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\dSr-l'yS?* f* ' PLAINTIFFS EXHIBIT JM 1042 Aug. 29,1950 e. r poweu. 2,520,169 method and apparatus for fiberizing molten material Filed Sept. 29, 1948 2 Sheets-Sheet l * ` ` 1.1. 'to A\ ; $ inventor. 0hh#o-/?. J'oreiL. k!Lr~*- attorney. MTC 017036 Patented Aug. 29, 1950 2,520,169 UNITED STATES PATENT OFFICE 2,520,169 METHOD AND APPARATUS FOR FIBERIZING MOLTEN MATERIAL Edward R. Powell, North Plainfield, N. J,, assignor to Johns-Manville Corporation, New Fork, N. Y,, a corporation of New York Application September 29,1948, Serial No. 51,750 12 Claims. (Cl. 18--2.6) The present invention relates to the manufac^l minimum of unflberized particles or shot is ture of mineral wool and, more particularly, to 1 achieved. an Improved apparatus and method for convert It has been found that by the present method ing a molten mineral material into fibers. The a fiber yield as high as 45% can be obtained on application is a continuation in part as to all 6 a commercial scale in contrast to the conven common subject matter with my copending appli- ^ tional blowing operations where it has been un cation, S. N. 742,064, filed April 17, 1947 now '' usual to obtain yields greater than, say, 27% ol abandoned which, in turn, was a continuation in the molten slag. Furthermore, the fibers pro part of copending applications, S. N. 485,009, filed duced are longer and finer than those obtained April 29, 1943, now Patent No. 2,428.810 and S. N. 10 by the prior processes and a cleaner, more shot- 555,359, filed September 22, 1944. The term "min free product is achieved. eral wool" is employed in the instant application My invention will be more fully understood and as in my said prior applications in a generic sense further objects and advantages thereof will be to include wool or fibers formed from rock, slag, come apparent when reference is made to the glass, mixtures thereof and like raw materials___ _ 15 more detailed description which is to follow and Heretofore molten raw materials of the type re to the accompanying drawings in which: ferred to above have been converted into fibers in Fig. 1 is a diagrammatic, front elevational view a number of ways, including the commonly used of an apparatus embodying the invention; method of disintegrating a stream of the molten Fig. 2 is a top plan view of the flberizing ap material by the action of a high pressure steam 20 paratus of Fig. 1; jet. More recently, it has been proposed to flber- Fig. 3 is a side elevational view of the flberizing ize the material by a spinning process in which apparatus of Fig. 1. the stream is discharged onto spinners or rotors Fig. 4 is a view similar to Fig. 3 but with parts rotated at high speed, the centrifugal forces set broken away, illustrating a minor modification of up causing portions of the material to leave the 23 the invention; and rotors and to be drawn into fibers. The instant Fig. 5 is a view similar to Fig. 1 but illustrating invention has for its principal object the provision the modification of Fig. 4. of an improved apparatus and method of the lat Referring now to the dawings, there is shown ter type which will handle larger quantities of an apparatus comprising a melting furnace 10 the molten material, provide a greater fiber yield, 3u which may be of any suitable type, such as a and produce finer and more uniform fibers. cupola, tank furnace, or the like. The furnace One of the major difficulties of adapting th&~ includes a discharge trough 12 from which a spinning method to operations on a commercial stream of molten material is drawn from the fur scale has been the inability of the equipment to nace and discharged in position for flberization. effectively handle the output of the modern cupola 35 The raw material melted in the furnace and con conventionally used in mineral wool operations. verted into the molten stream may be rock, slag, An object of the instant invention is the provision glass, mixtures thereof, or other liquefiable ma of an improved apparatus and method employing terials, suitable for conversion into fibrous wool a plurality of rotors or spinners which secure a by the method hereinafter described, all such ma wider distribution or spreading of the molten ma- 40 terials being herein referred to as "mineral ma terial to substantially increase the flberization terials". area and, hence, the capacity and efficiency of The major flberizing operation is performed by the operation. __ a pair of rotors 16 and 18 having relatively wide, Another object of the invention is the provision peripheral surfaces IT and 19, respectively. The of a method and apparatus in which the move- 45 rotors are mounted for rotation on shafts 20 and ment of the molten material is gradually ac 22, respectively, the shafts as best illustrated celerated as its passes through the equipment and, in Fig. 2, preferably extending at a slight angle, at the same time, the stream is gradually divided say, an angle of 9 to each other. or spread, whereby conversion of the greater Rotors 16 and 18 are driven in opposite direc portion of the stream into fibers with only a 60 tions, as indicated by the arrows, and at rela- MTC 017038 2,820,160 34 tively high speeds. The rotors are of heat-re vertical line through the axis of the rotor, as sistant steel or other alloy of a character to