CA1101217A - Method and apparatus for fiberizing attenuable materials and product thereof - Google Patents

Method and apparatus for fiberizing attenuable materials and product thereof

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Publication number
CA1101217A
CA1101217A CA265,560A CA265560A CA1101217A CA 1101217 A CA1101217 A CA 1101217A CA 265560 A CA265560 A CA 265560A CA 1101217 A CA1101217 A CA 1101217A
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Canada
Prior art keywords
jet
blast
stream
carrier jet
orifice
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA265,560A
Other languages
French (fr)
Inventor
Marcel Levecque
Jean A. Battigelli
Dominique Plantard
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Saint Gobain Industries SA
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Saint Gobain Industries SA
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Classifications

    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01Manufacture of glass fibres or filaments
    • C03B37/06Manufacture of glass fibres or filaments by blasting or blowing molten glass, e.g. for making staple fibres

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Manufacturing & Machinery (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Organic Chemistry (AREA)
  • Manufacture, Treatment Of Glass Fibers (AREA)
  • Nonwoven Fabrics (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Preliminary Treatment Of Fibers (AREA)
  • Inorganic Fibers (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
Method and apparatus are disclosed for con-verting a stream of attenuable material into a fiber by a two-stage attenuation technique, the two stages being effected sequentially by employment of a gaseous jet and a gaseous blast, thereby producing a single long fiber from each stream of attenuable material.

Description

~Q3~ 7 !
METHOD AND APPARATUS FOR
FIBERIZING ATTENUABLE MATERIALS
_AND PRODDCT THEREOF ~

BACKGROUND: ~ -The invention relates to the production of fine fibers from attenuable materials, particularly attenuable materials which soften upon entering a molten state as a result "~
of the application of hea-t and which harden or become relatively solid upon cooling. ~
`' -The method and equipment of the invention are espec-ially suited to the formation of fibers from glass and the disclosure herein accordingly emphasizes production of glass fiber~ from molten glass.
. .
: "
Many techniques are already known for production of fibers from molten glass, some o~ the techniques most widely used heretofore being identified and briefly described ..
just below.

1. Longitudinal Blowing: Other terms sometimes ~`~
used include "blown fiber", "steam blown wool", "steam blown bonded mat", "low pressure air blowing", or "lengthwise jets".

. ~ ~
~ 2. Strand: Other terms some~imes used are "continu~
- ous filament", or "textile ibers".

3. Aerocor: Another term sometimes used is "flame attenuation". .

4. Centrifugin~: Other terms sometimes used include "rotary process", "centrifugal process"~ "tel process", or "supertel process".

There are numerous variants of each of the above four processes, and some efforts in the art to combine certain of the processes. Further, there are other techniques discuss- ;
ed in the prior art by which prior workers have attempted to make glass fibers. However, the variants, attempted combi-nations, and attempted other techniques, for the most part have not met with sufficient success to achieve a separate ,', and recognizable status in the art.
~ ' The four techniques above referred to may briefly be described as follows.

1. Longitudinal Blowi~

,-Longitudinal blowing (examples of which are referred to as items 1, 2, 3 and 4 in the hi~liography herebelow) is a glass fiber manufacturing process according to which melted glass flows ~rom the forehearth of a furnace through orifices in one or two rows o~ tips protruding downwardly from a bushing, the glass being thereby formed into multiple glass streams which flow down into an attenuating zone where the streams pass between downwardly converginy gaseous blasts.

The blast emit~ing means are located in close proximity to the streams so that the converging blasts travel in a downward direction substantially parallel to the direction of travel - of the glass streams. Generally the glass streams bisect the angle between the converging blasts. The blasts are ~`
typically high pressure steam. ~ -~
';` .
:

.', `:
There are two longitudinal blowing techniques.
In the first technique the attenuating blasts engage already drawn fibers ana the product resulting is typically a mat, commonly known as "steam blown bonded mat", suitable for S reinforcement. In the second longitudinal blowing technique the attenuating blasts strike directly on larger streams oE molten glass and the product resulting is typically an ~
insulation wool commonly known as "steam blown wool". ~ ~-In a variation (see item 5) of the first longitudinal `
blowing technique, the entire bushing structure and associated furnace are enclosed within a pressure chamber so that, as the streams of glass emerge from the bushing, th~ streams are attenua~.ed by pressurized air emerging from the pressure chamber through a slot positioned directly beneath the glass emittin~ tips of the bushing, this variation being commonly referred to as "low pressure air blowing", and products being commonly known as "low pressure air blown bonded mat and ";~
staple yarn".
~ '., '
2. Strand The strand glass fiber manufacturing process (see items 6 and 7) begins in the manner described above in connec~
tion with longitudinal blowing, that is, multiple glass streams are formed by flow through orifices in tips protruding down~
wardly from a bushing. However, the strand process does ~ not make use of any blast for attenuation purposes but, onthe contrary, uses mechanical pulling which is accomplished at high speed by means of a rotating drum onto which the ~;~
fiber is wound or b~ means of rota-ting rollers between which ~3~

the flber passes. The prior art in the field of the strand process is extensive but is of no real significance to the present invention. Strandtechniques therefore need not be further considered herein.
3. Aerocor .

