Apparatus for transforming the physical structure of thermo-flow materials

Claim 2

A spinning machine comprising: a spinner head including a chamber and a heater assembly defining a wall of said chamber; means for rotating said spinner head about an axis, said heater assembly including an annular heater element, the heater element including a plurality of spaces through which material undergoing flash flow pass, a removable non-conductive band having a plurality of openings therethrough and positioned around and in close proximity to said heater element, and an annular support ring, the annular support ring having openings therein and positioned around said band for holding said heater element and said band within said spinner head, wherein a combination of a size of the spaces in the heater element and a size and shape of the openings in the non-conductive band provides a working orifice for flow of material through said heater assembly to produce a resultant product having a desired morphology.

Claim 3

A spinning machine as defined in claim 1, wherein said spinner head further comprises a base portion, and a cap portion, said heater assembly being positioned between said base and cap portions.

Claim 4

A spinning machine as defined in claim 1, further comprising: a basin, said spinner head being positioned within said basin for receipt of a material being processed in said spinner head.

Claim 5

A spinning machine as defined in claim 1, wherein said plurality of openings in said non-conductive band are substantially circular having a diameter ranging from about 0.01 inches to about 0.05 inches.

Claim 6

A spinning machine as defined in claim 1, wherein said non-conductive band comprises a heat-resistant material.

Claim 7

A spinning machine as defined in claim 5, wherein said heat-resistant material comprises aromatic polyimide having up to 1% dimethyl acetamide.

Claim 8

A spinning machine as defined in claim 1, wherein said band comprises polytetraflouroethylene.

Claim 9

A spinning machine as defined in claim 1, wherein said annular support ring includes a plurality of slotted openings and wherein the non-conductive band openings are arranged such that an opening in said non-conductive band aligns with each of said plurality of slotted openings so that feedstock material undergoing flash flow passes through the aligned support ring slots and band openings.

Claim 10

A spinning machine as defined in claim 1, wherein the heater element comprises a narrow ribbon of resistance wire wound in a flat coil having spaces between each coil so that feedstock material undergoing flash flow passes therethrough.

Claim 11

A spinning machine as defined in claim 9, wherein the band openings are arranged so that an opening of the band aligns with each space between the coils of the heating element and feedstock material undergoing flash flow passes through the aligned coil spaces and band openings.

Claim 12

A spinning machine as defined by claim 1, wherein the non-conductive material has a dielectric strength greater than 5.75 v/micron.

Claim 13

A spinner head comprising: a base portion; a cap portion; a heater assembly mounted between said base and cap portions, said heater assembly including an annular heater element, the heater element including a plurality of spaces through which material undergoing flash flow pass, a removable non-conductive band having a plurality of openings therethrough and positioned around and in close proximity to said heater element, and an annular support ring, the annular support ring having openings therein and positioned around said band for maintaining said heater element and said non-conductive band in close proximity; a chamber defined by said base portion, heater assembly and cap portion; an opening defined within said cap portion for introducing material into said chamber; whereby said heater assembly provides a path for said material for processing by undergoing flash flow and being projected therefrom for resolidifying and wherein a combination of a size of the heater element spaces and a size and shape of the openings in the band produce a resultant product having a desired morphology.

Claim 14

A spinner head comprising: a base portion; a cap portion; a heater assembly mounted between said base and cap portions, said heater assembly including an annular heater element, the heater element including a plurality of spaces through which material undergoing flash flow pass, a removable non-conductive band having a plurality of openings therethrough and positioned around and in close proximity to said heater element, and an annular support ring, the annular support ring having openings therein and positioned around said band for maintaining said heater element and said non-conductive band in close proximity; a chamber defined by said base portion, heater assembly and cap portion; an opening defined within said cap portion for introducing material into said chamber; whereby said heater assembly provides a path for said material for processing by undergoing flash flow and being projected therefrom for resolidifying and wherein a combination of a size of the heater element spaces and a size and shape of the openings in the band produce a resultant product having a desired morphology.

Claim 15

A spinner head as defined in claim 12, wherein said band openings are substantially circular and each has a diameter ranging from about 0.01 inches to about 0.05 inches.

Claim 16

A spinner head as defined in claim 12, wherein said band comprises heat-resistant material.

Claim 17

A spinner head as defined in claim 14, wherein said heat-resistant material comprises aromatic polyimide having up to 1% dimethyl acetamide.

Claim 18

A spinner head as defined in claim 12, wherein said band comprises polytetraflouroethylene.

Claim 19

A spinner head as defined in claim 12, wherein said annular support ring includes a plurality of slotted openings and wherein the non-conductive band openings are arranged such that an opening in said non-conductive band aligns with each of said plurality of slotted openings so that feedstock material undergoing flash flow passes through the aligned support ring slots and band openings.

Claim 20

A spinner head as defined in claim 16, wherein each non-conductive material has a dielectric strength greater than 5.75 v/micron.

Claim 21

A spinning machine as defined in claim 12, wherein the heater element comprises a narrow ribbon of resistance wire wound in a flat coil having spaces between each coil so that feedstock material undergoing flash flow passes therethrough.

Claim 22

A spinning machine as defined in claim 19, wherein the band openings are arranged so that an opening of the band aligns with each space between the coils of the heating element and said material undergoing flash flow passes through said aligned band openings and heater element spaces.