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|HAO WAKAT I AKITELUS009771294B1 ANIMAUX AMI AM HET (12 ) United States Patent (10 ) Patent No. : US 9 ,771 , 294 B1 Zubko et al. (45 ) Date of Patent: Sep . 26 , 2017 5 ,674 , 307 A * 10 / 1997 Huey .. C03B 37/ 045 ( 54 ) BASALT FIBERS PRODUCED FROM HIGH 264 / 8 TEMPERATURE MELT 5 , 954 , 852 A * 9 / 1999 Jensen .. .. .. CO3B 37/ 055 65 / 377 (71 ) Applicant: Americas Basalt Technology , LLC , 6 , 125 , 660 A * 10 /2000 Gorobinskaya .. .. CO3B 5 / 04 Fort Lauderdale , FL (US ) 65 /474 6 , 158 ,249 A 12/ 2000 Battigelli et al. (72 ) Inventors : Yevgeniy Zubko, Ivano -Frankivsk 6 ,577 ,667 B1 * 6 / 2003 Romer . .. CO3B 5 /021 (UA ) ; Yurii Zubko , Ivano - Frankivsk 373 / 138 (UA ) (Continued ) (73 ) Assignee : Americas Basalt Technology , LLC , FOREIGN PATENT DOCUMENTS Fort Lauderdale , FL (US ) EP 2000442 A2 12 /2008 KR 2012116031 * 10 / 2012 Û( * ) Notice : Subject to any disclaimer , the term of this patent is extended or adjusted under 35 ( Continued ) U . S . C . 154 (b ) by 0 days. OTHER PUBLICATIONS (21 ) Appl. No. : 15 / 135 ,478 Cold -Crucible Induction Melter Design and Development Dirk Gombert and John R . Richardson Bechtel BWXT Idaho , LLC Idaho ( 22 ) Filed : Apr. 21, 2016 National Engineering and Environmental Laboratory , P . O . Box 1625 Idaho Falls , Idaho 83415 - 3710 Sep . 25 , 2002. * ( 51 ) Int. Ci. (Continued ) CO3B 5 / 02 ( 2006 . 01 ) CO3B 37 /04 ( 2006 .01 ) Primary Examiner — Jodi C Franklin (52 ) U .S . CI. ( 74 ) Attorney , Agent, or Firm — Cooley LLP CPC .. CO3B 5 / 021 (2013 . 01 ) ; C03B 37/ 04 ( 2013 .01 ) (57 ) ABSTRACT (58 ) Field of Classification Search Methods, systems and apparatus for producing continuous None basalt fibers , microfibers , and microspheres from high tem See application file for complete search history . perature melts are disclosed . A cold crucible induction furnace is used to super heat crushed basalt rock to form a ( 56 ) References Cited melt . The melt is cooled prior to forming a fiber. The fiber produced from the superheated melt possesses superior U . S . PATENT DOCUMENTS properties not found with conventional basalt fibers pro 4 , 199 , 336 A * 4 / 1980 Rittler . .. .. .. CO3B 32 /02 duced in gas furnaces. In some implementations , the super 501/ 35 heated melt is spun into continuous basalt fibers . In some 5 ,601 , 628 A * 2 / 1997 Battigelli .. .. C03B 37/ 045 implementations, the superheated melt is blown into micro 65 / 461 fibers and microspheres. 5 ,622 ,671 A * 4 / 1997 Pellegrin .. .. .. DO1D 5 / 18 264 / 209 . 2 18 Claims, 6 Drawing Sheets 300 PREPARE CHARGE 310 SUPERHEAT CHARGE TO FORM MELT 320 COOL MELT 330 ACCUMULATE COOLED MELT IN FEEDER FURNACE 340 COAT ROVING SPIN FBER WITH SIZING 350 355 SORT AND PROCESS CUT ROVING ROVING DOUBLE perangkat365 dan 360 enROVING 5366 DRY , PROCESS, AND PACKAGE PRODUCTS 900 WAREHOUSE 910 US 9 ,771 , 294 B1 Page 2 (56 ) References Cited 2010 / 0313606 A1 12 / 2010 Kibol et al. 2013/ 0239503 AL 9 /2013 Miller et al . U . S . PATENT DOCUMENTS 2013 /0303822 A1 * 11 / 2013 Pegg .. G21F 9 / 16 588 / 11 6 ,647 ,747 B1 * 11 /2003 Brik .. .. B82Y 20 /00 65 / 135 . 1 7 , 073 , 353 B2 7 / 2006 Noack FOREIGN PATENT DOCUMENTS 7 , 968 ,620 B2 6 / 2011 Gajiwala WO WO 2007 / 147571 12 /2007 8 , 042 ,362 B2 10 / 2011 Kibol et al. WO WO 2015 /028380 3 /2015 8 , 042 , 363 B2 10 / 2011 Kibol et al . 8 ,501 ,643 B2 8 / 2013 Kamiya et al . 8 ,806 , 900 B2 * 8 / 2014 Brik . .. .. .. CO3B 5 / 265 OTHER PUBLICATIONS 65/ 145 9 ,090 ,508 B2 7 / 2015 Gong et al . Tatarintseva et al. " Effect of Production Conditions of Basalt 2004 /0056026 A1 * 3 / 2004 Jakes .. .. .. .. .. .. CO3B 5 /023 Glasses on Their Physicochemical Properties and Drawing Tem 219 / 701 2004 /0115439 A1 6 / 2004 Degroote perature Range of Continuous Fibers ” , Glass Physics and Chem 2005 / 0005646 Al * 1 / 2005 Leister CO3B 1/ 02 istry , 2012 , vol. 38 , No . 