Method and apparatus for making steel sheets

An apparatus for producing a continuous thin sheet of material, comprising:

• first means for heating a first material having a first melting temperature and having a first specific gravity into a first molten material;
• second means for heating a second material having a second melting temperature and having a second specific gravity into a second molten material, the second melting temperature being less than the first melting temperature, and the second specific gravity being greater than the first specific gravity, said first and second molten materials being immiscible with respect to each other;
• third means for containing the second molten material to expose an upper surface thereof;
• fourth means for floating said first molten material onto the upper surface of the second molten material to thereby form the continuous thin sheet;
• and
• exhaust means over the said upper surface of said second molten material for removing the fumes, gases and vapors released therefrom, means to entrain said fumes, gases and vapors in an air flow, and a liquid bath to thereby scrub the air flow of a portion of said fumes, gases and vapors.

The method of forming a continuous thin sheet of material, comprising the steps of:

• (a) heating a first material having a first melting temperature and a first specific gravity to produce a first molten material;
• (b) heating a second material having a second melting temperature and a second specific gravity to produce a second molten material, the second melting temperature being less than the first melting temperature, and the second specific gravity being greater than the first specific gravity, the first and second molten material being immiscible with respect to each other;
• (c) containing the second molten material between opposed sides of a tank to expose an upper surface of said second molten material;
• (d) floating the first molten material onto the upper surface of the second molten material uniformly along a path extending transversely between the opposed sides of said tank, wherein the step of floating the first molten material onto the upper surface of said second molten material further comprises the steps of:
• (i) partially immersing a cylindrical roller into the first molten material;
• (ii) rotating the roller about its longitudinal axis so that a layer of first molten material is picked up and carried upon the surface of the roller;
• (iii) removing the layer of first molten material from the surface of the roller;
• and
• (iv) uniformly delivering the layer of first molten material to the upper surface of the second molten material;
• (e) maintaining the upper surface of the second molten material at a temperature less than the first melting temperature of the first molten material and greater than the second temperature;
• and
• (f) allowing the first molten material to solidify while floating on the upper surface of the second molten material to form a solidified sheet of the first material.

An apparatus for producing a continuous thin sheet of material, comprising:

• (a) first means for heating a first material having a first melting temperature and a first specific gravity into a first molten material;
• (b) second means for heating a second material having a second melting temperature and having a second specific gravity into a second molten material;
• the second melting temperature being less than the first melting temperature, and the second specific gravity being greater than the first specific gravity, said first and second molten materials being immiscible with respect to each other;
• (c) third means for containing the second molten material to expose an upper surface thereof;
• and
• (d) a roller having a cylindrical surface partially immersed into the first molten material and a rotation means for rotating said roller, said roller causing a layer of the first molten material to be picked up and carried upon the cylindrical surface thereof when said roller is rotated by the rotation means, for floating said first molten material onto the upper surface of the second molten material to thereby form a solidified sheet of said first material.