Patent Publication Number: US-RE39656-E

Title: Apparatus and method for producing metal fiber

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of PCT/KR01/00253 filed Feb. 21, 2001 which claims priority from Korean application No. 2000/0008414 filed Feb. 22, 2000. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an apparatus and a method for producing metal fiber. More particularly, the present invention relates to a apparatus and a method for producing metal fiber, which can extract fiber by melting a metal plate with an induction coil and then contacting with a bar-type rotary disk. 
     2. Description of the Prior Art 
     In general, a metal fiber is used in a filtering system for lubricating oil or refined oil and a filler for conductive plastics. Conventionally, the metal fiber is produced by melting a plurality of metal bars. However, because there is an interval between the metal bars, there are much electric consumption wasted in melting the metal bars by a heating device, and thereby production efficiency of metal fiber to power consumption is lowered. Furthermore, because a device for feeding the plural metal bars is required, it is very complex in structure and is inconvenient in management of the device. In addition, a controlling system for keeping the metal bars in an even temperature or in a uniform speed are required. 
     BRIEF SUMMARY OF THE INVENTION 
     It is, therefore, an object of the present invention to provide an apparatus and a method for producing metal fiber, which can increase production efficiency of a metal fiber using a metal plate and simplify equipments and a controlling system. 
     To achieve the above object, the present invention provides a method for producing metal fiber including the steps of: making a frame in a vacuum condition by removing the air; vertically inserting an end of a metal plate between two induction coils arranged horizontally at an interval in the inside of the frame and heating and melting the end of the metal plate with heat generated by the induction coils; gradually moving the metal plate downwardly and bringing the end of the metal plate into contact with blades of a rotary disk, the rotary dish being horizontally mounted at a lower portion of the induction coils in the inside of the frame and rotating in a high speed; and solidifying metal fiber separated by the blades of the rotary disk. 
     Furthermore, to achieve the above object, the present invention provides an apparatus for producing metal fiber including: a frame; two induction coils mounted horizontally at an interval in the inside of the frame, each induction coil heating a metal plate dropped vertically between the induction coils; and a rotary disk having a plurality of blades formed on a round bar at regular intervals, the rotary disk being horizontally mounted at a lower portion of the induction coil in the inside of the frame, the rotary disk rotating in a high speed. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Further objects and advantages of the present invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a schematic view of a metal fiber producing apparatus according to the preferred embodiment of the present invention; and 
         FIG. 2  is a side view of FIG.  1   
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail in connection with preferred embodiments with reference to the accompanying drawings. For reference, like reference numerals designate corresponding parts throughout all views. 
       FIG. 1  is a schematic view of a metal fiber-producing device according to the preferred embodiment of the present invention, and  FIG. 2  is a side view of FIG.  1 . 
     The metal fiber producing apparatus according to the preferred embodiment of the present invention includes a rectangular frame  10 , two induction coils  12  disposed horizontally in the inside of the frame  10  and a rotary disk  11  disposed horizontally at a lower portion of the induction coils  12 . 
     The frame  10  is in a sealed structure and thereby metal fiber can be produced in a vacuum condition. The frame  10  may be filled with inert gas, such as argon or helium instead of the vacuum condition. The induction coils  12  are horizontally disposed at an interval in the inside of the frame  10 . A metal plate  20  is dropped into a space between the induction coils  12  and then melted with heat generated by the induction coils  12  while passing between the induction coils  12 . The rotary disk  11  rotating in a high speed is horizontally disposed at the lower portion of the induction coils  12 . The rotary disk  11  has a plurality of blades formed vertically on a round bar, and the metal plate  20  dropped vertically is brought into contact with the blades of the rotary disk  11  and thereby extracted into a fiber form. 
     A method for producing metal fiber according to the preferred embodiment of the present invention includes steps of: making the frame  10  in a vacuum conduction by removing the air, dropping the metal plate  20  between the induction coils  12  and heating and melting an end of the metal plate  20  with heat generated by the induction coils  12 ; and bringing the end of the metal plate  20  into contact with the blades of the rotary disk  11  by moving the metal plate  20  gradually downward and separating and solidifying metal fiber. 
     In the step of making the frame  10  in the vacuum condition by removing the air, it is preferable that the pressure in the vacuum condition is 10 −1 ˜10 −3  atm. The frame  10  may be filled with inert gas, such as argon or helium instead of the vacuum condition. In this case, an oxidation of the metal fiber in a high temperature can be prevented. 
     Preferably, a thickness of the metal plate  20  is about 2˜15 mm, but may be adjusted according to materials of the metal plate  20 . It is preferable that a heating temperature of the induction coils  12  is about 1,000˜1700° C., but it also may be adjusted according to the materials of the metal plate  20 . A rotational speed of the rotary disk  11  is about 3,000˜5,000 rpm. 
     The metal fiber extracted by the blades of the rotary disk  11  is cooled and solidified. At this time, a cooling speed of the metal fiber is about 1,000˜100,000° C./sec. The rotary disk  11  is water-cooled. The extracted metal fiber is about 15 μm˜500 μm and it may be adjusted according to uses. 
     In the present invention, not a metal bar but the metal plate is used to extract the metal fiber and thereby production efficiency of the metal fiber is increased. Especially, the production efficiency of the metal fiber to power consumption is very increased, and manufacturing equipments are simplified. 
     While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated by those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.