Abstract: Methods and apparatus for producing fibers from igneous rock, including basalt include heating igneous rock by electrical conductive coils to achieve an homogenous melt and forming homogenous fibers from the melt.

Abstract: A bushing system may include a bushing that is configured to receive a molten material. The bushing may include a plate defining a first plurality of apertures through which the molten material flows. The plate may include a longitudinal axis, as well as a first side wall and a second side wall disposed on a side of the plate opposite the first side wall. The first side wall and the second side wall may extend at an upward angle from the plate. The plate may also include a plurality of ribs extending along at least a portion of the plate. The bushing system may also include a tip plate coupleable with the bushing. The tip plate may be configured to receive the molten material from the bushing and may define a second plurality of apertures through which the molten material flows to form fibers.

Abstract: The present invention concerns a bushing assembly comprising: (a) a liquid glass feeding unit arranged upstream of and in fluid communication with, (b) a first and second tip plate assemblies (1A, 1B) extending along a longitudinal direction, arranged side by side, and each surrounded by side walls and end walls and, the first and second tip plate assemblies being separated from one another by a stiffening rib structure (21) extending along said longitudinal direction, characterized in that, the feeding unit comprises a glass distribution manifold (2), which defines two separate fluid communication paths to the first and second tip plate assemblies (1A, 1B), and in that, the stiffening rib structure (21) forms an integral part of the floor of the manifold (2).

Abstract: Processes and systems for producing glass fibers having regions devoid of glass using submerged combustion melters, including feeding a vitrifiable feed material into a feed inlet of a melting zone of a melter vessel, and heating the vitrifiable material with at least one burner directing combustion products of an oxidant and a first fuel into the melting zone under a level of the molten material in the zone. One or more of the burners is configured to impart heat and turbulence to the molten material, producing a turbulent molten material comprising a plurality of bubbles suspended in the molten material, the bubbles comprising at least some of the combustion products, and optionally other gas species introduced by the burners. The molten material and bubbles are drawn through a bushing fluidly connected to a forehearth to produce a glass fiber comprising a plurality of interior regions substantially devoid of glass.

Abstract: An exemplary bushing system utilizes a bushing having a bottom plate having a plurality of holes from which filaments are drawn, and a plurality of support-receiving elements that are each configured to receive an elongated support. The support-receiving elements extend through the bushing generally along a longitudinal axis. A frame supports the bushing and includes a pair of horizontal rails upon which the supports rest. The horizontal rails comprise a treated surface that permits movement of the elongated supports relative to the frame in the longitudinal direction as the bushing expands and contracts due to thermal heating and cooling.

Abstract: An electrical discharge, suitable for heating optical fibers for processing, is made in a controlled partial vacuum, such that saturation of available ionizable gas molecules is reached. The workpiece temperature is thereby made to be a stably controlled function of the absolute air pressure and is insensitive to other conditions. A system and method accomplishing the foregoing are provided.

Abstract: A bushing assembly (2) is provided including terminal ears coupled to opposed end walls (2A) of the bushing assembly, each of said terminal ears comprising an electrically conductive plate (1) comprising a first terminal edge (1D) coupled to a bushing first end wall (2A), and extending away from said first end wall to a second, free terminal edge (1A) and having a curved geometry; the curvature, 1/(2R), at any point of the curved second end (3C) of the slot is less than the reciprocal, 1/Wo, of the smallest gap width, Wo, of both slot first open end (3A), WA, and elongated portion (3B), We, wherein R is the radius at any point of the curved second end (3C).

Abstract: Several versions of ceramic bushing/s consisting local heating element/s integrated in apparatus for manufacturing mineral/basalt fibers from natural basalt rocks have been designed based on alternatives to Pt/Pt-Rd bushings approach. The ceramic bushing/s having local heating element/s concept promotes minimization or complete replacement of platinum group metals from the process of continuous basalt fiber manufacturing. More specifically, the invention discloses ceramic bushing/s comprising in combination apparatus are designed for manufacturing continuous mineral (basalt) fibers from 7 to 20 micrometers (?m), and also the coarse fibers from 20 ?m to 100 micrometers (?m) in amorphous structural state which exhibit flexible/ductile properties.