In the aerocor process (see items 8 and 9) for making glass fibers, the glass is fed into a high temperature and high velocity blast while in the form of a solid rod rather than flowing in a licluid stream as in the longitudinal blowing and stranc1 processes discussed above. The rod, or sometimes a coarse filament, of glass is fed from a side, usually substantially perpendicularly, into a hot gaseous blast~ The end of the rod is heated and softened by the blast so that fiber can be attenuat:ed therefrom b~ the force of the blast, the fiher being carr:Led away entrained in the blast.
4 Centrifuging In the centrifuging glass fiber manufacturing process (see items 10 and 11) molten glass is fed into the interior of a rapidly rotating centrifuge which has a plurality of orifices in the periphery. The glass flows through the orifices in the form of streams under the action of centrifuyal force and the glass streams then come under the influence of a ~; concentric and generally downwardl~l directed hot blast of flames or hot gas, and may also, at a location concentric with the first blast and farther outboard from the centrifuge, - come under the action of another high speed downward blast, ;

~ 12~

which latter is generally high pressure air or steam. The glass streams are thereby attenuated into fine fibers which are cooled and discharged downwardly in the form of glass -wool.

In addition to the four categori~s of fiber forming techniques which have been very generally referred to and distinquished above, various refinements and variations of those techniques have also been known and repeated efforts have been made to optimize the manufacture of glass fibers ~
by one or more of the processes which start with molten streams ~ -of glass. Various of these prior art techniques have been concerned with trying to optimize the attenuation process ;~
by extending or lengthening the attenuation zone, either by providing special means to accomplish the addition of heat to the streams of glass and to the embryonic fibers ~see item 12), or through the use of confining jets (see items 13 and 14), or both (see item 15)~

The approach taken in the just mentioned prior ~-~ art technique suggests that the realization of optimum ~iberiza- :
`; 20 tion lies in extending the lenc~th o a single attenuating ~`
zone.

In contrast, in th~ practice of the present invention, ; at~enuation is accomplished by subjecting a glass stream to two sequential stages of attenuation, performed under different conditions, as will further appear.
~ :;.

Various other approaches have been suggested for introducing glass in the molten state into an attenuating ~ .

blast (see i~ems 16, 17, 18 and 19). In such attempts to introduce a stream of molten glass into an attenuating blast it has been noted that there often is a tendency for the glass stream to veer to a path of travel on the periphery of the blast, that is, to "ride" ~he hlast, rather than pene~
trating into the core region of the blast where attenuating conditions are more effective. Suggestions have been made to deal with this "riding" problem, including the use of physical baffles as in Fletcher (item 16), and the transfer of substantial kinetic energy to the glass stream as, for example, by the modifications of the centrifuging process taught in Levecque (item 11), Paymal (item 18), and Battigelli ; (item 19).
' '~.

An alternate approach to the problem, more closely ~:

akin to the aerocor process, has been the introduction of the glass in the form of a solid (item 9) or pre-softened ~`` (item 20) glass rod or in the form of powdered glass (item '~ 14).

:.
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,, ~ ;.

.`''-`' ' '`'`''`` ' .. ' .
-~', 7 ~:

BIBLIO~ lY ~ _~ PRI~R PATF`NTS ;~

(1) Slayter et al 2~133~236 ~ ~-(2) Slayter et al 2,206 r 058 (3) Sla~ter et al 2~257~767 :-(4) Slayter et al 2r810,157 `.
(5) Dockert~ 2 ~ 286 ~ 903 ` ~ "
(6) Slayter et al 2r729rO27 .~`~
(7) Da~ et al 3~269~820 ;~ ~ .
(8) Stalego 2r489~243 ~ -
(9) Stalego 2 r 754 r 541 ~ .
(lO) Levecque et al 2r991r507 (11) hevecque et al 31215 r 514 ;
: (12) Stalego 2r687~551 `:~
` (13) Stalego 2~699~631 (14) ICarlovitz et al 2,925r620 (15) Karlovitz 2,982r991 ~16~ Fletcher 2r717r416 ~ -~- (17~ Eberle 3r357r808 (18) Paymal 3r634~055 (19~ Battigelli 3,649r232 (20) Stalego 2, 607,075 '~ , .
;, :
' ~:

: ,' .. . . . .

Z~7 General Statement of the Invention and Objects .`, '~
In contrast with all of the foregoing prior art techniques, it is a major objective of the present invention .
to provide certain improvements in the production of fibers from streams of molten glass or similar attenuable materials. ~:
The technique of the present invention in part utilizes the fiber "toration" techniques or principles disclosed in our prior Canadian applications above identified Serial No.
245,501, and Serial No. 196,097, filed February 11, 1976 and March 27, 1974, respectively. ~Such toration techniques are also disclosed in U.S.A. patent No. 3,885,940, issued May 27, ;~
1975. Thus, the technique of the present invention makes ~:
: use of the attenuating capabilit~ of a zone of interaction developed by ~he direction of a secondary jet of relatively ~.
small cross section transversely into a principle blast or jet of relatively larcJe cross sect.i.on. Elowever, according `. to the present invention, instead of directly admitting or ~; delivering a stream of molten glass to the zone of interaction, ; ~:.
the glass stream is delivered ~rom an appropriate orifice ;

spaced an appreciable distance above the zone of interaction.
. . ,':, .

