NL8020249A - METHOD AND APPARATUS FOR MANUFACTURING CELLIC GLASSY PRODUCTS - Google Patents

Description

* PCT / N / 30.434-tM / id 8020249 i ...................................... ........... ....... 'ij Method and device for the production of cellular forms j glassy products.

| ! Reference to related application i! : j | '; : This application is a continuation-in-part of my United States patent application serial no. 888,507, filed | as of March 2.0, 1978, now not further discussed.

5: Background of the invention ! 1. Field of the invention

This invention relates to the manufacture of cellular glassy plates or shapes of which: an important part of the volume consists in cells 10; trapped gases, in particular the method and apparatus for producing cellular glassy refractory in prescribed shapes and products i; of which with lower densities than conventional brick i or tiles, and which are more impermeable.

! ! : 'i j ·; 15; 2. Description of the Prior Art There is a commercial producer of cellular glass blocks using a process in which powdered or pulverized glass is the major raw material. The fine particle glass powder is mixed with! 20; two chemical constituents that react to form gas at 1 1 8 0 2 0 2 4 9 a temperature above the point where the glass sintered to trap the glass. The same company owns the United States; U.S. Patent 2,890,127, which discloses the use of powdered quartzite as charge and discrete carbon: 25; particles or silicon carbide, where the carbon reacts j! with SiO2 to form the foaming gas. It also owns U.S. Patent 2,890,126, which supports

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j! describes the charge through graphite plates and the addition of I! I compounds, such as feldspar, to the blend of patent: 2,890,127 to decrease viscosity and improve sintering and cell formation. Commercial production became.

_J intermittently held for several years and then not '<.

-2- i Ί .......... ............ ........... "" "......... ........................

continued further. These two patents pointed to the radical; improved properties obtained when the glass blocks consist of almost pure silica glass.

| The oven for the above described commercial. i i | The process was made from graphite plates that acted as resistance heaters. The load was carried in graphite pans that were pushed in a row through the oven. The process i was unsuccessful, as far as i understand this matter, because it! i was too expensive and the graphite plates and pans would not last long; come along. My process avoids expensive grinding to a fine | | particle size and the application of the expensive graphite of! high quality for oven parts and load pans.

Several patents describe the skewing! one of different minerals to avoid the cost of making powder glass first. None have resulted in continued commercial production of a plate or mold; however, for market development, Dow Chemical produced quantities of foamed glass-like clay blocks intended for several years using clay as raw material. The well-known state of the tech- I! not like swelling from clay to clumps of cellular ma-! 1; material Dow supplied the hot lumps which they pressed and thus welded them into blocks (U.S. Patent 3,056,184).

! For centuries, prescribed forms of roof tiles ï 25 | walls, wall tiles, floor tiles, bricks and various ke-j; ramic objects such as flower pots, porcelain and the like manufactured by pressing a mixture of clay and water: I! and then to dry and sinter it. Such products i *! j as bricks are produced by mixing the clay! extrude so that the load is packed into fairly dense | masses. Pressing the clay mixture at high pressure is "dry"! also extensively applied.

| Such dry clay mixtures which are produced by dry pressing or wet pressing usually contain about 5% to 8% moisture and are subject to unrestricted use. spring 70 bar to about 350 bar. Extruding clay mixtures according to the known state of the art is | moisture content of the clay mixture is usually higher, namely i! : I i near 15% to 20% J however a very important 8020249 \ -3- i .......................... ................................. ................. ...-.....................

j i! pressure still needed.

i: I Each of the resulting dense mixtures must! I can be dried rather slowly over a long period of time to allow the gradual migration of the moisture through the i: 5 clay. If such a procedure is not! continued, the clay may crack or explode during drying. The resulting sintered clay is quite dense and covered ! keeps its original shape without cracks or tears.

I | The sintering takes place at a temperature below the melting temperature of the clay which is used. I use a mixture that has a low moisture content and is pressed at low pressures. This makes the rapid heating of i! ; need the charge that can crack during sintering, but these cracks will be fixed later. In the past, the cell was 15; formation of clay materials used. For example, in Ford U.S. Patent 2,485,724, Ford taught that by applying i! | flux foaming foaming at low temperature! a special Albany slip clay could be made using an oxygen-containing agent and carbon in the form of carbon black. Ford also taught that urea, sugar, or dextrose. molasses could be used instead of the 1 | carbon black to produce objects with densities of 160 I; up to 320 kg. per cubic meter. The baking temperature was close to 815® to 983® C.

| 25; In my U.S. Patent 3,967,970, I produce a swollen clay by baking at about 1150® C to! 0! 1260 C of a mixture of clay, sugar, sodium or potassium hydroxide and water. In Example 4 of that patent I used sodium phosphate instead of the sodium hydro: 30 xyde.

j The method of the present invention; ! avoids the costs, effort and risks of applying | ! a flux and thus has yielded a foam product which has a higher melting point and is more resistant to water and chemical agents.

