CA1181558A - Apparatus for producing flake particles - Google Patents

Apparatus for producing flake particles

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Publication number
CA1181558A
CA1181558A CA000424321A CA424321A CA1181558A CA 1181558 A CA1181558 A CA 1181558A CA 000424321 A CA000424321 A CA 000424321A CA 424321 A CA424321 A CA 424321A CA 1181558 A CA1181558 A CA 1181558A
Authority
CA
Canada
Prior art keywords
heat extracting
extracting member
flake particles
producing flake
heat
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
CA000424321A
Other languages
French (fr)
Inventor
Takashi Onoyama
Osamu Ando
Tsuyoshi Minakata
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.)
Nippon Yakin Kogyo Co Ltd
Original Assignee
Nippon Yakin Kogyo Co Ltd
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
Priority claimed from JP5851582A external-priority patent/JPS5939224B2/en
Priority claimed from JP15566782A external-priority patent/JPS5945060A/en
Priority claimed from JP1917183A external-priority patent/JPS59144562A/en
Priority claimed from JP1917083A external-priority patent/JPS59144561A/en
Application filed by Nippon Yakin Kogyo Co Ltd filed Critical Nippon Yakin Kogyo Co Ltd
Application granted granted Critical
Publication of CA1181558A publication Critical patent/CA1181558A/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
    • 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
    • B22D11/0611Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a single casting wheel, e.g. for casting amorphous metal strips or wires

Abstract

ABSTRACT OF THE DISCLOSURE
A plurality of discrete small cooling surfaces are arrayed on the surface of a journally or movablely received heat extracting member in both the axial and rotational directions.
These discrete small cooling surfaces can be formed by a plurality of one set of parallel grooves formed between two axial ends and obliquely to the axial ends having been crossed by a plurality of the other set of parallel grooves formed in a similar manner but in different direction.
An opening of nozzle means are directed toward the outer peripheral surface of the heat extracting member.
A continuing stream of molten material is projected upon the discrete small cooling surfaces of the rotating heat extracting member, thereby the heat of the molten material is extracted by each of these discrete small surface and solidifies on it in a discrete flake particle.
Since the discrete small cooling surfaces are formed in a number of arrays extending in both axial and rotational direction by crossing the one set of grooves with the other set of grooves, opening or openings of the nozzle means can be extended in long length in the axial direction of the heat extracting member or can be arranged as a plurality of nozzles in same direction.
Accordingly, the molten material can be applied concurrently onto a plurality of discrete small cooling surface.
By virtue of the apparatus of the construction, flake particles can be obtaiined at a greatly increased production efficiency.

Description

APPARA~US FOR PRODUCING FLAK~ PARTICLES

BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to an apparatus for pro-ducing flake particles, and more particularly, it relates to an apparatus for carrying out the art of producing flake particles by projecting a stream of molten metallic material upon the rota-ting or moving surface of a heat extracting member, thereby extracting the heat from the molten material so as to solidify it into a large number of flake particles and then remove the thus solidified flakes from the heat extracting member by means of centri-fugal force imparted thereto by the rotation.
Prior Art Heretofore, various kind of flake particle making apparatuses have been provided which produce flake particles with contacting the molten metal on the rotat~
ing surface of a heat extracting member and allowing the molten metal to solidify thereon.
The most typical invention known to the inventor of this application is U.S.P. 4,215,084.
According to the U.S.P., the heat extracting member is constructed as a rotating drum, upon the outer surface of which a continuing stream of molten material is projected.
The outer rotating surface of the U.S.P. is constructed to have a number of serrations formed substan-tially parallel to the axis of rotation of the rotating drum.
When a continuing thin stream of molten metal is projected upon the surface of these serrations, the heat contained in the metal is extracted by the serra-tions, resulting in solidification of the metal into a large number of flake particles.
Accordingly, if it is required to increase the production rate of flake particles by carrying out the process in parallel, it becomes necessary to lengthen each rotating drum and to provide a plurality of nozzles.
However, it is also demanded to effect fine and correct adjustment of the nozzle opening to obtain flake particle as much fine and as equal in size as possible.
Such adjustment not only accompanies technical difficulties, but such a fine nozzle also resulted in troubles with respect to its service life, process control and costs.
Since such metal flake particles are most generally mixed into plastics for use as electric magne-tic interference shielding material, it is also required to be capable of being uniformly mixed and dispersed.
However, flake particles produced according to such conventional apparatus(es) as mentioned contained considerable amount of deformed particles or smaller sized one although they weré generally made square in shape, thereby obstructed uniform mixing and dispersion of the flake particles into plastic material.
The main cause for bringing about such a non-uniformity in size and shape of the particles is consi-dered that the serrated surface of the heat extracting mernber is higher at the rear part of each upper surfaced serration than at the front part of one with respect the direction of the rotation of the rotating member, thereby the molten metal is liable to be repelled or shed such that the phenominon hinders smooth transferring of the molten metal onto the heat extracting member.
As typical prior arts for obtaining fine soli-dified metal particles, there havebeen found several U.S.
Patents such as Nos. 37108~2, 3838185, 3896203, 390434 and 3908745.
However, all of these prior art inventions relate to methods or apparatus(es) for producing filaments or fibers.
Although the aforesaid patents have common feature with regard to the fact that high production efficiency should be performed with low costs.
OBJECTS OF THE INVENTION
The present inventicn solves aforementioned problems in the prior art.
The main object of the present invention is to provide an apparatus for making flake particles especial-ly a metal flake particles from molten material in high efficiency and low costs.
Another object of the present invention is to provide an apparatus for making flake particles which is readily controllable in operation.
A further obJect of the present invention is to provide an apparatus for producing flake particles which can be operated for long service period.
Still further object of this invention is to provide an apparatus capable of producing flake particles of uniform shape and size.
SUMMARY OF THE INVENTION
According to the present invention, a plurality of discrete small surfaces are formed in arrays on the outer periphery of the heat extracting member in both axial and rotational directions by engraving a plurality of grooves of one group, parallel and obliquely extend-1~ ing between the both axial ends and in an angle to the both axial ends and by engraving plurality of similar grooves of the other group which also extending at a different angle to the both axial ends.
And yet, among the sides defining said discrete small surfaces two of them are arrayed to cross the aixal line of said heat extracting member.
The heat extracting member as mentioned may constructed as either one of drum type of endless belt type one so long as it is journally received for rotatio-nal or travelling movement.
As explained, the discrete small surfaces defined on the heat extracting member can be forrned by merely cutting grooves.