re viewed in Figs. 1 and 5; that is, on a down- sist the high temperature of the material, which turning segment of the rotor. This is diagram- may run as high as 2200 F., without excessive matically illustrated in Figs. 1 and 5 where the erosion or wear. The surfaces of the rotors are 6 course of the main body of the stream to the also preferably provided with a series of grooves initial rotor and from there through the equip 24, suitably of U-shape, to insure the bonding of a ment is indicated by broken lines. The rotors ring or rings of the molten material thereto, are tilted to have the shafts slant downwardly, although bonding of the rings is not necessarily shafts 20, 22 and 32 extending at an angle of dependent on such grooves. It has been found 10 about 12 to the horizontal, as indicated in Fig. 4 that, even if plane surfaced rotors are used, after but retaining what is herein termed an "approxi the rotors' are subjected- for a' period of time to mately horizontal" position. The- main purpose - the action.1 of the molten-material, toe latter will of the tilting of the shafts is to avoid inter tend to bond to the surfaces. However, the use ference between the fibers being formed and the of more positive means for this purpose, such 13 molten stream. Inasmuch as the fibers are drawn as the grooves 24, is preferred. out in planes approximately at right angles to Supported above the main flberizing rotors fB the shafts of the rotors by which they are and 18 are a pair of rotors 28 and 28. Rotors'26 formed, if the shafts are horizontal, at least and 28 are supported on shafts- 38 and M. re part of- the-fibers are projected directly into the spectively. Shaft 32 lies in an approximately 20 path of the stream. It will be appreciated that, horizontal plane substantially parallel to the as indicated in Fig. 1, the rotors are forwardly planes of shafts 20 and 22, but shaft 30 prefer of the melting furnace 10. ably extends upwardly at a small angle to define Molten material issuing from the cupola and an acute angle, say, an angle of about 6 between forming a molten stream is in a highly fluid, the planes of the shafts, as illustrated. Rotors 25 incandescent condition and, for economy, the 26 and 28, similarly- to the other rotors, have stream is of considerable size of, say, Vi" diam surfaces of steel or other heat-resistant metal, eter. The condition of fluidity employed for the capable of resisting the temperatures of the molten material in mineral wool fiberization by molten material without excessive erosion. the conventional steam jet process is an example, Rotors 26 and 28 constitute what is, in effect, a 39 although somewhat more fluid streams may be stream spreading or distributing device, although, used if desired. The rotors are driven at suc particularly rotor 28, also performs a flberizing cessively- higher speeds to constantly aocelerate funct'on as will be later pointed out. the movement of the molten material on Its way In the form of the invention Illustrated In Figs. to fiberization. Also, the contact with the first 1, 2 and 3, the rotors 26 and 28 are of frusto- 35' rotor is at only a slight angle to avoid spatter conical form with the coned surfaces preferably ing this very large and Su'd stream. As ike- in reversed relationship. Rotor 26 may be stream is gradually dispersed, it is possible to smooth surfaced, as illustrated, while rotor 28 direct it more directly against the surfaces for may be provided with one or more grooves 34 of better bonding. Thus, the impact on the first- relatively large cross-section. It will be ap- 40 rotor surface is nearly tangent to it while the prec'ated that these grooves, as well as the Impact on the surface of rotor 16 may be sub- grooves in the main flberizing rotors, are shown staht'ally perpendicular. The molten material of somewhat -exaggerated size. In the embodi Impinging upon rotor 26 or 36 is only lightly ment illustrated in Figs. 4 and 5 the upper rotors, bonded, if bonded at all, and is discharged at a indicated in these figures by the reference char acters 83- and 38, are of cylindrical, rather than 45- greatly accelerated speed and in tributed. or partially disintegrated a spread, condition dis onto conical form. Rotor 36 preferably has a deep the peripheral surface of rotor 28 or 38, as the groove 40, while the surface of rotor 38 is prefer case may be. The spread'ng of the material ably smooth. This embodiment of the inven apparently is caused in most part by the separa tion is otherwise similar to the previous embodi ment. 50 tion of the stream into a plurality of components as it leaves the initial rotor. In the embodiment The several shafts are supported from a suit of Figs. 1-3, spreading is further encouraged by able framework 42 on bearings 44. At least the the fact that some of the material is discharged front bearings are carried by yieldable mount at approximately right angles to the rotor axis, ings of any suitable or conventional type which will permit the rotors to move apart in the 55 and other of the material is discharged approxi mately normal to the conical surface. How event a solid chunk of slag or fuel should fall ever, it has been found that the rotors of the between them. The rotors may be driven by indi form shown in Figs. 4 and 5 produce adequate vidual motors or by a suitable drive, illustrated