U.S. Patent 2,337,672 describes the manufacture of multicellular glass by heating! of a load of glass, arsenic, zinc or cadmium oxide I! and carbon powder to obtain a reaction between οι · '·; · 8020249 -4- i! J. sen the oxide and the carbon.

i Other less applicable US patents! scriptures related to the swelling of ceramic materials:! rial include the following: 5! 3,174,870 3,150,988 i 3,666,506 2,880,099! 3,536,503 2,564,978 | 3,307,957 2,670,299

None of the earlier discussed prior patents discloses a practical means of quickly and economically producing a foamed mineral block or plate.

! Therefore, an object of the present invention is to provide an apparatus and method to provide fast, efficient; | | and a low-cost foamed mineral object at 15; manufacture.

| Another object of the present invention is | providing a foam-like mineral object that is highly insulating and light-weight, yet resistant to aging, corrosion and water absorption.

: Another object of the present invention is to provide a method and apparatus for producing a foamed mineral material and producing the | I material itself which has a high structural strength and can form load bearing walls and roofing with widely spaced supports and can be manufactured in | large plates.

I Other purposes, features and benefits of the! The present invention will become apparent from the following detailed description.

! | | '! 30 | Overview of the invention! i: Briefly described, the method completes! The present invention utilizes low pressure to form a charge mixture of clay, carbonaceous material and moisture

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compaction, followed by rapid heating to dry the clay charge and gradually baking the shaped load above the melting temperature on rolls J without the need of carrier plates to form a preformed cell 02 0 2 4 9 -5-

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I can make a glassy, impermeable, light-weight refractory material. The movement of the load through the box i zone is slow; however, no significant sagging! The loading belts occur due to the high viscosity of the molten clay in question. Cracks that time 5; if drying and preheating occur, they are concealed! | pen by swelling the clay.

j Essentially the same procedure is followed for [manufacturing a preformed foam melted; a silica object, using finely divided silica and a carbonaceous foaming agent as lsding.

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When preparing a clay or silica tape to be passed over rolls of the device, in some cases a separating or release agent [is applied to the bottom and optionally the sides of the 15 | band.

| The device according to the present invention comprises a plurality of juxtaposed sets of moist attachments i pressure rollers, and a j i; ! mixture supplied of clay and / or shale of which the content is.

I i; ! 20 carbonaceous material and moisture content are | I set. Each set of rollers also extrudes a release or release agent around the sides and bottom of | the strip of raw clay material that is extruded. Mouthpieces add enamel or engobe to the top of the band.

The force of the rollers carries the belts along I; parallel horizontal vertically spaced paths i j to the first heating or preheating chamber of the! oven and thence in the combustion chamber along the top surfaces of rollers. The ends of the rollers protrude outwards j away from the walls of the oven, and the end portions are supported on circumferentially spaced free-running wheels and can be rotated at the same time by a common belt.

35 Fuel and air are supplied through manifolds to staggered burners i | in opposite parallel rows running along the sides of the oven in the combustion chamber. exhaust ports are counter- 8020249 -6-! ............! ............................ ...................................... ........ "i! j I i placed over the nozzles and lead to manifolds leading to the outlet part of the preheating chamber of the oven Exhaust fans exhaust the flue gases I [from the input part of the preheating chamber. sintering the j bands instead.

[| The foaming of the sintered clay belts is j! place above about 1095 ° C in the combustion chamber, while the belts are gradually moved along the rollers in the combustion 1D chamber. j! "The tires come out of the exhaust of the combustion! chamber in the form of impermeable cellular fire | solid streams and are fed into a cooling oven where the temperature temperature is quickly reduced to the cooling temperature; 15 | and then cooled. These products are then supplied from there to conveyors where they are cut into rectangular blocks. i

In another embodiment of the invention, a batch of silica, carbonaceous material and water is formed in a heated, low pressure press. A sheet formed from aluminum foil or other release agent and a layer of pitch or coke or coal is placed on the bottom surface of the sheet. while the load is being pressed.

This packed silica loading on its plate is passed through the oven from end to end and preheated and foamed in the manner previously described for clay. Cell I; shaped molten silica blocks are formed.

; The third embodiment includes two-stage extruders, i; each of which has three feed rollers for feeding a load as a belt from a cistern horizontally to the oven. The separating agent is sprayed onto the belt from below and the glaze or engobe from above. The third embodiment furnace has muffle plates to form vertically spaced chambers, above and below the belts, and these chambers drain into the oven drying or preheating zone.

