - - 0.16 0.150.28 H 2O - - - - - no more than L OI 1,77 5.0 0,17 1,13 0,76 T otal 100.23 - 99.61 99.9999.64 Ma (modulus5.23 - 5.92 3.97 14,96 of acidity) Mv (modulus of2.6 2.2-2.7 2.44 1.76 3,67 viscosity) Adenosite- Adenosite- TAS basalt - basalt Basalto Dacito

[0068] Table 5: Chemical composition

[0069] The acid modulus and viscosity modulus, shown in Tables 4, 5, and 6, of each sample were also determined based on the results of the chemical composition analyses. The acid modulus ( ^^ ^^ ) and viscosity ( ^^ ^^ ) are given, respectively, by the following equations: ^^SiO + ^0] ^^2^Al O [007 2 3 ^^ = ^^CaO+ ^^MgO ^^SiO +2 ^^Al O

[0071] ^^ 2 2 3 ^^ = 2 ^^Fe2O3+ ^^FeO+ ^^CaO+ ^^MgO+ ^^K2O+ ^^Na2O

[0072] Where ^^R ^^ THE ^^ corresponds to the mass fraction of oxides in the composition and ^^R ^^ THE ^^ corresponds to the fraction of moles of oxides in the composition.

[0073] A person skilled in the art can, from the information displayed in figures 4, 5 and 6, note that, in relation to the chemical composition and viscosity modulus, the compositions of the BRE and DAC samples with BAS reach the recommended values ​​for the production of continuous basalt fibers.

[0074] The final temperature at which the material melts and the time for homogenization of the melt are relevant properties for the industrial-scale manufacture of basalt fibers. Table 7 shows the initial melting temperature ( ^^ ^^ ^^ ) and the final melting temperature ( ^^ ^^ ^^ ) for the BAS, BRE and DAC samples.

[0075] Table 7: Melting temperature range. Test number, rock, Temperature °C deposit tbf tff BAS (basalt bulk) 1150 1450 BAS (with white 1150 >1450 inclusions) DAC 1200 >1450 BRE (with reddish 1100 >1450 hue (fox color)) BRE (with pink 1100 >1450 hue) BRE (dark gray) 1150 >1450 BRE (dark gray with white 1150 >1450 waves) Andesite-basalt, 1165 1375 Podgornjansky, Ukraine

[0076] After melting, to analyze the amorphous structure of basalt glass, the melt is poured into water to obtain rapid cooling. The results of glass formation were analyzed for six compositions comprising different weight percentages of BAS, BRE, and DAC.

[0077] In one embodiment, the ^^ ^^ ^^ is 1280ºC and is 1310ºC. The glass formed by the composition contains homogeneous regions with crystalline inclusions and segregated material.

[0078] In one embodiment, the ^^ ^^ ^^ is 1280ºC and is 1310ºC. The glass formed is mostly homogeneous with crystalline inclusions and segregated material.

[0079] In one embodiment, the ^^ ^^ ^^ is 1280ºC and is 1380ºC. The glass is mostly homogeneous with few crystalline inclusions and segregated material.

[0080] In one embodiment, the ^^ ^^ ^^is 1280ºC and is 1320ºC. The glass obtained is mostly homogeneous with few crystalline inclusions and segregated material.

[0081] In one embodiment, the ^^ ^^ ^^ is 1280ºC and is 1310ºC. The glass formed contains homogeneous regions with crystalline inclusions and segregated material.

[0082] In one embodiment, the ^^ ^^ ^^ is 1300ºC. The glass is mostly homogeneous with few crystalline inclusions and segregated material.

[0083] The viscosity of the melt, its variation with temperature, and its crystallization capacity are properties that influence the ability of the premix to produce fiber. Typically, high-viscosity melts perform better in fiber production. Viscosity is given by the equation: is the viscous activation energy, ^^ is the universal gas constant and ^^ is the absolute temperature.

[0086] Table 8 shows the dependence of viscosity on temperature and the upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the compositions organized in a table.

