Rotary spinner apparatuses, systems and methods for producing fibers from molten materials are disclosed. Certain exemplary embodiments include substantially net shape single pattern rotary spinner castings that include gussets extending radially inward from a side wall and axially upward form a lower wall to an upper wall. A dispenser may be structured to supply molten material in a downward direction through a hollow interior of the casting to the lower wall. A plenum may be structured to direct elevated temperature glass toward an exterior surface of the casting.

Described herein are apparatuses and methods of creating fibers, such as microfibers and nanofibers. The methods discussed herein employ centrifugal forces to transform material into fibers. Apparatuses that may be used to create fibers are also described. Use of material transfer conduits allows the continuous production of fibers without the need to stop the process to refill the fiber producing device.

Methods, systems and apparatus for producing continuous basalt fibers, microfibers, and microspheres from high temperature melts are disclosed. A cold crucible induction furnace is used to super heat crushed basalt rock to form a melt. The melt is cooled prior to forming a fiber. The fiber produced from the superheated melt possesses superior properties not found with conventional basalt fibers produced in gas furnaces. In some implementations, the superheated melt is spun into continuous basalt fibers. In some implementations, the superheated melt is blown into microfibers and microspheres.

Among other things, the inventive subject matter generally relates to nonwoven textiles consisting of webs of superfine fibers, i.e., fibers with diameters in nanoscale or micronscale ranges, for use in articles that have, for example a predetermined degree of waterproofness with breathability, or windproofness with breathability.

A mineral fiber forming device including: a centrifuge configured to rotate about a rotation axis, the centrifuge including an annular wall pierced by a plurality of orifices, the axis of symmetry of the annular wall being the rotation axis; a first annular inductor configured to heat a top part of the annular wall; a second annular inductor configured to heat a bottom part of the annular wall. The device makes it possible to increase its energy efficiency and very greatly reduce, even cancel altogether, its carbon dioxide emission level.

A mineral fiber forming device including: a centrifuge configured to rotate about a rotation axis, the centrifuge including an annular wall pierced by a plurality of orifices, the axis of symmetry of the annular wall being the rotation axis; a first annular inductor configured to heat a top part of the annular wall; a second annular inductor configured to heat a bottom part of the annular wall. The device makes it possible to increase its energy efficiency and very greatly reduce, even cancel altogether, its carbon dioxide emission level.

The invention relates to a method and facility for manufacturing a cross-linked fiberglass material, in which melted glass is produced in a melting furnace heated via combustion of a fuel with an oxygen-rich oxidant. The melted glass is converted into glass filaments, the filaments are bonded, a sheet is made from the bonded filaments, and the sheet is then cross-linked. The fumes from the melting furnace are used to preheat a combustion reagent in two steps: a first step in which air is heated via heat exchange with the fumes, and a second step in which the combustion reagent is preheated via heat exchange with the hot air. The air is then used in the cross-linking step of the method for converting the melted glass into a fiberglass material.

The invention relates to a method and facility for manufacturing a cross-linked fiberglass material, in which melted glass is produced in a melting furnace heated via combustion of a fuel with an oxygen-rich oxidant. The melted glass is converted into glass filaments, the filaments are bonded, a sheet is made from the bonded filaments, and the sheet is then cross-linked. The fumes from the melting furnace are used to preheat a combustion reagent in two steps: a first step in which air is heated via heat exchange with the fumes, and a second step in which the combustion reagent is preheated via heat exchange with the hot air. The air is then used in the cross-linking step of the method for converting the melted glass into a fiberglass material.

A thermal insulation product based on mineral wool, characterized in that the fibers have a micronaire of less than 10 1/min, preferably less than 7 1/min and especially between 3 and 6 1/min, and in that the material has a thermal conductivity of less than 31 mW/m.K, especially less than 30 mW/m.K. The parameters for obtaining this product are in particular the pressure of the burner, the rotation speed of the fiberizing spinner and the daily fiber output per spinner orifice.

A thermal insulation product based on mineral wool, characterized in that the fibers have a micronaire of less than 10 1/min, preferably less than 7 1/min and especially between 3 and 6 1/min, and in that the material has a thermal conductivity of less than 31 mW/m.K, especially less than 30 mW/m.K. The parameters for obtaining this product are in particular the pressure of the burner, the rotation speed of the fiberizing spinner and the daily fiber output per spinner orifice.