Abstract: A method for producing ferro-nickel shots which comprises adding a manganese source to molten ferro-nickel, pouring the molten ferro-nickel containing manganese onto a rotating disc to granulate the molten ferro-nickel stream, and cooling the granules thus obtained in water.

Abstract: An apparatus for producing mineral fibers comprising a container having means for heating the mineral material to form a molten pool therein, a plurality of discs having a portion thereof immersed in the molten pool, and means for rotating the discs in the same angular direction at high speed. In a preferred embodiment means are provided for moving a gas such as air or steam across the edges of the rotating discs to assist in the attenuation of the fibers.

Abstract: A mass of normally solid material, e.g. metal or metal alloy, which at a temperature within 25 percent of its equilibrium melting point .degree.K has a surface tension of 10 to 2500 dynes/cm. and a viscosity of 0.001 to 1 poise, is changed into fine solid particulates, preferably flake-like to almost spherical shape. A solid mass of the material has a portion thereof, e.g. tip or edge, unconfined by a crucible or the like, heated, such as by a flame or electron beam to alter that portion to a molten state whereby molten droplets or globules fall therefrom to contact a rapidly moving wall of a centrifugally disposed rotating liquid quench fluid, e.g. water or oil, and upon contacting are disrupted and broken up into finer globules or particles which are swept away with and quenched in the rapidly moving quench fluid to become rapidly solidified as fine particulates.

Abstract: Shaped articles of amino-formaldehyde resins having reduced released formaldehyde emission are made using a curing catalyst mixture of a volatile acid (or salt thereof) and a small amount of a non-volatile acid (or salt thereof).

Abstract: A method for producing urea prills by passing molten droplets of substantially water free urea downwardly through a cooling zone countercurrent to a cooling gas. A dispersion of crystalline particles is maintained in at least a portion of the cooling zone, the crystalline particles having average dimensions of between 2 and 10 microns and being dispersed in the cooling gas in a quantity of between about 8 and 25 mg per m.sup.3 of the cooling gas at ambient temperature and pressure, whereby urea prills, built up of relatively small crystallites with random orientation having improved impact strength are formed.

Abstract: A method and apparatus for producing particulate directly from a supply of molten material by the use of a rotating member having discrete serrations in the periphery thereof. The leading surfaces of the serrations contact the molten material and propel a portion into a cavity formed by the surfaces of the serration while under the effect of a surface of a dam means, in proximity to which the serrations pass. The dam means is immersed in the supply of molten material adjacent to the periphery of the rotating member.

Abstract: Methods and apparatus for manufacturing rapidly cooled powder particles is disclosed. Concepts discussed include both convection cooling and conduction cooling of molten material from which the particles are fabricated.By one effective technique of the present invention, seed particles are dropped across the path of a molten droplet stream causing impact and solidification of the molten droplets on the seed particles. Particles of increased size which are formed of conductively quenched material result.

Abstract: A process for the production of heterogeneous articles such as heterofilaments and fibres containing a plurality of solid phases, comprises supplying a thermoplastic first material in particulate solid form to a surface of rotation of a rotating body so that it travels across said surface towards a discharge zone due to forces generated by the rotation of the body, melting the thermoplastic first material as it travels across the surface, supplying a second solid material to the surface, discharging both materials together from the discharge zone by centrifugal forces, and solidifying the thermoplastic material to form the heterogeneous article. The second material is preferably also thermoplastic and further solids, especially reinforcing fibres, can also be incorporated likewise.

Abstract: An apparatus is set forth for the continuous production of highly cooled metal splats. Melted metal is poured onto a spinning atomization disc means whereby liquid metal droplets leave the disc means in a horizontal plane. An annular cooling gas jet flowing normal to the particle plane around the disc deflects the heavier liquid droplets to a conical splat plate which is fixed to rotate with said disc, where the droplets splat and cool, and are ejected by centrifugal force. An annular space is located between said conical splat plate and said rotary atomization means for permitting the gas and other solidified particles to pass downwardly to a shield which directs the particles to a collection area.

Abstract: Fibrils prepared by a differential temperature precipitation process of the type described in U.S. Pat. No. 4,013,751 are refined in isopropanol at a subambient temperature not higher than about 10.degree. C., and subsequently are treated with an aqueous solution of polyvinyl alcohol to sorb at least 1.0 weight % of polyvinyl alcohol on the fibrils. The treated fibrils, as compared with fibrils prepared by prior art processes disperse more readily in aqueous media and provide water-laid sheets having greater strength. The fibrils preferably are prepared from an olefin polymer having a weight average molecular weight of at least one (1) million.