Moreover, these discrete small surfaces, regardless of their shape, either formed as faces arrayed along the direction of rotation, flat faces normal to the diametrical line of the heat extracting member, or as planes higher at the rear portion with respect to the direction of rotation while being sectioned by an edge line into two surfaces inclining down both -to the axial and rotational direction, they all receives molten material without repelling it from -their surface.
The discrete small surfaces formed by crossing many number of grooves as mentioned above usually take the form of parallelogram, but they can be made as tri angular planes by cutting each triangles by grooves formed parallel to the axis of rotation.
Since these small surfaces are arranged in an array in axial direction and further in number of arrays in peripheral directions one after another, the nozzle or orifice for projecting molten material onto these surface can be made to have a length extending over the almost entire axial ~ength of said heat extracting member such that the molten metal can be applied through a single nozzle or orifice onto all of the discrete small surfaces in the array.
By virtue of the fact that the molten materail can be projected concurrently onto a plurality of these discrete small surfaces through the orifice or nozzle as mentioned above, proje~cted molten material is concurrently cooled and solidifies on each discrete srnall surface.

As explained above, the molten material pro-jected through the nozzle solid~fies and ormed into a number of flake particles closely similar to the shape and size of the discrete small surfaces formed on the outer periphery of the heat extracting member, and yet with greatly increased production efficiency.
In addiion, since the nozzle or orifice of the present invention is able to be made as one having width corresponding to the axial length of the heat extracting member, it is not required to make the diameter or cali-ber very small as done in the conventional ones.
This makes adjustment or size controlling of the nozzle far much easier and contributes to lengthen the service life of the apparatus as a whole as well as in lowering the running cost.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. lA is a partly cross sectioned elevational view showing a typical embodiment of the present invention.
Fig. lB is a cross sectioned front view of a nozzle opening and the shape of the molten material being ejected through the opening.
Fig. 2 is a front view of the surface of a heat extracting member in the form of a drum.
Fig. 3 is a perspective schematic view showing the way of forming a number of small discrete surfaces on the surface of heat extracting member by a number of spirally formed gooves formed on the surface thereof.
Fig. 4 is a cross sectioned elevation showing a typical embodiment of the present invention.
Fig. 5 is an enlarged side view showing a part of the heat extracting member.
Fig. 6 is a perspective view showing a stream of the molten material being ejected onto the surface of the heat extracting member.
Fig. 7A is an enlarged fragmented plan view showing a part of the heat extracting member.
Fig. 7B is a plan view showing the shape of a flake particle formed by the present invention.
Fig. 8 is a schematic elevation showing a part of an heat extracting member of cylindrical drum type having a number of small discrete cooling surfaces formed on the outer surface.
Fig. 9A through Fig. 9D are fragmented sectio-nal views showing several type nozzle openings.
Fig. 10 is a plan view showing the surface of a heat extracting member of an embodiment.
Fig. 11 is a cross sectional side view taken along line 11 - I1 of Fig. 10.
Fig. 12 is an enlarged perspective view show-ing some of the discrete srnall cooling surfaces of the embodiment of the present invention.
Fig. 13 is a front view showing another way of forming discrete small cooling surfaces different from those previously described.
Fig. 14 is a partially cross sectional front view showing the present invention provided with a plura-lity of orifices.
Fig. 15 is a partly perspective cross sec~ional view showing a plurality of nozzle for projecting molten material.
Fig. 16 is an enlarged sectional view showing the part of the nozzle.
Fig. 17 is a partly cross sectioned plan view taken along line 17-17 of Fig. ~6.
Fig. 18 is a cross sectional elevation of the protruding nozzle provided with a heating means.
Fig. 19 is a schematic perspective view showing a manner of forming a large number of small discrete cooling surfaces by a number of looped grooves.
Fig. 20 is a schematic front view showing a part where the two looped grooves intersect with each other.
Fig. 21 is a schematic side elevation of a heat extracting member having each discrete small cool-ing surface is formed normal to each diametral line of the drum.
Fig. 22 is a schematic side elevation showing the portion of the discrete small cooling surface being connected by a radius to a gently inclined wall of a groove.
Fig. 23 is a schematic front view, wherein grooves of one group of grooves out of two groups cross-ing each other are formed in parallel with the axis of the heat extracting drum.

