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US4671994A
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Method for producing fiber reinforced hollow microspheres
Assignee: MICRO TECHNOLOGY Corp A CORPORATION OF
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Filing: 1986-02-10
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Granted: 1987-06-09
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Expires: 2006-02-10
Abstract
Abstract Fiber reinforced hollow film forming material microspheres 17 made from a fiber and film forming material composition are described. The fiber reinforced hollow microspheres 17 are used to make shaped and molded articles and to make insulation materials. The fibers can be made from ceramic materials, glass, metal, metal glass and plastic. The reinforcing fibers can be one-half to five microns in diameter and five to one hundred microns in length.
Inventors
- 👤 Joe K. Cochran, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 12:33
CPC Classifications
B; B22; B22F; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F9/082; B22F1/00; B22F1/06; B22F1/065; B22F1/0655; B29; B29C; B29C49/00; B29C49/0042; B29C70/00; B29C70/04; B29C70/06; B29C70/10; B29C70/12; B29C70/14; B29C70/58; B29C70/66; C; C03; C03B; C03B19/00; C03B19/10; C03B19/107; C03B19/1075; C22; C22C; C22C47/00; B22F2009/088; B29K; B29K2105/00; B29K2105/06; B29K2105/16; B29K2105/165; Y; Y10; Y10S; Y10S376/00; Y10S376/916; Y10T; Y10T428/00; Y10T428/25; Y10T428/252; Y10T428/254; Y10T428/256; Y10T428/29; Y10T428/2982
Claims Analysis
Total Claims: 69
Claim 1
Independent Claim
130 words
A method for making fiber reinforced hollow microspheres from a film forming material which comprises adding fibers to a film forming material, uniformly dispersing said fibers in the film forming material, forming a liquid film of said fibers and film forming material across an orifice, applying a blowing gas at a positive pressure on the inner surface of the liquid film to blow the film and form the microsphere, subjecting the microsphere during its formation to an external pulsating or fluctuating pressure field having periodic oscillations, said pulsating or fluctuating pressure field acting on said microsphere to assist in its formation and to assist in detaching the microsphere from said orifice, hardening said microspheres and obtaining hollow fiber reinforced microspheres having fibers uniformly distributed in the walls of said microspheres.
Claim 2
Independent Claim
130 words
A method for making fiber reinforced hollow microspheres from a film forming material which comprises adding fibers to a film forming material, uniformly dispersing said fibers in the film forming material, forming a liquid film of said fibers and film forming material across an orifice, applying a blowing gas at a positive pressure on the inner surface of the liquid film to blow the film and form the microsphere, subjecting the microsphere during its formation to an external pulsating or fluctuating pressure field having periodic oscillations, said pulsating or fluctuating pressure field acting on said microsphere to assist in its formation and to assist in detaching the microsphere from said orifice, hardening said microspheres and obtaining hollow fiber reinforced microspheres having fibers uniformly distributed in the walls of said microspheres.
Claim 3
Dependent Claim
114 words
The method of claim 1 wherein an entraining fluid is directed at an angle to a coaxial blowing nozzle having an orifice, an inner nozzle and an outer nozzle, the liquid film of film forming material is formed across the orifice, the blowing gas is conveyed to the inner surface of the liquid film through said inner nozzle, the fiber and film forming material is conveyed through said outer nozzle to said orifice, and the entraining fluid passes over and around said coaxial nozzle to fluid dynamically induce a pulsating or fluctuating pressure field at the opposite or lee side of the blowing nozzle in the wake or shadow of the coaxial blowing nozzle.
Claim 4
Dependent Claim
67 words
The method of claim 2 wherein the lower portion of the outer nozzle is tapered inwardly to form with the outer edge of the orifice of the inner nozzle a fine gap and the fiber and film forming material is fed under pressure and extruded through said gap to form a thin film of the fiber and film forming material across the orifice of the blowing nozzle.
Claim 5
Dependent Claim
41 words
The method of claim 2 wherein said entraining fluid is directed at said coaxial blowing nozzle at an angle of 15° to 85° relative to a line drawn through the center axis of said coaxial blowing nozzle and said outer nozzle.
Claim 6
Dependent Claim
24 words
The method of claim 2 wherein quench means provide a quench fluid to contact with said microsphere to rapidly cool and solidify said microsphere.
Claim 7
Dependent Claim
18 words
The method of claim 2 wherein the film forming material has a viscosity of 10 to 600 poises.
Claim 8
Dependent Claim
18 words
The method of claim 2 wherein the film forming material has a viscosity of 20 to 100 poises.