[0087] Table 8: Dependence of viscosity on temperature and upper limit of crystallization. Rock, Viscosity, η dPA.s, in t °C tulc Deposition energy, 1450 1400 1350 1300 1250 °C activation Eη Sample number 152 259 470 892 1750 1230 266 No. 2 163 274 495 998 2080* 1230 277 No. 3 88 145 240 437 905 1230 254 No. 4 203 330 600 1078 2300* 1230 264 No. 5 57 93 153 293 650 1230 265 No. 6 155 250 490 945 1800 1240 267 Andesite- Podgornianske basalt *estimated values

[0088] From the upper limit temperature values ​​of crystallization ( ^^ ^^ ^^ ^^), it is concluded that fiber formation can occur at lower temperatures (above 1230ºC).

[0089] Another relevant characteristic for the manufacture of basalt fibers is the wetting angle. To determine it, the wetting angle of the molten material is observed when in contact with a platinum-rhodium alloy. Table 9 and Figure 13 show the dependence of the wetting angle on temperature for the compositions.

[0090] Table 9: Limiting wetting angle Rock, field, Limiting wetting angle θ at temperature t °C In test 1200 1225 1250 1275 1300 1325 1350 42 32 25 19 14 10 7 No. 2 50 37 29 23 18 13 9 No. 3 47 32 22 16 12 9 7 No. 4 46 34 26 20 15 11 8 No. 5 30 25 20 15 11 7 3 No. 6 45 34 258 23 17 12 8 Andesite- Podgornianske basalt

[0091] In another object, the present invention presents a process for the preparation of basalt fiber, comprising: at least one step of melting the premix as defined above; shaping the molten premix forming a continuous fiber; and winding the basalt fiber.

[0092] The premix melting step occurs within an optimal temperature range. This range is known as the fiber production temperature range ( ^^ ^^ ^^ ^^ ) and must have a minimum value of 60ºC.

[0093] In the basalt fiber preparation process, the flow rate of molten material is determined according to the mold diameter, the fiber generation temperature and the material flow speed through the mold.

[0094] The forming step of the molten premix to form a continuous fiber, in one embodiment, is performed by passing the constantly heated molten material through a mold, also heated, where the mold has a diameter consistent with the viscosity and crystallization ability of the material. In one embodiment, the material is drawn.

[0095] Figure 11 shows a concretization of fiber manufacturing conditions. Table 10 shows the ^^ ^^ ^^ ^^ together with mold diameters for the samples.

[0096] Table 10: Fiber production temperature ranges and continuous diameter, coarse fibers. Rock, field typf °C Fiber diameter µm Continuous fibers, d of 1.88 mm mold No. 2 1360-1450 8.5-13.5 No. 3 1360-1450 10.0-12.5 No. 4 1360-1450 9.0-15.5 No. 5 1370-1450 10.5-15.0 No. 6 1340-1420 8.5-18.5 Andesite-basalt 1370-1450 8.0-11.0 Podgornianske Continuous fibers, d of 1.6 mm mold No. 6 1320 – 1390 (7.5-15.5 level cast 4.5-5.0 mm) 1330-1430 (8.0-14.0 level cast 3.5-4.5 mm)

[0097] In one embodiment, the basalt fiber winding step comprises winding the continuous fiber obtained in the basalt fiber composition forming step, so that the winding speed matches the material flow speed through the mold.

[0098] In another object, the present invention presents a basalt fiber comprising high tensile strength and high chemical resistance to extreme pH values.

[0099] In one embodiment, the basalt fiber comprises from 0 to 100 wt % BAS; from 0 to 100 wt % BRE; from 0 to 100 wt % DAC; or combinations thereof.

[0100] In one embodiment, the basalt fiber comprises greater than 0 to 100 wt % BAS; greater than 0 to 100 wt % BRE; greater than 0 to 100 wt % DAC; or combinations thereof.

[0101] In one embodiment, the fiber comprises greater than 0 to 100% by weight BAS; greater than 0 to 100% DAC; or combinations thereof.

[0102] In one embodiment, the fiber comprises greater than 50 to less than 100% by weight BAS; greater than 0 to 50% DAC; or combinations thereof.

[0103] In a preferred embodiment, the fiber comprises above 0 to 100% by weight of a percentage by weight of BAS.