Abstract: A method for producing atomized metal particles, particularly of titanium-base alloys and superalloys, that are free from contamination by foreign material; this is achieved by providing a rod of the metal to be atomized and contacting an end portion of the rod with a plasma arc gas jet which simultaneously melts and atomizes the metal from the rod to form the atomized particles and preventing contamination of the particles.

Abstract: A process is disclosed for producing spherical particles or fibers with a specially fixed size from a melt of metal, slag, or flux, by introducing the melt onto the center of a rotating disk through a conduit so as to form a thin film stream of boundary layer on the disk; projecting the thin film stream at a high speed from the disk periphery into surrounding space to split up the film stream into linear streams; and cooling the linear streams for producing fibers or cooling droplets after further splitting of the each linear stream into droplets for producing spherical particles, with or without parallel or countercurrent gas flow to the linear streams.

Abstract: Hollow fibers are prepared by spray drying a solution of a film-former in a volatile solvent. The viscosity of the solution must be 1.5 to 10 times the viscosity that usually results in spheres or microspheres. The preferred film-forming substance is a combination of sodium silicate and a "polysalt.

Abstract: Method and apparatus for forming filaments are provided by centrifugally forming a veil of primary fibers or streams of material and moving a fluid along a path within the veil at a velocity sufficient to attenuate said primary fibers into filaments.

Abstract: A method of manufacturing granules from slags produced in metallurgical furnaces such as blast furnaces, converter furnaces, electric furnaces and reverberatory furnaces. A molten slag stream from a container at a velocity of at least two meters per second is impinged upon a non-wetting target surface, from which the stream rebounds in a film of projected droplets having the shape of an inverted cone. Cooling and solidifying the droplets by their projected flight in air forms solid granules.

Abstract: A reactant medium is transported across the surface of a body rotating at high speed and discharged therefrom by centrifugal force. A chemical reaction is caused to occur in the medium after the said discharge while the reactant medium is still connected to the surface of the body.

Abstract: A process is disclosed for producing a non-woven, boron nitride fiber mat, suitable for use as an electric cell separator in a lithium-sulfide battery. Molten boron oxide is centrifugally spun into strands and attenuated by an annular gas stream into fibers which are compacted at a controlled relative humidity into a mat. The mat of fibers passes through a needler, which repeatedly drives arrays of needles into the mat from either one or both sides, to reorient and intertwine the fibers, producing additional mechanical bonds thereamong. The needled mat then is heated in an anhydrous ammonia atmosphere to convert boron oxide in the fibers into boron nitride (BN). In an alternate embodiment the boron oxide fibers within the mat are converted into boron nitride before being passed through the needler.

Abstract: Methods and apparatus for manufacturng rapidly cooled powder particles is disclosed. Concepts discussed include both convection cooling and conduction cooling of molten material from which the particles are fabricated.By one effective technique of the present invention, seed particles are dropped across the path of a molten droplet stream causing impact and solidification of the molten droplets on the seed particles. Particles of increased size which are formed of conductively quenched material result.

Abstract: Slag sand and slag wool are formed by a method wherein molten slag is poured at a temperature above 1300.degree. C. in a thin flowing stream onto a vaned drum rotating at a peripheral speed of at least 25 m/sec. This drum, which may have forwardly directed nozzles for mixing the falling slag stream with a cooling medium such as water, breaks the slag up into droplets and projects these droplets through the air so they cool and form filaments and granules. The granules are collected separately from the filaments so that the installation simultaneously produces slag sand and slag wool.

Abstract: Disclosed herein is a process for the production of the precursor of alumina fiber. The process comprises causing a thick solution for alumina fiber having a viscosity in the range of from 500 to 2000 cps to be continuously fed through the feed pipe protruding into the opening at the center of a funnel-shaped disk and to be sent flying with hot compressed air and thereby converting the thick solution into fibers.

Abstract: Spheroidal granules or balls are prepared from molten metallurgical slags and scorias by pouring the molten material onto an uncooled rotary cylinder, after possible passage on an inclined feed plate or table, without any cooling being assured by liquid or gaseous means other than the ambient atmosphere between pouring of the material and the reception area where hard spherical granules pile up and can be sorted by screening. The spheroidal granules can be formed from all types of slags, especially basic, phosphated or not, steel mill slags.

Abstract: Described are a method and apparatus for freezing molten metals and metalloids in particulate or flake form at very rapid cooling rates. A volatile coolant liquid is fed to the center of a rapidly rotating disc-like member to create an outwardly flowing film of coolant across the surface of the member. The material to be processed is fed to the coolant film at a location spaced from the center and is thrown outwardly by centrifugal forces while being cooled by vaporization of the liquid. The rotating member may include upwardly projecting vanes for collision with the outwardly flowing material to produce a higher surface area product.