P1oreover, in a typical technique according to the -~ present invention, the blast is discharged in a generally horizontal direction, the glass admission orifices are arrang-~:.
`. ed in spaced relation above the blast, and at an intermediate `.
` 25 elevation, secondary jets are discharged downwardly toward ; the blast from jet orifices positioned adjacent to the decend- :

ing glass streams, and preferably inclined somewhat with respect to the vertical, 50 that the glass streams enter the influence of the jets at a point above the upper boundary .
~8-of the blast, but well below the glass orifices. Preferably also each secondary jet orifice and the associated glass stxeam are spaced from each other in a direction upstream and downstream of the direction of flow of the blast, with the jet orifice located, with respect to the direction of ;~
flow of the blast, on the upstxeam side of the glass stream.
.~';
The system of the invention, as just briefly describ-ed, functions in the following manner:
:'''~,. ~' Each secondary jet, being spaced appreciably above the upper boundary of the blast, causes induction of the ~ ;~

am~ient air so that the jet develops a sheath or envelope of induced air which progressively increases in diameter as the upper boundar~ of the blast is approached. The jet thus is comprised of two portions, i.e. the core itself which is initially delivered from the jet orifice and the main ; body of the jet which is frequently referred to as the mixing zone, i.e. the zone represented by the mixture of the gas ~; of the core with induced air.
,~ :
~. .
In a typical embodiment, the jet core extends for -~ 20 a distance beyond the jet orifice e~ual to from 3 to 10 times the diameter of the jet orifice, depending primarily upon the velocity of the jet through the orifice. Since in installa-tions of the kind here involved, the jet orifices are of only very small diameter, the extent to which the jet core is projectea bevond the orifice is relatively short. The ;
jet core is conical and the mixing zone surrounds the jet core from the region of delivery from the jet orifice and is of progressively increasing diameter downstream of the jet, including a length of travel extended well beyond the -~
tip of the jet core cone. In such a typical installation, the spacing between the jet orifice and the boundary of the ~:
blast is such that the point of intersection of the blast lies beyond the tip of the core, although with certain propor-tions the jet core may come close to or somewhat penetrate the blast. In any event, it is contemplated that at the point of intersection of the jet and blast, the body of the jet or jet stream retains sufficient kinetic energy or velocity to penetxate the blast and thereby develop a zone of interaction between the jet and the blast. This zone of interaction has the same general characteristics as the zone oF interaction referred to and fully described in the prior Canadian applica-~ tions and in the U.S.A. patent, above identified.

.~ 15 With the foregoing in mind, attention is now directed to the glass stream and its behavior in relation to the jet and blast. As already noted, the glass stream is delivered from an orifice spaced above the blast and also spaced appre~
ciably above the point of delivery or discharge of the secondary jet~ Pre~erably the glass discharge orifice is so located ~`
`~ as to deliver a stream of glass which by free-fall under the action of gravity will follow a path which would intersect the axis of the jet at a point appreciably above the upper boundary of the blast and thus also above the zone of interaction.
As the glass stream approaches the jet r it is influenced by the currents of induced air and is thereby caused to deflect toward the jet above the point where the glass stream would otherwise have intersected the axis of the jet. The induction effect causes the stream of glass to approach the jet and, : . . , 9l7 : -depending upon the position of the glass orifice, the induction effect will either cause the glass stream to enter the envelope ~ ~
of induced air surrounding the core, or will cause the glass ~ ~-stream to enter the main body of the jet at a point downstream of the jet core. In either case, the glass stream will follo~
a path leading into the mixing zone and the glass stream will travel within the body of the jet downwardly to the zone of interaction with the blast.

~` ',~
Thus, the glass stream is carried by the induced ;~
air currents into the mixing zone of the jet, ~ut does not penetrate the jet core. The glass stream may be carried ~- -, ~, ; .
`~ by the induced air to the surface of the jet core, but will `~

~ not penetrate the core, which is desirable in order to avoid : . . . : :' fragmentation of the glass stream. Since the glass stream ;~ 15 is at this time in the influence of the mixing zone of the jet, the stream of glass will be subjected to a preliminary attenuating action and its velocity will increase as the ~ :.
~ upper boundary of the blast is approached.
`'`" :~
In addition to this attenuating action, which is aerodynamic in character, the attenuating stream is subjected to certain other dynamic forces tending to augment the attenu- ~ i ation. This latter attenuation action is caused by the tendency ~; for the attenuated stream to move toward the center of the jet and then be reflected toward the boundary of the ]et into the influence of the air being induced. The attenuating stream is then again causeA to enter into the interior of the jet. This repeated impulsion supplements the aerodynamic attenuating action.

.

31~

In the region of interaction with the blastl the partially attenuated stream of glass will be caused to enter the zone of interaction, in part because of the acceleration of the glas~ resulting from the action of gravity and from the preliminary attenuation described just above, and in part under the influence of the currents established in the ~-zone of interaction itself, in the manner fully explained in our prior applica-tions above identified.

Thus it ~rill be seen, that according to the invention, the glass stream is subjected to two successive stages of attenuation. Xt is also to be observed that since the ylass ~ -~` stream i5 caused to come under the influence of the jet by virtue of ~he induced currents surrounding the jet, the prelimi-nary attenuation is accomplished without fragmentlng the ;~
g:Lass stream. Moreover the succeecling or second stage of attenuation which is effected in the zone of interaction between the jet and the hlast is also accomplished without fra~menting the fiber being formed. By this two stage attenua-ting techniclue it is thus possible to produce long fibers.