In the fourth embodiment, the oven is shown with a cylinder containing pre-assembled pans with drawers gene of green or crude silica. The sections of the I pan are preassembled to a hand-pressed? 8020249

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-7- i; To take up the load or to provide it with pressed charges which form a monolithic or fused product when melted.

i! Brief description of the drawings i; Fig. IA is a schematic vertical section! of an embodiment of a device for manufacturing of refractory cellular material according to the present invention, the apparatus being shown in the processing of clay loads; ! Fig. 1B is a continuation of the image | of the device shown in Fig. 1A;

Fig. 1C is a continuation of the representation of FIG. 1B; j Fig. 2 is a vertical section, at least afterwards! name along the line 2-2 in Fig. 1A; Fig. 3 is a vertical section at least substantially along the line 3-3 in FIG. 1A; s Fig. 4 is a vertical section at least substantially along line 4-4 in FIG. 1B;

Fig. 5 is a vertical section at least substantially along the line 5-5 in FIG. 1B; ; Fig. 6 is a vertical section at least substantially along the line 6-6 in FIG. 1C; S Fig. 7 is at least a vertical section 1; ί name along line 7-7 in Figure 1C;

Fig. 8 is a similar vertical section i to FIG. 4 of a modified embodiment of the oven | according to the present invention; | ] FIG. 9 is a similar vertical section! as Fig. 5 of a modified embodiment of the bottom; present invention; | Fig. 10 is a vertical sectional view of the front portion of a second embodiment of the present invention and shows a press assembly to form subsequent rectangular charges fed to the oven; | j Fig. 11 is a partial side view on a larger scale and shows the drive of the horizontal drive. ί. .......... ...... .............

8020249 -8-! ] Feed rolls of the oven of FIGS. 1A, 1B and 1C; ! ; Fig. 12 is a similar view to FIG.

1: 11 but shows the drive for the feed rollers which are further apart than the rollers of FIG. 11; i f | 5j FIG. 13A is a similar vertical section; The one shown in FIG. 1A but shows a third embodiment of the apparatus for manufacturing cellular refractory materials rial;

| Fig. 13B is a continuation of the one shown in FIG. 13A

; 10; displayed image;

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Fig. 13C is a continuation of the one shown in FIG. 13B

i shows the image and shows the glaze applicators and j the cooling oven; | Fig. 14 is a vertical section, at least afterwards! ; 15; name along line 14-14 in Figure 13A;

Fig. 15 is a vertical sectional view at least approximately along line 15-15 in FIG. 1A; j s Fig. 16 is a vertical section, at least afterwards! name along line 16-16 in Figure 13A; Fig. 20 17 is at least a vertical section! | ; name along line 17-17 in Figure 13B; Fig. 18A is a similar vertical section; as Fig. 1A and Fig. 13A and shows a fourth embodiment J! of my invention; 25i FIG. 18B is a continuation of FIG. 18A; and I FIG. 19 is an exploded perspective view of abutting sections that form a first pan for receiving an unpressed load. j of sand or briquettes; i30: FIG. 20 is an exploded perspective i; view of multiple abutting sections forming a pan, the sections imaged after being pressed with their respective parts of the total load; FIG. 21 is a perspective view of the assembled pan of FIG. 20 with no load; and | Fig. 22 is a partial plan view of | part of the pan of FIGS. 20 and 21 with its load inside the furnace of FIGS. 13A, 13B and 13C, with the sides and vertical

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Horizontal alignment rollers of the oven are cross-sectional. statue.

ί i ί! i I; Description of the Preferred i; versions I! Referring now in detail to the versions! selected for displaying the device according to the present invention, reference numeral 10 in FIG. 1 gives a vertically disposed dump. ! bake with parallel triangular end walls 11 which are 10 | connected by downwardly converging side walls 12 terminating; in a rectangular opening on the bottom part of the cistern. A set of damp press rolls is carried on the! cistern opening 10. This set includes a pair of counter! i overlying compression rollers 13 carried by! 15! supports 14 to rotate about spaced apart parallel horizontal axes 15 rotated in opposite directions for compression; | and supplying the material or cargo contained in the cistern 10 to a curved conduit 16 with a rectangular cross-sectional area. End rollers 19 that are engaged! | brought along axes perpendicular to the axes 15 works | together with the rollers 13 to pack the material and drive [I into the conduit 16.

| | The rollers 13 and 19 thus extrude a rectangular band 20 of the raw material or load in a vertical downward path to the upper end portion of the ji. | pipe 16. The curved contour of pipe 16 changes | ; gradually the path of the belt 20 from a vertical path into a horizontal path, the lower end portion 17 of which

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130 j the pipe 16 horizontally outwards from the! conduit 16 protrudes to form a slide along which the belt 20 gradually moves. The top face of the slide plate 17 is aligned with the top circumference of several parallel; brought feed conveyor rollers 18 formed of steel 135; or ceramic material. The feed rollers 18 become synchronous. rotated to form a moving deck for transport of the tape 20 in the front input port 9 or the 8029i49 *%

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-10-:! : ί entry end 26 of an oven generally indicated i i i! I! by the reference numeral 25. Thus, the tape 20 forms one! continuous charge of rectangular cross section moved through the oven 25 from the inlet end 26 to the outlet; corridor end 27 of the oven 25.