[0104] In one embodiment, the basalt fiber comprises above 0 to 100 wt % BAS and additionally 0 to 100 wt % BRE; and / or 0 to 100 wt % DAC.

[0105] In one embodiment, the basalt fiber comprises tensile strengths between 1770 MPa and 1950 MPa for a fiber diameter range of 1 µm to 100 µm.

[0106] The chemical resistance of basalt fibers, in one embodiment, includes resistance to pH values ​​in the ranges of 1 to 4 and 10 to 14. Chemical resistance is understood as the amount of fiber mass lost in a surface of 5000 cm² exposed to a chemically aggressive environment, e.g., highly acidic or highly basic.

[0107] In one embodiment, the basalt fiber of the present invention is used as an alternative to carbon fiber. Unlike carbon fiber, the basalt fiber of the present invention has a golden coloration, and this attribute can be used as a design feature, e.g., in automotive parts. A disadvantage of carbon fiber is its high cost, so the basalt fiber of the present invention presents itself as a much cheaper alternative (around one-tenth the price of carbon fiber).

[0108] In another object, the present invention presents a use of basalt fiber, as defined in any of the previous objects, for preparing a structural, functional and / or finishing composite. Yet another object is a composite comprising said basalt fiber.

[0109] In one embodiment, the functional composite is useful in friction materials. In another embodiment, the friction materials are used in brake pads or linings. For these applications, basalt fiber is particularly advantageous because it provides high resistance to high temperatures.

[0110] In one embodiment, said structural, functional, and / or finishing composite of the present invention is useful in automotive / vehicle parts. In one embodiment, said structural, functional, and / or finishing composite of the present invention is useful in civil construction materials, such as rebar.

[0111] In one embodiment, the composite comprises a matrix associated with basalt fibers. In one embodiment, said matrix is ​​a metallic, ceramic, and / or polymeric matrix. In one embodiment, said matrix is ​​a polymeric-only matrix.

[0112] In a further embodiment, the basalt fibers are long continuous fibers. In one embodiment, said continuous fibers form ribbons. In another embodiment, said ribbons form a woven mesh.

[0113] In a further embodiment, the basalt fibers are chopped fibers. In one embodiment, the composite comprises a matrix associated with chopped basalt fibers. In one embodiment, said matrix is ​​a polymer matrix.

[0114] In one embodiment, basalt fiber composites are used in friction materials. Non-limiting examples of friction materials include brake pad and / or lining friction materials.

[0115] In one embodiment, basalt fiber composites are used in automotive / vehicle parts. In a further embodiment, basalt fiber composites are used in construction materials, such as rebar.

[0116] For the purposes of the present invention, “application in automotive / vehicle parts” means the application of the composite in parts of land vehicles, such as cars, motorcycles, railway vehicles, etc.; aircraft, including application in the aerospace field; and aquatic vehicles.

[0117] For the purposes of the present invention, “application in civil construction materials” is understood as the application in structural and / or decorative components related to civil construction, such as rebars.

[0118] In another object, the present invention presents a premix for the preparation of a composite comprising an amount of basalt fiber as defined above.

[0119] In one embodiment, the premix for preparing the composite comprises an amount of the basalt fiber as defined above mixed with a polymer.

[0120] In one embodiment, said premix for preparing a composite comprises an amount of basalt fiber and at least one resin. In one embodiment, said amount of basalt fiber is 1 to 50% by volume. In one embodiment, the amount of basalt fiber is 5 to 30% by volume.

[0121] In another object, the present invention presents a composite preparation process comprising at least one step of incorporating the premix for the composite preparation as defined above.

[0122] In one embodiment, the composite preparation process comprises at least one prior step of mixing the components of said premix for the preparation of the composite in a mixer by rotating only the plow with the intensifier switched off.

[0123] In another object, the present invention presents a composite comprising an amount of basalt fiber as defined above dispersed in a matrix.

[0124] In one embodiment, the composite comprises a metallic, ceramic, polymeric matrix, or combinations thereof.