Abstract: The present invention concerns a bushing assembly including a tip plate supported by reinforcing ribs. The reinforcement ribs have a planar portion having a shape inscribed in a triangle of vertices ?1, ?2, ?3, wherein ?1 is the smallest angle of the three vertices, and the side of the triangle opposed to the smallest vertex, ?1, matches exactly one side of the planar portion. It also concerns a bushing assembly including a tip plate reinforced with the reinforcing ribs discussed supra, wherein the reinforcing ribs are coupled to the bushing assembly by three sides, adjacent two by two.

Abstract: A bushing system includes a bushing having a bottom plate with a plurality of holes from which filaments are drawn. At least one elongated support extends through the bushing generally along a longitudinal axis to hold and stabilize the bushing. To handle the harsh conditions under which the bushing is subjected, the support comprises an alumina-based ceramic that generally resists sagging or excessive expansion and contraction during heating and cooling.

Abstract: The present invention relates to a novel bushing for producing fibres from molten mineral material.

Abstract: Processes and systems for producing glass fibers having regions devoid of glass using submerged combustion melters, including feeding a vitrifiable feed material into a feed inlet of a melting zone of a melter vessel, and heating the vitrifiable material with at least one burner directing combustion products of an oxidant and a first fuel into the melting zone under a level of the molten material in the zone. One or more of the burners is configured to impart heat and turbulence to the molten material, producing a turbulent molten material comprising a plurality of bubbles suspended in the molten material, the bubbles comprising at least some of the combustion products, and optionally other gas species introduced by the burners. The molten material and bubbles are drawn through a bushing fluidly connected to a forehearth to produce a glass fiber comprising a plurality of interior regions substantially devoid of glass.

Abstract: The object of the invention is to provide a spinning nozzle arrangement, which enables an increase, and thus an improvement, in productivity without the said drawbacks and displays as homogeneous a temperature distribution as possible in the region of the nozzle. The object is achieved by a spinning nozzle arrangement (10) for the manufacture of glass fibres, having a melting chamber (11) which is formed by side walls (12,12?), cover plates (14,14?), end plates, a base plate (1), which is provided with a multiplicity of openings or nozzles (2) aligned parallel to the side walls (12) of the spinning nozzle (10), and a feed line (13) for the glass melt (17), characterized in that the base plate (1) is provided on its top side with additional stiffening elements (4), which are connected to the cover plates (14,14?).

Abstract: According to the invention, a system for forming glass fiber from molten glass is disclosed. The system may include a tip plate, a plurality of tips, and a plurality of support members. The plurality of tips may include a plurality of rows of tips. Each of the plurality of support members may support the tip plate. Each of the plurality of support members may be located between two of the plurality of rows of tips.

Abstract: An exemplary bushing systemutilizes a bushing having a bottom plate having a plurality of holes from which filaments are drawn, and a plurality of support-receiving elements that are each configured to receive an elongated support. The support-receiving elements extend through the bushing generally along a longitudinal axis. A frame supports the bushing and includes a pair of horizontal rails upon which the supports rest. The horizontal rails comprise a treated surface that permits movement of the elongated supports relative to the frame in the longitudinal direction as the bushing expands and contracts due to thermal heating and cooling.

Abstract: A bushing system includes a bushing having a bottom plate with a plurality of holes from which filaments are drawn. At least one elongated support extends through the bushing generally along a longitudinal axis to hold and stabilize the bushing. To handle the harsh conditions under which the bushing is subjected, the support comprises an alumina-based ceramic that generally resists sagging or excessive expansion and contraction during heating and cooling.

Abstract: An exemplary bushing systemutilizes a bushing having a bottom plate having a plurality of holes from which filaments are drawn, and a plurality of support-receiving elements that are each configured to receive an elongated support. The support-receiving elements extend through the bushing generally along a longitudinal axis. A frame supports the bushing and includes a pair of horizontal rails upon which the supports rest. The horizontal rails comprise a treated surface that permits movement of the elongated supports relative to the frame in the longitudinal direction as the bushing expands and contracts due to thermal heating and cooling.