[As shown in Fig. 1A, the cistern 10 is 1! divided into compartments around a compartment 21 for receiving the main charge and a compartment 22 for the | incorporating a release or separating agent. A U-shaped dividing wall 23 separates the two compartments 21 and 22. More in detail, dividing wall 23 comprises oppositely! opposite truncated triangular downwardly converging parallel sides 24 connected to their leading edges: | j with the side walls 11. The rear edges of the side walls 24 | > 15 'are respectively connected to the edges of a transverse; rectangular separator plate 26A. Thus, a U-shaped sequence is | secondary or separating agent compartment 22 formed by a part of the cistern 10 and the separating wall 23 which also have three i! sides of the chamber 21 for receiving the main charge i: 20i surrounded.

| A mixture consisting of clay-like material, water and carbonaceous material (adjusted with respect to the carbonaceous material and moisture) is granulated after being fed and mixed through the main compartment 21. Thoroughly separated. or release agent is added, | fed to the compartment 22. This separating or releasing agent may be any of a variety of agents used to prevent adhesion of the surfaces in a shape. To keep rollers 35 and 36 clean, I prefer to use a moist mixture of refractory clay and refractory clay slurry that has the double J function of the extruded tape 20 of clay-like material from limit the rollers in the oven 25 and also the expansion width of the belt 20 in the transverse direction.

I i ί 35; Furthermore, the separating or releasing means around the sides and bottom of the belt 20 can be made strong enough to resist breaking off in the event that | from a sticky spot on rollers 35 and 36 resulting j________! of accidental contamination.

8020249

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I! ! I An alternative separating agent mixture of si-; : lica sand bonded with damp clay to about 8-20% clay1; can be used to provide sufficient binding to the! separating layer at least substantially through the green and dry state; 5: hold slide. This would provide a stronger bond at the bake f | ! except that the sudden expansion of the sand grain I i 'η I! travel at about 579 C largely disconnects.

I i In the case of a sticky spot of molten material i or rolls, the grains of sand are then delivered to the spot 10 | until the stickiness is covered.

! In the case where the charge is silica or clay with a melting temperature above about 1595 ° C, the pitch-bound separator carbonaceous material i; i are like coke or coal.

15: When a pitch or tar-bonded coke or coal is to be used as a separating agent, it is preferable to use a rectangular low-pressure press 202 of FIG. in which the plate 203 of the press 202 receives the separating agent as a first layer and the clay or silica load is loaded over it.

| In more detail, the press 202 includes a vertical deployed double-acting hydraulic or air cylinder 204; i of which the piston rod in a vertical path is rectangular; i '1 - Flat metal press plate 205 moves back and forth.

125 The heated rectangular plate 203 is attached ...

| aligned in a fixed position under plate 205. Under plate 203 is a vertically movable edge support plate 206 | : which carries an upright edge portion 207 which surrounds the edge portions of the plate 203. Legs 208 protruding through 30 | holes in the support plate 206 support the plate 203.

I '! ! A cylinder 209 moves the plate 206 and thus the rare part 207 back and forth in a vertical path from the position shown in broken lines to the full lines; Fig. 10 shown position.

Movable horizontally across the plate 203 is a push plate 211 mounted by the piston; rod of a horizontal cylinder 213. A sliding plate 213 on | The side of plate 203 forms a deck over which I | j; subsequent batches 220 from the press 202 into the furnace 225 are fed 8 02 0 2 4 9-12 for processing.

i: [In operation, plate 205 is withdrawn! and the edge portion 207 moved upwardly around the plate 206. The | charge which may consist of an aluminum plate, a carbon-5 | material and a binder on the plate as a thin-! One layer and the silica charge thereon is placed in the edge portion 207 on the plate 203. The material is then passed through! J the plate 205 pressed by operating the press cylinder 204 | [and then the plate 205 is withdrawn. Then it becomes! 10! edge part 207 pulled down and cylinder 213 actuated at moving the pusher plate 211 over the plate 203 and pushing the load 220 into the oven 225. Consecutive loads 220 form! a belt entering the oven 225 in which it is treated in the same manner as the belt 20 in the oven 25, 15; The low pressure press 202 is normally used to apply a pressure between about 3.5 bar and below; i | | about 70 bar and can be used instead of the rollers; | : 13 and 19 for forming clay loads with or without I separating agent along the bottom face or bottom and the j | ! | 20; side surfaces of the clay load.

; ; Above the slide plate 17 is a drying heater ! 28, the function of which is to dry the top surface of the belt 20 as it emerges from the conduit 16 in a horizontal path. The heater 28 may be 25; desires an electric resistance heater or a gas heater; ter or one of a variety of heaters are those! provide sufficient heat to simply dry the top surface of the ί tape 20. Backward from the heater 28 along the path of the belt 20 is a color application nozzle assembly 29i 30 arranged transversely over and above the path of movement! i extends from the belt 20. The function of this nozzle assembly 29 is to add engobes or enamel to the top; ; surface of the belt 20 after the surface has dried. Na-I | Of course, the color layer can be omitted if desired.

| 35: So at this stage, the band 20 moves in a ......

ί | j horizontal path and has a release means along its j | | bottom surface and side surfaces and glaze or engobe along its bottom surface. A second cistern 110 equal to the cistern.