Abstract: A method is set forth wherein powder is produced by melting metal in a melting furnace where it is then poured into a tundish which directs the molten metal onto a spinning disc means. The tundish is located at the center of a nozzle plate which contains a plurality of annular nozzle means for directing a coolant flow downwardly around the spinning disc means at different radial positions. Controls are provided for controlling atmosphere in said apparatus. Further, controls are provided to control the speed of the disc means and the mass flow of the cooling fluid through each of the nozzle means.

Abstract: Powders of thermoplastic resins such as polyethylene homopolymer and ethylene-vinyl acetate copolymer are obtained by agitating molten resin in admixture with water and in the presence of a dispersing amount of a substantially water insoluble ionomer polymer.

Abstract: Powders of thermoplastic resins such as polyethylene homopolymer and ethylene-vinyl acetate copolymer are obtained by agitating molten resin in admixture with water and in the presence of a dispersing amount of a substantially water soluble salt of an interpolymer of (i) at least one ethylenically unsaturated ester derived from an alpha, beta-ethylenically unsaturated carboxylic acid and a lower alkanol and (ii) at least one alpha, beta-ethylenically unsaturated carboxylic acid as dispersing agent.

Abstract: Powders of self-dispersing ionomer polymer of controlled particle size distribution are obtained by agitating molten resin in admixture with water and in the presence of a particle size distribution regulating amount of acid or base.

Abstract: A process disclosed for producing spherical articles or fibers with a specially fixed size from a melt of metal, slag, or flux, by introducing the melt onto the center of a rotating disk through a conduit so as to form a thin film stream of boundary layer on the disk; projecting the thin film stream at a high speed fom the disk periphery into surrounding space to split up the film stream into linear streams; and cooling the linear streams for producing fibers or cooling droplets after further splitting of the each linear stream into droplets for producing spherical particles, with or without parallel or countercurrent gas flow to the linear streams.

Abstract: Fibres are produced by centrifugally spinning a formaldehyde resin, e.g. a UF resin, plus catalyst and contacting the spun fibres with a stream of hot dry air to dry the fibres. Cold, humid air is fed to the spinning cup to inhibit premature drying of the resin. The rotation of the cup causes the cold humid air to be thrown out of the cup with the fibres entrained therein. This entrainment serves to retard drying of the fibres while they attenuate.

Abstract: The process relates to the preparation of a shaped body having at least one dimension less than 100 microns and comprising alumina or an alumina hydrate. An aqueous composition comprising a water-soluble aluminum compound, for example aluminum chloride, sulphate, acetate, formate, propionate, oxalate, phosphate or nitrate and a water-soluble organic polymer is formed into the desired shape. The body so formed is dried, and is subjected to hydrothermal treatment at a temperature of at least 200.degree. C. to decompose the aluminum compound to alumina or an alumina hydrate. The body is optionally further heated subsequent to the hydrothermal treatment.

Abstract: A blower for discharging a gaseous flow to attenuate molten mineral material into mineral fibers comprises a body member and a lid member defining a gas supply manifold and a gas discharge slot, and a screw having lower and upper threaded portions to engage the body member and lid member, respectively, the screw being adapted to raise and lower the lid member to control the size of the gas discharge slot.

Abstract: An apparatus is disclosed for producing spherical particles or fibers with a specially fixed size from a melt of metal, slag, or flux, by introducing the melt onto the center of a rotating disk through a conduit so as to form a thin film stream of boundary layer on the disk; projecting the thin film stream at a high speed from the disk periphery into surrounding space to split up the film stream into linear streams; and cooling the linear streams for producing fibers or cooling droplets after further splitting of the each linear stream into droplets for producing spherical particles, with or without parallel or countercurrent gas flow to the linear streams.

Abstract: A rotary atomization apparatus for making metal powders from liquid metals comprises an atomizer disk having a concave top surface for receiving a flow of molten metal thereon. The disk is preferably made from a high strength zirconium-containing copper base alloy. The disk is driven by a surrounding drive portion thru a radial spline-type connection. Higher rotational speeds than the prior art are the major advantage of this invention.