The technique of the present invention has important advantages as compared with various prior techniques. Thus, it provides a technique for the production of long fihexs while at the same time making possible greater separation between certain components of the equipment, notably the blast generator or burner, with its nozzle or lips, the jet nozzle and the gas or air supply means associated -therewith --~
and the glass supply means including the bushing or similar equipment having glass orifices. This separation of components is not only of advantage from the standpoint of facilitating ,:.:, -the structural installationr but is further of advantage because the separation makes possible more convenient and accurate regulation of operating conditions, notably temperature of the blast, jets and ylass supply means. Still another advantage of the arrangement according to the present invention, is that the spacing of the glass supply means with its orifices for discharging streams of glass makes possible the utilization of larger glass orifices (which is sometimes desirable for special purposes or materials) because, in the distance of I0 free-fall provided for the glass streams, such s-treams decrease -in diameter under the influence of the gravitational accelera-tion. The streams should of course be of relatively small diameter at the time of initiation of ~ttenuation, and the desired small diameter can readily be achieved, hecause of the distance of free-fall, notwithstanding the employment of clelivery orifices of relatively large size.

The foregoing has still another advantageous feature, ~ namely the fact that a higher temperature may be utilized - in the glass bushing or other supply means, thereby enabling use of attenuable materials at higher temperatures, because during the distance of free-fall of the glass stream, the stream is somewhat cooled because of contact with the surround-ing air, thereby bringing the stream down to an appropriate -temperature for the initiation of attenuation.

Because of various of the foregoing factors, the system of the present invention facilitates the use of certain types of molten materials in the making of fibers, for instance slag or certain special gLass formulations which do not readil~
maintain uniformity of flow through discharge orifices of small size. However, since both larger diameter discharge orifices and higher temperatures may be used in the supply of the molten material, it becomes feasible to establish uniformity of feed and attenuation even with certain classes -`
of attenuahle materials which could not otherwise be employed in a technique based upon production of fibers by attenuation - of a stream of molten material.

It is also noted that various of the Eour principle ~
prior art techniques referred to above are subject to a number ~ -of limitations and disadvantages. For example, various of the prior techniques are limited from the standpoint of pro~
duction capacity or "orifice pull rate", i.e. the amount of proc~uction accomplished within a given time by a single . . .
fiber producing center. In other cases, the fiber product contains undesirable quantities of unfiberized material.
. . .
5trand type oE operations, while effective for producing strand material, are not best suit~3d for production of in- ;
sulation type of fiber blanket and other similar types of products. Centrifuging, while effective for producing fi-ber insulation blanket has the disadvantage that the centrifuge must rotate at high speed, thus necessitating special working parts and maintenance t and further because the centrifuge is required to be formed of special alloys capable of withstanding the high temperatures.

Another general objective of the present invention ~5 is to provide a technique which overcomes various of the foregoing disadvantages or limitations of the prior art techniques referred to.

i, ~ . : '; . . , !

Moreover, the technique of the present invention provides for high production rates and utilizes only static ~.
equipment.
In summary of the above, therefore, the present ;~
invention may be considered as providing a process for converting attenuable material into a fiber comprising generating a gaseous blast and a gaseous carrier jet, the direction and the kinetic energy per unit of volume of the jet being such that the jet penetrates into the blast, thereby forming a zone of interaction in proximity of the path of :
penetration of the carrier jet into the blast, and delivering ~ -a stream of the attenuable material to the boundary of the ~:
blast so as to enter into the æone of interaction, the carrier jet being delivered from a source spaced from the blast and ` the said stream of material being first introduced into a zone in which currents of air are induced by the carrier jet to aubject the stream to an initial or partial attenuation and ~orm a continuous filament before reaching the boundary .
o the blast, the partially attenuated stream being thereafter drawn into a fiber by a second attenuation in the.zone of . ~
interaction~ ~ :
The above method may be carried out by way of ::
apparatus for making fibers from attenuable material compris-.
ing supply means for the material having a delivery orifice positioned for downward delivery of a stream of the material, `~
means including a discharge outlet for establishing a gaseous :~
blast spaced below the material delLvery orifice and directed transverse to the stream, and means for establishing a gaseous carrier jet including a jet discharge orifice directing the jet downwardly toward and penetrating the blast, the blast having a transverse dimension in the direction of the path of penetration by the carrier jet, which dimension is appreciably greater than the transverse dimension of the carrier jet to , sd/~ 15~

12~7 thereby establish a zone o interaction between the blast and the carrier ~et, the carrier jet orifice and the material :
delivery orifice being relatively positioned to provide for impingement of the stream of attenuable material on the carrier jet at a point spaced from the blast and thus provide for travel of the stream of attenuable material with the : carrier jet to the zone of interaction of the jet with the ::
: blast.
Detailed Description of the Invention The accompanying drawings illustrate, on an enlarged :
:; scale, a preferred embodiment of the present invention, and ~ in these drawings -:. Figure 1 i5 a fragmentary isometric view showing :
equipment including means for developing a blast, means for developing a series of secondary jets above the blast and ~:
` directed downwardly toward the blast, together with means for :~
establishing glass streams delivered by gravity from a xegion above the jets downwardly into the zone of influence of the jets and ultimately into the influence of the zone of inter-action with the blast;
Figure 2 is a vertical sectional view through equip- -ment for establishing a single fiberizing station as arranged according to the present invention; and Figure 3 is a view similar to Figure 2 but more diagrammatic and further illustrating certain dimensional relationships to be taken into account in establishing oper- :
ating conditions in accordance with the preferred practice of :
the present invention.
In the drawings, the glass supply means includes a crucible or bushing 1 which may be supplied with molten glass in any o~ a variety of ways, for instance by means sd/ 15A-of the forehearth indicated at 2 in Figure 3. Glass supply orifices 3 deliver streams of molten glass downwardly under the action of gravity as indicated at S.