I] bin 10 is arranged next to the cistern 10 for the provision! ______ I ................... '8 0 2 0 2 4 9 -13-

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Filling of a second belt 120 for supplying to the furnace 25. This second cistern 110 comprises rectangular down converging side walls 112 and truncated triangular walls 111 which form a rectangular down converging cistern. The cistern. 110 also includes opposed feed rollers 112 which rotate; Run on shafts 115 and are supported by supports 114. Furthermore, the cistern 110 includes side rollers 119 which cooperate with the feed rollers 113 to form a downward flow or belt 120 which is received in the bent conduit 10 '116. The conduit 116 gradually changes the trajectory of the belt I 120 from a vertically downward trajectory to a horizontally oriented trajectory. Like the cistern 10, the cistern! I bake 110 a separating means 123 so that the belt 120 passes along ! its bottom surface and side surfaces are provided with a release jl5; agent. Furthermore, the top surface of belt 120 as it exits in a horizontal path is supported by a slide; plate 117 and heated by a heater 128 at its top surface.

! A glaze application nozzle assembly 129 is applied to spray glaze onto the heated and dried top surface 201 of the belt 120. The belt 120 then enters the oven 25 i through a rectangular opening or port 109 which extends vertically on the top. a distance above the rectangular entrance port 9 for the i! i; band 20. The bands 20 and 120 are thus fitted and | pass through the oven 25 from the inlet end 26 to the outlet 25 end 27 along parallel horizontal in vertical direction I! spaced orbits.

! In more detail, the oven 25 or at least the lining of the oven is formed of refractory material. It is generally rectangular in shape along its entire length.

30; In the central part of the oven 25 there is a vertical The dividing wall 30 covering the interior of the oven 25! I separate in a drying and preheating chamber 31 and a heating ; combustion chamber 32. In other words, chambers 31 and j '| 32 is arranged in tandem along the longitudinal path which is passed through the belts 20 and 120. The dividing wall 30 has! two vertically spaced openings or ports 30a and, 130a through which belts 20 and 120 pass, j Ports 9, 30a and 60 are horizontally aligned ports; 109, 130a and 160 are in horizontal alignment above the! ! 8 0 2 0 2 4 9 -14-

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ports 9, 30a and 60.

! All burners 40 that heat oven 25 are located! preferably in the combustion chamber 32, while the j! drying and preheating chamber 31 receives the exhaust, flue or 5i flue gases from the combustion chamber 32.

As indicated above, the oven is 25 and in | in particular, the combustion zone or chamber 32 made of or lined with refractory material that can withstand temperatures in the region of 1260 ° C and up to 1815 ° C in some 100; cases. Chamber 31 is less critical in that it is always 1 ! is at a lower temperature than chamber 32, but refractory | ! material must be used to enter this chamber 31.

| | The rollers 35 and 135 in the preheating chamber 31 and the rollers 36 and 136 in the combustion chamber 32 are suitable | ; 15 'refractory material, such as high alumina or molten silica.

t; Rollers 35 and 36 are arranged along a horizontal track and extend transversely of the oven 25, the ends of each roller 35 and 36 protruding outwardly through I | arranged holes opposite inner side walls 37 | 20 "and 38 and outer side walls of oven 25.

j The top circumferences of the rollers 35 and the top i I ·. The circumferences of the rollers 36 lie along a common horizontal plane and support the belt 20 on its bottom surface. Similarly, the rollers 135 and 136 protrude outwardly through suitable holes in the sidewalls 37 and 38 and form top circumferences which lie in a common plane and receive the bottom surface of the belt 120! to support it. The plane of rollers 135 and 136 | is parallel to and lies above the plane of rollers 35 and 30 36. iji Although I have used an oven 25 with two movement paths for the raw material or belts 20 and 120 j fed through the oven 25 respectively by j rolls 13, 19, 18, 113 and 119, the number of flows can be rough! 35! material can be enlarged if desired by duplicating | the systems described here.

| Additional lines of cistern 10, 110, rollers 13, 113, 15, 115 etc and a corresponding number of rollers 35, 36 and 135, 136 can thus be used in an array if desired. cool oven.

To provide means for heating.

of the combustion chamber 32 I have a number remote from i: | placed side-facing combustion nozzles 5! or burners 40 for fuel, for example oil or gas, which protrude through the walls 38 forming the chamber 32 I. The nozzles 40 on one side of the chamber 32 are offset from the nozzles 40 on the other! side wall 38 of the chamber 32. Furthermore, there are horizontal rows 10 of such staggered nozzles 40 below the row of rollers 36 and between the row of rollers 36 and the rollers 136, and between the roof 41 and the row of rollers 136. Thus, the flames of the nozzles 40 are fed sideways in alternating directions both above and below the belts 20 and 120.

15! The gas exhaust ports 42 in the side walls 38 are disposed transversely opposite the nozzles 40, respectively.