Fig. 24 is an enlarged side view showing a heat extracting drum composed o~ an outer peripheral member and a separately formed inner body portion.
Fig. 25 is an enlarged side view showing an endless belt type heat extracting member composed of an outer heat extracting layer and a separately formed inner supporting member.
Fig. 26 is a schematic illustration of an apparatus for producing flake particles employing an end-less belt type heat extracting member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIM~NTS
Example I
In Figs. 1 through 23, and 24, numeral 10 denotes a heat extracting member formed as a drum of substantially round cross section, the outer surface of which is made of a material having high heat conductivity and good wear resistance such as copper chromium alloy.
A coolant, for example, water can be introduced into the interior of the heat extracting member 10. The heat extracting member or drum is rotated by means of a shaft lOa having a through hole (not shown) through which the coolant is introduced.
In Fig. 1, numeral 11 is a driving means coupled to sai~ shaft lOa so as to rotate the heat extract-ing member 10 at high speed of rotation. The driving means 11 is consisting of an electric motor, transmission means and other well known devices and is capable of adjusting the rotational speed of the heat extracting member of drum.
The shaft lOa is connected to a means (not shown) for supplying the coolant through a swivel (not shown).
In FigsO 1 through 4, 13 denotes a means for supplying molten material disposed above the heat extract-ing member 10, and is generally composed of a reservoir 17 made of a refractory material or materials such as graphite and/or quartz, wrought steel or iron and a heater 18 disposed around said reservoir 17.
At the bottom of the reservoir 17, an nozzle 12 having an elongated opening extending along the axis of the heat extracting member 11 is provided, through which a continuing stream of molten material such as aluminum alloy is projected in the form of a band or a ribon upon the outer peripheral surface of the heat extracting drum 10.
Since the nozzle 12 extends over the surface of the heat extracting member along the axis of the heat extracting member, the molten material 2 is ejected as a continuous stream, as shown in Fig. 1, on the entire surface of the width of the heat extracting member in the form of a band or a curtain.
Numeral 19 is a conduit which communicates a gas supply source, not shown, to the molten metal reser-voir 17. Gas such as air or argon is supplied from the gas supply source.
In the drawing, numeral 21 is a temperature measuring device to detect the temperature of the molten rnaterial contained in the reservoir.
Explanation will now be made on t~e outer sur-face of the heat extracting member 10.
In Fig. 1, a large number of grooves 4a of one group are engraved on the outer surface of the heat extracting member 10, in paralleled with each other extending obliquely with a predetermined angle of incli-nation between both axial ends of the extracting member 10. Also a large member of grooves 4b of the other group are engraved on the surface of the heat extending member in a similar manner but with an angle of inclina-tion in different direction from that of the grooves 4a, such that each of the grooves 4b crosses the groove 4a, finally, the groups of the groove 4a and groove 4b define a large number of small discrete heat extracting or cool-ing surface 6 on the outer peripheral surface of the heat extracting drum such that a plurality of the cooling surfaces 6 is arrayed in both the rotational and axial directions of the heat extracting member 10.
In this embodiment, each of the grooves 4a and 4b defining a unit small discrete heat extracting surface is directed to cross a line lOb on the surface depicted parallel to the axis of the heat extracing member 10.
As particularly shown in Fig. 3, grooves 4a and 4b are formed along a pair of imaginary lines 4c and 4d going spirally around the cylindrical surface lOc defining the outer peripheral surface of the heat ex~ract-ing member 10, the entire or part of the grooves cross each other and form a large number of small discrete heat extractin~ sur~ace.
In Fig. 2 these grooves 4a and 4b are posi-tioned at an equal angle of ~ 2 of 45 to the both axial end faces, namely, to the axis of the heat extract-ing members 10 at the equal spacing, accordingly, the shape of a small discrete cooling surface 6 defined by two pairs of grooves 4a and 4b takes the form of a square having four equal sides of length M as shown in Fig. 7A.
~owever, the shape of the small discrete cool-ing surface 6 is not limited to be a square as shown in the example of Fig. 7A and the angle of each of the ~l, and 92 can be selected within the ranges, as shown in a formula:
~ ~ ~/ or e~ < ~so When both of the angles ~land ~2 are set equal but other tha~ 45 , the small discrete surface will become a rhombus, when the angles ~l and ~2are set different, the discrete cooling surface will become a quadrangles other than a square or a rhomboid.
Since the small discrete cooling surfaces 6 are formed directly on the substantially cylindrical surface of the heat extracting member 10, they take the cross sectional configuration along the surface of the member 10 as shown in Fig. 8, in addition a gentle slope in front of the small discrete cooling surface and the 5~

