Method of solidifying molten material

Claim 2

Method for solidifying molten material into amorphous form while substantially avoiding crystallinity thereof and water occlusion therein, comprising pouring the molten material onto a uniformly extending solid planar substrate and in direct contact therewith and maintaining such molten material in static disposition on such uniformly extending substrate for controlled stage cooling, initially selectively mildly forming a solidified, crystallinity inhibiting, protective stabilizing skin on the melt surface of such molten material on the substrate without substantial disturbance and rippling of the molten surface and without disturbance of the uniformly extending disposition of the substrate and correspondingly of the static disposition of the molten material thereon and in the substantial absence of attendant liquid, thereafter finally solidifying such material by intensively cooling such material with a fluid coolant directed against the solidified protective skin likewise without disturbance of the uniformly extending disposition of such substrate and correspondingly of the static disposition of such material thereon, and recovering the solidified material in substantially amorphous form.

Claim 3

Method according to claim 1 wherein the molten material is molten sulfur, the fluid coolant for the final solidifying comprises at least one of water spray and vigorous air jet, and the substrate is an endless uniformly extending belt.

Claim 4

Method according to claim 1 wherein the molten material prior to pouring contains dispersed therewithin an effective minor amount of amorphous solidification-promoting and increased hardness on aging-promoting property improving modifying additive from the group of silicone liquid, kerosene, other corresponding hydrocarbons of lower boiling range, and mixtures thereof.

Claim 5

Method according to claim 3 wherein the modifying additive is a dimethyl silicone or a phenyl-methyl silicone.

Claim 6

Method for solidifying molten material into amorphous form while substantially avoiding crystallinity thereof and water occlusion therein, comprising pouring the molten material onto a uniformly extending solid planar substrate and in direct contact therewith and maintaining such molten material in static disposition on such uniformly extending substrate for controlled stage cooling, initially selectively forming a solidified, crystallinity inhibiting, protective stabilizing skin on the melt surface of such molten material on the substrate by mildly cooling such surface with an air jet directed thereagainst at a relatively gentle air flushing flow pressure which is insufficient to cause substantial disturbance and rippling of the molten surface, and without disturbance of the uniformly extending disposition of the substrate and correspondingly of the static disposition of the molten material thereon, thereafter finally solidifying such material by intensively cooling the mildly cooled material with a fluid coolant directed against the solidified protective skin likewise without disturbance of the uniformly extending disposition of such substrate and correspondingly of the static disposition of such material thereon, and recovering the solidified material in substantially amorphous form.

Claim 7

Method for solidifying molten material into amorphous form while substantially avoiding crystallinity thereof and water occlusion therein, comprising pouring the molten material onto a uniformly extending solid planar substrate and in direct contact therewith and maintaining such molten material in static disposition on such uniformly extending substrate for controlled stage cooling, initially selectively forming a solidified, crystallinity inhibiting, protective stabilizing skin on the melt surface of such molten material on the substrate by mildly cooling such surface with an air jet directed thereagainst at a relatively gentle air flushing flow pressure which is insufficient to cause substantial disturbance and rippling of the molten surface, and without disturbance of the uniformly extending disposition of the substrate and correspondingly of the static disposition of the molten material thereon, thereafter finally solidifying such material by intensively cooling the mildly cooled material with a fluid coolant directed against the solidified protective skin likewise without disturbance of the uniformly extending disposition of such substrate and correspondingly of the static disposition of such material thereon, and recovering the solidified material in substantially amorphous form.

Claim 8

Method according to claim 5 wherein the molten material is molten sulfur.

Claim 9

Method according to claim 6 wherein the molten sulfur is poured at a temperature of about 130° to 150° C, the fluid coolant for the final solidifying comprises at least one of water spray and vigorous air jet, and the substrate is a heat exchange endless uniformly extending belt maintained in cooled condition.

Claim 10

Method according to claim 7 wherein the belt is cooled on its underside by a stream of water spray directed there against.

Claim 11

Method according to claim 5 wherein the molten material prior to pouring contains dispersed therewithin an effective minor amount of an amorphous solidification-promoting and increased hardness on aging-promoting property improving modifying additive from the group of silicone liquid, kerosene, other corresponding hydrocarbons of lower boiling range, and mixtures thereof.

Claim 12

Method according to claim 9 wherein the molten material is molten sulfur.

Claim 13

Method for solidifying molten material into amorphous form while substantially avoiding crystallinity thereof and water occlusion therein, comprising pouring the molten material onto a uniformly extending solid planar substrate and in direct contact therewith and maintaining such molten material in static disposition on such uniformly extending substrate for controlled stage cooling, initially selectively forming a solidified, crystallinity inhibiting, protective stabilizing skin on the melt surface of such molten material on the substrate by mildly treating such surface with powdered material gently applied thereto which is insufficient to cause substantial disturbance and rippling of the molten surface, and without disturbance of the uniformly extending disposition of the substrate and correspondingly of the static disposition of the molten material thereon, thereafter finally solidifying such material by intensively cooling the mildly cooled material with a fluid coolant directed against the solidified protective skin likewise without disturbance of the uniformly extending disposition of such substrate and correspondingly of the static disposition of such material thereon, and recovering the solidified material in substantially amorphous form.

Claim 14

Method for solidifying molten material into amorphous form while substantially avoiding crystallinity thereof and water occlusion therein, comprising pouring the molten material onto a uniformly extending solid planar substrate and in direct contact therewith and maintaining such molten material in static disposition on such uniformly extending substrate for controlled stage cooling, initially selectively forming a solidified, crystallinity inhibiting, protective stabilizing skin on the melt surface of such molten material on the substrate by mildly treating such surface with powdered material gently applied thereto which is insufficient to cause substantial disturbance and rippling of the molten surface, and without disturbance of the uniformly extending disposition of the substrate and correspondingly of the static disposition of the molten material thereon, thereafter finally solidifying such material by intensively cooling the mildly cooled material with a fluid coolant directed against the solidified protective skin likewise without disturbance of the uniformly extending disposition of such substrate and correspondingly of the static disposition of such material thereon, and recovering the solidified material in substantially amorphous form.

Claim 15

Method according to claim 11 wherein the molten material is molten sulfur and the powdered material is fine sulfur particles.

Claim 16

Method according to claim 12 wherein the molten sulfur is poured at a temperature of about 120° to 150° C, the powdered material has a particle size not exceeding about 1/64 inch, the fluid coolant for the final solidifying comprises at least one of water spray and vigorous air jet, and the substrate is a heat exchange endless uniformly extending belt maintained in cooled condition.

Claim 17

Method according to claim 13 wherein the belt is cooled on its underside by a stream of water spray directed thereagainst.

Claim 18

Method according to claim 11 wherein the molten material prior to pouring contains dispersed therewithin an effective minor amount of an amorphous solidifcation-promoting and increased hardness on aging-promoting property improving modifying additive from the group of silicone liquid, kerosene, other corresponding hydrocarbons of lower boiling range, and mixtures thereof.

Claim 19

Method according to claim 15 wherein the molten material is molten sulfur.