The discharge ports 42 are thus arranged in horizontal row; 1 and corresponding to the rows of nozzles 40 and are also staggered with respect to the transversely arranged ports 42. It now appears that each side wall 38 has three I vertically spaced rows II in which alternately a discharge port 42 and a mouthpiece! i 40 equally spaced in the longitudinal direction are i; i brought. Each nozzle 40 directs its flame across the transducer; Combustion chamber 32 so that a considerable amount of combustion * "i combustion gases through the opposite port 42 from the 1 2 8 02 0 2 4 9 ............................... .......... 'room 32 flows.

Since the nozzles 40 are staggered transversely in each horizontal row, rotating gas streams are discharged! alternately in and counterclockwise from an hour-1 work above and below bands 20 and 120.

Each nozzle 40 is aligned longitudinally! ; Clear distance between two adjacent rollers 36 and 136 brought and protrudes through the side wall 38 and is thereby supported. Combustible gas such as natural gas is supplied from a gas manifold 43 through separate branch lines 43a to the nozzles 40. An air manifold 47 delivers! j pressurized air through lines 44a to supply air for mixing with the gas to nozzles 40. Manifolds 43 and 44 are located on opposite sides! 48 of the combustion chamber 32. A similar embodiment; can be used to burn oil or other IS fuel.

j 1 | 5! As best seen in Figure 5f, the oven is | 25 provided with outer walls 44 which are outwardly spaced! of and parallel to the inner side walls 38. Top and bottom horizontal walls 45 and 46 are i the upper and lower edges of the walls 44 with 10i bind their respective inner sidewalls 38 around horizontally extending channels or passages 47 | opposite sides of the inner side walls 37. End walls 56 that are parallel to the rear end wall 27 close the downstream ends of channels 115; 47.

The walls 44, 45, 46 form manifolds that enclose the entire outlet port 42 so that they communicate on their respective sides with the channels 47 extending horizontally. Spaced block 20. 57 under the walls 46 form a support for these manifolds.

The walls 44, 45, 46 extend in a flow! upwardly across opposite side walls 37 of the upstream end portion of chamber 31 and ends at end walls 58. Opposite, in vertical | direction remote smoke or chimney gas inlet; ports 59 are provided in the end portions of the sidewalls: 37, as shown in FIG. 1B, so that they connect! with channels 47, as best shown in FIG.

30: 4. The channels 47 thus exhaust all flue gases from the combustion chamber 32 and pass them sideways through ports 59 on opposite sides of the chamber 31 both above and below the belts 20 and 120 in the downstream end of the j; chamber 31 and these gases flow in an upstream direction as indicated by the arrows and are received by discharge ports 48 disposed in the walls 37! I at the front end 26 or entrance end of the chamber 31,

The transversely opposite discharge I ports 48 communicate with opposite ones 8020249 -17- .--- ...........................

''! upwardly extending suction lines 55 communicating with outlet manifolds 49 disposed outward from the oven 25 at the walls 37. These outlet manifolds 49 lead up into a receiving conduit 50 which is 5! connected to the inlet ports of an exhaust fan 51 I driven by a motor 52 via a belt 53. The! fan 51 delivers through a chimney 54 to the outside 1.

1 air.

j Separate nozzle controls 10; 40, including strategically located pyrometers and valves (not shown), allow an operator to control the transverse heating zones of the combustion chamber 32 I so that the heat in the combustion chamber 32 can be within fairly close tolerances. kept. The transverse flow of these gases both above and below the moving belt! ! den 20 and 120 allows the combustion chamber 32 I 1; is held at a suitable temperature to gradually bake the subsequent parts of the clay belts 20 and 120 and form I into foam or cells as they move along the combustion chamber 32. The ratio of air to combustion! dust is held in different zones as desired for oxidizing, neutral or reducing conditions. The cellular or expanded glassy clay that! is indicated by reference numerals 20a and 120a. 1; 25 'thus gradually and continuously out through the discharge ports I 60 and 160 in the rear end 27 on support rollers 61, 161. While the cellular glassy clay belts 20a and 120a are out of the; If desired, the top surfaces thereof may be treated with additional surface material, such as 130, a dry granular fritted glaze 62. I: 1 material 62 is contained in a cistern 63 at one side! of the oven 25. The bottom part of the cistern 63 is provided i; of a transversely extending hollow divider cylinder 65 which carries a horizontal screw conveyor 64. The distribution cylinder 65 is at one end in communication with | the cistern 63 and is provided with a! number axially spaced j holes 66.

| ! Since the cylinder 65 is exposed to an 8020249 -18- ii ...................... '.............. ............

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; i ί very significant heat, because it is across the top:! of the path of movement of the expanded or swollen clay; When tape 20a is provided, a means is provided to both to cool the deck material 62 as the cylinder or trough 65. This 5 | means for cooling comprises a hollow central shaft 67 for j the conveyor 64 through which water is pressurized conducted. The shaft 67 and the screw conveyor 64 which is connected to the shaft 67 are rotated by a motor 68 and a | chain drive 69. Water is supplied to shaft 67 10! by a pump 70 via a pipe 71, a shaft 167, pipes 72 and i! 73, from a tank 74. A return line 75 provides it cooling water back to the tank 74.