crossing of the grooves 4a and 4b are connected so as to define a radius contour r-Since the discrete surface 6 is formed to have such a configuration, molten material projected upon this portion will exactly ride on each o~ the discrete small cooling surfaces without beeing repelled, even i~
the heat extracting member is rotated at a considerably high speed.
As can be clearly understood ~rom Figs. 4, 5 and 8, the grooves 4a and 4b of the preferred embodiment are defined by two sloped walls, the one at the rear side with respect to the rotation of the heat extracting member is gently sloped, while the other wall immediately forward is formed to constitute a upstanding wall of half conduit trough.
By virtue of such sectional configuration, forward edge of each discrete small cooling surface can be prevented from rebounding or repelling the molten impinging material continuously ejected from the orifice 12.
As shown in Fig. 6, the grooves 4a and 4b defining the discrete small surface, of course, can be made as those having a trough like simple configuration.
When a molten material 2 is projected as a continuous stream through the nozzle 12 upon the small discrete cooling surfaces 6 of the heat extracting mernber 10 while it is being rotated, the molten material, as shown in Fig. 4, simultaneously contacts to the plurality of discrete small surfaces 6 so as to be extracted its heat by the small cooling surfaces S and solidifies thereon and is disintegrated, and peels off due to the centrifugal force of the rotation of the member 10, into flake particles 23 and then fall into a pile.
Although the nozzle 12 of this embodiment has a length extending almost over the axis of the heat ext-racting member 10 such that the molten material 2 can be projected from the single nozzle 12 located at the por-tion above the heat extracting member, simultaneously on a plurality of said small surfaces 6 aligned in the axial direction, but it is not required to follow this type of construction.
Beneath the heat extracting member 10, a con-veyor 22 is positioned to receive thereon flake particles 23 laid as a pile, and the conveyor is driven from time to time to transfer the thus piled flake particles into a box 22b positioned immediately below the front end of the conveyor. In the drawing numeral 22a is a partition plate for partitioning the right side and left side of the conveyor, and 24 is a wiper wheel which wipes and removes the flake particles 23 which are still kept left on the small cooling surfaces 6 without being stripped off by the centrifugal force imparted by the rotation of the heat extracting member 10.
Production tests have been conducted by using the apparatus described above and in the following test conditions.

5~

As a result, flake particles 23 of substantially square shape each having equal sides or two pairs of equal sides as shown in Fig. 7B were obtained.

A. Material and size of the heat extracting member 10 ¦ Copper-Chromiun alloy Material ¦ ~containing 1. 5% by weight¦
¦ of Cr.) I ~
Diameter (D) ¦ 300.0 mm ' ~
) Length (L) ~ 40.0 mm Number of spiral i grooves 4a and 4b 3 560 (number of division) l i, Depth of the grooves :
20. 4a and 4b ~H) I, 0.12 mm '.
Width of the grooves l I
- 4a and 4b (N) , 0.4 mm 1, Length of the one side of the discrete , 0.79 mm small surface (M) -Length of the dia-gonal of the small 0.12 mn~
surface (S) B. Condition of Test Running _ Example I Example II

Kind of Molten Aluminum of 99.7% Aluminum of 99.7~ , Material purity ~purity , Atmosphere of I argon gas air Melting Heating Tempera- ¦
~ 8509C 780 C
ture -Size of Nozzle ~ 10.0(1) x 0.4mm(b~15.0(1) x 0.35(b~
Opening Pressure of Pro- l0.6 Kg/cm2 above 0.8 Kg/cm2 above ;jection latomospheric atomospheric pressure pressure . ! . , Number of Rotatio~
of the heat ext- ! 1800 rpm 2200 rpm racting member 10 ~ -- ----Peripheral speed of the above 28.3 m/S 34.5 mts ~ member Material of the Cotton Cloth Cotton Cloth wiper _ _ C. Results (1) According to the Example I, flake particles 23 each having a length of a side M of 0~79 mm and thick-ness T of 30 - 40,~m, were obtained at a production efficiency of 48 Kg per hour and the average weight of one flake particle was proved to be 0.060 mg.
(2) According to the Example II, 68 Kg/hour of square flake particles 23 were obtained each having a length of one side M=0.79 mm and thickness T=30 to 35 microns ~m).
As can be clearly o~served from the examples, flake particles of very fine surface area can be obtained continuously, according to the present invention.
In addition, since the orifice or nozzle 12 has a considerably wide opening, there is no ~ear of clogging of the nozzle 12 and is readily handled or operated with very less chance of troubles.
Preferably, although the length of the opening of the orifice or nozzle 12 can be selected within a i5~