Claim 9
Dependent Claim
18 words
The method of claim 2 wherein the film forming material has a viscosity of 100 to 400 poises.
Claim 10
Dependent Claim
24 words
The method of claim 8 wherein said entraining fluid has a linear velocity in the region of microsphere formation of 40 to 100 ft/sec.
Claim 11
Dependent Claim
24 words
The method of claim 8 wherein said entraining fluid has a linear velocity in the region of microsphere formation of 5 to 40 ft/sec.
Claim 12
Dependent Claim
35 words
The method of claim 2 wherein said entraining fluid has a linear velocity in the region of microsphere formation of 1 to 120 ft/sec and entrains and transports the microspheres away from the blowing nozzle.
Claim 13
Dependent Claim
26 words
The method of claim 1 wherein the film forming material is selected from the group consisting of glass, metal, metal glass and plastic film forming material.
Claim 14
Dependent Claim
23 words
The method of claim 1 wherein the fiber is selected from the group consisting of ceramic, glass, metal, metal glass and plastic fibers.
Claim 15
Independent Claim
272 words
A method for making fiber reinforced hollow film forming material microspheres which comprises adding fibers to said film forming material, uniformly dispersing said fibers in the film forming material, forming a molten or liquid film forming material, forming a liquid film of said material across an orifice of a coaxial blowing nozzle, said blowing nozzle having an inner nozzle to convey a blowing gas to the inner surface of the liquid film and an outer nozzle to convey said liquid or molten material to said orifice, applying said blowing gas through said inner nozzle at positive pressure on the inner surface of the liquid film to blow the film downwardly and outwardly to form the microsphere, continuously feeding said film forming material to said outer nozzle while said microsphere is being formed, directing an entraining fluid at said coaxial blowing nozzle at an angle relative to a line drawn through the center axis of said coaxial blowing nozzle, said entraining fluid passing over and around said coaxial blowing nozzle to fluid dynamically induce a pulsating or fluctuating pressure field having periodic oscillations at the opposite or lee side of the blowing nozzle in the wake or shadow of said blowing nozzle, said entraining fluid acting on the microsphere to pinch and close-off the microsphere at a point proximate to the coaxial blowing nozzle and said entraining fluid acting to detach the microsphere from the coaxial blowing nozzle, surface tension forces causing the detached microsphere to form a spherical shape, and solidifying said microsphere and obtaining fiber reinforced hollow microspheres in which the fibers are uniformly dispersed in the walls of the microspheres.
Claim 16
Independent Claim
272 words
A method for making fiber reinforced hollow film forming material microspheres which comprises adding fibers to said film forming material, uniformly dispersing said fibers in the film forming material, forming a molten or liquid film forming material, forming a liquid film of said material across an orifice of a coaxial blowing nozzle, said blowing nozzle having an inner nozzle to convey a blowing gas to the inner surface of the liquid film and an outer nozzle to convey said liquid or molten material to said orifice, applying said blowing gas through said inner nozzle at positive pressure on the inner surface of the liquid film to blow the film downwardly and outwardly to form the microsphere, continuously feeding said film forming material to said outer nozzle while said microsphere is being formed, directing an entraining fluid at said coaxial blowing nozzle at an angle relative to a line drawn through the center axis of said coaxial blowing nozzle, said entraining fluid passing over and around said coaxial blowing nozzle to fluid dynamically induce a pulsating or fluctuating pressure field having periodic oscillations at the opposite or lee side of the blowing nozzle in the wake or shadow of said blowing nozzle, said entraining fluid acting on the microsphere to pinch and close-off the microsphere at a point proximate to the coaxial blowing nozzle and said entraining fluid acting to detach the microsphere from the coaxial blowing nozzle, surface tension forces causing the detached microsphere to form a spherical shape, and solidifying said microsphere and obtaining fiber reinforced hollow microspheres in which the fibers are uniformly dispersed in the walls of the microspheres.
Claim 17
Dependent Claim
65 words
The method of claim 14 wherein the lower portion of the outer nozzle is tapered inwardly to form with the outer edge of the orifice of the inner nozzle a fine gap and feeding the fiber and liquid film forming material under pressure through said gap to form a thin film of the fiber and film forming material across the orifice of the blowing nozzle.
Claim 18
Dependent Claim
38 words
The method of claim 15 wherein fibers as they pass through said gap are aligned in a direction such that the length of the fiber is parallel to the wall of the film of the film forming material.
Claim 19
Dependent Claim
13 words
The method of claim 15 wherein the film forming material comprises molten glass.
Claim 20
Dependent Claim
13 words
The method of claim 15 wherein the film forming material comprises molten metal.