1 , pp . 89 - 95. * 65 / 134 . 5 ASM International The Theory of Heating by Induction Practical 2005/ 0083989 A1 * 4 / 2005 Leister . CO3B 5 /021 Induction Heat Treating 2001 as viewed at http : / / www . 373 /27 asminternational. org /documents / 10192 / 1849770 / ACFAA5C .pdf on 2006 /0218972 Al* 10 / 2006 Brik . .. .. CO3B 5 /265 Mar. 16 , 2017 . * 65 /492 Consarc An inductotherm group as early asMar . 19 , 2014 as viewed 2009 /0031759 A1 * 2 / 2009 Evans .. .. .. .. .. CO3B 37 /048 at http : / / consarceng . com /wp - content/ uploads / sites / 12 / 2015 /04 / ism . pdf . On Mar . 16 , 2017 . * 2009/ 0320528 Al * 12/ 2009 Skarzenski .. B23K65 31 /525 / 02 65 /494 * cited by examiner U . S . Patent Sep. 26 , 2017 Sheet 1 of 6 US 9 ,771 , 294 B1 100 CHARGE ROCK0 000000000000000000000000000000000000000000 FROM METERING HOPPER 110 wwwwwwwwwwwwwwwwwww + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww * * * * * * * * * * * * * * * * * * * HEAT ROCK WITHIN INDUCTION FURNACE TO FORM MELT wwwwwwwwwwwwwwwwwww 120 wwwwwwwwwwwwwwwwwwwww COOL MELT IN WATER www wwwwwwwwwwwwwwwwwwwww COOLED TRAYS FORM FIBERS IN FORMATION UNIT wwwwwwwwww wwwwwwwwwwwwwwwwwwwwwwww 140 FIG . 1 U . S . Patent Sep. 26 , 2017 Sheet 2 of 6 US 9 ,771 , 294 B1 200 210 6555555555 VVVV 220 - - Hun * ws W WY 14-07 lomsterwe * W . wwwRak . 230 w 225 7Miniji . rose fra : * * 24 n poteka bo ** TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT FIG . 2 U . S . Patent Sep. 26 , 2017 Sheet 3 of 6 US 9 ,771 , 294 B1 300 Y TYYKKYYDOMAYOKWENYEKYOCYYORKYKYKYYYYYYYYYTTTTT PREPARE CHARGE 310 SUPERHEAT CHARGE TO FORM MELT horm on 320no no no ne COOL MELT?? = ?? ??? . ??? ??? ???? ?????? ????? 330 P WWWWWWW ACCUMULATE COOLED MELT IN FEEDER FURNACE 340 wowwwwwwwwwww .00 ano ano no no no no no no no non COAT ROVING SPIN FIBER BAR.IILALA 350 000.LULU000 WITH SIZING . 355 . 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Though the composition of be about at least 80 % amorphous , about at least 90 % basalt varies , basalt typically is comprised of 45 -55 wt. % amorphous, about at least 95 % amorphous, about at least silica (SiO , ), 2 - 6 wt. % total alkalis , 0 . 5 - 2 . 0 wt. % titanium 98 % amorphous, and greater than about 99 % amorphous. dioxide ( TiO2 ), 5 - 14 wt. % iron oxides, and 14 wt. % or 10 more ( A1 ,0z ) . Contents of calcium oxide ( Cao ) are typi The method can further include cooling the melt to a cally around 10 wt % , and magnesium oxide (MgO ) typi second temperature less than 1500° C . prior to forming the cally ranges 5 to 12 wt % . The composition of Basalt can fiber . The method can also include forming the fiber from the also be describe in terms of its mineral compositions which melt by spinning the melt though a bushing . include amphibole , pyroxene, feldspar, plagioclase feldspar 15 The fiber can be I micron to 3 microns. The fiber can also feldspathoids, augite , and olivine . be 4 microns to 13 microns. The fiber can also be 7 microns Basalt can be melted and processed into a fiber . Basalt to 13 microns. The fiber can also be 8 microns to 10 microns. rock is plentiful and inexpensive, however a great deal of The method can further include applying a spin finish to energy is required to melt the basalt rock and form it into a the fiber. The spin finish can contain silicone . fiber. Conventional basalt fibers may not be suitable for 20 In the various exemplary embodiments discussed herein , certain applications due to the prevalence of defects which a method of producing a fiber includes charging the quantity cause the fibers to break .