range of from 1 mm to 50 mm, longer one also can be used, similarly preferable width of the opening may be 0.1 to 5 mm but is not limited to this value mentioned above.
Also the shape of the opening of the nozzle or orifice can be modified, as shown in Fig. lB to have its middle portion narrowed in space as compared with that at its both axial ends, with an intention to restrain the thickness of the ejected molten material at the middle portion so as not to become larger due to the less extent of resistance to projection as compared with higher resistance to the ejection of molten material at the both axial end of the opening.
In the examples explained above, aluminum was used as a molten material, however, various other material such as copper base or nickel base alloys, iron, amorphus alloys and the like.
Example II
Fig. 14 shows a plurality of nozzles or orifices 12 extending along the axis of the heat extracting member 10, and in the construction of this device all other parts excepting these nozzles are the same as shown in Fig. 1, so further detailed explanation will be omitted.
Fig. 14 also shows that each of the streams 2 of the molten material spreads over a plurality of small discrete surfaces 6.
Example III
Figs. 15 through 18 show an embodiment using a nozzle 12 having a projected portion 12c detatchably 5S~

attached to a molten material reservoir 17.
Especially in Fig. 15, the reservoir 17 is arranged above the heat extracting member 10 and is provided with a first heating means 18 using a burner for maintaining the temperature of the molten material received in the reservoir and a heating jacket surround-ing the heating means 18.
In the drawing, 24 is a wiper wheel coupled to the driving means 11 through a shaft 2~a.
The heat extracting member 10 in this example has a construction the same as that of the Example I, so it will not be explained again.
Now, the nozzle 12 will be explaiined in detail.
The molten material reservoir 17 has7 at its bottom, an opening and the nozzle 12 is detachably fixed to the bottom of the reservoir being in alignment with the opening.
The nozzle 12 is composed of a flange 12a, and a projecting cylindrical portion 12b formed integral with the flange 12a and defining at its tip end a project-ing slo-t 12c of narrow elongated rectangular shape for projecting the molten material such as aluminum or alminum alloys received in the reservoir 17 in the form of a band or a curtain.
As also shown in Fig. 16, this nozzle 12 is positioned, at first, by aligning its axially extending hole 12d with the opening of the reservoir 17 and then tightly secured to the bottom of the reservoir by the aid of a fixture 30 consisting of a plurality of holdin~
blocks 32 each having at least one oblong aperture, a plurality of stud bolts 31 threaded into the bottom of the reservoir 17 and the same number of tightning nuts 33.
The distance between the upper surface of the heat extracting member 10 and the lowermost end of the projection opening 12c is selected for allowing adjust ment within the range of at least 0.05 mm upto 50 mm.
In Figs. 16 and 17, numeral 26 denotes a secon~
heating means using a burner positioned such that the flame coming from the burner can heat the projection 12b so as to prevent the molten material 2 flowing through the nozzle 12 from being cooled by the tempera-ture of the surrounding air down to below the required temparature.
Numeral 22 is a reflector plate which surrounds the nozzle 12 and reflects the amount of heat supplied by the second heating means 26 toward the nozzle 12 so as to uniformly heat the projection 12b of the nozzle 12.
Such a reflecting plate 22 in practical use is fixed tightly to the holding block 32 and is bent into a semicircular cross section to cover almost half peri-phery of the projection 12b.
Example IV
Fig. 18 shows another form of heating means for the nozzle 12 having a projection portion 12b.
In this instance, the second heating means 26 is integrally provided at the projecting portion 12b o~