A gaseous blast is discharged in a generally hori-zontal direction from the discharge no~zle 4, the blast beingindicated by the arrow 5. The blast may originate in a gener-ator, usually comprising a burner, so that the blast consists ~~~
of the products of combustion, with or without supplemental air.

As will be seen from the drawings, the blast is directed generally horizontally below the orifices 3 from which the glass streams S are dischargecl.

~t an elevation intermediate the crucible and the blast discharye device 4, jet tubes 6 are provided, each having a discharge orifice 7, the jet tubes receiving gas rom the manifold 8 which in turn may be supplied through the connection fra~mentarily indicated at ~.

The gases for delivery to and through the jet tubes 6 may originate in a gas generator talcing the form of a burner and the products of combustion may serve for the jet, either ;~ ;~
with or without supplemental air. Preferably the combustion gases are diluted with air so as to avoid excessively high temperature of the gas delivered through the jet tubes.

Each jet tube 6 ancl its orifice 7 is arranged to discharge a gaseous jet downwardly at a point closely acljacent to the feed path of one of the glass streams S and preferably at the side of the stream S which, with respect to the direction : . : , `:, : . . . .

217 ~ ~ ~

of flow of the blast 5, is upstream of the glass stream.
; Moreover, each jet tube 6 and its oriEice 7 i5 arranged to discharge the jet in a path directed downwardly toward the blast and which is inclined to the vertical and so that the projection of the paths of the ylass stream and the jet inter-sect at a point spaced above the upper boundary of the blast ~`
S. ', " ~

It is contemplated that the vertical dimension of the blast and also the width thereof be considerably greater :- ~- ~-than the cross sectional dimensions of each secondary jet, so that adequate volume of the blast will be available for each jet to develop a zone of interaction with the blast. ~ `~
For this purpose also, it is further contemplated that the kinetic energy of the jet in relation to that of the blast, in the operational zone of the jet and blast, should be suf- ;
ficiently hi~h so that the jet will penetrate the blast.
~s pointed out in our applications above referred -to, this requires that the kinetic energy be substantially higher than that of the blast, per unit of volume. Still further, , ::
the jet preferably has a velocity considerably in excess of the velocity of the glass stream as fed under the action of gravity downwardly toward the point of contact with the jet and sometimes also in excess of the velocity of the blast.

The operation of each fiherizing center is as follows:
~ , From the drawings and especially from Figure 2, it will be seen that the core C of the jet causes the induction of currents of air indicated by the lines A, the amount of air so induced progressively increased along the path of the jet. When the body of the jet, i.e. the gas of the core ~17- -,. - . ,, .. , : , "

intermixed wi-th the induced air, reaches the boundary of the blast, a zone of interaction is established in the region indicated by cross-lining marked I in Fiyure 2.

As the stream S of molten glass descends and approach~
es the jet clelivered from the orifice 7, the currents of air induced by the action of the jet cause the stream of glass to deflect to~ard the jet core as indicated at lO.
Although the glass orifice 3 may be of substantially larger ~ ;
diameter or cross section than the jet orifice 7, the gravity feed of the glass stream S results in substantial reduction in diameter of the glass stream, so that when the stream meets the jet, the diameter of the stream is much smaller than the diameter of the glass orifice. With the higher velocity of the jet, as compared with that of glass stream, even when the glass stream meets the jet in the upstream region adjacent the jet core, the glass stream will not pene-~trate the jet core. Howeverr because of the induced air currents surrounding the jet, the glass stream is caused to "ride" on the surface of the jet core within the surrounding sheath of induced air or to enter the body of the jet downstream of the jet core. ~-The action of the induced air in bringing the glass stream to the jet stabilizes the feed of the glass stream and will also assist in compensating Eor minor misalignment of the glass orifice with respect to the jet orifice. Because of the reli.ance upon induction effects of an .isolated jet, the glass stream is brought into the mi~ing zone of the gas originating in the jet core and ~he induced air without subdivision or breakage of the stream or the fiber being 2'~7 .

formed. This action is enhanced by virtue of the fact that ;
in the arrangement as above described and illustrated, the glass stream is not subjected to any sharp angled change `;
in its path of movement before it has been subjected to some appreciable attenuation, thereby reducing its diameter and inertia.