Abstract: A glass-melting device for producing glass fibers capable effectively reducing inclusion of bubbles into glass fibers to be spun, and a method for producing glass fibers using the same are provided. A glass-melting device 100 for producing glass fibers comprises: a first glass-melting tank 12; a conduit 14 extending downward from the first glass-melting tank 12; a sucking device 18 for exposing the first glass-melting tank 12 to a reduced-pressure atmosphere; a second glass-melting tank 20 provided on a lower portion of the conduit 14 and exposed to an atmospheric-pressure atmosphere; and a bushing 22 provided at a bottom portion of the second glass-melting tank 20 and equipped with a number of nozzles 22a.

Abstract: Forehearths that create a substantially homogeneous temperature to molten glass forming materials across the end position are provided. A gas cavity, a weir, a refractory block, or a heating element in the forehearth may be utilized to reduce a temperature gradient of molten glass forming materials across the end position. Reducing the temperature difference of the molten glass forming material across the end position permits for improved chemical and physical properties of the glass fibers and the end products formed from the glass fibers. In addition, a reduction in the temperature gradient across the end position produces a more homogenous glass fiber and glass product. Further, a reduction in the shear break rate occurs when the molten glass forming material has a temperature that is substantially the same across the end position, which results in a reduction in the breakage of glass fibers and an increase in manufacturing efficiency.

Abstract: A cooling bushing flange having a reduced amount of precious metal is provided for a glass fiber production apparatus. The flange includes a first portion formed of a precious metal or a precious metal alloy extending outwardly from a bushing and a second portion formed of a non-precious metal. The non-precious metal portion of the flange may be affixed to the precious metal portion by known metal bonding methods. A cooling tube is positioned on the non-precious metal portion to create a thermal seal and prevent molten glass from leaking from the interface of the bushing block and bushing. The precious metal portion of the inventive flange is a fraction of the size of precious metal present in conventional bushing flanges. By reducing the amount of precious metal incorporated in the flange, a significant reduction in the overall cost of the bushing and in the manufacture of glass fibers can be obtained.

Abstract: Forehearths that create a substantially homogeneous temperature to molten glass forming materials across the end position are provided. A gas cavity, a weir, a refractory block, or a heating element in the forehearth may be utilized to reduce a temperature gradient of molten glass forming materials across the end position. Reducing the temperature difference of the molten glass forming material across the end position permits for improved chemical and physical properties of the glass fibers and the end products formed from the glass fibers. In addition, a reduction in the temperature gradient across the end position produces a more homogenous glass fiber and glass product. Further, a reduction in the shear break rate occurs when the molten glass forming material has a temperature that is substantially the same across the end position, which results in a reduction in the breakage of glass fibers and an increase in manufacturing efficiency.

Abstract: According to the invention, a system for forming glass fiber from molten glass is disclosed. The system may include a tip plate, a plurality of tips, and a plurality of support members. The plurality of tips may include a plurality of rows of tips. Each of the plurality of support members may support the tip plate. Each of the plurality of support members may be located between two of the plurality of rows of tips.

Abstract: Various embodiments of the present invention relate to glass fiber forming bushings, to methods of controlling the temperature of bushings having multiple segments, to systems of controlling the temperature of bushings having multiple segments, and to other systems and methods. In one embodiment, a method of controlling the temperature of a bushing having multiple segments comprises forming a plurality of filaments from a bushing comprising at least two segments, gathering the filaments into at least two ends, measuring the size of each of the at least two ends, comparing the measured size of the at least two ends to a desired end size, adjusting the amount of current passing through the at least two bushing segments in response to the end size comparisons.

Abstract: According to the invention, a system for forming glass fiber from molten glass is disclosed. The system may include a tip plate, a plurality of tips, and a plurality of support members. The plurality of tips may include a plurality of rows of tips. Each of the plurality of support members may support the tip plate. Each of the plurality of support members may be located between two of the plurality of rows of tips.

Abstract: Fiberizing bushings for fiberizing molten materials including molten glass are heated by applying a voltage drop across the bushings wherein molten material flows through an array of hollow tips attached to, or integral with, a tip plate having orifices therein that generally align with channels through the hollow tips to form fibers. The uniformity of the diameter of the fibers produced is much improved by using tips of different lengths and/or tips having channels of differing ID's to compensate for unequal electrical heating and/or cooling effects of drawn-in ambient air that cools the tips on the extreme outer periphery and/or cooling or heating effects of external supports or cooling members running through the array of tips that cools or heats adjacent tips more than the interior tips.