the nozzle 12, namely, the outer surface of the project-ing portion ~2b is covered by a heat insulation material 27 within which a heater 28 is embedded so as to heat the nozzle 12 for preventing lowering of the temperature of the molten material 2 passing through the nozzle from occurring. As an actual heating means, heating element using a nichrome wire can be used.
By constituting the nozzle 12 as shown above, meritorious effect similar to that obtained by the above example III can be obtained.
Example _ Alternatively, as shown in Fig. 24, heat ext-racting member 10, can be composed of an outer peripheral portion lOd and a main body port~on lOe for supporting the peripheral portion, so as to allow replacement of the outer peripheral portion in case of possible wear, damage and/or repairing.
Example VI
Fig. 21 shows an embodiment wherein the small cooling surfaces 6 are formed normal to the diametric line to the center of the each surface 6, by forming the small cooling surfaces in this manner, molten material impinging on these small surfaces can be exactly applied thereon without being repelled or rebounded.
If the gentle slope at the rear side of each groove with respect to the direction of rotation and each flat part of the small surface 6 is connected by a curved face having a radius r as shown in Fig. 22, molten ii5~3 material projected on these small surface can be applied more exactly thereon without being repelled or rebounded even if the heat extracting member is rotated at a considerably high speed.
Example VII
Shown in Fig. 23 is another form of a discrete small cooling surfaces 6. In this example, a heat ext-racting member 10 is also formed on a cylindrical drum, one of the two group of grooves crossing each other is spirally formed as 4a and the groove of the other group represented as 4b is formed in parallel with the axis of the heat extracting member 10, thus the surface 6 consti-tutes a rhomboid.
Example VIII
As shown in Fig. 13, each of the number of rhomboids defined by two kinds of grooves 4a and 4b is further separated by a groove 4f to constitute a unit discrete cooling surface 6 of substantially triangular shape.
Example IX
Shown in Fig. 19 is an embodiment following a different manner of forming discrete small surfaces 6.
In this embodiment, the heat extracting member 10 is also formed as a cylindrical drum.
Grooves 4a extend obliquely along the surface of the drum at a certain angle, while the remaining grooves 4b similarly extending but at another angle, both between the two opposite axial ends of the drum.

.

.They are constituted by engraving them as a plurality of endless loops along the lines 4c and 4d, respectively, which are formed around the cylindrical surface lOc.
In order to constitute discrete small cooling surfaces in uniform size and shape as many as possible, each loop of groove is required as sho~ln in Fig. 20, to have a portion having a sharp point and deviated from the remaining part of the looped groove.
A11 of the looped groove are also required to have such deviated portions with their sharp points being aligned on the same line parallel to the axis. Such manner of positioning the looped grooves is required such that a pair of grooves 4a and 4b can form a discrete small cooling surface 6 as shown in Fig. 20, and thus enabling all other pair of grooves to form similar surfaces 6.
Example X
Figs. 10, 11 and 12 show an another embodiment, having different type discrete small cooling surfaces 6 in stead of aforementioned surface of square, rhomoboid or other quadrangles shape sectioned by a large number of grooves 4a and 4b shown in the preceding examples.
Each of such cooling surface 6 is composed of two gently sloped triangular faces 6a and 6b at the upper surface part and inclining down in the direction of rotation as well as to the axial direction of the heat extracting member 10, and these faces 6a and 6b intersects each other to constitute a crest edge line or ridge 6c running in the direction of rotation.
The triangular surfaces 6a are formed on groove engraved along lines 4a9 while the surfaces 6b on grooves on lines 4b.
Rearmost end of the gently sloped face 6a terminates into a steep wall 5b like a cliff defined by a crest line 9a, similarly, the sloped face 6b terminated into a steep wall 5a being defined by a crest line gb.
A pair of gently sloped faced 6a and 6b consti~
tute a discrete small convex cooling surface 6 for form-ing thereon a flake particle, while each steep wall 5a or 5b acts as a step for separating each discrete convex surface 6 from all other neighbouring ones successively formed along grooves 4a and 4b, one after another.
In the drawings, numeral 23 denotes a flake paricle solidified on the small convex cooling face 6, while numeral 2 denotes a stream of molten material being projected and falling upon same small surface 6. A
number of such gentle slopes 6a and 6b and the steep walls 5b and 5a are formed, by cutting parallel grooves 4b, at first, and then by cutting or grinding off a half portion of the thus formed grooves in transverse direc-tion along 4b, or vice versa. This crossed machining will result in many number of convex surfaces 6 separated by steps 5a and 5b.
Example XI
In Fig. 9A, nozzle 12 is formed as having a circular opening, while in Fig. 9B the nozzle 12 of circular opening is directed upward toward the heat ext-racting mernber 10 disposed above the no~zle 12 to inject the molten material 2 upwardly from a molten material supplying means 13 positioned below the heat extracting 5~ member 10.
Fig. 9C shows another type of noz~le, in which outlet of the oening is placed being very close to the upper outer surface of the heat extracting member 10, while Fig. 9D shows still another type of nozzle arrange-ment, wherein nozzle opening is positioned being directed to and very close to the lower surface of the heat ext-racting member 10 disposed above the nozzle, so as to minimize oxidation and/or nitriding of the molten material during its flowing onto the discrete surfaces 6.
Example XII
Fig. 26 shows another embodiment in which the heat extracting member 10 is arranged as an endless type one.
As shown in Fig. 25, the heat extracting member 10 is composed of a body portion lOe made of a flexible endless metal belt, around the outer surface of which an outer endless surface member lOd are detachably fixed by means of a number of protrusions and grooves lOf being disposed in the direction transverse to the movement of the belt.
On the surface of the outer endless surface member lOd, discrete small cooling surfaces 6 are formed by forming a number of parallel grooves of one group extending obliquely to the direction of movement and forming the same number of parallel grooves of the other group which obliquely crossing the former grooves.
The heat extracting member 10 of this exan,ple 5 ~ is supported by a driving pulley 40 supported on an axis lOa9 a pair of follower pulley 41 and 42, and a tension pulley 43.
A means for supplying a molten material 1~ is disposed above and the nozzle 12 is directed to the posi-tion where the follower pulley 41 turns the heat extract-ing member 10.
In the drawing, numeral 44 is a cooling box into which a coolant is introduced to cool the device~
A wiper wheel 24 is disposed between the follower pulley 41 and 42 so as to be in contact with the outer surface of the heat extracting member 10 together with a box 22b to surround the part lower than the follower pulley 41.
As can be clearly understood from the drawing, the box 22b and the portion where the follower pulley 41 confronting the nozzle 12 are substantially shielded from the interior o~ the cooling box 44.
By moving the heat extracting member 10 const-ructed as mentioned above while cooling it, molten material was ejected through the nozzle 12 upon the heat extracting member, the stream of molten material contacts the small surfaces 6 of the heat extracting member, and solidifies thereon into a great number of flake particles 23.
In this example, too, the discrete small sur-faces formed on the endless belt type heat extracting member can be optionally made as, quadrangles, triangles or any other configuration.
Nozzle 12 can also be optioned to have any desired configuration.

