Document dQrXVkzVkpGnn6MNgYGaBvBBQ

PLAINTIFF'S EXHIBIT JM 1044 Dec. 18, 1956 a a. graybeal 2,774,10? APPARATUS FOR FIBCRIZING MOLTEN MATERIAL Filad Juls 22. 1955 i \ i i INVENTOR 3/tuce Amdkcw Gx*rj,At. mrn A pirvrCXT'T' OT MTC 017050 ,United States Patent Office 2 774,103 Patented Dec. 18, 1986 12 stream 12 is the primary or sfaig distributing rotor 14. 2,7744*3 Am tiaown in cross-section in Fig. 2, this rotor is cup shaped to receive the slag which is then rapidly ejected AFPARATUB FW FIBERIZING MOLTEN MATERIAL tangentially from the inride across the sharp edge ova I the 360* periphery to produce the desired skirt of dis hn A. Gretul, Dew, N. I. persed molten slag. I prefer to make the rotor 14 with a hollow central Apportion *ffy , !, Serial No. 323406 3Ctea (CL IS--24) haft 14a and diametrically opposed openings 146 through which I can pass the bending solution as well as sufficient 10 water for cooling purposes. This gives a high dispersion of the Under at the best area. The rotor 14 will be driven at a suitable speed through a belt and pulley or by TU* invention relates to improvement! in apparatus an individual drive as may be found preferable. tot the manufacture of mineral wool, which, in a generic Concentrically mounted with respect to the slag dis- sense, includes wool or fiber, formed from rock, slag, U triboting rotor 14 and suitably spaced therefrom, and fused clay or mixtures thereof, and other heat liquefiable with an overlap of edges are the fiberizing rotors 16, 18, raw material, capable of being converted into fibers. 20 and 22 At least three of these rotors are found es In accordance with some presently known practices, sential but for best operations, I have had especially sat such materials are fiberized by a spinning prooess in isfactory remits with four as shown. More than four which a stream of the molten material is discharged from 00 can be used. point to point onto one or more adjacent spinners or Each of these rotors is also driven by suitable means rotors rotated at high speed whereby the centrifugal such as the pulleys 16c and 18c, but it will be apparent forces set up cause portions of die material on the rotors that individual drives such as high speed motors (not to be thrown out as fibers. While the practice as disclosed above has several sig 00 shown) may be used. A preferred form of fiberizing rotor is shown in detail nificant advantages over the prior practice of steam blow in Fig. 4. It consists of a relatively thin alloy corrugated ing, I have found by further experimenting that even disc surmounted by a grooved and transversely curved greater advantages are possible in rotor Aberration. channel rim 20a which is of a heat and abrasion resistant An important feature of my invention is the provision alloy. With such a thin and concentrically expansible of a unique slag distributor and fiber forming rotor nest * disc construction, I have the advantage of a light weight consisting of at least three very high speed rotors so unit which may be rotated at the super high speeds I find arranged that each fiber forming rotor not only receives necessary. The rotor is adequately cooled by air, how the molten slag over a very wide arc of its periphery, ever, and the complications of water cooling can he com- but also so that each fiber forming rotor takes substan pletely eliminated. Such expansion or contraction as tially the same load. With such a construction, increased *0 does occur is readily taken up by the corrugated disc con yields are obtained and maintenance greatly reduced. struction without deformation. Another principal feature of my invention is an im As will appear from Fig. 1, the faces of the various proved construction of the slag distributing rotor and rotors are all preferably in a common plane at an angle fiber forming rotors, the latter of which are formed of a of about 45* with the horizontal to assure free flow of heat and erosion resistant alloy in a light-weight manner 40 tiig m the inside of the distributor rotor 14. The slag which permits very high speed operation and air cooling, is then discharged at moderate velocity onto the rims and thus avoids die prior practice of water cooling and all of the fiberizing rotors 16, 18, 28, and 22 which are its attendant mechanical problems. operated at a much higher surface speed. A small angu- In general I am enabled by my apparatus to produce larity of the central rotor throws a wider band of slag greater yields of higher purity product than is otherwise " on the fiberizing rotor. possible and this is accomplished with simpler apparatus In my operation I find that the slag adheres to the and with longer operating life. concave peripheral surface of the fiberizing rotors and Further objects and advantages of my invention wiB forms an incandescent band around the rotor. This appear from the following description of a preferred molten slag is discharged tangentially from die fiberizing form of embodiment thereof, taken in conjunction with 60 rotors and travels in a straight path until it cools to the the attached