Claim 21
Dependent Claim
14 words
The method of claim 15 wherein the film forming material comprises molten metal glass.
Claim 22
Dependent Claim
17 words
The method of claim 15 wherein the film forming material comprises a liquid organic plastic or resin.
Claim 23
Dependent Claim
29 words
The method of claim 15 wherein fiber reinforced hollow microspheres having uniform diameters of 200 to 10,000 microns and uniform wall thickness of 1 to 1000 microns are obtained.
Claim 24
Dependent Claim
29 words
The method of claim 15 wherein fiber reinforced hollow microspheres having uniform diameters of 500 to 6000 microns and uniform wall thickness of 5 to 400 microns are obtained.
Claim 25
Dependent Claim
20 words
The method of claim 15 wherein the fibers comprise 3 to 30 percent by volume of the film forming material.
Claim 26
Dependent Claim
20 words
The method of claim 15 wherein the fibers comprise 10 to 25 percent by volume of the film forming material.
Claim 27
Dependent Claim
24 words
The method of claim 15 wherein the fibers have a diameter of 0.4 to 5 microns and a length of 5 to 100 microns.
Claim 28
Dependent Claim
24 words
The method of claim 15 wherein the fibers have a diameter of 0.5 to 3 microns and a length of 5 to 20 microns.
Claim 29
Dependent Claim
73 words
Fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, wherein the fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 30
Dependent Claim
73 words
Fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, wherein the fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 31
Dependent Claim
31 words
The fiber reinforced hollow film forming material microspheres of claim 27 wherein the microspheres have a diameter of 500 to 6000 microns and a wall thickness of 5 to 400 microns.
Claim 32
Dependent Claim
28 words
The fiber reinforced hollow film forming material microspheres of claim 28 having a diameter of 500 to 3000 microns and a wall thickness of 5.0 to 200 microns.
Claim 33
Dependent Claim
18 words
The fiber reinforced hollow microspheres of claim 27 having a contained gas pressure of 5 to 100 psia.
Claim 34
Dependent Claim
15 words
The fiber reinforced hollow microspheres of claim 27 wherein the film forming material comprises glass.
Claim 35
Dependent Claim
15 words
The fiber reinforced hollow microspheres of claim 27 wherein the film forming material comprises metal.
Claim 36
Dependent Claim
16 words
The fiber reinforced hollow microspheres of claim 27 wherein the film forming material comprises metal glass.
Claim 37
Dependent Claim
19 words
The fiber reinforced hollow microspheres of claim 27 wherein the film forming material comprises an organic plastic or resin.
Claim 38
Dependent Claim
24 words
The fiber reinforced hollow microspheres of claim 27 wherein the fibers comprise 3 to 30 percent by volume of the film forming material composition.
Claim 39
Dependent Claim
24 words
The fiber reinforced hollow microspheres of claim 27 wherein the fibers comprise 10 to 25 percent by volume of the film forming material composition.
Claim 40
Dependent Claim
26 words
The fiber reinforced microspheres of claim 27 wherein the fibers have a diameter of 0.4 to 5 microns and a length of 5 to 100 microns.
Claim 41
Dependent Claim
26 words
The fiber reinforced microspheres of claim 27 wherein the fibers have a diameter of 0.5 to 3 microns and a length of 5 to 20 microns.
Claim 42
Dependent Claim
28 words
The fiber reinforced microspheres of claim 27 wherein the fiber is selected from the group consisting of ceramic, glass, metal, metal glass and organic plastic or resin fibers.
Claim 43
Dependent Claim
68 words
Filamented, fiber reinforced hollow film forming material microspheres having a diameter of 200 to 10,000 microns and having a wall thickness of 1.0 to 1000 microns, wherein the fibers are uniformly dispersed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are the same film forming material from which the microspheres are made.
Claim 44
Dependent Claim
68 words
Filamented, fiber reinforced hollow film forming material microspheres having a diameter of 200 to 10,000 microns and having a wall thickness of 1.0 to 1000 microns, wherein the fibers are uniformly dispersed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are the same film forming material from which the microspheres are made.
Claim 45
Dependent Claim
105 words
Filamented, fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same film forming material from which the microspheres are made, and said microspheres are free of latent solid or liquid blowing gas materials or gases, and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 46
Dependent Claim
105 words
Filamented, fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same film forming material from which the microspheres are made, and said microspheres are free of latent solid or liquid blowing gas materials or gases, and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 47
Dependent Claim
27 words
The hollow microspheres of claim 41 wherein the length of the connecting filaments are substantially equal and is 2 to 20 times the diameter of the microspheres.
