Atomization die and method for atomizing molten material

Claim 3

The method of atomizing molten material as in claim 1, wherein said shock waves have a frequency of at least about 20,000 cycles per second.

Claim 4

The method of atomizing molten material as in claim 2 wherein the frequency of the shock waves ranges from about 20,000 to 100,000 cycles per second.

Claim 5

The method of atomizing molten material as in claim 1, wherein the molten material is molten metal.

Claim 6

The method of atomizing molten material as in claim 3, wherein the molten material is fed as a molten sheet by confining it in a funnel having a slotted opening of predetermined dimensions in spaced communication with the longitudinally configurated die space and by maintaining a head of said material in said funnel as the material flows uniformly through the slotted opening of predetermined dimensions and between the die elements.

Claim 7

The method of atomizing molten material as in claim 11, wherein the thickness of the sheet is at least about 2 mm, and wherein the width of the sheet is at least about 10 times the sheet thickness.

Claim 8

The method of atomizing molten material as in claim 6, wherein the thickness of the sheet is about 2 to 5 mm, and wherein the width of the sheet is at least about 10 times the sheet thickness.

Claim 9

The method of claim 1, wherein the molten material is selected from the group consisting of metals, glasses, ceramics and polymers.

Claim 12

The method of producing a spray-cast metal shape as in claim 9, wherein said shock waves have a frequency of at least about 20,000 cycles per second.

Claim 13

The method of producing a spray-cast shape as in claim 10, wherein the frequency of the shock waves ranges from about 20,000 to 100,000 cycles per second.

Claim 14

The method of producing a spray-cast shape as in claim 11, wherein the molten metal is fed as a sheet by confining it in a funnel having a slotted opening of predetermined dimensions in spaced communication with the longitudinally configurated die space and by maintaining a head of said metal in said funnel as the metal flows uniformly through the slotted opening of predetermined dimensions and between the die elements.

Claim 15

The method of producing a spray-cast shape as in claim 9, wherein the thickness of the sheet is at least about 2 mm, and wherein the width of the sheet is at least about 10 times the sheet thickness.

Claim 16

The method of producing a spray-cast shape as in claim 13, wherein the thickness of the sheet is about 2 to 5 mm, and wherein the width of the sheet is at least about 10 times the sheet thickness.

Claim 17

A linearly configurated atomization die for atomizing molten material which normally exists in the solid state at room temperature, said die comprising: at least one set of opposed linearly configurated die elements spaced in substantially parallel relationship to define a longitudinally configurated die space therebetween dimensioned to pass therethrough a sheet of said molten material having a thickness of at least about 1 mm and a width of at least 5 times the thickness, said die elements defining a nozzle assembly characterized by oppositely disposed orifice-bearing surfaces, one on each of said linear die elements, each of said linear die elements having a chamber for receiving atomizing gas under superatmospheric pressure, exit ducts for delivering said atomizing gas therefrom and a cooling chamber for receiving a circulation of cooling fluid therein, each of said oppositely disposed nozzle-defining surfaces forming said nozzle assembly having an array of orifices disposed along and embracing each side of said longitudinally configurated die space, orifice conduit means communicating said orifices with said gas chamber via said exit ducts, each of said exit ducts intersecting with and being disposed transverse to said orifice conduits such as to provide resonating cavities in both the exit ducts and the orifice conduits which cooperate to generate pulsating high frequency shock waves, said array of orifices on each die element being convergently directed towards the other and oriented such as to direct atomizing gas under laminar flow conditions against a predetermined focal region of a sheet of molten material as it is leaving said die space near said orifices, said high frequency shock waves generated by the resonating cavities disintegrating said sheet of molten material at said focal region into fine particles of controlled particles size.