In consequence of the glass stream being carried in the mixing zone of the jet, the glass stream is partially attenuated, this action representing the first stage of the two-stage attenuation above referred to. In turn, in consequence of this partial attenuation, the length of the embryonic fiber i5 increased, and this increase in length is accommodated by an undulating or whipping action, thereby forming loops, as indicated at 12. It is to be noted, however, that the gla9s stream remains intact, the loops of the embryonic fiber being carried downwardly in the mix ng zone. `

At the point where the blast 5 intercepts the jet, the jet penetrates the blast. This penetration of the blast by the jet establishes currents in the zone of interaction of the jet with the blast, which currents carry the partially attenuated glass stream into the interior of the blast and in consequence a second staye of attenuation occurs. This results in further increase in the length of the fiber being formed. The increase in fiber length is accommodated by additional undulating or whipping ac-tion, forming further enlarged loops as indicated at 13 within the blast. Not~
withstanding this action, a typical fiber will remain intact and will be carried away by the blast flow in the form of a fiber of considerable lenyth. Thus a single stream of molten .,~

glass is converted into a single glass fiber by a two-stage attenuation operation. It will be understood that in effect-ing this two-stage attenuation, the temperature of the glass `~
and the temperature of the jet, as well as the temperature -oE the blast, are established at values which will retain the glass in attenuable condition throughout the first stage of attenuation and throughout the second stage until the attenuation has been completed in the 20ne of interaction between the jet and the blast.

In connection with the arrangement of the invention, it is to be understood that fiberizing centers may be arranged in multiple, as illustrated in Figure 1. This is accomplished by employing a blast 5 which is broad or of large dimension in the direction perpendicular to the plane of Figure 2, and by employing a similarly extenlded crucible 1 having a multiplicity of glass orifices, and further by employing a multiplicity of jet tubes 6 each having an orifice adjacent to one of the streams S of glass being delivered from the several glass orifices, all as shown in Figure 1. Such ;~
a multiplicity o~ jet tubes may be supplied with the jet ; gas from a common manifold 8.
.
In connection with various dimensional relation~
ships involved in the equipment of the present invention, particular attention is directed to Figure 3 on which cer- -tain symbols have been applied to identify some of the dimen-sions. These are identified in the following table which also gives an average or typical value in millimeters, as well as a usable range for each such value.

;

AVERAGE VARIATION ~ -VAI,UE LIMITS
FEATURE DIMENSION SYMBOL (mm) (mm) ~:
.- , Bushin~ Diameter of glass d~ 4 1 - 10 orifice :~
Distance between 2 holes 10 5 Jet Inner diameter of jet tube dt 1 0.3 - 3 Outer diameter of jet tube 1.5 0.7 - 5 Separation between 2 tubes 10 5 ~-Blast Vertical distance between lB 25 10 - 50 the lips or thickness of the discharge section Width of the discharge 300 20 - 500 section In addition to the foregoing dimensions, certain ~
spacing relationships and also angular relationships should ~:
be observed, as indicated in the following table which gives :':
an average or typical value in millimeters or degrees, as well as a usable range for each such value.
AVERAGE VARIATION :~
:: VALUE LIMITS :
~mm or (mm or FEATURES SYMBOL degree) degree) : Vertical distance of jet discharge ~ -~
; 25 orifice to the upper boundary of flow ZJB 45 30 - 60 of the blast Vertical distance from the dis-charge opening of the glass stream ZJF 85 0 - 150 to the jet discharge orifice :~
: ', ', ~0 Horizontal distance from the axis : :
of the glass stream to the jet XJF 5 1 - 15 ~:
discharge orifice Horizontal distance from the axis of the glass stream to the lip of the XB~ 5 0 - 30 blast nozzle . .
~ ~-z~

AVERAGE VARIATION
VALUE LIMITS
(mm or (mm or FEL~TIJ~ES SYMBOL degree) degree) 5 Angle of jet tube to the axis ~ 10 3 - 45 of glass stream gle of jet tube to the direction ~ 80 87 - 45 of flow of the blast ' . ~

With fuxther reference to parameters of operation when employing the technique of the present invention, it is first pointed out that it is of course important that the glass be discharged from the glass orifice in a continuous stable stream. For -this purpose, the rate of glass flow, -the temperature of the bushing and the diameter of the glass discharge orifice should preferably be above certain predeter- ~ ~
mined limits. Thus, the pull rate of glass should be greater ~ -than 60 kg/hole for each 2~ hour pexiod; the bushing temperature should be greater than 1250C, and the diameter o~ the glass discharge orifice should be greater than 2.5 milimeters. -With at least certain types of glass formulations, observing these limits may assist in avoiding pulsations which have ~`~
a tendency to accentuate until distinct droplets are formed. ~ `
This phenomenon is incompatible with proper fiberization.
In a typical or average working condition, the following ~ ;
values are appropriate; 100 kg/hole per day, bushing temperature ~- 1400C, glass orifice diameter 3 milimeters.

Addi~ional operating ranges are as follows:
`;:
Velocity - jet 200 mtsec - 900 m/sec blast 200 m/sec - 800 m/sec 7 ~ ~

Pressure - jat .5 to 50 bars :
blast .05 to .5 bars .~

'~'' :', Temperature - jet 20 to 1800C .-blast 1300 to 1800C
,:
Klnetic Energy Ratio - jet to blast 10/1 - 1000/1 . :~

A typical operation according to the present inven-tion may be carried out as given in the Example below. ` ;~

Example Glass formulation: ~

SiO2 46.92 ~ `
Fe 0 1.62 2 3 : `
A1203 9.20 MnO 0.16 ~': CaO 30~75 ~gO 3.95 :::,.'? Na20 3.90 ;~ ~
~ K20 3.50 : s ;~-; . .
.^~, -. -: .
, , .
~ All parts by weight. :

`` Physlcal Properties .. - ;. :

': 20 Viscosity 30poises at 1310C
: 100poises at 1216C
~. 300poises at 1155C :
:~ -23-,.