Claim 48
Dependent Claim
32 words
The hollow microspheres of claim 41 wherein the length of the connecting filaments is substantially equal and the diameter of the connecting filaments is 1/2500 to 1/20 the diameter of the microspheres.
Claim 49
Dependent Claim
84 words
A shaped form or formed mass of cemented or bonded together fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 50
Dependent Claim
84 words
A shaped form or formed mass of cemented or bonded together fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 51
Dependent Claim
84 words
A shaped form or formed mass of cemented or bonded together fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 52
Dependent Claim
84 words
A shaped form or formed mass of cemented or bonded together fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein said fibers are uniformly distributed in the walls of said microspheres and said microspheres are free of latent solid or liquid blowing gas materials or gases and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 53
Dependent Claim
36 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the microspheres are cemented together by fusion or sintering or are bonded together with an organic or inorganic bonding agent or adhesive.
Claim 54
Dependent Claim
18 words
The shaped form or formed mass of microspheres of claim 46 formed into a thin sheet or panel.
Claim 55
Dependent Claim
22 words
The microspheres of claim 45 having a diameter of 500 to 3000 microns and a wall thickness of 5.0 to 200 microns.
Claim 56
Dependent Claim
10 words
The microspheres of claim 23 having an oblate spheroid shape.
Claim 57
Dependent Claim
37 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the film forming material comprises a member selected from the group consisting of glass, metal, metal glass and an organic plastic or resin.
Claim 58
Dependent Claim
29 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the fibers comprise 3 to 30 percent by volume of the film forming material composition.
Claim 59
Dependent Claim
29 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the fibers comprise 10 to 25 percent by volume of the film forming material composition.
Claim 60
Dependent Claim
32 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the fibers have a diameter of 0.4 to 5 microns and a length of 5 to 100 microns.
Claim 61
Dependent Claim
32 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the fibers have a diameter of 0.5 to 3 microns and a length of 5 to 20 microns.
Claim 62
Dependent Claim
36 words
The shaped form or formed mass of fiber reinforced microspheres of claim 45 wherein the fiber is a member selected from the group consisting of ceramic, glass, metal, metal glass and organic plastic or resin fibers.
Claim 63
Dependent Claim
83 words
A shaped form or formed mass of cemented or bonded together filamented, fiber reinforced hollow film forming material microspheres having a uniform diameter of 200 to 10,000 microns and having a uniform wall thickness of 1.0 to 1000 microns, wherein the fibers are unformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same inorganic film forming material from which the microspheres are made.
Claim 64
Dependent Claim
83 words
A shaped form or formed mass of cemented or bonded together filamented, fiber reinforced hollow film forming material microspheres having a uniform diameter of 200 to 10,000 microns and having a uniform wall thickness of 1.0 to 1000 microns, wherein the fibers are unformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same inorganic film forming material from which the microspheres are made.
Claim 65
Dependent Claim
116 words
A shaped form or formed mass of cemented or bonded together filamented, fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein the fibers are uniformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same film forming material from which the microspheres are made, and said microspheres are free of latent solid or liquid blowing gas materials or gases, and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 66
Dependent Claim
116 words
A shaped form or formed mass of cemented or bonded together filamented, fiber reinforced hollow film forming material microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, wherein the fibers are uniformly distributed in the walls of said microspheres and said microspheres are connected to each other by filament portions which are continuous with the microspheres and are of the same film forming material from which the microspheres are made, and said microspheres are free of latent solid or liquid blowing gas materials or gases, and the walls of said microspheres are substantially free of holes, relatively thinned wall portions or sections and bubbles.
Claim 67
Dependent Claim
36 words
The shaped form or formed mass of fiber reinforced microspheres of claim 57 wherein the microspheres are cemented together by fusion or sintering or are bonded together with an organic or inorganic bonding agent or adhesive.
Claim 68
Dependent Claim
20 words
The shaped form or formed mass of fiber reinforced microspheres of claim 57 formed into a thin sheet or panel.
Claim 69
Dependent Claim
21 words
The shaped form or formed mass of fiber reinforced microspheres of claim 57 wherein the microspheres have an oblate spheroid shape.
References Cited (Backward Citations)
US4303731A
Cited
USPTO Annuity & Maintenance Windows
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| 3.5 Years (Year 4) | 1990-06-08 | 1990-12-08 | 1991-06-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-06-08 | 1994-12-08 | 1995-06-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-06-08 | 1998-12-08 | 1999-06-09 | $7700.00 | Window Closed / Lapsed |