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  • 1
    Publication Date: 2019-08-17
    Description: An apparatus is described for producing a lightweight structural material (12), by forming gas-filled shells (38) of molten material from a matrix of nozzles (22) that form shells of very uniform size at very uniform rates. The matrix of molten shells coalesce into a multi-cell material of controlled cellular structure. The shells can be of two different sizes (38, 44) that are interspersed, to form a multicell material that has a regular cell pattern but which avoids planes of weakness and localized voids. The gas (50) in the shells can be under a high pressure, and can be a fire extinguishing gas.
    Keywords: Nonmetallic Materials
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  • 2
    Publication Date: 2019-08-15
    Description: Hollow shells of high uniformity are formed by emitting liquid through an outer nozzle and gas through an inner nozzle, to form a hollow extrusion, by flowing the gas at a velocity between about 1.3 and 10 times the liquid velocity. The natural breakup rate of the extrusion can be increased to decrease shell size by applying periodic perturbations to one of the materials prior to exiting the nozzles, to a nozzle, or to the extrusion.
    Keywords: Nonmetallic Materials
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  • 3
    Publication Date: 2019-08-15
    Description: An apparatus is provided for forming gas-filled spheres of metal, glass or other material, which produces spheres (12) of uniform size and wall thickness in a relatively simple system. The system includes concentric nozzles, including an inner nozzle (18) through which gas flows and and an outer nozzle (20), which jointly define an annular passageway (50) through which a liquid flows. The flow rates are adjusted so that the gas flows at greater velocity than does the liquid, out of their respective nozzles, e.g. three times as great, in order to produce an extrusion (30) which undergoes axisymmetric oscillations resulting in the pinch off into hollow spheres with very uniform spacing. The system is useful not only where gas-filled spheres are required, but also is useful to accurately control the dispensing of solid, liquid, or gaseous materials.
    Keywords: Nonmetallic Materials
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  • 4
    Publication Date: 2019-08-15
    Description: A system is described for forming accurately spherical and centered fluid-filled shells, especially of high melting temperature material. Material which is to form the shells is placed in a solid form in a container, and the material is rapidly heated to a molten temperature to avoid recrystallization and the possible generation of unwanted microbubbles in the melt. Immediately after the molten shells are formed, they drop through a drop tower whose upper end is heated along a distance of at least one foot to provide time for dissipation of surface waves on the shells while they cool to a highly viscous, or just above melting temperature so that the bubble within the shell will not rise and become off centered. The rest of the tower is cryogenically cooled to cool the shell to a solid state.
    Keywords: Nonmetallic Materials
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