~ 12~7 . ~.
G-lass - orifice 3 mm flow 100 kg/day per orifice ~`
Blast - temperature 1550C ~ :
pressure .25 bar :
velocity 530 m/s ,~
Jet - temperature 20C
p.ressure 6 bar velocity 330 m/s orifice diameter 1 mm ':~
10 Ratio o~ Rinetic ener~ies Jet = 24 Blast Fiber diameter ~ 6 microns ;

,' , :
~ ':

I ''~ . .
"` ' '~
~' `, :, `' ~ '`' ''~ `

- ,' ; ` : ,; ,

Claims (30)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for converting attenuable material into a fiber comprising generating a gaseous blast and a gaseous carrier jet, the direction and the kinetic energy per unit of volume of the jet being such that the jet penetrates into the blast, thereby forming a zone of interaction in proximity of the path of penetration of the carrier jet into the blast, and delivering a stream of the attenuable material to the boundary of the blast so as to enter into the zone of inter-action, the carrier jet being delivered from a source spaced from the blast and the said stream of material being first introduced into a zone in which currents of air are induced by the carrier jet to subject the stream to an initial of partial attenuation and form a continuous filament before reaching the boundary of the blast, the partially attenuated stream being thereafter drawn into a fiber by a second atten-uation in the zone of interaction.
2. A process as defined in Claim 1 in which the source of the carrier jet is located in a position which with respect to the direction of flow of the blast is upstream of the stream of attenuable material.
3. A process as defined in Claim 2 in which the blast is directed generally horizontally and in which the carrier jet is directed at an angle to the vertical so as to intercept the path of the stream of attenuable material at a point above the upper boundary of the blast.
4. A process as defined in Claim 1 in which the stream of attenuable material is fed by gravity from a point spaced appreciably above the elevation at which the stream is delivered to the carrier jet.
5. Process according to Claim 4 characterized in that the angle of the direction of the carrier jet with respect to the stream of attenuable material is 3 to 45°.
6. Process according to Claim 5 in which the angle referred to is approximately 10°.
7. Process according to Claim 4 or 5 characterized in that the stream of attenuable material is delivered from a point spaced above the zone of introduction of the stream into the currents of air induced by the jet, and in which the flow of the stream from said point to said zone of inter-action results in reduction in diameter of the stream before it reaches said zone of interaction.
8. A process for converting attenuable material into a fiber comprising establishing a stream of the attenuable material, subjecting the stream to a two-stage attenuation operation of which the first stage is effected by delivering the stream of the material to an isolated gaseous carrier jet to be carried thereby and thus partially atten-uated in the form of a continuous filament, the approach of the stream to the carrier jet being effected by induction effects of the jet, the second stage being effected by establishing a gaseous blast which is directed in a path transverse to and intercepting the carrier jet downstream of the point of delivery of the stream of material to the carrier jet, the transverse dimensions of the blast being greater than those of the carrier jet and the carrier jet having greater kinetic energy per unit of volume than the blast, thereby providing for establishing a zone of interaction of the carrier jet and blast by penetration of the blast by the jet and for carrying of said filament to the zone of interaction and thereby completing the conversion of the stream into the fiber.
9. A process according to Claim 8 in which the cross section of the stream of attenuable material is smaller than the cross section of the carrier jet in the region where the stream meets the carrier jet.
10. A process according to Claim 8 in which the stream of attenuable material is a stream of thermoplastic material such as molten mineral material.
11. Apparatus for making fibers from attenuable material comprising supply means for said material having a delivery orifice positioned for downward delivery of a stream of said material, means including a discharge outlet for establishing a gaseous blast spaced below the material delivery orifice and directed transverse to the said stream, and means for establishing a gaseous carrier jet including a jet discharge orifice directing the jet downwardly toward and penetrating the blast, the blast having a transverse dimension in the direction of the path of penetration by the carrier jet, which dimension is appreciably greater than the transverse dimension of the carrier jet to thereby establish a zone of interaction between the blast and the carrier jet, the carrier jet orifice and the material delivery orifice being relatively positioned to provide for impingement of the stream of attenuable material on the carrier jet at a point spaced from the blast and thus provide for travel of the stream of attenuable material with the carrier jet to the zone of interaction of the jet with the blast.
12. Apparatus as defined in Claim 11 in which the means for establishing the gaseous carrier jet, is located in a position, with relation to the blast, which is upstream of the stream of attenuable material.
13. Apparatus as defined in Claim 12 in which the means for establishing the gaseous carrier jet is angularly positioned to cause the jet to penetrate the blast in a zone horizontally offset from the delivery orifice of the supply means for the attenuable material.
14. Apparatus as defined in Claim 12 in which the means for establishing the carrier jet is positioned to direct the jet in a path at an angle to the general direction of flow of the blast which angle is from about 45° to about 87°.
15. Apparatus according to Claim 11 in which the means for producing the carrier jet is spaced from the blast from 30 to 60 mm.
16. Apparatus according to Claim 15 in which the spacing referred to is about 45 mm.
17. Apparatus according to Claim 11 in which a jet orifice is used having a diameter of 0.3 to 3 mm.
18. Apparatus according to Claim 17 in which the jet orifice has a diameter of about 1 mm.
19. Apparatus according to Claim 11 in which the means for delivering the stream of attenuable material is spaced, with reference to the direction of flow of the stream, at a distance below the orifice of the means for producing the carrier jet, but not more than 150 mm below the carrier jet orifice.
20. Apparatus according to Claim 19 in which the spacing referred to is about 85 mm.
21. Apparatus according to Claim 11 in which the means for delivering the stream of attenuable material comprises a metering orifice having a diameter of from 1 to 10 mm.
22. Apparatus according to Claim 21 in which the diameter of the metering orifice is about 4 mm.
23. Apparatus according to Claim 11 in which the carrier jet orifice and the orifice for the attenuable material are spaced from each other in the direction of flow of the blast by a distance of from 1 to 15 mm.
24. Apparatus according to Claim 23 in which the spacing referred to is about 5 mm.
25. Apparatus according to Claim 11 in which the means for producing the blast includes a gas discharge outlet having a dimension in the direction from which the stream of attenuable material approaches the blast, which dimension is from 10 to 50 mm.
26. Apparatus according to Claim 25 in which the dimension of the discharge outlet referred to is about 25 mm.
27. Apparatus according to Claim 11 in which the blast discharge outlet and the center line of the material delivery orifice are positioned in spaced relation to each other in a direction transverse to the flow of the stream of attenuable material, such spacing being less than 30 mm.
28. Apparatus according to Claim 27 in which the spacing referred to is about 5 mm.
29. Apparatus according to Claim 11 in which a plurality of fiberizing centers are provided each including supply means for attenuable material and each including means for pro-ducing a carrier jet associated with the supply means, and blast producing means cooperating with the jet of each fiberizing center to provide a zone of interaction for each jet.
30. Apparatus according to Claim 29 in which the blast producing means comprises common blast producing means associated with the plurality of said fiberizing centers.
CA265,560A 1976-02-09 1976-11-12 Method and apparatus for fiberizing attenuable materials and product thereof Expired CA1101217A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR76.03416 1976-02-09
FR7603416A FR2362222A1 (en) 1976-02-09 1976-02-09 PROCESS AND DEVICES FOR TRANSFORMING A STRETCHABLE MATERIAL INTO FIBERS