J The shaft 167 is equal to the shaft 67 and carries a screw screw transistor 64 in a cylinder or trough 165 of a 15 | cistern 163 which is driven by a motor 168 and chain 169 to feed fried glaze 162 through holes 166 | on the top surface of the belt 120a. The cylinder 165 extends across the belt 120a. Outlets 76 and 176 at the ends of the cylinders; 20: 66, 166 feeds excess fried enamel 62 or 162 to containers 77, 177.

I i I By selective operation of motors 68, 168 | fried enamel 62, 162 is delivered to the hot top surfaces of the belts 20a, 120a. The glaze is immediately melted (to form a glaze surface thereon).

I As indicated above, the end parts stick out! of the rollers 35, 36, 135, 136 outwardly by suitable means holes in walls 37, 38, 44, 237, 238, 244 of oven 25 | and 225. As can be seen in Figure 12, for example, the rollers 35 which support the load prior to sintering and are located in the drying and preheating chamber 31 may be spaced further apart. than the Ι distance from the rollers 36. At this greater distance, each! I! End portion of the rollers 35 bounded outwardly of the oven by three three circumferentially spaced freely rotating wheels 70a, 70b, 70c. The free-turning wheels 70a; 70b, 70c are rotatably supported by axle stubs 71 which protrude into the outer walls 44. The axle of each lower wheel j 70c is vertically below the roller 35 which is thereby supported.

A continuous steel belt 72 passing between I each wheel 70c and its associated roller 35 to the next and i then to the next provides a synchronized drive

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b; for all reels 35. The same belt 72 also passes under al-! The rollers 36, as shown in FIG. 11, are sandwiched between the end portion of each roll 36 and its associated rollers. roll 73c underneath.

Since the rollers 36 are closer together, they can take up an additional wheel 73b, which is in between lies and runs against the contours of the adjacent rollers 36 above the axial plane of this roller 36. These wheels 73b | the belt 72 assists in synchronizing the rotation of the rollers 36. The outer roll 36 has an outer free space. rotating wheel 73a circumferentially spaced i i.

| ! of wheels 73b and 73c for that roller 36.

; The belt 72 passes about suitable drive or j; guide rollers 74 outward from rollers 35 and 36. One1! motor (not shown) can drive the belt 72. The rollers 20: 135, 136 have a similar drive. The cooling oven 80: is provided with a similar drive for its rollers. The drives can be located on one or both sides of the oven or cooling oven about one or both end parts of f! i power the rollers.

25 | At points along the path of movement of the belt 20, | 120, if expansion or contraction of the tires can occur! it appears desirable one or more of the roles such as the | let rollers 35, 36, 135, 136 turn freely. This can be done easily reached by the appropriate associated wheel | 30 | or wheels 70c and / or 73c sideways, inwards or outwards! ! shifting them out of alignment with the belt i ί 'i be 72.

; I

! After the swelling bands 20a and 120 emerge from the oven 25 and additional glaze 62 is applied to the top surface of the material, if desired, the bands pass. den 20a and 120a in a cooling oven generally designated by the reference numeral 80. The cooling oven 80, like the oven 25, is separated into compartments, the first of which is a cooling chamber 81 and the other annealing chambers 82a, 8020249 -20- 82b, 82c. The cooling oven 80 includes a front wall 83, intermediate Lying partitions 84a, 84b, 84c, 84d and a rear wall 85. Furthermore, it has a front side wall 86 and an i: j | rear side wall 87 and a top wall 88 and a bottom 89.

5; Rollers 87 and 187 form horizontal transport for the tires 20a and 120a in the first chamber 81. The | rollers 88 and 188 form horizontal conveyors in the two | room 82. The front wall 83 is provided with ports 90 and! 190 through which the respective bands 20a and 120a pass 10 in the chamber 81. The dividing walls 84a, 84b, 84c, 84d are provided with ports, such as the gates 91 and 191, through which the bands 20a and 120a pass from the chamber 81 in the subsequent rooms 82a, 82b, 82c, 82d. Back wall 85 is provided with ports 92 and 192 through which belts 20a and 120a 15; exit from the cooling oven 80.

i! Additional cross rollers 93 and 193 form hori! ! zonal conveyors for the cooled belts 20a and 120a exiting the cooling oven 80.

In order to cool the belts 20a, 120a quickly in the cooling chamber 81, an air circulation system 119 with perforated | provided draft. This system 119e includes three located in i; | transversely extending metal slate plates 95, 96, 97 and a bottom plate 98 in the chamber 81. The plate 95 was mounted above the belt 120a; plate 96 under band 120a and 25! the rolls 187; plate 97 above belt 20a and below plate 96; plate 98 under belt 20a and rollers 87 and! plate 99 under plate 98. Plates 96 and 97 were formed from transverse valleys and ridges to receive rollers 87 and 187. The plates 95, 96, 97 and 98 are perforated or provided with holes.

