CA1180860A - Melt spinning crucible - Google Patents

Melt spinning crucible

Info

Publication number
CA1180860A
CA1180860A CA000417461A CA417461A CA1180860A CA 1180860 A CA1180860 A CA 1180860A CA 000417461 A CA000417461 A CA 000417461A CA 417461 A CA417461 A CA 417461A CA 1180860 A CA1180860 A CA 1180860A
Authority
CA
Canada
Prior art keywords
crucible
orifice
molten
reservoir
filament
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
CA000417461A
Other languages
French (fr)
Inventor
Edward K. Shapiro
John E. Keem
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Energy Conversion Devices Inc
Original Assignee
Energy Conversion Devices Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Energy Conversion Devices Inc filed Critical Energy Conversion Devices Inc
Application granted granted Critical
Publication of CA1180860A publication Critical patent/CA1180860A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637Accessories therefor
    • B22D11/064Accessories therefor for supplying molten metal

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Silicon Compounds (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE

An improved crucible (10) for use in melt spin processes which include a gas current deflecting skirt (22) surrounding an orifice (38) to provide a protected zone (42) for a molten jet (24) as it travels to contact a moving chill body (18). In a preferred embodiment, the crucible (10) is formed of boron nitride material to sub-stantially eliminate temperature gradients which can cause nonuniformity in mass flowrates through the crucible orifice (38) and other variations in the melt spin process.

Description

This invention relates to crucibles which are used in melt spinning devices, and more particu-larly, to an improved crucible formed of boron nitride and having a wind deflecting skirt which ellminates air currents from the area where the molten jet of material meets a moving chill sur-face.
Devices for forming a continuous filament of material by cooling a jet of molten material by contacting it with a moving chill surface are well known in the art. Tsuya and Arai report on exper-iments with such apparatus in the Japan Journal of Applied Physics, Vol. 18, 207-208 (1979~. The process for forming this ribbon, called the melt spin process, operates on the principle that a liquid jet of molten material will solidify on a moving heat sink to produce a continuous filament of material. Molten material is placed inside a reservoir portion o a crucible, where it is main-tained at a temperature above the melting point ofthe material. By providing a means for effecting expulsion of the molten material through a nozzle or orifice in the crucible/ a jet of molten mate-rial is impinged upon the surface of a moving chill surface. The jet of molten material then wets the surface of the chill surface, causing a puddle of material to form. The puddle of materi al can then solidify on the chill surface, thus producing a continuous ribbon or filament which can be removed from the chill surface.
The melt spin process and the melt drag pro-cess are both discussed in the ~ackground Section of U.S. Patent 4~147,571 issued to Narasimhan on March 6, 1979. In that patent, it is noted that "the key to success in the melt spin process is to stabilize the liquid jet until it solidifies.l' Stability of the jet is affected by a number of factors including the viscosity of the molten ma-terial which in turn is controlled by the tempera-ture of the melt. ~s noted at Column 5, Lines 43to 47 of the patent, gas currents created by the moving chill surface can also disturb the molten jet and/or the puddle which normally forms at the point where the molten jet meets the moving chill surfaceO It is of interest that these problems are recognized in the Narasi n patent even though it discloses a "planar flow casting" pro-cess in which there is actually no free flight re-gion between the nozxle and the moving chill sur-face.

We have found that the above discussed dis-advantages may be overcome by employing a crucible formed from a nonconductive refratory material, and having an orifice through which material is expelled toward a moving chill surface and a wind deflecting skirt formed around the orifice. The refractory material, which can be quartz, alumina, or, in a preferred embodiment, boron nitride, is preferred because it has a higher thermal conduc-tivity than materials used in prior art cruci-bles. Therefore, this preférred crucible would maintain a more uniform temperature within the molten mass of material and would thereby reduce possihle defects in the ribbon caused by tempera-ture gradients.
A melt spinning crucible according to thepresent invention includes a reservoir portion for holding molten material and having an orifice through which the material is expelled towards a moving chill surface and a wind deflecting skirt formed around said orifice to protect the molten jet from gas currents as it travels from the cru cible orifice to the moving chill surface. In a preferred form, ~et stability is also improved by close temperature control achieved by forming the crucible for boron nitride material.

