Method and apparatus for the rapid solidification of molten material in particulate form

Claim 1

A method for solidification of molten material to particulate form, said method comprising atomization of molten materials to form a mist of finely divided molten material by expelling said molten material from the surface of a mechanical centrifugal atomizer into discharge tube, and introducing an atomized coolant or atomized mixture of coolants into the discharge tube, wherein the coolant or each coolant in a mixture of coolants has a boiling point below the temperature of solidification of the molten material and is a liquid at atmospheric temperature and pressure, and wherein an intimate mixture of said mist of atomized molten material and said atomized coolant or atomized mixture of coolants occurs off of the surface of the mechanical atomizer and in the space above said mechanical centrifugal atomizer or within the discharge tube, whereby the atomized mist of molten material is solidified and a particulate product is thereby formed.

Claim 2

A method for solidification of molten material to particulate form, said method comprising atomization of molten materials to form a mist of finely divided molten material by expelling said molten material from the surface of a mechanical centrifugal atomizer into discharge tube, and introducing an atomized coolant or atomized mixture of coolants into the discharge tube, wherein the coolant or each coolant in a mixture of coolants has a boiling point below the temperature of solidification of the molten material and is a liquid at atmospheric temperature and pressure, and wherein an intimate mixture of said mist of atomized molten material and said atomized coolant or atomized mixture of coolants occurs off of the surface of the mechanical atomizer and in the space above said mechanical centrifugal atomizer or within the discharge tube, whereby the atomized mist of molten material is solidified and a particulate product is thereby formed.

Claim 3

A device for solidification of molten material to particulate form, said device comprising: (A) a means of introducing a stream of molten material essentially directly onto the inclined surface of a cone shaped rotating disc with a plurality of vanes positioned radially with respect to the axis of rotation of said cone shaped rotating disc, wherein said cone shaped rotating disc has essentially no horizontal surface, whereby said molten material is expelled from said rotating disc to form an atomized mist of molten material; (B) a discharge tube into which the atomized mist of molten material is expelled; and, (C) a means for introducing into the discharge tube an atomized mist of finely divided coolant or coolants, whereby the coolant is or the coolants are added off center of, and not directly to the apex of, the cone shaped rotating disc thereby cooling the atomized mist of molten material by the transfer of the heat of said atomized mist of molten material to the atomized mist of finely divided coolant, whereby the cooling atomized molten material solidifies.

Claim 4

A device for solidification of molten material to particulate form, said device comprising: (A) a means of introducing a stream of molten material essentially directly onto the inclined surface of a cone shaped rotating disc with a plurality of vanes positioned radially with respect to the axis of rotation of said cone shaped rotating disc, wherein said cone shaped rotating disc has essentially no horizontal surface, whereby said molten material is expelled from said rotating disc to form an atomized mist of molten material; (B) a discharge tube into which the atomized mist of molten material is expelled; and, (C) a means for introducing into the discharge tube an atomized mist of finely divided coolant or coolants, whereby the coolant is or the coolants are added off center of, and not directly to the apex of, the cone shaped rotating disc thereby cooling the atomized mist of molten material by the transfer of the heat of said atomized mist of molten material to the atomized mist of finely divided coolant, whereby the cooling atomized molten material solidifies.