drawing illustrative thereof and in which: optimum temperature for fiberizatioa, the resistance of Fig. 1 is a side elevation of a cupola or melting furnace air against the moving molten particles causes very fine and adjacent mineral wool distributing and fiberizing fibrous tails to be attenuated from the molten particles. rotors. ,, The core of the particle usually remains as an unfiberized Fig. 2 is a front elevation of the niton shown in Fig. 1 66 -shot" particle. with a diagrammatic showing of the fiber path. According to my practice, this "shot" is kept to a mini Fig. 3 is a central vertical cross section through file mum. Laboratory tests have shown that (here is a direct hollow distributor rotor. correlation between average fiber diameter and percent Fig. 4 is a central vertical cross section through a fiber- M of "shot" on a given mesh screen. Finely dispersed izing rotor. ------ 90 molten slag trajected at high velocity through air is the As .hereinafter described, mjr mineral wool fiberizing prerequisite for fine fibers with a minimum of unfiberized machine is adapted to produce high quality mineral wool slag. fiber from molten sOkious raw materials commonly wrf As the four fiberizing rotors 16, 18, 28 and 22 are in the mineral wool industry. This is generally slag which each arranged symmetrically about the distributing rotor is produced in a blast furnace type cupola and it may be 88 14 and preferably have the same peripheral speed, each remelted in a suitable furnace It. This is usually a rotor takes its proportionate share of the load and over cupola similar to a blast furnace cupola bat may be an loading is avoided. Contact is over approximately a off or gas fired or arc type furnace and it produces a 90* are when four rotors are used (or 120* when three continuous stream 12 which is drawn off from the cus rotors are used) and acceleration is greatly facilitated as tomary tap, not shown. 7 compared to a point to paint discharge. There is no Below this tap, and in position to meet the faffing slag dooMe contact of the slag on any single fiberizing rotor. MTC 017051 ' 8,774,108 34 of die fiberizing roton If, 18, 28 and 22 may be rotated la die " direction or in any desired dime* tkm at water cooling reduce* the amount of crusty solid matter found in die fiber and a separation step is thus don, as, for example, an adjacent pair may be run counter avoided. current to each other to produce a double tongue of mate The resulting symmetrical pattern of fiber formation is rial. A rotor may be reversed to dreamvent a collec 8 conducive to more uniform felting which is otherwise a tion problem or to influence blanket, formation. It is portion when spinning wool for mineral wool batt manu found that direction of rotation does not materially affect facture. Uniform distribution of the binding material the quality of fiber and other considerations, such as con among the fibers is abo facilitated by using the centrally venience of fiber collection may be paramount located spreading rotor to disperse the binding miterial. It is also not critical that the fiberizing roton be in 10 This is accomplished as follows: exactly the same plane as the slag distributing rotor and A water solnble phenolic binder in water solution is some angularity may be helpful to permit fiber to throw introduced through the hollow shaft of the central rotor free. Am an example of best operating condition*, I find that 14 Due to file transverse I4h, this solution issues from the periphery of the spreading rotor which a central rotor of about 6" in diameter is most effective 15 thus coincides with the symmetrical pattern of fiber at about 1000 R. P. M. which is sufficient far slag ejec formation. The fog of binder misses the fiberizing rotors tion aa no fiber is produced. On the other rotors, how as it moves outward in all direction* and intermingles ever, I find that a peripheral speed of about 35,000 with the fiber. A substantially superior binder distribu feet per mhmtu is preferable, not only to produce the tion results. best fiber, but also to produce the leak waste. 1 have 80 My improved operation thus provides * much higher driven 14" diameter roton at 10,000 R. P. M. for sus fiberizing efficiency which is the result not only of higher tained periods without water cooling and with very little quality, but greater quantity of fiber produced. erosion. This is about the maximum rate available I claim: with present drives and bearings. 1. A fiberizing rotor assembly consisting of a central The successful results of my operations appear to be 88 cop shaped rotor having a hollow liquid conduit therein, due in part to the higher speed and somewhat higher tem perature of operation. With the higher temperature, a better "wetting" of the rim is accomplished, and as a at least three symmetrically mounted, symmetrically shaped fiberizing roton adjacent to and equally spaced from said central rotor, means to drive said 09 shaped consequence there is less slipping in giving the slag rotor, mean* to drive each at the fiberizing roton, said the necessary acceleration. 