The preferred embodiment of this invention will now be described by way of example, with re-ference to the drawings accompanying this specifi-cation in which:
Fig. 1 is a simplified view of melt spinning apparatus including a crucible according to the present invention as it would appear in operation;
and Fig. 2 is a cross-sectional view of a portion of the apparatus of Fig. 1.
With reference now to Fig. 1, melt spinning apparatus including an improved crucible 10 ac-cording to the present invention is illustrated.
Crucible 10 may be formed from a nonconductive re-fractory material such as quartz, alumina, zirco-nia, or titania. In a preferred embodiment, cru-cible 10 is formed Erom boron nitride as e~plained in more detail below. A heating coil 12 is formed about crucible 10 to maintain a mass of material 20 within the crucible in the molten state. Heating element 12 may be either an RF induction coil or a resistive heating element. Either heating tech-nique is well known. The upper end 14 of crucible 10 is provided with an airtight seal and a gas in-5 let 16 for providing force to control ~he flow of--4--~u~3~a3 the molten material within the crucible through an orifice on its lower end. The orifice (not shown in Fig. 1) is positioned above a rotating chill s~rface in the form of a wheel or roll 18. ~r-rangements for rotating and cooling wheel 18 arewell known. One technique for cooling wheel 18 involves directing a cool gas stream at the sur-face of wheel 18, for example, by means of a con-duit 20. For this or other possible reasons, the melt spin process may be conducted in the presence of a gas atmosphere. For this reason, a skirt 22 is formed around the lower end of crucible 10 to protect the jet of molten material 24 from gas currents. The gas currents are generated primari-ly by movement of wheel 18 itself and are, thus,present primarily at the surface of the wheel where stability of the jet 24 is most critical.
An opening 26 is formed in one side of skirt 22 to allow a filament or ribbon 28 to move along with
2`0 the surfa~e of wheel 18 without contacting skirt 22. In the Figures, the opening 26 is greatly ex-aggerated or the purposes of illustra~ion. As is conventional in the melt spin processl the ribbon material 28 typically separates from wheel 18, for 5 example, at point 30r due to centrifugal forces.

l~V~

With reference now to Fig. 2, more details of the crucible 10 are illustrated in a cross-sec-tional viewO In Fig. 2, it is seen that the bulk of crucible 10 forms an inner reservoir 32 in the lower portion of which is positioned a mass of molten material 34. Material 34 may be, for exam-ple, molten silicon material intended for use in manufacturing semiconductor devices. An upper portion 3S of reservoir 34 is typically filled t with an e*e~ gas such as argon. The pressure of gas in region 36 is controlled through inlet 16 of Fig. 1 to control the rate of material flow through the orifice 38 at the bottom of reservoir 32. Gas pressure is typically controlled in the range of 0.5 to 2.0 pounds per square inch to re-gulate flow rate through orifice 38. Negative pressure in the upper portion oE reservoir 32 re-lative to external pressure may be used to retain material 34 within reservoir 32 while appropriate process conditions are established. As illustrat-ed in Fig. 2, the jet 24 tends to form a puddle of molten material 40 ~t its point of contact with moving chill surface 18. Ideally/ the molten ma-terial solidifies to some extent before the ribbon 5 28 exits through opening 26. The solidified por~

tion 2a is indicated by the cross hatched section thereof. It will be appreciated that skirt 22 should essentially contact the chill surface 18 in order to provide maximum isolation of the zone 42 from moving gas currents~ In practice, some spacing must be provided between the lower edges of skirt 22 and the chill surface 18. We believe that a maximum distance of about 0.40 inches may be allowed between the skirt 22 and chill surface 18. The frontal opening 26 is sized to allow the filament 28 to exit from the protected zone 42 with a like amount of clearance. The opening 26 has been exaggerated in the drawings for purposes of illustration only. ~hus, if filament 28 is 0.20 inches thick, the height of opening 26 would likewise be 0.20 inches~
The crucible 10 will normally be constructed from refractory materials such as quartz, alumina, zirconia, or titania or, in a pre~erred embodi-ment, boron nitride. The use of b~ron nitride ispreferred because it has a hi~her thermal conduc-tivity than materials used in prior art cruci-bles. This preferred crucible would, ~herefore, have a more uniform temperature within the molten mass of material and would thereby reduce possible 8~

defects in the ribbon caused by temperature gradi-ents. For example, by maintaining a more uniform temperature within the melt, the viscosity of the molten mass is more easily controlled and uniform and as a result, the flow rate through orifice 38 will remain more constant.
The crucible 10 can be constructed by a hot pressing technique. For some materials sintering may be required. For fused silica, the crucible could be formed by glass-blowing techniques. Some materials which contain binders must be heat treated at elevated temperatures to remove the binders prior to use of the crucible in a melt spinning device. It is preferred that the base of the crucible be formed in a solid orm which is then machined to generate the skirt 22 and orifice 38. This machining step is primarily a matter of boring out the protected zone 42 and orifice 38.
In the initial manufacturing step, it is preferred 2~ that skirt 22 have some excess length. The excess length may then be machined off as the optimum distance between orifice 38 and chill surface 18 is determined~ The thickness of skirt 22 is not believed to be critical so long as there is suffi-cient thickness for appropriate mechanicalstrength.

