US5125574A — Atomizing nozzle and process

Claim 1

Independent Claim 108 words

A high pressure gas atomizing nozzle for atomizing a melt, comprising: a) a melt supply member, b) a gas manifold for receiving high pressure gas, said manifold comprising a gas inlet in communication with a source of high pressure gas, a divergent first manifold chamber in communication with the gas inlet, and a second manifold chamber in communication with said divergent manifold chamber, said first manifold chamber diverging from the gas inlet toward the second manifold chamber, and c) a plurality of discrete gas discharge orifices disposed around the melt supply member and in communication with the manifold for discharging high pressure gas streams to atomize said melt.

Claim 2

Dependent Claim 108 words

A high pressure gas atomizing nozzle for atomizing a melt, comprising: a) a melt supply member, b) a gas manifold for receiving high pressure gas, said manifold comprising a gas inlet in communication with a source of high pressure gas, a divergent first manifold chamber in communication with the gas inlet, and a second manifold chamber in communication with said divergent manifold chamber, said first manifold chamber diverging from the gas inlet toward the second manifold chamber, and c) a plurality of discrete gas discharge orifices disposed around the melt supply member and in communication with the manifold for discharging high pressure gas streams to atomize said melt.

Claim 3

Dependent Claim 17 words

The nozzle of claim 1 wherein said second manifold chamber comprises a constant cross-section, arcuate manifold chamber.

Claim 4

Dependent Claim 54 words

The nozzle of claim 2 wherein the arcuate manifold chamber has an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold, and said expansion chamber has a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ).

Claim 5

Dependent Claim 15 words

The nozzle of claim 3 wherein r 2 -r 0 δ2.5(r 1 -r 0 ).

Claim 6

Dependent Claim 24 words

The nozzle of claim 1 wherein the gas manifold is disposed in a nozzle body having a bore that receives said melt supply member.

Claim 7

Dependent Claim 22 words

The nozzle of claim 5 wherein the gas discharge orifices each intersect the bore at a tangency thereto not exceeding 0.002 inch.

Claim 8

Dependent Claim 17 words

The nozzle of claim 6 wherein the tangency of said discharge orifices does not exceed 0.001 inch.

Claim 9

Dependent Claim 20 words

The nozzle of claim 1 wherein the expansion chamber diverges at an included angle of about 40° to about 90°.

Claim 10

Dependent Claim 13 words

The nozzle of claim 8 wherein the included angle is about 64 degrees.

Claim 11

Dependent Claim 116 words

In a method of atomizing a rare earth-transition metal alloy melt by supplying high pressure gas to a gas manifold communicating to a plurality of discrete gas discharge orifices disposed around a melt supply member, the improvement comprising supplying the high pressure gas to a gas manifold having a divergent first manifold chamber disposed between a manifold gas inlet and a second manifold chamber communicating to said orifices, said first manifold chamber diverging from said gas inlet toward said second manifold chamber so as to reduce standing shock wave patterns in said manifold and thereby improve filling of said manifold with the high pressure gas that is discharged from the discharge orifices for atomizing the melt.

Claim 12

Dependent Claim 116 words

In a method of atomizing a rare earth-transition metal alloy melt by supplying high pressure gas to a gas manifold communicating to a plurality of discrete gas discharge orifices disposed around a melt supply member, the improvement comprising supplying the high pressure gas to a gas manifold having a divergent first manifold chamber disposed between a manifold gas inlet and a second manifold chamber communicating to said orifices, said first manifold chamber diverging from said gas inlet toward said second manifold chamber so as to reduce standing shock wave patterns in said manifold and thereby improve filling of said manifold with the high pressure gas that is discharged from the discharge orifices for atomizing the melt.

Claim 13

Dependent Claim 32 words

The method of claim 10 wherein the high pressure gas is supplied to gas discharge orifices that each intersect a melt supply member-receiving bore at a tangency thereto not exceeding 0.002 inch.

Claim 14

Dependent Claim 17 words

The method of claim 11 wherein the tangency of said discharge orifices does not exceed 0.001 inch.

Claim 15

Dependent Claim 67 words

The method of claim 10 wherein the high pressure gas is supplied form the divergent manifold chamber to the second manifold chamber having an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold via said divergent manifold chamber having a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ).

Claim 16

Dependent Claim 15 words

The method of claim 13 wherein r 2 -r 0 δ2.5(r 1 -r 0 ).

Claim 17

Dependent Claim 24 words

The method of claim 10 wherein the divergent manifold chamber is formed to diverge at an included angle of about 40° to about 90°.

Claim 18

Dependent Claim 13 words

The method of claim 15 wherein the included angle is about 64 degrees.