Claim 18

A linearly configurated atomization die for atomizing molten material which normally exists in the solid state at room temperature, said die comprising: at least one set of opposed linearly configurated die elements spaced in substantially parallel relationship to define a longitudinally configurated die space therebetween dimensioned to pass therethrough a sheet of said molten material having a thickness of at least about 1 mm and a width of at least 5 times the thickness, said die elements defining a nozzle assembly characterized by oppositely disposed orifice-bearing surfaces, one on each of said linear die elements, each of said linear die elements having a chamber for receiving atomizing gas under superatmospheric pressure, exit ducts for delivering said atomizing gas therefrom and a cooling chamber for receiving a circulation of cooling fluid therein, each of said oppositely disposed nozzle-defining surfaces forming said nozzle assembly having an array of orifices disposed along and embracing each side of said longitudinally configurated die space, orifice conduit means communicating said orifices with said gas chamber via said exit ducts, each of said exit ducts intersecting with and being disposed transverse to said orifice conduits such as to provide resonating cavities in both the exit ducts and the orifice conduits which cooperate to generate pulsating high frequency shock waves, said array of orifices on each die element being convergently directed towards the other and oriented such as to direct atomizing gas under laminar flow conditions against a predetermined focal region of a sheet of molten material as it is leaving said die space near said orifices, said high frequency shock waves generated by the resonating cavities disintegrating said sheet of molten material at said focal region into fine particles of controlled particles size.

Claim 19

A linearly configurated atomization die for atomizing molten material which normally exists in the solid state at room temperature, said die comprising: at least one set of opposed linearly configurated die elements spaced in substantially parallel relationship to define a longitudinally configurated die space therebetween dimensioned to pass therethrough a sheet of said molten material, said linear die elements each being adjustably mounted to provide lateral and/or angular positioning relative to an axis between said die elements, said die elements defining a nozzle assembly characterized by oppositely disposed orifice-bearing surfaces, one on each of said linear die elements, each of said linear die elements having a chamber for receiving atomizing gas under superatmospheric pressure, exit ducts for delivering atomizing gas therefrom and a cooling chamber for receiving a circulation of cooling fluid therein, each of said oppositely disposed nozzle-defining surfaces forming said nozzle assembly having an array of orifices extending along and embracing each side of said longitudinally configurated die space, orifice conduit means communicating said orifices with said gas chamber via said exit ducts, each of said exit ducts intersecting with and being disposed transverse to said orifice conduits such as to provide resonating cavities in both the exit ducts and the orifice conduits which cooperate to generate pulsating high frequency shock waves, said array of orifices on each die element being convergently directed towards the other and oriented such as to direct atomizing gas under laminar flow conditions against a predetermined focal region of a sheet of molten material as it is leaving said die space near space orifices, said high frequency shock waves generated by the resonating cavities disintegrating said sheet of molten material at said focal region into fine particles of controlled particle size.

Claim 20

A linearly configurated atomization die for atomizing molten material which normally exists in the solid state at room temperature, said die comprising: at least one set of opposed linearly configurated die elements spaced in substantially parallel relationship to define a longitudinally configurated die space therebetween dimensioned to pass therethrough a sheet of said molten material, said linear die elements each being adjustably mounted to provide lateral and/or angular positioning relative to an axis between said die elements, said die elements defining a nozzle assembly characterized by oppositely disposed orifice-bearing surfaces, one on each of said linear die elements, each of said linear die elements having a chamber for receiving atomizing gas under superatmospheric pressure, exit ducts for delivering atomizing gas therefrom and a cooling chamber for receiving a circulation of cooling fluid therein, each of said oppositely disposed nozzle-defining surfaces forming said nozzle assembly having an array of orifices extending along and embracing each side of said longitudinally configurated die space, orifice conduit means communicating said orifices with said gas chamber via said exit ducts, each of said exit ducts intersecting with and being disposed transverse to said orifice conduits such as to provide resonating cavities in both the exit ducts and the orifice conduits which cooperate to generate pulsating high frequency shock waves, said array of orifices on each die element being convergently directed towards the other and oriented such as to direct atomizing gas under laminar flow conditions against a predetermined focal region of a sheet of molten material as it is leaving said die space near space orifices, said high frequency shock waves generated by the resonating cavities disintegrating said sheet of molten material at said focal region into fine particles of controlled particle size.