spreading of the stream and, inasmuch as it Is only diagrammaticaily, and mounted in any de sired location on the frame structure 42. The 60 easier to control the operation, their use is often preferred. drive is arranged so that the rotors 26 and 28 or The material discharged on rotor 28 or 38, as the 36 and- 38, as the case may be, rotate in opposite case may be. Is partially bonded thereto to form directions, as indicated by the arrows in Figs. 1 a molten ring, but is mostly projected tangen and- 5, with their and rotors 16 and upper surfaces approaching, 18 also rotate in opposite di 65 tially from the rotor in a spread, distributed, or partially disintegrated stream which, at least-for rections with their upper surfaces approaching, the most part, strikes rotor 16. Some of the as previously mentioned. material may also pass directly from rotor 28 or In the operation of the apparatus described 38 to rotor (8. The material discharged onto above, and in carrying out the method of the 70 rotor 16 is partially bonded thereto to form a instant invention, the flberizing device is posi ring of.incandescent material, the grooved sur tioned to have the molten material stream issu face promoting such bonding, and the excess ma ing from the cupola impinge against rotor 26 terial over that bonded Is discharged by rotor 16 or 36, depending upon the embodiment of the onto rotor 18 where it, together with any mate invention employed, at a point to the right of a 7-5 rial reaching rotor 18 directly from rotor 28 or MTC 017039 2,520,169 s6 18 bonds to the surface of the rotor to form an acceleration of the stream and its reduction from incandescent ring of the molten material, bond an original, relatively solid stream to, what is in ing of the material again being promoted by effect, a partially disintegrated stream or streams the grooved surface. Any excess of the molten of droplets. material over that bonded may again be projected s Having thus described my invention in rather back against rotor 16, this action continuing un full detail, it will be understood that these de til the excess material is bonded to one or the tails need not be strictly adhered to but that other of the rotors. various changes and modifications may suggest The high speed rotation of rotors 16 and 18 themselves to one skilled in the art, all falling causes portions of the incandescent rings to be ID within the scope of the invention as defined by thrown or drawn from the rotors by the centrif the subjoined claims. ugal forces created, these portions being drawn What I claim is: out into long, fine fibers. Although rotors 16 and 1. In an apparatus for converting a molten raw 18 perform the main fiberlzlng function, rotor 28 material to fibers having means for discharging or 68, depending upon which is used, also op IS a fluid stream of the molten material, the im erates as a fiberizer to a substantial extent. provement comprising means in the path of the Rotor 26 or 36 may also flberlze to a minor ex stream for spreading the stream laterally, said tent, but its primary function is that of receiv stream spreading means including a rotor having ing the stream of molten material, increasing its a coned peripheral surface, a shaft supporting velocity, and initiating its distribution on the 20 said rotor for rotation with said surface in the other rotors. path of the stream, a second rotor having an Critical features of the invention, as pre oppositely coned peripheral surface, a shaft sup viously pointed out, are the increase in velocity porting said second rotor for rotation with its and the spreading or gradual disintegration of surface adjacent the first rotor, said shafts ex the stream as it passes to the main fiberlzlng 25 tending at an acute angle to each other; a third rotors, whereby the material bonds thereto rather rotor having a peripheral surface, means mount than being thrown off or splattered and lost as ing said rotor for rotation with its peripheral would be the case if a concentrated, high volume surface in the path of the spread stream, a stream of the type here used was discharged fourth rotor having a peripheral surface in the directly and perpendicularly onto the high speed 30 path of the material discharged by said third rotor or rotors. rotor, and means for rotating said rotors. The particular dimensions of the rotors are not critical within reasonable limits and may be se 2. In an apparatus for converting a molten raw material to fibers having means for discharging lected on the basis of the capacity desired: i. e., a fluid stream of the molten material, the im the quantity per hour of molten material to be 35 provement comprising means in the path of the delivered by the melting furnace. However, the stream for spreading said stream laterally, said size relationship between these elements is pref stream spreading means including a rotor having erably approximately that illustrated in the a peripheral surface, a shaft supporting said rotor drawings. Also, the particular peripheral speeds at which the rotors are driven will depend upon 40 for rotation with said peripheral surface in the path of the stream, a second rotor having a the operating conditions, such as the fluidity peripheral surface, and a shaft supporting said of the molten material, and the like, but again, second rotor for rotation