Sphere forming method and apparatus

A method for forming a rounded object, comprising:

• supporting an object on the updraft of hot gas emitted from an opening of a conduit lying under the object;
• rapidly moving the conduit out from under said object and allowing the object to move downward in free fall, including moving the conduit both downwardly and sidewardly;
• and
• cooling to solidify the object during freefall in a vacuum chamber.

Apparatus for forming rounded objects, comprising:

• walls forming a conduit with an opening which is oriented to emit gas in a largely upward direction;
• means for flowing gas through said conduit to emit the gas from said opening, to support an object at said opening;
• means for moving the portion of said conduit which contains said opening, suddenly out of the free fall path of an object supported at said conduit opening to allow the object to fall;
• and
• walls forming a chamber that surrounds an object supported at said conduit opening;
• means for establishing a vacuum in said chamber.

Apparatus for forming a spherical object comprising:

• walls forming a chamber and a drop tower under said chamber;
• vacuum pump means for maintaining a vacuum in said chamber and in said tower;
• a conduit located in said chamber, said conduit having an upwardly facing outlet;
• means for flowing hot gas through said conduit and out of said outlet, to support an object on the updraft of gas from said outlet;
• means for jerking said conduit at a downward incline, to allow a supported object to fall;
• and
• means for briefly opening said valve to allow a falling object to pass from the chamber to the drop tower.

A method for processing a material at elevated temperatures at which it is molten, while avoiding contamination by direct contact with a crucible or other container, comprising:

• applying the material in a solid form to the opening of a conduit, and flowing gas in a largely upward vertical direction out of said conduit opening to support the object on the gas flow;
• heating the material to a temperature at which it is molten, including heating said gas;
• and
• cooling said material in a vacuum chamber during freefall to a temperature at which it is substantially solid.