Abstract: A process is disclosed for producing non-woven, yet internally cohesive, boron nitride fiber batts, suitable for use as an electric cell separator in a lithium-sulfide battery. Molten boron oxide is centrifugally spun into strands and attenuated by an annular gas stream into fibers at a controlled relative humidity. The fibers are funnelled into a chamber and subjected to a turbulent air flow, which causes random orientation and intertwining of the fibers, resulting in multiple mechanical bonds thereamong. The compacted boron oxide fiber bundle thus produced is heated in an anhydrous ammonia atmosphere to convert boron oxide in the fibers into boron nitride (BN).

Abstract: The hollow glass vacuum microspheres are made by forming a liquid film of molten glass across the coaxial blowing nozzles, applying the metal vapor blowing gas at a positive pressure on the inner surface of the glass film to blow the film which combines with the centrifugal force to form an elongated cylinder shaped liquid film of molten glass. A transverse jet is used to direct the inert entraining fluid over and around the blowing nozzle at an angle to the axis of the blowing nozzle. The entraining fluid as it passes over and around the blowing nozzle fluid dynmically induces a pulsating or fluctuating pressure field at the opposite or lee side of the blowing nozzle in the wake or shadow of the coaxial blowing nozzle.

Abstract: Process and apparatus for centrifugally spinning a fibre-forming material, e.g. a urea-formaldehyde resin, in which the fibre-forming material is supplied in liquid form to the interior of a spinning cup wherein it is divided into separate streams which are led to the outlets of passages through the wall of the spinning cup.

Abstract: A method for producing "dogbone" filament fibers having nodules at each end comprising rotating a heat extracting disk having an edge tapering to a narrow peripheral surface and having the peripheral surface notched at intervals with each notch comprising a leading edge, connected to a trailing flat surface, the trailing flat surface supporting an expanded land on the peripheral edge; introducing the rotating disk into the surface of a pool of molten material to form a film of the material on the edge; and removing heat from the film and at least partially solidifying the film on the edge. By the method, the segmented filament fiber products which are produced have a nodule formed on the leading end, a nodule formed on the trailing end, and continuous fiber inbetween, with the general appearance of a dogbone.

Abstract: Process and apparatus for centrifugally spinning a fibre-forming material, e.g. a urea-formaldehyde resin, in which the fibre-forming material is supplied in liquid form to the interior of a spinning cup wherein it is divided into separate streams which are led to the outlets of passages through the wall of the spinning cup.

Abstract: In apparatus for producing metal powder by rapid solidification of molten metal particles flung into a quenching chamber from a rotating disk through vertical zones of cooling fluid, improved cooling fluid flow, improved operating efficiency and low pressure losses are provided by having the cooling fluid introduced into the quenching chamber via a plurality of cylindrical tubes each having an inlet within a coolant fluid manifold and an outlet opening into the quenching chamber. Each tube including means for creating a cooling fluid vortex flow therein which exits from the tube outlet into the quenching chamber as an expanding cone of swirling fluid. A plurality of these tubes are appropriately located around the rotating disk to create a desired pattern of cooling fluid flow around the disk and through which the molten metal particles will pass as they solidify into the powder.

Abstract: Apparatus for the extrusion of a flowable mass onto a conveyor, comprises first and second cylindrical containers. The first container is disposed for rotation about a longitudinal axis and includes first passages for depositing the flowable mass. The second container includes a wall portion which contains a plurality of second passages. The wall portion is disposed against the first container, the latter rotating relative to the second container so that the first and second passages are periodically aligned to enable the flowable mass to be deposited onto the conveyor. The first and second containers define a gap therebetween which creates a negative pressure to suck-in excess mass from the outer periphery of the apparatus. A spatula is provided to push the mass into the gap.

Abstract: A method for coagulating a latex of a synthetic polymer having a coagulated latex particle formation temperature to form substantially spherical particles, the method comprising: forming substantially spherical latex particles by dispersing substantially spherical drops of the latex into a vessel or chamber containing a coagulating atmosphere which can be (i) a gaseous coagulant or (ii) a liquid coagulant in the form of a mist of drops having diameters such that the terminal settling velocity of the drops under free-falling conditions is in accordance with Stokes' Law, while maintaining the coagulant at the coagulated latex particle formation temperature and while causing water at the coagulated latex particle formation temperature to flow downward over the inner surface of the coagulation vessel to cause pluralities of polymer particles in a drop of the latex to coagulate to form substantially spherical coagulated latex particles.

Abstract: A process and apparatus for the manufacture of ceramic oxide fibers from solvent solution. The process comprises spinning a solution of a ceramic oxide precursor through openings having a diameter of from about 0.3 to about 1.5 millimeters, attenuating the resulting fibers with a stream of air to a diameter of less than 10 microns and heating the fibers in an oxygen atmosphere to form ceramic oxide fibers having a diameter of less than 5 microns. The apparatus comprises a hollow rotatable disc having about 0.3 to about 1.5 millimeter holes in its circumferential edge; means for rotatably mounting the disc; means for introducing a solution of a ceramic oxide precursor into the disc; means for rotating the disc to force solution through the openings in fiber form; means for attenuating the fibers with a stream of air; and means for calcining the fibers.