Claim 19

Independent Claim 88 words

A method of making an improved high pressure gas atomizing nozzle having a bore for receiving a melt supply member, comprising the steps of: a) forming said bore to an initial, undersized, lateral dimension, b) forming a plurality of discrete gas discharge orifices about said bore and intersecting therewith at a given angle, and c) forming the bore to a final, lateral dimension larger than said undersized dimension such that the gas discharge orifices are each at a tangency to said final-dimensioned bore not exceeding about 0.002 inch.

Claim 20

Independent Claim 88 words

A method of making an improved high pressure gas atomizing nozzle having a bore for receiving a melt supply member, comprising the steps of: a) forming said bore to an initial, undersized, lateral dimension, b) forming a plurality of discrete gas discharge orifices about said bore and intersecting therewith at a given angle, and c) forming the bore to a final, lateral dimension larger than said undersized dimension such that the gas discharge orifices are each at a tangency to said final-dimensioned bore not exceeding about 0.002 inch.

Claim 21

Dependent Claim 24 words

The method of claim 17 wherein the said discharge orifices are formed at a tangency to said final-dimensioned bore not exceeding about 0.001 inch.

Claim 22

Dependent Claim 60 words

In a high pressure gas atomizing nozzle having a melt supply member for supplying a melt for atomization, the improvement wherein the melt supply member comprises an inner refractory tubular member having a melt supply orifice, and an outer metallic tubular member spaced from the inner refractory body to form a thermal insulating space between the inner and outer members.

Claim 23

Dependent Claim 60 words

In a high pressure gas atomizing nozzle having a melt supply member for supplying a melt for atomization, the improvement wherein the melt supply member comprises an inner refractory tubular member having a melt supply orifice, and an outer metallic tubular member spaced from the inner refractory body to form a thermal insulating space between the inner and outer members.

Claim 24

Dependent Claim 28 words

The combination of claim 19 wherein the inner member includes a lateral, annular flange disposed on an annular shoulder of the outer member proximate an upper end thereof.

Claim 25

Dependent Claim 144 words

A high pressure gas atomizing nozzle for atomizing a melt, comprising: a) a melt supply member, b) a gas manifold for receiving high pressure gas, said manifold comprising a gas inlet in communication with a source of high pressure gas, a divergent first manifold chamber in communication with the gas inlet, and a second manifold chamber in communication with said divergent manifold chamber, said arcuate manifold chamber having an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold and said divergent first manifold chamber having a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ), and c) a plurality of discrete gas discharge orifices disposed around the melt supply member and in communication with the manifold for discharging high pressure gas streams to atomize said melt.

Claim 26

Dependent Claim 144 words

A high pressure gas atomizing nozzle for atomizing a melt, comprising: a) a melt supply member, b) a gas manifold for receiving high pressure gas, said manifold comprising a gas inlet in communication with a source of high pressure gas, a divergent first manifold chamber in communication with the gas inlet, and a second manifold chamber in communication with said divergent manifold chamber, said arcuate manifold chamber having an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold and said divergent first manifold chamber having a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ), and c) a plurality of discrete gas discharge orifices disposed around the melt supply member and in communication with the manifold for discharging high pressure gas streams to atomize said melt.

Claim 27

Dependent Claim 15 words

The nozzle of claim 23 wherein r 2 -r 0 δ2.5(r 1 -r 0 ).

Claim 28

Dependent Claim 146 words

In a method of atomizing a rare earth-transition metal alloy melt by supplying high pressure gas to a gas manifold communicating to a plurality of discrete gas discharge orifices disposed about a melt supply member, the improvement comprising supplying the high pressure gas to a gas manifold having a divergent first manifold chamber disposed between a manifold gas inlet and a second manifold chamber communicating to said orifices and having an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold, said first manifold chamber having a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ) so as to reduce standing shock wave patterns in said manifold and thereby improve filling of said manifold with the high pressure gas that is discharged from the orifices for atomizing the melt.

Claim 29

Dependent Claim 146 words

In a method of atomizing a rare earth-transition metal alloy melt by supplying high pressure gas to a gas manifold communicating to a plurality of discrete gas discharge orifices disposed about a melt supply member, the improvement comprising supplying the high pressure gas to a gas manifold having a divergent first manifold chamber disposed between a manifold gas inlet and a second manifold chamber communicating to said orifices and having an inner radius r 0 and an outer radius r 1 relative to a central axis of said manifold, said first manifold chamber having a dimension r 2 relative to said central axis wherein r 2 -r 0 ≧2(r 1 -r 0 ) so as to reduce standing shock wave patterns in said manifold and thereby improve filling of said manifold with the high pressure gas that is discharged from the orifices for atomizing the melt.

Claim 30

Dependent Claim 15 words

The method of claim 23 wherein r 2 -r 0 δ2.5(r 1 -r 0 ).

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1995-06-30	1995-12-30	1996-06-30	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1999-06-30	1999-12-30	2000-06-30	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2003-06-30	2003-12-30	2004-06-30	$7700.00	Window Closed / Lapsed

Atomizing nozzle and process

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