Abstract: An in-line system converts raw, unrefined glass-forming material directly into continuous glass filaments. The system includes a reinforced melting assembly with electrically conductive melting and reinforcing members. The melting and reinforcing members are connected to a transverse melting member and lie in a plane parallel to the flowing material. This expands the melting and refining zone to the height of the melting and reinforcing members, thereby improving the quality of the filaments. The melting and reinforcing members also prevent sagging of the assembly during high temperature operation. The outermost melting and reinforcing members reduce or eliminate bypass flow of un-refined or un-homogenized material around the melting assembly, further improving quality.

Abstract: A terminal clamp assembly for a fiberizing bushing includes a clamp body having a firsts end face and a lower jaw, an auxiliary heat sink body selectively displaceable with respect to the clamp body, a contact assembly carried on the auxiliary heat sink body and an actuator to displace the heat sink body toward or away from the face of the clamp body. The invention also includes a bushing assembly incorporating the terminal clamp assembly and an expansion compensating mounting bracket for the clamp assembly.

Abstract: Flow block (1), intended for a fiberizing installation and for receiving molten material, comprising a single cavity (10) which has a flow channel (11) bounded by a wall (11a). The inlet orifice (12) has a shape which is asymmetrical with respect to the mid-plane (Y) of the block extending along the shortest extension and has an upstream part on the glass inflow side which is wider than its opposite downstream part with respect to the mid-plane. Furthermore, the slope of the wall (11a) on the upstream side is advantageously steeper than the slope of the downstream side. The invention also relates to the bushing block, which is very squat compared with the flow block.

Abstract: According to the invention, a system for forming glass fiber from molten glass is disclosed. The system may include a tip plate, a plurality of tips, and a plurality of support members. The plurality of tips may include a plurality of rows of tips. Each of the plurality of support members may support the tip plate. Each of the plurality of support members may be located between two of the plurality of rows of tips.

Abstract: An inner seal ring 16 is composed by connecting a plurality of inner seal ring pieces 16A, an outer seal ring 17 is composed by connecting a plurality of outer seal ring pieces 17A provided at an outer periphery of the inner seal ring 16, and a coil spring 18 is arranged at an outer periphery of the outer seal ring 17. The inner seal ring 16 and the outer seal ring 17 are piled for two or more stages, respectively. A connecting part of the inner seal ring pieces 16A and a connecting part of the outer seal ring pieces 17 are arranged not to overlap each other. An inner diameter of the inner seal ring 16 is variable in accordance with an outer diameter in vertical direction of a drawing-preform 1 by using a coil spring 18.

Abstract: The automatic strand take-up installation comprises at least one gripping member (12) for taking hold of at least one strand coming from a bushing (2), the gripping member being guided by a single conveying loop (1) to the vicinity of a chopper (7). One system for maneuvering the gripping member allows the gripping member (12) to be opened and closed in such a way as to release said strand at the chopper (7).

Abstract: A reinforcement device, especially for the bottom of a bushing having a multitude of holes from which filaments, e.g., glass filaments, are drawn, including a reinforcement piece that includes a hollow first part defining at least one receiving housing and a second part that extends at least partly over the length of the hollow part, and also at least one stiffener inserted into the receiving housing of the hollow part. The cross section of the stiffener is substantially identical to the internal cross section of the hollow part.

Abstract: Fiberizing bushings for fiberizing molten materials including molten glass are heated by applying a voltage drop across the bushings wherein molten material flows through an array of hollow tips attached to, or integral with, a tip plate having orifices therein that generally align with channels through the hollow tips to form fibers. The uniformity of the diameter of the fibers produced is much improved by using tips of different lengths and/or tips having channels of differing ID's to compensate for unequal electrical heating and/or cooling effects of drawn-in ambient air that cools the tips on the extreme outer periphery and/or cooling or heating effects of external supports or cooling members running through the array of tips that cools or heats adjacent tips more than the interior tips.

Abstract: A fiberizing apparatus for converting molten material into continuous fibers has an internal support structure to minimize high temperature creep and sagging of a tip plate, the reinforcing structure forming at least about 16 internal cells and the hole pattern in a bushing screen is engineered such that the hole area in each screen area above each of the at least 16 cells controls the amount of molten material flowing into each cell to produce a substantially improved tip plate temperature profile and fiberizing efficiency.