The actual dimensions of a crucible 10 will vary depending upon the type of crucible material and the scale of the desired process. An initial design of a crucible intended for casting a ther moelectric material may have the following dimen-sions. The overall length of the crucible from the lower end of skirt 22 to the upper end 14 would be approximately 100 millimeters. The inner diameter of reservoir 3~ would be approximately six millimeters while the outer diameter of the crucible would be approximately twelve milli-meters. Orifice 38 would have a length of about one millimeter and a diameter of about 0.3 milli-meters. The depth of cavity 42 and, therefore, the length of skirt 22 would be approximately two millimeters. The inner diameter of cavity 42 would be about eleven millimeters.
The height of frontal opening 26 could cor-respond to the thickness of ribbon 28, while the width of opening 26 would be about one millimeter wider than ribbon 28.
While the present invention has been illus-trated and described with respect to specific ap-paratus and methods of use, various modifications and changes can be made within the scope of the appended claims.

_g

Claims (18)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A melt spinning crucible for forming a continuous filament of material in a melt spinning apparatus, said crucible comprising:
an integral body;
said body including a reservoir for holding molten material;
said reservoir including an orifice connected to said reservoir for depositing a jet of molten material from said reservoir upon a moving chill surface of a melt spinning apparatus, said moving chill surface having edges which define the width of said surface;
said body including means for deflecting wind and gas currents from said orifice, said means integrally formed with said body and forming an isolation zone around said orifice, said means disposed directly above said moving chill surface and having outer dimensions less than or equal to said width of said moving chill surface; and an opening integrally formed in said body connected to said isolation zone and providing an exit for a filament of material formed on the moving chill surface to pass from said isolation zone.
2. The melt spinning crucible according to claim 1, wherein said wind deflecting means include a skirt depending from said body; said skirt forming said isolation zone about said orifice through which the molten jet can, pass and having said exit opening formed in one side of said skirt to permit the filament to pass therethrough.
3. The melt spinning crucible according to claim 2, wherein said exit opening permits the moving chill surface and the filament formed within said isolation zone to exit from said zone without contacting said skirt.
4. The melt spinning crucible according to claim 3, wherein the height of said exit opening is designed to define the thickness of the filament of material and the width of said opening is designed to define the filament width.
5. The melt spinning crucible according to claim 2, wherein said body is sufficiently spaced above the moving chill surface to permit the filament to exit from said isolation zone through said opening while isolating the molten jet within said zone from gas currents.
6. The melt spinning crucible according to claim 1, said body further including pressure means for expelling molten material from said reservoir and controlling the mass flow rate of the molten jet through said orifice, and said pressure means connected to an upper portion of said body.
7. The melt spinning crucible according to claim 6, said body further including heating means for maintaining temperature of molten material in said reservoir above the melting point of said material, said heating means contacting and surrounding said body in a coil-like fashion.
8. The melt spinning crucible according to claim 1, wherein said body is formed from a material having high thermal conductivity to promote temperature uniformity within the molten mass of material in said crucible so as to minimize the temperature gradients which cause defects in the filament of material and allow for the control of viscosity and the uniformity of viscosity of the molten material in said crucible.
9. The melt spinning crucible according to claim 8, wherein said crucible material is boron nitride.
10. The melt spinning crucible according to claim 9, wherein said body further includes pressure means for expelling molten material from said reservoir and controlling the mass flow rate of the molten jet through said orifice, said pressure means connected to an upper portion of said body; said body also includes heating means for maintaining temperature of molten material in said reservoir above the melting point of the material, said heating means contacting and surrounding said body in a coil-like fashion; and said wind deflecting means include a skirt depending from said body, said skirt forming said isolation zone about said orifice through which the molten jet can pass and having said exit opening formed in one side of said skirt to permit the filament to pass therethrough.
11. In a crucible for a melt spinning apparatus, the crucible adapted to deposit a jet of molten material upon a moving chill surface of a melt spinning apparatus, the moving chill surface having edges which define the width of the surface, the improvement comprising:
a body formed from boron nitride, said body including a reservoir adapted to hold molten material, said reservoir including an orifice connected to said reservoir to form a jet of molten material, said body having outer dimensions less than or equal to the width of the chill surface, said body including means integrally formed therewith for deflecting wind and gas currents from said orifice, said deflecting means including an opening to provide an exit for a filament of material formed on said moving chill surface.
12. The improved crucible according to claim 11, wherein said boron nitride body is formed having high thermal conductivity to promote temperature uniformity within the molten material in said crucible so as to minimize the temperature gradients which cause defects in a filament of material and allow for control of the viscosity and the uniformity of viscosity of the molten material in the crucible.
13. The improved crucible according to claim 11, wherein said orifice is integrally formed in said reservoir; said means for deflecting wind and gas currents includes an isolation zone formed around said orifice; and said opening is integrally formed in said body, is connected to said isolation zone, and provides said exit for a filament of material formed on the moving chill surface to pass from said isolation zone.
14. The improved crucible according to claim 13, wherein said wind deflecting means include a skirt depending from said body; said skirt forming said isolation zone about said orifice through which the molten jet can pass and having said exit opening formed in one side of said skirt, and said opening permits the filament to exit from said zone without contacting said skirt.
15. The improved crucible according to claim 14, wherein the height of said exit opening is designed to define the thickness of the filament of material and the width of said opening is designed to define the filament width.
16. The improved crucible according to claim 11, wherein said body further includes pressure means for expelling molten material from said reservoir and controlling the mass flow rate of the molten jet through said orifice, and said pressure means connected to an upper portion of said crucible.
17. The improved crucible according to claim 16, wherein said body further includes heating means for maintaining temperature of molten material in said reservoir above melting point of said material, said heating means contacts and surrounds said body in a coil-like fashion.
18. The improved crucible according to claim 14, wherein said body further includes pressure means for expelling molten material from said reservoir and controlling the mass flow rate of the molten jet through said orifice, said pressure means connected to an upper portion of said body; said body also includes heating means for maintaining temperature of molten material in said reservoir above the melting point of the material, said heating means contacting and surrounding said body in a coil-like fashion.
CA000417461A 1981-12-31 1982-12-10 Melt spinning crucible Expired CA1180860A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US33621781A 1981-12-31 1981-12-31
US336,217 1981-12-31