Claims (29)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An apparatus for producing flake particles from a continuing stream of projected molten material comprising;
a heat extracting member rotatably received on a shaft and having an outer peripheral surface carrying a plurality of heat extracting sections, a molten material reservoir for containing said molten material provided with a nozzle or nozzles for directing said molten material onto the outer peripheral surface of said heat extracting sections and a means for driving said heat extracting member to rotate said heat extracting sections, wherein;
each of said heat extracting section is formed to be a unit discrete small cooling surface defined by two adjacent paralelly and obliquely extending grooves formed on the outer surface of said heat extracting member between and with respect to both axial ends and two other grooves parallelly extending in a different direction from that of said two adjacent grooves, and said plurality of said heat extracting sections are composed of as an integrated member consisting of said unit discrete small cooling surfaces being succes-sively arrayed in large number both in the axial and rotational directions, and at least the two sides of said discrete small cooling surface cross a line parallel to the axis of the heat extracting member.
2. An apparatus for producing flake particles as claimed in claim 1, wherein said other parallel grooves extending in a different direction are those which extend ing parallel and obliquely at the same angle but inclin-ing opposite to the former parallel grooves thereby defining each of said discrete small cooling surfaces as a parallelogram.
3. An apparatus for producing flake particles as claimed in claim 1, wherein said other parallel grooves extending in different direction are those which extend-ing parallel to the axis of rotation of said heat extend-ing member thereby difining each of said discrete small cooling surfaces as a parallelogram.
4. An apparatus for producing flake particles as claimed in claim 1, wherein each of said discrete small cooling surfaces formed substantially as quard-rangles are sectioned into two halves of substantially triangular shape by a groove formed parallel to the axis of said heat extracting member.
5. An apparatus for producing flake particles as claimed in claim 1, wherein said nozzle or orifice extends in the axial direction of the heat extracting member with a length sufficient enough to apply the same molten material onto the discrete small cooling surfaces alligned on the axial direction.
6. An apparatus for producing flake particles as claimed in claim 1, wherein a plurality of nozzles or orifices are disposed being alligned along the axis of rotation of the heat extracting member.
7. An apparatus for producing flake particles as claimed in claim 1, wherein said nozzle is constructed as a nozzle assembly comprising a flange to be detachably fixed to said molten material reservoir, a protruding body member integrally formed with said flange and directed toward said heat extracting member and a nozzle opening provided at the tip end of said protruding body member.
8. An apparatus for producing flake particles as claimed in claim 1, wherein the space between the opening of said nozzle and the outer peripheral surface of said heat extracting member is set adjustable between the range of from 0.05 mm to 50 mm.
9. An apparatus for producing flake particles as claimed in claim 7, wherein said protruding body member is provided with a heating means.
10. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is constructed as a drum type one.
11. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is a drum type one and said grooves are formed along a plurality of endless loops around the cylindrical surface of said heat extracting member.
12. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is a drum type one and said grooves are formed along a spiral line around the cylindrical surface of said heat extracting member.
13. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is a drum type one and said grooves are formed along a plurality of spiral line around the cylindrical surface of said heat extracting member.
14. An apparatus for producing flake particles as claimed in claim 1, wherein said discrete small cool-ing surfaces are formed normal to the diametral line of said heat extracting member.
15. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is constructed as a drum of substantially exact circular cylinder and said discrete small cooling surface is formed as an arcuated face along the circular peri-pheral surface of said drum.
16. An apparatus for producing flake particles as claimed in claim 1, wherein said groove is composed of a wall at the front side with respect to the direction of rotation, and a wall at the other side at the rearward of the direction of rotation and having an inclination more gentle than the former wall.