Abstract: A fiber forming bushing assembly includes a frame and a bushing within the frame. One or more sections formed of a pre-cast refractory material are positioned between at least a lower sidewall of the bushing and the frame.

Abstract: An apparatus for producing continuous filaments for streams of molten inorganic material includes a feeder for supplying the molten streams, cooling fins for cooling the molten streams, and cooling support fins for supporting the feeder and for cooling the molten streams. The cooling support fin has an upper open channel that holds a support bar for at least partially supporting the feeder.

Abstract: A fiberizing device includes a housing, a receiving seat mounted on the housing, and a drawing device. The receiving seat includes a receiving groove having a discharge port. The receiving groove receives molten fluid formed by heating waste. A heating device is provided for heating the molten fluid in the receiving seat. The drawing device draws the molten fluid from the discharge port to form a solid fiber after the molten fluid comes in contact with cool air. The solid fiber possesses excellent fire-resistant properties and thus can be used as fire-resistant materials.

Abstract: A bushing for fiberizing molten material, such as molten glass, having a screen mounted in the bushing spaced above the tip or orifice plate with a central portion of the screen having a significantly lower percent of hole area than the percent of hole area in end portions of the screen. This bushing improves fiberizing efficiency in channel positions of a fiberizing operation. Also, such a screen can be laid on top of a conventional screen to convert a normal bushing to a channel position bushing. Methods of using these types of bushings to improve fiberization in the channel positions and for modifying conventional bushings for other uses are also disclosed.

Abstract: A bushing for fiberizing molten material, such as molten glass, having a screen mounted in the bushing spaced above the tip or orifice plate with a central portion of the screen having a significantly lower percent of hole area than the percent of hole area in end portions of the screen. This bushing improves fiberizing efficiency in channel positions of a fiberizing operation. Also, such a screen can be laid on top of a conventional screen to convert a normal bushing to a channel position bushing. Methods of using these types of bushings to improve fiberization in the channel positions and for modifying conventional bushings for other uses are also disclosed.

Abstract: The double crucible for a glass drawing method has a heatable outer crucible (1) and an inner crucible (2) surrounded by the outer crucible (1), which is heatable separately from the outer crucible (1). Both crucibles (1,2) have an outlet nozzle (1a, 2a) for the glass to be drawn. To make glass fibers from heavy metal oxide glass (HMO-glass) with higher quality and comparatively simple crucible features, the outlet nozzle (1a) of the outer crucible (1) extends a certain distance beyond the outlet nozzle (2a) of the inner crucible (2). Surfaces of the outlet nozzles coming in contact with the glass melt are polished and are provided on a material, which has a reducing action on heavy metal glass in the melt in all cases. These surfaces also have sufficient mechanical strength for and chemical inertness to heavy metal oxide glass.

Abstract: Electrical resistant bushings and methods for making fibers such as glass fibers by passing molten glass through these bushings to form fibers wherein the bushings have novel ears for attaching to electrical terminal clamps bringing electrical current to the bushing are disclosed. The novel ears have at least one generally V shaped notch at or near the unattached end of the ear to produce an improved temperature profile on the tip plate of the bushing. One preferred bushing of the invention has ears having 5 generally V shaped notches therein.

Abstract: An inlet arrangement for inserting a preform (3?) into a furnace (1?) for drawing a fiber (2?). The furnace includes an enclosure (4?) at the top of which there are both an opening to allow insertion of a preform which moves in translation, and a preform inlet arrangement (13?). The inlet arrangement comprises both an injector (6?) situated at the level of the opening to inject inert gas around the preform and to fill the enclosure, and at least one seal (17B) fixed above the injector and designed to allow the preform to pass therethrough, with its cylindrical main body (9?) being surrounded. The inlet arrangement further comprises an airlock (13) for closing and sealing the top of the furnace, above the injector, whether a preform is present or absent, which airlock is pressurized to prevent the surrounding air entering. The rods of the equipped preforms carry respective continuity tubes (20) of the same diameter as the bodies.