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DE2849357A1 (en) * 1978-11-14 1980-05-29 Saint Gobain METHOD AND DEVICE FOR INFLUENCING THE PROPERTIES OF FIBERS IN THE PRODUCTION OF FIBERS FROM THERMOPLASTIC MATERIAL
FR2778179A1 (en) * 1998-04-29 1999-11-05 Saint Gobain Isover FIBERING DEVICE AND METHOD FOR PRODUCING MINERAL WOOL

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DE1017516B (en) * 1953-12-30 1957-10-10 Statens Skogsind Ab Method and apparatus for making fibers from molten minerals
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AT244011B (en) * 1960-10-24 1965-12-10 Gruenzweig & Hartmann Process for producing fibers from viscous masses and apparatus for carrying out the process
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OA05416A (en) 1981-03-31
IE43838L (en) 1977-08-09
FR2362222A1 (en) 1978-03-17
GR59989B (en) 1978-03-28
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AU504349B2 (en) 1979-10-11
PT65481A (en) 1976-09-01
PT65481B (en) 1978-02-13
DK369876A (en) 1977-08-10
ZA764910B (en) 1977-07-27
AT366353B (en) 1982-04-13
HU178094B (en) 1982-03-28
EG12094A (en) 1978-06-30
JPS5296238A (en) 1977-08-12
CS207363B2 (en) 1981-07-31
IL50238A0 (en) 1976-10-31
LU75597A1 (en) 1977-04-22
FI762275A (en) 1977-08-10
FI59979C (en) 1981-11-10
IL50238A (en) 1979-11-30
DE2636835A1 (en) 1977-08-11
IN145289B (en) 1978-09-23
TR19123A (en) 1978-07-01
NZ181762A (en) 1979-04-26
ES450747A1 (en) 1977-09-01
AR207531A1 (en) 1976-10-08
NO142170C (en) 1981-12-16
PL112619B1 (en) 1980-10-31
BE845194A (en) 1977-02-14
YU191976A (en) 1982-06-30
FR2362222B1 (en) 1979-03-02
SE7609056L (en) 1977-08-10
RO69328A (en) 1981-04-26
AU1686376A (en) 1978-02-23
NO762829L (en) 1977-08-10
PH15339A (en) 1982-12-02
BR7605350A (en) 1978-03-07
MX144202A (en) 1981-09-10
NL7608476A (en) 1977-08-11
SE418608B (en) 1981-06-15
FI59979B (en) 1981-07-31
DE2636835C2 (en) 1987-01-15
NO142170B (en) 1980-03-31
IE43838B1 (en) 1981-06-03
GB1513060A (en) 1978-06-07
IT1064744B (en) 1985-02-25
DD125343A5 (en) 1977-04-13
ATA612376A (en) 1981-08-15

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