with its surface ad for purposes of example, it may be stated that, jacent to the surface of the first rotor to receive in employing a substantially conventional min eral wool melt, successful operation was obtained 45 the material from the first rotor, a third rotor having an unobstructed, molten material retain by driving rotors 26 or 36 and 28 or 38 at periph ing peripheral surface, means mounting said third eral speeds in the ranges of 2500 to 5000 feet per rotor for rotation with its peripheral surface in minute and 6500 to 10,000 feet per minute, while the path of the material discharged by said rotors 16 and 18 were driven in ranges of 12,000 to 16,000 feet per minute and 14,000 to 20,000 feet SO stream spreading means, whereby a portion of the material of said stream is retained on said surface per minute, respectively. The peripheral speeds and another portion is thrown off, a fourth rotor of the rotors, the fluidity of the melt, and the having an unobstructed, molten material retain like, may be varied to meet given conditions, as ing peripheral surface, means mounting said pointed out above. It will be understood, how ever, that the molten material must be of a suffi 65 fourth rotor for rotation with its peripheral sur face in the path of the material discharged by ciently high temperature, the specific tempera said third rotor, and means for rotating said ture range depending upon the character of the rotors. material, to maintain the molten material on the 3. In an apparatus for converting a molten raw surfaces of the bonded rings in a highly fluid or SO material to fibers having means for discharging a incandescent state to permit flberization to take fluid stream of the molten material, the im place. provement comprising means for spreading the The fiber formed as described above may be stream, said spreading means including a collected in any suitable manner and a binder frusto-conical rotor, a shaft supporting said rotor may be introduced if desired, either before or 65 for rotation on an approximately horizontal after initial fiber collection, the particular ap axis, a second frusto-conical rotor in reversed paratus for these purposes forming no part of relationship to said first rotor, a shaft support the instant invention. ing said second rotor for rotation on an ap The construction has been found to deliver a proximately horizontal axis and means for ro greatly increased fiber yield over the earlier types TO tating said rotors in opposite directions; a third of rotor flberization apparatus. The original rotor having a peripheral surface with means to stream which may have a diameter of, say, V2" retain molten material thereon, a shaft mount is greatly expanded in width when received on ing said third rotor for rotation with its periph the surfaces of the main fiberizing rotors. The eral surface in the path of material discharged production of fine fibers is enhanced through the 75 by the spreading means, whereby a portion of MTC 017040 78 the material Is retained on the rotor and another -8. In -an apparatus for converting molten portion Is thrown off, a fourth rotor having a raw material to fibers having means for dis peripheral surface with means to retain molten charging a fluid stream of the molten material, material thereon, a shaft for mounting said the improvement comprising means in the,path fourth rotor for rotation with Its peripheral sur face in the path of the material thrown oft by 6 of the stream Jar spreading and accelerating.the stream, said stream spreading and accelerating said third rotor, and means for rotating said means including a substantially cylindrical rotor third and fourth rotors In opposite directions at having a peripheral surface, means supporting high speeds. said rotor for -rotation with said surface in the 4. An apparatus as defined by claim 2, having 10 path of the stream,, a second substantially cylin means for yieldably supporting the shafts for drical rotor having a peripheral surface, -and the rotors. means supporting said second rotor ior rotation 5. A method of making mineral wool from a with its peripheral .surface adjacent the first molten mineral material comprising discharging rotor, a third rotor .having an unobstructed, a stream of the molten material onto the 15 molten material retaining peripheral .surface, peripheral surface of a rotating rotor, discharg means mouhting said third rotor for rotation ing the material from the rotor onto the with said surface in the path of the spread peripheral surface of an adjacent rotor rotating stream, a fourth rotor having an unobstructed, at a higher peripheral speed to spread and molten material retaining peripheral surface,, divide the stream, discharging the spread and 20 means mounting said fourth rotor for rotation divided stream at a relatively high velocity onto with its peripheral surface in the path nf mate the peripheral surface of a third rotor to form rial .discharged by said third rotor, and . means an incandescent ring thereon from a portion of for rotating said rotors at successively higher the mater'al. discharging another portion of the peripheral speeds. material from the third rotor onto the peripheral 25 9. In an apparatus for converting a molten surface of a fourth rotor to form an incandescent raw material to fibers, said apparatus having ring thereon, and rotating said third and fourth means for discharging the molten material, -the rotors at higher speeds than said first and sec improvement comprising, a rotor in the path of ond rotors to form fibers from said incandescent discharged material to receive material and pro- rings. 