Abstract: A plurality of different structural members for reinforcing a plate-like structure, such as a bushing tip plate for intended use in forming fibers from a fluid material supplied to a bushing assembly, are disclosed. Each reinforcing member includes a body having a first portion for attachment to the structure and a second portion having a profile with a variable height including at least one apex. The body may be integrally formed of a single piece of material, or two or formed from more separate pieces of material bonded or secured together. The body may be T-shaped, L-shaped, or F-shaped in cross-section. The second portion of the body may have an inverted V-shaped profile, an inverted W-shaped profile, or an arcuate profile. The at least one apex may be located at the midpoint or elsewhere along the length of the body.

Abstract: The invention relates to an in-line process for producing high-temperature stable glass. A sizing composition is advantageously used to reduce plasticizing between the resinous matrix and the glass fibers. The in-line process uses a melter or furnace apparatus, including a top charging and melting section and an intermediate flow regulator section having a baffle system improving the heat pattern across the glass flow, and a bushing having a tip plate for receiving molten glass from a furnace. The bushing has an enlarged size that allows drawing of a significantly increased number of glass fibers at one time. The fibers have essentially no catenary and may be wound to create a tightly wrapped package of glass fibers of uniform exterior diameter throughout their width. High-strength, high-silica fiber made according to the invention may be advantageously used in filament-winding, pultrusion and weaving processes.

Abstract: A bushing assembly/support structure arrangement is provided. The arrangement comprises a bushing assembly and a support structure. The bushing arrangement includes a bushing main body comprising at least first and second side walls and a tip plate extending between the side walls. The tip plate contains a plurality of orifices through which molten mineral material flows prior to being attenuated into fibers. The bushing assembly further comprises a first support rail coupled to the main body first side wall, and at least one first bracket having an intermediate member coupled to the main body first side wall. The support structure comprises a bushing frame, and at least one first support strap. The support strap has a first end fixedly coupled to the bushing frame and second end extending toward a first location on the support rail adjacent the first bracket for supporting the bushing assembly.

Abstract: A screen comprises an electrically conductive elongate inner screen plate. The inner screen plate has at least one elongate fold therein and at least two elongate divergent surfaces on opposing sides of the fold. Each divergent surface has an upper end and opposing edges tapering downward from the upper end. The upper ends of the divergent surfaces diverge from one another. Each of the divergent surfaces has a plurality of holes therein. The screen further comprises at least two electrically conductive outer screen plates. The outer screen plates are attached to the edges of the divergent surfaces and extend between the divergent surfaces. Each of the outer screen plates has a plurality of holes therein. Another embodiment of the invention is directed toward a glass fiber bushing system comprising a bushing body and a screen within the bushing body. The bushing body has opposing end plates. The screen comprises opposing ends. Each of the ends has an upper portion and a lower portion.

Abstract: A fiber forming bushing assembly comprises a bushing and a support. The bushing includes a bushing body and a flange. The bushing body is defined at least in part by a throat and a side wall beneath the throat. The side wall has an upper portion. The flange extends from the throat. The support is positioned between the flange and an upper portion of the side wall. The support is formed of a ceramic material.

Abstract: The invention discloses a multifunctional apparatus and method to manufacture mineral (basalt) fibers to be drawn/attenuated into a continuous strand made from natural rock basalts with and without supplemental minerals. More specifically this invention discloses apparatus designed to manufacture a high quality continuous amorphous mineral (basalt) fibers with flexible/ductile properties from 7 &mgr;m to 100 &mgr;m in diameter without traces of crystalline phases which are suitable for a variety of industrial applications.

Abstract: A bushing for fiberizing molten material, such as molten glass, having a screen mounted in the bushing spaced above the tip or orifice plate with a central portion of the screen having a significantly lower percent of hole area than the percent of hole area in end portions of the screen. This bushing improves fiberizing efficiency in channel positions of a fiberizing operation. Also, such a screen can be laid on top of a conventional screen to convert a normal bushing to a channel position bushing. Methods of using these types of bushings to improve fiberization in the channel positions and for modifying conventional bushings for other uses are also disclosed.

Abstract: A fiber-forming bushing comprises a tip plate and a lateral support. The tip plate comprises at least two tip sections and the section spacing between the tip sections. The lateral support extends laterally along the section spacing.