Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
152 words
A method of producing flake particles from molten material which is at a temperature within 25% of its equilibrium melting point in degrees K., said molten material having a viscosity of 0.001 to 1 poise and a surface tension of 10 to 2500 dynes per centimeter at said temperature, comprising: (a) rotating a heat extracting disk having a tapering serrated edge, the serrations of which are formed to present a leading edge surface at an angle to the tangent of the circle generated by the rotation of the base of the serration; (b) impacting the serrations of said serrated edge onto the surface of said molten material to form a discrete flaked particle on the leading edge surface of each serration and removing heat from said particle at least partially solidifying said particle on said serration; (c) releasing said particle from said serration; and (d) cooling said particle in a surrounding atmosphere.
Claim 2
Independent Claim
152 words
A method of producing flake particles from molten material which is at a temperature within 25% of its equilibrium melting point in degrees K., said molten material having a viscosity of 0.001 to 1 poise and a surface tension of 10 to 2500 dynes per centimeter at said temperature, comprising: (a) rotating a heat extracting disk having a tapering serrated edge, the serrations of which are formed to present a leading edge surface at an angle to the tangent of the circle generated by the rotation of the base of the serration; (b) impacting the serrations of said serrated edge onto the surface of said molten material to form a discrete flaked particle on the leading edge surface of each serration and removing heat from said particle at least partially solidifying said particle on said serration; (c) releasing said particle from said serration; and (d) cooling said particle in a surrounding atmosphere.
Claim 3
Dependent Claim
19 words
The method of claim 1, wherein said molten material contacted in step (b) is contained in a molten pool.
Claim 4
Dependent Claim
19 words
The method of claim 1, wherein said molten material contacted in step (b) is formed in a pendant drop.
Claim 5
Dependent Claim
42 words
The method of claim 1 wherein said serrations of step (a) are formed to present a leading edge at an angle of at least 3°, to the tangent of the circle generated by the rotation of the the base of the serration.
Claim 6
Dependent Claim
24 words
The method of claim 1, wherein said molten material is contacted by between 300 and 1200 serrations per revolution of said heat extracting member.
Claim 7
Dependent Claim
32 words
The method of claim 1, wherein the peripheral speed of the outer tips of said serrations is in the range between about 200 feet per minute and about 3000 feet per minute.
Claim 8
Dependent Claim
70 words
The method of claim 4, wherein the leading edge surface of each serration on said heat extracting disk member is brought into contact with the said molten material at an angle to impact said leading edge surface against the surface of said material providing a quench rate sufficient to cool said molten material in contact with said surface at a rate of at least 10 5 C. degrees per second.
Claim 9
Dependent Claim
25 words
The method of claim 1 wherein said heat extracting disk member has multiple adjacent peripheral rows of serrations to contact said molten material substantially simultaneously.
Claim 10
Dependent Claim
22 words
The method of claim 1 wherein said edge taper angle is in the range between about 60 degrees to about 90 degrees.
Claim 11
Dependent Claim
37 words
The method of claim 1 wherein said edge taper angle is in the range between about 60 degrees and about 90 degrees and the angle of contact of said leading edge surface is at least 3 degrees.
Claim 12
Dependent Claim
18 words
The method of claim 1 wherein the releasing of said particles in step (c) is by centrifugal force.
Claim 13
Dependent Claim
28 words
The method of claim 1 wherein the releasing of said particles in step (c) is assisted by wiping said serrations after said particles are at least partially solidified.
Claim 14
Dependent Claim
20 words
The method of claim 1 wherein said molten material is selected from the group consisting of metals and metal alloys.
Claim 15
Dependent Claim
24 words
The method of claim 1 wherein said molten material is selected from the group of a metal, a metal alloy, and an inorganic compound.