[0125] The examples shown here are intended only to illustrate one of the numerous ways of carrying out the invention, without limiting its scope. Example 1

[0126] In this embodiment, the melting onset temperature ( ^^ ^^ ^^ ) of the premix is ​​1280ºC and the final melting temperature ( ^^ ^^ ^^ ) is 1310ºC.

[0127] A glass from the premix is ​​obtained by pouring the molten material into water, preserving the amorphous structure during rapid cooling. Figure 4 presents a set of microscopy images of the resulting glass. This evaluation showed that the bulk glass is inhomogeneous, with regions of unmelted inclusions, crystalline inclusions, and segregation. Example 2

[0128] In this embodiment, the melting onset temperature ( ^^ ^^ ^^ ) of the premix is ​​1280ºC and the final melting temperature ( ^^ ^^ ^^ ) is 1310ºC. Figure 5 shows a set of microscopies of the glass obtained. This evaluation showed that the bulk of the glass is homogeneous, with areas of unfused inclusions, crystalline inclusions and segregation, unlike glass that has been aged for 4 h.

[0129] The viscosity of the melt is a function of temperature. Table 8 presents a compilation of some viscosity values ​​for a given set of temperatures. The upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the composition is 1230ºC.

[0130] The limiting wetting angle for the composition is presented for a range of temperatures in Table 9.

[0131] In one embodiment, a 1.8 mm diameter mold is used to obtain basalt fibers. Table 10 shows the temperature range for fiber production ( ^^ ^^ ^^ ^^ ) and the range of fiber diameters obtained for this embodiment.

[0132] For an average fiber diameter of 10.2 µm, the average tensile stress limit supported by the fiber is 1770 MPa, as illustrated in Table 11.

[0133] Table 11: Physical and mechanical properties of the obtained fibers, measured diameter and tensile stress parameters. Sample No., Average diameter Average tensile stress limit type, µm deposit tensile MPa No. 2 10.2 1770 No. 3 9.8 1910 No. 4 11.1 1950 No. 5 11.23 1870 No. 6 14.6 1280 No. 6 10.7 1830 Andesite-basalt, 12.0 1880 Podgornyanskoe Andesite-basalt, 9.3 2000 Podgornyanskoe

[0134] In one embodiment, the basalt fiber has an average diameter of 10.9 µm. For this embodiment, Table 12 shows the mass lost when the fiber is subjected to different baths with different pH ranges.

[0135] Table 12: Chemical resistance of continuous fibers. Environment No. 2 d. medium No. 3 No. 6 Aggressive andesite-basalt, 10.9 µm d. medium 11.1 µm d. medium 11.9 µm Podgornyanskoe indicators d. average 11.2 µm H2O Weight loss mg 10.0 41.0 22.0 33.6 Strength % 99.7 99.0 99.5 99.2 0.5 N NaOH Weight loss mg 145.0 112.0 439.0 502.6 Strength % 96.3 97.2 89.0 87.5 2N NaOH Weight loss mg 531.5 585.0 694.5 943.0 Strength % 86.4 89.5 82.6 77.6 2N HCl Weight loss mg 833.0 1268.5 1356.5 523.0 Strength % 78.7 68.0 66.0 87.0 Example 3

[0136] In this embodiment, the melting onset temperature ( ^^ ^^ ^^ ) of the composition is 1280ºC and the final melting temperature ( ^^ ^^ ^^ ) is 1380°C. Figure 7 presents a set of microscopy images of the glass obtained from the premix in this example. This microscopic evaluation shows that the glass bulk is homogeneous, with rare regions of segregation, unmelted inclusions, and crystalline inclusions in the form of "needles."

[0137] Table 8 presents a compilation of some viscosity values ​​for a given set of temperatures. The upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the composition is 1230ºC.

[0138] The limiting wetting angle for the composition is presented for a range of temperatures in Table 9.

[0139] In one embodiment, a 1.8 mm diameter mold is used to obtain basalt fibers. Table 10 shows the temperature range for fiber production ( ^^ ^^ ^^ ^^ ) and the range of fiber diameters obtained for this embodiment.

[0140] For an average fiber diameter of 9.8 µm, the average tensile stress limit supported by the fiber is 1910 MPa, as illustrated in Table 11.