6. In an aDoaratus for converting a molten raw material to fibers having means for discharging a flu`d stream of the molten material, the im provement cor"pri-ing means for accelerating the stream including a rotor located to have its peripheral surface in the path of the stream to receive the material and discharge It therefrom, means for rotating said rotor, a second rotor having a peripheral surface to receive material discharged by the first rotor, means for rotating said second rotor at a higher peripheral sjieed than the first rotor: and flberiring means In cluding a third rotor having a molten material retaining peripheral surface, means mounting said rotor for rotation vdth its peripheral surface in the path of matria! di'char^ed bv the ac 30 35 40 I.'. ject it therefrom, a second rotor in the path ot material projected by said first rotor to receive material from said first rotor and project it therefrom, a third rotor having an unobstructed, molten material retaining annular surface posi tioned to receive material projected by said:seoond rotor, a fourth rotor having an unobstructed, molten material retaining annular surface posi tioned to receive material from said third retar, and means for rotating said rotors. 10. The method comprising, discharging mdltea mineral wool forming material and converting the same into fibers by intercepting discharged mate rial on a rotating annular surface and project ing material therefrom, intercepting material projected by said surface on a second rotating celerating means, a fourth rotor having an un annular surface and projecting it therefrom, in obstructed, molten material retaining peripheral tercepting material projected by said second an surface, means mounting said fourth rotor for nular surface on an unobstructed, molten mate rotation with its peripheral said third rotor, and means surface adlacent for rotating said 50 rial retaining annular surface rotating at ' high speed and discharging material therefrom -te third and fourth rotors at a sneed-greater than another unobstructed, molten material retaining that of said flr~t and second rotors. annular surface rotating at high speed. 7. In an apparatus for converting a molten raw 11. In an apparatus including means for dis material to fibers having means for discharging * charging a stream of molten material, devices a fluid stream of the molten material, the im lit* positioned in the path of the discharged mate provement comprising means for spreading and ria] for converting the material into fibers, said accelerating the stream including a substantially devices comprising a first pair of rotors having cylindrical rotor having an annular surface, annular surfaces to receive molten material wf means supporting said rotor for rotation with its annular surface in the path of the stream, a 60 the stream and convert a portion of the same into fibers and to accelerate the movement of second, substantially cylindrical rotor having an another portion of the material, and a second annular surface and means supporting said sec pair of rotors having unobstructed, molten mate ond rotor for rotation with its annular surface rial retaining annular surfaces to receive mate adjacent the first rotor; and fiberizing means in 65 rial of said other portion and form fibers there cluding a third rotor having an unobstructed, from, and means for rotating said rotors. molten material retaining, annular surface, 12. The method comprising, discharging molten means mounting said third rotor for rotation mineral wool forming material and converting with its annular surface in the path of the the same into fibers by intercepting discharged spread stream, a fourth rotor having an unob 70 material on a rotating annular surface and pro structed, molten material retaining annular sur jecting material therefrom, intercepting material face, means mounting said rotor for rotation projected by said surface on a second rotating with its annular surface in the path of ma annular surface and projecting it therefrom, in terial discharged by said third rotor, and means tercepting material projected by said second an for rotating said rotors. 75 nular surface on an unobstructed, molten mate- MTC 017041 3,520,109 9 10 rial retaining annular surface rotating at high REFERENCES CITED speed and discharging material therefrom to another unobstructed, molten material retaining annular surface rotating at high speed, the angles of impact of the material against said The following references are of record in the file of this patent: UNITED STATES PATENTS annular surfaces increasing from relative tangency with respect to said first surface to sub stantially right angular-relationship with respect to the last surface. Number 998,358 2,136,988 2,153,739 Name Date LessingJuly 18, 1911 WhiteNov. 15, 1938 BussApr. 11 1939 2,243,122 RamseyerMay 27, 1941 isuWARP R. POWELL. 2.428,810 PowellOct. 14, 1947 MTC 017042 May 18, 1954 vv. t. tillotson etal 2,678,466 apparatus and uethod of fiberization of mineral wool Filed Jan. 16. 1953 * Sheet-Sheet 3 MTC 017045