Publications (1)

Publication Number Publication Date
CA1180860A true CA1180860A (en) 1985-01-15

Family

ID=23315081

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000417461A Expired CA1180860A (en) 1981-12-31 1982-12-10 Melt spinning crucible

Country Status (8)

Country Link
JP (1) JPS58116957A (en)
AU (1) AU9164182A (en)
CA (1) CA1180860A (en)
DE (1) DE3246671A1 (en)
FR (1) FR2519418A1 (en)
GB (1) GB2112913B (en)
IT (1) IT1155014B (en)
NL (1) NL8204912A (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4649984A (en) * 1984-07-23 1987-03-17 Allied Corporation Method of and apparatus for casting metal strip employing a localized conditioning shoe
JPS62183944A (en) * 1986-02-10 1987-08-12 Nippon Steel Corp Production of rapid cooling foil metal and its nozzle
US5063988A (en) * 1990-06-22 1991-11-12 Armco Inc. Method and apparatus for strip casting
US5201359A (en) * 1990-09-24 1993-04-13 General Motors Corporation Rapid solidification apparatus
CN107324816A (en) * 2017-07-25 2017-11-07 云南省科学技术院 The preparation method and Preparation equipment of a kind of high temperature resistant high purity aluminium oxide cotton
CN109290536B (en) * 2018-09-18 2020-12-22 洛阳中赫非晶科技有限公司 Amorphous strip production system

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5938062B2 (en) * 1978-03-15 1984-09-13 日本碍子株式会社 Continuous metal casting method
DE2952620C2 (en) * 1979-01-02 1984-07-05 Allied Corp., Morris Township, N.J. Device for the continuous casting of vitreous metal alloy threads
US4282921A (en) * 1979-09-17 1981-08-11 General Electric Company Method for melt puddle control and quench rate improvement in melt-spinning of metallic ribbons
DE2950406C2 (en) * 1979-12-14 1986-12-04 Hitachi Metals, Ltd., Tokyo Device for the continuous casting of a metal strip

Also Published As

Publication number Publication date
GB2112913A (en) 1983-07-27
IT1155014B (en) 1987-01-21
NL8204912A (en) 1983-07-18
JPS58116957A (en) 1983-07-12
DE3246671A1 (en) 1983-07-21
IT8224847A1 (en) 1984-06-17
FR2519418A1 (en) 1983-07-08
AU9164182A (en) 1983-07-07
GB2112913B (en) 1985-02-06
IT8224847A0 (en) 1982-12-17

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