[0141] In one embodiment, the basalt fiber has an average diameter of 11.1 µm. For this embodiment, Table 12 shows the mass lost when the fiber is subjected to different baths with different pH ranges. Example 4

[0142] In this embodiment, the melting onset temperature ( ^^ ^^ ^^ ) of the composition is 1280ºC and the final melting temperature ( ^^ ^^ ^^ ) is 1320°C. Figure 8 presents a set of microscopy images of the glass obtained from the premix in this example. This microscopic evaluation showed that the bulk glass is homogeneous, with rare areas of segregation, unmelted inclusions, and crystalline inclusions.

[0143] Figure 8 presents a table where some viscosity values ​​are compiled for a given set of temperatures. The upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the composition is 1230ºC.

[0144] The limiting wetting angle for the composition is presented for a range of temperatures in Table 9.

[0145] In one embodiment, a 1.8 mm diameter mold is used to obtain basalt fibers. Table 10 shows the temperature range for fiber production ( ^^ ^^ ^^ ^^ ) and the range of fiber diameters obtained for this embodiment.

[0146] For an average fiber diameter of 11.1 µm, the average tensile stress limit supported by the fiber is 1950 MPa, as illustrated in Table 11. Example 5

[0147] In this embodiment, the melting onset temperature ( ^^ ^^ ^^ ) is 1280ºC and the final melting temperature ( ^^ ^^ ^^ ) is 1310°C. Figure 9 shows a set of microscopies of the glass obtained from the premix of this example. This evaluation showed that the glass bulk is homogeneous, there are regions with unmelted inclusions, crystalline inclusions and segregation.

[0148] The viscosity of the melt is a function of temperature. Table 8 shows a compilation of some viscosity values ​​for a given set of temperatures. The upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the composition is 1230ºC.

[0149] The limiting wetting angle for the composition is presented for a range of temperatures in Table 9.

[0150] In one embodiment, a 1.8 mm diameter mold is used to obtain basalt fibers. Table 10 shows the temperature range for fiber production ( ^^ ^^ ^^ ^^ ) and the range of fiber diameters obtained for this embodiment.

[0151] For an average fiber diameter of 11.23 µm, the average tensile stress limit supported by the fiber is 1870 MPa, as illustrated in Table 11. Example 6

[0152] In this embodiment, the final melting temperature ( ^^ ^^ ^^) is 1300°C. Figure 10 presents a set of microscopy images of the glass obtained from the premix in this example. This evaluation showed that the bulk glass is homogeneous, with only insignificant single regions of unmelted inclusions, segregations, and small crystals in the form of "needles," "stars," or "fishbones."

[0153] The viscosity of the melt is a function of temperature. Table 8 presents a compilation of some viscosity values ​​for a given set of temperatures. The upper limit temperature of crystallization ( ^^ ^^ ^^ ^^ ) of the composition is 1230ºC.

[0154] In one embodiment, a 1.8 mm diameter mold is used to produce basalt fibers. In an alternative embodiment, the mold diameter is 1.6 mm. Table 10 shows the temperature range for fiber production ( ^^ ^^ ^^ ^^ ) and the range of fiber diameters obtained for these embodiments.

[0155] For a mold diameter of 1.8 mm, the average fiber diameter is 14.6 µm, with an average tensile stress limit of 1280 MPa. For a mold diameter of 1.6 mm, the average fiber diameter is 10.7 µm, with an average tensile stress limit of 1830 MPa. The cited embodiments are illustrated in Table 11.

[0156] In one embodiment, the basalt fiber has an average diameter of 11.9 µm. For this embodiment, Table 12 shows the mass lost when the fiber is subjected to different baths with different pH ranges. Example 7 – Basalt Fiber Production Process

[0157] In this embodiment, the basalt fiber production process (1) is carried out by melting the mineral composition, generating a molten material (2) that passes through a mold (3) of suitable diameter. The melting process and the formation of a homogeneous melt were carried out in the furnace outside the Platinum-Rhodium tank. The mineral composition can be formed by combining the BAS, BRE, and DAC samples.