Abstract: A spinner for the production of molten glass fibers is disclosed. The spinner is adapted with a plurality of projections affixed to the spinner bottom and extending inwardly of the spinner. The projections are intended to inhibit inward flow towards the spinner support and aid wetting of the inner bottom surface of the spinner.

Abstract: The present invention relates to the manufacture of fibrous wool by the rotary process. In the rotary process heat softenable material, such as molten glass, is supplied to a centrifuge wherefrom streams of said heat softenable material emanate and are acted upon by a fiber attenuating high velocity gaseous medium located about the periphery of the centrifuging means. As a result thereof, a cylindrically shaped veil of high velocity gases having attenuated fibers contained therein flows axially away from the centrifuging means to a suitable collecting means. By the present invention improved method and apparatus are provided for distributing the entrained fibers upon the collecting means. The cylindrically shaped veil is intermittently acted upon by finite planes of high velocity gas thereby interrupting the otherwise columnar flow of the cylincrical veil and establishing diverging flows of fibers.

Abstract: Improved method for making generally spherical particulate shot-like product comprising permitting a siliceous-aluminous composition of specified characteristics onto a rotating squirrel cage rotor near top dead center thereof and causing said impinging molten material to be projected in droplet form and cooled while suspended in a gaseous cooling medium, such as air, into an amorphous generally spherical product, suitable for use as an abrasive or filler material.

Abstract: An incompletely miscible liquid mixture, e.g. a suspension polymerization mixture, is mixed by flowing through a rotating substantially horizontal tube that is incompletely filled with the mixture, so as to form pairs of vortices each with its axis transverse to the axis of the tube. The apparatus comprises the tube, that must be free of internal means for agitating the liquid within the tube, means for rotating the tube and means for feeding the liquid mixture to and through the tube.

Abstract: An apparatus is disclosed for manufacturing splat foils by disintegration and rapid solidification of metallic melts. The apparatus has a self-consuming electrode disposed above a rotatable counter electrode. Attached to the counter-electrode is a conical plate which is cooled by a fluid circulating through its interior. The application of electrical energy to the electrodes causes the self-consuming electrode to melt and drop melt droplets onto the rotating counter-electrode. Centrifugal force causes the melt droplets to fly off the counter-electrode and contact the conical plate at which point they are rapidly cooled to form thin foils. A housing surrounds the electrodes and conical plate to collect the cooled foils and to permit the apparatus to operate in an inert atmosphere, if desired.

Abstract: Apparatus and method for making small spherical particles comprising rotating a toothed disc at a constant speed. Heating means are provided to heat the spinning toothed disc so that when material from which the particles are to be made touches the toothed disc the material will melt and migrate to the teeth and form beads on the teeth. As the tooth disc rotates, centrifugal force causes the beads to be thrown off and form spheres as the falling beads cool off and re-solidify.

Abstract: A method and apparatus for forming fibers from molten mineral material comprising a rotatably mounted spinner having an orificed peripheral wall through which the material flows to form primary fibers, and a blower adapted to discharge a flow of gases to further attenuate the primary fibers into a veil of secondary fibers, a curved surface being positioned so that the flow of gases follows the contour of the curved surface according to the Coanda effect.

Abstract: A process and apparatus therefor are described for reclaiming waste material from a fiberizing system and for converting a molten stream of material into reclaimable cullet when the system is not fiberizing. When the system is fiberizing the waste is collected in a dry environment and continually conveyed away; when the system is not fiberizing the molten stream is reduced to cullet and collected in a wet environment and continually conveyed away; and when fiberizing is resumed there is a return to the collection of waste in a dry environment.

Abstract: A method for producing metal flake of small length-to-width ratio or small length-to-thickness ratio directly from a pool or like source of molten metal or molten inorganic compound, or from an unconfined drop of molten metal or an unconfined drop of molten inorganic compound having a surface tension and viscosity similar to that of molten metal, consisting of forming such products by the application of a rotating, generally circular serrated edge, heat-extracting disk-like member to the surface of the pool of molten material so as to form the material into discrete flake particles by extracting the flake particles from the supply of molten material; and controlling the final shape of the product by the physical shape of the member, the temperature and material composition of the melt, as well as the velocity of the member in contact with the melt.