80 fiberizing rotors having a corrugated disc body and a Another main benefit comes from the nearly uniform carved channel rim and mean* to introduce a liquid loading of each of the fiberizing roton. This materially - ihrougn mid cup shaped rotor. departs from prior practice wherein as much as 15% of 2. A fiberizing rotor assembly consisting of a central the feed was unfiberized. This was particularly objec rotor, at least three symmetrically mounted, symmetrically tionable not only in cutting down capacity, but the mate 30 shaped fiberizing roton adjacent to and equally spaced rial not fiberixed had to be separated from the product. from said central .rotor, means to drive said centre! rotor, I have opearted continuously with less than 5% waste. and means to drive each of the fiberizing roton. each of. Another advantage is, of crane, the uniform redial flow of file slag to the fiberizing rotors. The slag may said fiberizing rotors having s cqrrogatedJjK,bodXT. ,"A"flbEdhjf"tb{6r assembly consisting of a central be dispersed in a narrow band and I find that roton 40 rotor, at least three symmetrically mounted, symmetrically 1C, 18, 29 and 22 of only one inch in thickness are com shaped fiberizing rotors adjacent to and equally spaced parable in capacity with former constructions which were from said central rotor, means to drive said central rotor, as much as three inches thick. This lighter construction means to drive each of the fiberizing roton, each of said is of the utmost importance since it permits the use of fiberizing mtm [[nim a itipy body of concentrically cor- smaller shaft sizes and higher speeds with less power 48 rugated, expansible oonrtrncnoqjgrtendingfrom the cen^ consumption. ter portiofi"fhefSr~ihd~bdng formed with a concave It is also found that water coding at file roton is peripheral surface,.. .. ------- - ----------- unnecessary, and, in fact, is to be avoided. Better binding with less crust formation results with hotter surfkcet. It KrfnMti CM In tho file of will be apparent that with equal division of the feed, 60 UNITED STATES PATENTS the amount of molten slag striking each of the roton ia only the amount that is actually fiberizod. The elimina- 2499,383 2,678,466 Powell___ :Apr. 30, 1940 TIBotson ct aL ______ - May 18,1954 MTC 017052 COMMONWEALTH OF AUSTRALIA. PATENT SPECIFICATION 135,499 Application Date: 25th March, 1947. No. 10,924/47. Complete Specification Published........................... Complete Specification Accepted......................... Class 19.6 Drawing attached. 15th January, 1948. 28th November, 1949. COMPLETE SPECIFICATION. "Improvements relating to the manufacture of mineral wool." / We, INSULWOOL PRODUCTS PRO rotated rollers is provided and in which PRIETARY LIMITED, of 20 Queen Street, the molten material is fed in one or Melbourne, in the State of Victoria, more fine streams on to the top roller Commonwealth of Australia, carrying on and is projected from the said roller on business as Manufacturers, hereby declare to the next lower roller and so on down this invention and the manner in which through the series of rollers if more than it is to be performed, to be fully described two rollers are provided, the degree of and ascertained in and-by_the following fineness of said stream or streams and statement:-- the speed of rotation of said rollers being This invention relates to the manufac ture of mineral wool, the latter term being such that the material projected from the last roller solidifies in the form of "spun fibre". used, as is now customary to include glass' wool, slag wool, and rock wool. Another feature of this invention re sides in the means by~which that method In one method of - manufacturing of manufacturing mineral wool is carried* mineral wool, the molten material is fed out, such means comprising a horizontal on to a horizontal disc or the like rotating trough or other device adapted to be fed at relatively high speed, with the result from a cupola or other source of molten that the molten material is thrown out material and provided with one or more in fine globules which become drawn out , fine outlet openings for said molten and thus solidify in the form of fibre. material, a series of two or more positively This type of product is known as "spun rotated rollers so positioned in relation to fibre". It is a satisfactory form of mineral said horizontal trongh or other device and wool but the output of the plant tends to to each other that in operation said molten be relatively small as compared with other material, after passing through said outlet types of mineral wool plants of corres opening or openings, would strike the ponding size. uppermost roller and would be projected One feature of this invention comprises laterally and downwardly on to the next a method of manufacturing mineral wool lower roller, and so on throughout the in wihch a series of two or more positively series if more than two rollers are pro- MTC 017053 vided, receptacle being so disposed in rela tion to the last roller of the series that it is