[0158] In order to illustrate said process, Figure 11 shows an apparatus in which the mineral composition associated with a crucible (4) is melted in an electric furnace. The electric furnace is heated by a heating element (5). In one embodiment, the crucible (4) is a platinum alloy crucible.

[0159] The molten material (2) is forced through the mold (3) by the hydrostatic pressure of the molten material (2) associated with the crucible (4) and by the already formed basalt fiber (1) that is pulled through the mold (3).

[0160] The basalt fiber (1) is continuously wound onto a reel (6). The rotation speed of the reel (6) and the temperature of the electric furnace are controlled by a controller (7) that maintains the ideal conditions for obtaining continuous basalt fibers (1).

[0161] For a first part of the fibers produced, 54 kg of complex yarns were obtained from 150 kg of raw material, which were processed into chopped fibers.

[0162] For a second batch of fibers produced, five batches were produced. After drying, the complex yarns produced were processed into skeins (1100 tex, 150 kg), and the remaining bobbins were sent to be chopped to produce chopped fibers (100 kg, average length 4 mm).

[0163] A universal silane-based lubricant, compatible with both epoxy and phenolic resins, was used in the fiber production process. The lubricant consumption rate was 0.6 kg per kg of fiber.

[0164] The fibers produced had the following characteristics: Table 13 – Characteristics of the continuous fibers produced Average diameter of complex yarns, µm 20-28 Strength of a single fiber for fiber with an average diameter of 24.7 µm, Mpa Tensile strength for complex yarns 123 Tex, mN / tex 176 Mass fraction of substances removed during calcination, % Example 8 – Comparative characterization of fibers for composite preparation

[0165] Several samples were prepared with the chopped basalt fiber of the present invention, which were dispersed in resin in different mass proportions. These samples as obtained were compared with samples of the resin containing different proportions of glass fiber.

[0166] Fiberglass code: 1090833.

[0167] Basalt fiber code: 100000626042.

[0168] Simple fiber + resin composite prototype code: 100000030440. Table 14 – Characteristics of the tested samples Sample code Composition V18 Resin + 5% Fib Basalt in volume V19 Resin + 10% Fib Basalt in volume V20 Resin + 15% Fib Basalt in volume V21 Resin + 20% Fib Basalt in volume V22 Resin + 25% Fib Basalt in volume V23 Resin + 30% Fib Basalt in volume V30 Resin + 5% Fib Glass in volume V31 Resin + 10% Fib Glass in volume V32 Resin + 15% Fib Glass in volume V33 Resin + 20% Fib Glass in volume V34 Resin + 25% Fib Glass in volume V35 Resin + 30% Fib Glass in volume

[0169] The samples with the basalt mixture of the present invention showed superior results compared to the samples with fiberglass. In this non-limiting example, phenolic resin or other thermosetting resins were used.

[0170] The chemical analysis of the basalt fiber samples of the present invention generated the results presented in the following table, which show dimensional characterization, apparent density, specific mass and solids content. Table 15 – Results of basic characterization of basalt fiber Method Characteristic Result Unit APPARENT DENSITY Density MF80004 DENSAPAR 0.18 g / cm3 TESTER TUBE Apparent VOLATILE CONTENT Volatiles content MF81014 TEOVOLAT 0.44 - 0.53 % OVEN LENGTH_WIDTH MF80392 COMPRIME Length 4.73 - 4.89 mm CALIPER LENGTH_WIDTH MF80392 WIDTH Width 0.28 - 0.31 mm CALIPER SPEC. MASS SOLIDS Specific MF80008 MASSESP 2.74 g / cm³ PICNOMETER Mass Content of MF80357 SOLIDS CONTENT MUFLA TEOSOLID 1.26 % Solids