17. An apparatus for producing flake particles as claimed in claim 1, wherein said groove is composed of a wall at the front side with respect to the direction of rotation, and a wall at the other side at the rearward of the direction of rotation and having an inclination more gentle than the former wall so as to form said dis-crete small surface.
18. An apparatus for producing flake particles as claimed in claim 1, wherein said groove is composed of a wall at the front side with respect to the direction of rotation and a wall at the other side at the rearward of the direction of rotation and having an inclination more gentle than the former wall and said discrete small surface is connected to the latter wall with a radiously curved surface.
19. An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member consists of an outer peripheral portion and an inner body portion supporting said outer peripheral portion and said outer peripheral portion is detachably fixed to said inner body portion.
20, An apparatus for producing flake particles as claimed in claim 1, wherein said heat extracting member is constructed as an endless belt type member extending between and movably received by at least two shaft, and a plurality of discrete small cooling surfaces are formed by a plurality of grooves cut between and obliquely transversing two opposite lengthwise edge of said heat extracting member having been crossed by a plurality of other parallel grooves extending in a similar manner but in a different direction thereby arrayed as a plurality of arrays both in the axial and lengthwise directions, and at least two sides defining each of said discrete cooling surface are positioned to cross the axis of said heat extracting member.
21. An apparatus for producing flake particles as claimed in claim 20, wherein said other parallel grooves extending in a different direction are those which extend obliquely and parallel but in opposite direction, thereby each of said discrete small surface is formed as a parallelogram.
22. An apparatus for producing flake particles as claimed in claim 20, wherein said other parallel grooves extending in a different direction are parallel to the axis of said heat extracting member thereby each of said discrete small cooling surface is formed as a parallelogram.
23. An apparatus for producing flake particles as claimed in claim 20, wherein each of said discrete small surface is divided, by a groove extending parallel to the axis of said heat extracting member, into two triangular halves.
24. An apparatus for producing flake particles as claimed in claim 20, wherein said nozzle extends in the axial direction of the heat extracting member with a length sufficient enough to apply same molten material onto the plurality of discrete surfaces arrayed in the axial direction of the heat extracting member.
25. An apparatus for producing flake particles as claimed in claim 20, wherein a plurality of nozzles or orifices are arranged along the axis of said heat extracting member.
26. An apparatus for producing flake particles as claimed in claim 20, wherein the wall of the groove at the rear side with respect to the direction of the rotation has a more gentle inclination than that of the wall at the front side.
27. An apparatus for producing flake particles as claimed in claim 20, wherein the wall of the groove at the rear side with respect to the direction of rotation has a more gentle inclination than that of the wall at the front side and is connected to said discrete small cooling surface by a curved radious wall.
28. An apparatus for producing flake particles as claimed in claim 20, wherein said heat extracting member is composed of an outer peripheral portion and an inner body portion supporting said outer peripheral portion which is detachably fixed to said inner body portion.
29. An apparatus for producing flake particles as claimed in claim 20, wherein wall at the rear side with respect to the direction of rotation has a more gentle inclincation than that of the wall at the front and constituting said discrete small cooling surface.
CA000424321A 1982-04-08 1983-03-23 Apparatus for producing flake particles Expired CA1181558A (en)

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
JP58,515/1982 1982-04-08
JP5851582A JPS5939224B2 (en) 1982-04-08 1982-04-08 Foil piece manufacturing equipment
JP155,667/1982 1982-09-07
JP15566782A JPS5945060A (en) 1982-09-07 1982-09-07 Production device for foil pieces
JP1917183A JPS59144562A (en) 1983-02-08 1983-02-08 Device for producing foil piece
JP19,170/1983 1983-02-08
JP1917083A JPS59144561A (en) 1983-02-08 1983-02-08 Device for producing foil piece
JP19,171/1983 1983-02-08

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CA1181558A true CA1181558A (en) 1985-01-29

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US (1) US4552199A (en)
CA (1) CA1181558A (en)
DE (1) DE3312422C2 (en)
FR (1) FR2524834B1 (en)

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Also Published As

Publication number Publication date
DE3312422A1 (en) 1983-10-20
DE3312422C2 (en) 1985-03-21
US4552199A (en) 1985-11-12
FR2524834A1 (en) 1983-10-14
FR2524834B1 (en) 1987-07-17

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