adapted to receive the fibre formed by the solidification of the material so pro jected. It is essential that the stream or streams of molten material be sufficiently fine, otherwise it is not possible to produce a good quality fibrous product. The degree of fineness required to produce a satisfac tory type of spun fibre will depend on such factors as the type and quality of the raw material, the speed of rotation of the rollers, the temperature of the melt, and other conditions knowu to affect the fineness of spun fibre. The material projected from the last roller of the series solidifies and settles in the form of "spun fibre". It is also possible to replace one or more of the rollers by pairs or sets of aligned rollers, but the series of single rollers is quite efficient. The accompanying drawings show a diagrammatic representation of a suitable construction for use according to this in vention. In these drawings:--*' ~rrr,'r!' \~f.' < Figure 1 is a plan of the apparatus, and Figure 2 is an end' elevation of the apparatus shown in Figure 1. The molten material is fed down from a cupola 6 through a discharge spout 1 into a horizontally disposed trough 2 of tri angular cross-section and the trough 2 is provided with a series of spaced apertures along its base through which the material passes in a series of fine streams 3 on to an upper horizontal- roller 7 and zig-zags down between three other suitably dis posed horizontal rollers 8, 9 and 10 rota ting at suitable speeds. The rollers are posit ivelly rotated by any convenient means in the directions corresponding to the directions in which the spray of mol ten mineral leaves the various rollers. The rollers may range from 6" to 12" in dia meter, increasing in ' diameter and in length down the series, and suitable speeds of rotation are from 1000 to 4000 R.P.M. The stream of molten material, or each stream if there is more than one, may conveniently be of about one-sixteenth to three-sixteenths of an inch in diameter before it strikes the upper roller. The material passes off the lowermost roller 10 into a semi-closed chamber 11 in which it settles. In a modification of the invention, the number of rollers may be reduced to three or two. This invention thus provides a method of and means for the manufacture of mineral wool whereby a product of the spun fibre type is obtained with a more rapid output than has been possible with previous apparatus of approximately the same size. Having now fully described and ascer tained our said invention and the manner in which it is to be performed, we declare that what we claim is:-- 1. A method of manufacturing mineral wool in which a series of two or more posi tively rotated rollers is provided and in which the molten material is fed in one or more fine streams on to the top roller and is projected from the said roller on to the next lower roller and so on down through the series of rollers if more than two rollers are provided, the degree of fine ness of said stream or streams and the speed of rotation of said rollers being such that the material projected from the last roller solidifies in the form of "spun fibre". 2. Means for the manufacture of min eral wool comprising a horizontal trough or other device adapted to be fed from a cupola or other 'source of molten material and provided with one or more fine outlet openings for said molten material, a series- of two or more positively rotated rollers so positioned in relation to said horizontal trough or other device and to each other that in operation said molten material, after passing through said outlet opening or openings, would strike the uppermost roller and would be pro jected laterally and downwardly on to the next lower roller, and so on through out the series if more than two rollers are provided, a receptacle being so dis posed in relation to the last roller of the series that it is adapted to receive the fibre formed by the solidification of the material so projected. 3. Mineral wool manufactured accord ing to Claim 1 or Claim 2. 34 / / MTC 017054 135,499. 4. Means for the manufacture of mineral wool as claimed in Claim 2, in which the diameters of the rollers increase progress ively down the series. 5. Means for the manufacture of mineral wool as claime din Claim 2, in which the lengths of the rollers increase progressively down the series. 6. Means for the manufacture of min eral wool as claimed in Claim 2, in which one of the rollers is replaced by a pair or set of axially aligned rollers, or in which two or more of the rollers are re placed by two or more pairs or sets of axially aligned rollers. 7. Means for the manufacture of min eral wool as claimed in Claim 2, in which the axis of rotation of each roller is hori zontal. Dated this 27th day of October, 1947. DAVIES & COLLISON, Fellows Institute Patent Attorneys, Aust. Patent Attorneys for the Applicant. Witness:-------- J. N. Johnson. 5 -6 Printed for tbe DEPARTMENT OP PATENTS, COMMONWEALTH OF AUSTRALIA,. by MACARTHUR PRESS PTY. LIMITED, 66 Macartbur Street, Parramatta. MTC 017055 135,499 MTC 017056