[0171] For comparison purposes, Table 16 below illustrates the specification ranges for fiberglass. Compared to fiberglass, basalt fiber has a lower density, slightly longer fiber length, smaller bundle width, and higher density. Regarding solids content and volatiles content, the behavior can be considered similar to that of fiberglass. Table 16 - Specification ranges for fiberglass 1090833. Method Characteristic Result Unit APPARENT DENSITY Density MF80004 DENSAPAR 0.40 – 0.65 g / cm3 TESTER TUBE Apparent VOLATILE CONTENT Volatiles content MF81014 TEOVOLAT 0 – 1.0 % GREENHOUSE LENGTH_WIDTH MF80392 COMPRIME Length 4.00 - 4.40 mm CALIPER LENGTH_WIDTH MF80392 WIDTH Width 0.7 – 1.0 mm CALIPER SPEC. MASS SOLIDS Specific MF80008 MASSESP 2.35 g / cm³ PICNOMETER Mass Content of MF80357 SOLIDS CONTENT MUFFLE TEOSOLID 0.8-2.00 % Solids

[0172] Elemental chemical analysis by X-ray fluorescence detected five main elements: Si, Al, Fe, Ca, and Mg, as shown in the following table. Table 17- Elemental chemical analysis by X-ray fluorescence. Element % Si content 47.783 Al content 19.884 Fe content 13.883 Ca content 9.867 Mg content 4.598 K content 2.191 Ti content 1.285 Mn content 0.271 V content 0.073 Sr content 0.052 Cu content 0.032 Zr content 0.028 Zn content 0.025 Rb content 0.017 Cr content 0.011

[0173] Thermogravimetric analysis revealed a mass loss of 1.63% up to 980 °C. This value is expected for an inorganic material such as basalt. The small percentage loss is likely directly related to the sample moisture content and the sizing applied, which is composed of organic material. This result is similar to values ​​found for glass fibers. The TGA analysis results for the basalt fiber of the present invention are shown in Figure 12. Example 9 – Premix preparation process for obtaining the composite and composite obtained

[0174] Simple fiber and resin composites were evaluated, enabling the understanding of the levels of cold mechanical resistance provided by the type of fiber. The production of simple fiber + resin composites with different levels of fiberglass and basalt was initiated, to be evaluated comparatively. The mass proportions are described in the previous example.

[0175] The mixing tests were performed in an Eirich mixer with mixing loads of 5 kg, placing resin and fiber together in the mixer and starting the cycle according to the following process parameters: • Tank speed: 1; • Intensifier rotation direction: counterclockwise; • Intensifier speed: 1 (minimum); • Mixing time: 2 minutes.

[0176] During the initial execution of the mixtures with basalt fiber (V18), it was evident that the fibers agglomerated after being opened by the mixer.

[0177] To try to overcome this difficulty, modifications were made to the parameterization. The first modification tested was the following: • Bowl speed: 1; • Intensifier rotation direction: counterclockwise; • Intensifier speed: off; • Mixing time: 1 minute.

[0178] With this configuration, it was not possible to disperse the fiber in the mixture. Figure 13 shows the observed behavior, where the fiber clumps were not opened after 1 minute of the mixer bowl rotating.

[0179] The next attempt was made with the following configuration: • Bowl speed: 1; • Intensifier rotation direction: counterclockwise; • Intensifier speed: 1 (minimum); • Mixing time: 30 seconds.

[0180] With the action of the intensifiers, even if for a short time, it was possible to observe basalt fiber clusters, as shown in Figure 14. Subsequently, the material was subjected to another 30 seconds in the same configuration (totaling 60 seconds), where agglomerates were formed in practically the entire mixture, as can be seen in Figure 15.

[0181] The pressing of the premix V18 material generated pressed plates, being an example of the composite of the present invention, as can be seen in figure 16. Example 10 – Improved process of preparing the premix to obtain the composite

[0182] In order to solve the problem of dispersion and agglomeration of the basalt fibers of the present invention for preparing the premix, another mixer model was used.

[0183] The Eirich mixer used previously is a mixer capable of rotating both the bowl and paddles. When the paddles and bowl rotate in the same direction, it is considered "mixing," and when the paddles rotate in the opposite direction of the bowl, it functions as a "granulator." With this type of mixer, it was not possible to obtain a dispersed, agglomerated mixture, as can be seen in Figures 14 and 15.

[0184] Given the difficulties, a different type of mixer, SEMCO, was used to prepare the mixes. This mixer has different types of blades, resulting in a less agglomerated and more dispersed mix.

