There is provided a system and method for manufacturing continuous strand fiberglass of progressive density with varying skins. Glass media is melted into molten glass within a temperature controlled melter, the molten glass exits the melter through orifices of a bushing plate, which is oriented 6 degrees relative to the axis of a rotating drum. A rotating drum receives the molten glass exiting the bushing plate, and resin and water are applied. The fiberglass media is fed through rollers before it enters a curing oven.

An optical fiber draw furnace muffle includes a body portion defining a substantially cylindrical cavity extending along a centerline axis of the muffle. A tapered portion has an interior surface which defines a first curved portion with a first radius of curvature and a second curved portion with a second radius of curvature. At least one of the first and second radii of curvature has a radius greater than a radius of the cylindrical cavity.

An optical fiber draw furnace muffle includes a body portion defining a substantially cylindrical cavity extending along a centerline axis of the muffle. A tapered portion has an interior surface which defines a first curved portion with a first radius of curvature and a second curved portion with a second radius of curvature. At least one of the first and second radii of curvature has a radius greater than a radius of the cylindrical cavity.

The present invention is directed to a vertical volcanic rock melting furnace having a reduced spatial footprint relative to prior art furnaces. The melting furnace includes a top melting section, which raises the temperature of a charge above the liquidus temperature, a middle cooling section configured to reduce the temperature of the melt, and a bottom conditioning section configured to maintain the melt above a crystallization temperature before the melt is distributed to one or more bushing plates to extrude into fibers. The top melting section and the bottom conditioning sections are surrounding by induction coils for inductively raising the temperature of the melt.

The present invention is directed to a vertical volcanic rock melting furnace having a reduced spatial footprint relative to prior art furnaces. The melting furnace includes a top melting section, which raises the temperature of a charge above the liquidus temperature, a middle cooling section configured to reduce the temperature of the melt, and a bottom conditioning section configured to maintain the melt above a crystallization temperature before the melt is distributed to one or more bushing plates to extrude into fibers. The top melting section and the bottom conditioning sections are surrounding by induction coils for inductively raising the temperature of the melt.

A method for producing glass fiber nozzles, comprising the steps of: A) providing or producing a base plate comprising a first material, being chemically resistant to the glass melt and dispersion strengthened, B) printing at least one tube made of a second material being chemically resistant to the glass melt onto one side of the base plate, wherein the at least one tube each comprise at least one feedthrough, C) generating at least one passage in the base plate, the passage is connected to at least one of the at least one feedthrough in such a way that each of the at least one passage through the base plate forms a common line permeable to the glass melt, with at least one of the at least one feedthrough of an associated tube leads through the base plate and through the associated tube.

A method for producing glass fiber nozzles, comprising the steps of: A) providing or producing a base plate comprising a first material, being chemically resistant to the glass melt and dispersion strengthened, B) printing at least one tube made of a second material being chemically resistant to the glass melt onto one side of the base plate, wherein the at least one tube each comprise at least one feedthrough, C) generating at least one passage in the base plate, the passage is connected to at least one of the at least one feedthrough in such a way that each of the at least one passage through the base plate forms a common line permeable to the glass melt, with at least one of the at least one feedthrough of an associated tube leads through the base plate and through the associated tube.

A burner for synthesization to synthesize glass particles that form a porous glass base material is provided, the burner for synthesization including a raw material gas injection portion to inject raw material gas toward a target, a combustion assisting gas injection portion to inject combustion assisting gas in a direction in which the combustion assisting gas is merged with the raw material gas at a first merging point, and a combustible gas injection portion to inject combustible gas in a direction in which the combustible gas is merged with the combustion assisting gas at a second merging point that is positioned closer to the combustion assisting gas injection portion than the first merging point. In the above-described burner for synthesization, the combustion assisting gas injection portion may also include a plurality of injection ports arranged along one straight line.

A burner for synthesization to synthesize glass particles that form a porous glass base material is provided, the burner for synthesization including a raw material gas injection portion to inject raw material gas toward a target, a combustion assisting gas injection portion to inject combustion assisting gas in a direction in which the combustion assisting gas is merged with the raw material gas at a first merging point, and a combustible gas injection portion to inject combustible gas in a direction in which the combustible gas is merged with the combustion assisting gas at a second merging point that is positioned closer to the combustion assisting gas injection portion than the first merging point. In the above-described burner for synthesization, the combustion assisting gas injection portion may also include a plurality of injection ports arranged along one straight line.

A bushing system may include a bushing that is configured to receive a molten material. The bushing may include a plate defining a first plurality of apertures through which the molten material flows. The plate may include a longitudinal axis, as well as a first side wall and a second side wall disposed on a side of the plate opposite the first side wall. The first side wall and the second side wall may extend at an upward angle from the plate. The plate may also include a plurality of ribs extending along at least a portion of the plate. The bushing system may also include a tip plate coupleable with the bushing. The tip plate may be configured to receive the molten material from the bushing and may define a second plurality of apertures through which the molten material flows to form fibers.