[0185] In this case, the mixer was used with the intensifier turned off and only the plow rotating. The less agglomerated and more dispersed mix produced using the SEMCO mixer can be seen in Figure 17. The mix in this example was similar to the previously described V18 sample, comprising 5% basalt fiber by volume.

[0186] The friction material produced here was truck friction. This composite was subjected to mechanical tests, including flexure, compression, friction, internal shear, impact, and hardness.

[0187] Through chemical and thermogravimetric analysis, it was possible to observe that the fibers of the present invention presented characteristics that allow the replacement of fiberglass, most commonly used in the state of the art.

[0188] During the preparation of the premix before the preparation of the composite, a problem was observed in the dispersion of the fibers in the mixture with the resin and this problem was solved by the present inventors through the use of a specific mixer with adaptations in the process.

[0189] The inventive concept disclosed herein and exemplified in one or more ways was treated as a trade secret and was not previously disclosed until the filing of this patent application. This trade secret is an intangible asset of the applicant. Any future publication of the patent application does not, in itself, constitute authorization for use by third parties, but serves only to: (i) inform third parties of the existence of the trade secret at the filing date; (ii) unequivocal indication of its holder; and (iii) encourage the development of new improvements based on the concept disclosed herein, to avoid reinvestment in the development of the same asset already owned by the applicant. It is hereby noted that any commercial use requires the holder's authorization and that unauthorized use gives rise to sanctions provided for by law.In this context, it is immediately clarified that, following the disclosure of the present inventive concept, those skilled in the art may consider other ways of implementing the invention that are not identical to those merely exemplified above, but that in the event of intended commercial use, such ways may be considered as being within the scope of the attached claims.

Claims

1 / 2 Claims 1. Premix for the preparation of basalt fiber characterized by comprising - from 0 to 100% by weight of BAS; - from 0 to 100% by weight of BRE; - from 0 to 100% by weight of DAC; or or combinations thereof.

2. Premix according to claim 1 characterized by comprising - from 50 to less than 100% by weight of BAS; and - above 0 to 50% by weight of DAC.

3. Basalt fiber characterized by comprising high tensile strength and high chemical resistance to extreme pH values, comprising: - from 0 to 100% by weight of BAS; - from 0 to 100% by weight of BRE; - from 0 to 100% by weight of DAC; or or combinations thereof.

4. Basalt fiber according to claim 3, characterized in that it comprises - from 50 to less than 100% by weight of BAS; and - above 0 to 50% by weight of DAC.

5. Basalt fiber according to claim 3, characterized in that it comprises tensile strength between 1770 MPa and 1950 MPa. 6.Basalt fiber according to claim 3, characterized by comprising chemical resistance to pH values ​​in the ranges of 1 to 4 and 10 to 14.

7. Basalt fiber according to claim 3, characterized by being produced from a preparation process comprising: a. at least one step of melting the premix for preparing basalt fiber as defined in claim 1; b. shaping the molten premix into a continuous fiber; and c. winding the basalt fiber. 2 / 2 8. Use of the basalt fiber as defined in claim 3, characterized in that it is for preparing a structural, functional or finishing composite.

9. Use according to claim 8, characterized in that said functional composite is a friction material.

10. Use according to claim 8, characterized in that said structural, functional or finishing composite is an automotive / vehicle part.

11. Use according to claim 8, characterized in that said structural, functional or finishing composite is a civil construction material.

12. Premix for preparing a composite, characterized in that it comprises an amount of the basalt fiber as defined in claim 3 mixed with a polymer.

13. Process for preparing a composite, characterized in that it comprises at least one step of incorporating the premix for preparing a composite as defined in claim 12 into a matrix. 14.Composite preparation process according to claim 13, characterized in that it comprises at least one prior step of mixing the components of the premix for the preparation of the composite in a mixer by rotating only the plow with the intensifier turned off.

15. Composite characterized in that it comprises an amount of basalt fiber as defined in claim 3 dispersed in a matrix.

16. Composite according to claim 15, characterized in that said matrix is ​​a metallic, ceramic, polymeric matrix or combinations thereof.

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