; Thus, the plate 95 and the top wall of the cooling oven 80j formed an upper chamber, the plates 96 and 97 a middle chamber and the plates 98 and 99 a lower chamber. These chambers are connected to the outlet side of the fan 35 <100 via a branch pipe 101a and a manifold 101 so that the cooling air is forced into the chambers and directed against the i! top and bottom surfaces of the bands 20a and 120a as is i | ! indicated by the arrows in fig. 7.

...........: exhaust air is exhausted from chamber 81 8 0 2 0 2 4 9 "-21-

! ! i I

I I through lines 102 which cool from the opposite side; i! furnace 80 at the level of belts 20a, 120a. These lines 102 lead to an outlet manifold 103 located in i is connected to a manifold 104. A common outlet line 105 is connected by a branch line 106. with the manifold 105.

; A cross pipe 107 leads from the manifold j 104 through a tee 108a to the inlet of the fan 100.

| The other conduit 108b connected to the tee 108a 10 opens into the open air. By manipulating the valve 108 | i in the tee 108A, the ratio of outside air to! r recycled air manipulated around tires 20a, 120a | i to cool in room 81.

j ί I | The annealing furnace consists of a row of chambers j15: 82a, 82b, 82c, 82d which are equal to chamber 81 and res-! individually controlled air circulation systems 119a, 119b, 119c, 119d which are equivalent to the described system 119e. All manifolds, such as manifold 104, drain to common line 105 i 20i, the heat of which is used as needed in the factory or as preheated air for burners.

! j! After leaving the cooling oven 80, the belts 20a and 120a are cut transversely during their path of movement. den to obtain rectangular plates. These plates are 25 | from the order of 1.2 m to 2.4 m wide and cut to length, according to order. Finishing the edges, leveling the surfaces and cutting into smaller pieces: j is done as required. Roof tiles can be manufactured Intermediate with interlocking grooves.

i 1! 30! Periodically along the entire movement length of the! J bands 20 and 120 and the continuation of these bands, namely the belts 20a and 120a are vertically arranged guide rails rollers 121 arranged on opposite sides of the web of the belt 20, 120, 20a, 120a so that they have the ban-35; through the respective ovens 25 and 80.

In Figs. 8 and 9, an oven 225 is shown which is used similar to oven 25 except that this vertical guide i | has idler rollers 280 and drives therefor. More in the i ..... | tail oven includes 225 inner walls 238, outer side walls i; , l = 8 0 2 0 2 4 9 -22- j ~ j .................................. ................................... '...... ........ ..''.....

j | 244, horizontal walls 245, 246, a roof: 24l and a bottom I! 242 and rollers 235, 236, 335, 336 which the belts 220 and 320 I ί! receiving and transporting through the preheating chamber 231 and the dressing chamber 232. Fuel is fed into the combustion chamber 5; chamber 232 fed through nozzles 240.

j As shown in Figures 8 and 9, a | Numerous longitudinally spaced opposed pairs of vertically arranged guide rollers 280 are arranged in oven 225 projecting upwardly between adjacent horizontal rollers 235, 236, 335, 336. The function of these rollers 280 is to pass charges 220 and 320 in their longitudinal path through oven 225. The ends of the rollers 280 protrude through suitable holes in the top wall 241 and the bottom 242 of the oven 225. The bottom parts of the vertical rollers 280 are received and mounted in thrust bearings 281.

| The upper end portions of the rollers 280 pass through armies 282 and protrude outwardly therefrom.

! The upper ends of the rollers 280 receive sprockets 283 why a continuous chain 284 runs which drives the opposite pairs of rollers 280 in opposite directions at approximately the same peripheral speed of the rollers 235, 236, 335, 336.

The distance of the rollers 280 is a matter of choice; however, they must be close enough to prevent significant lateral movement of the load 220 or 320. The cooling oven 80 and the oven 25 may, if desired, be provided with such vertical rollers as the rollers 280.

Third Embodiment 30j The third embodiment shown in Figures 13A, 13B, 13C, 14, 15, 16 and 17 has multistage extruders which | are formed from rectangular vertical cisterns 310 and

! 410 with om-ii I connected by triangular end walls 311 and 411

| Low converging side walls 312 and 412 and compression rollers 35: 313, 313a, 313b, 319, 413, 413a, 413b, and 419.

I i i The power driven compression rollers 313: ί _______! 313a are located on opposite sides of the i_____. L __________

Gl-.. Ί · ”'. 0 8020249 -23- ί I mouth of the cistern 310 and with the end rollers 319 they press | the cargo together and feed it as a rectangular together! : packed flow down. The shafts 315 of these rollers 313, 313Λ! and the axis of the rollers 319 are thus in a common horizontal plane.

| The second stage force driven compression roller 313b is mounted below the roller 313 with its axis i parallel to the shafts 315 of the rollers 313, 313a. The roll- ! i! ! len 313 and 313b cooperate to compress the charge 10; and to feed horizontally as a stream. A curved | plate 317 concentric with the circumference of the roller 313 | forms an intermediate chamber between them. Plate 317 | extends from the vicinity of the inner periphery of the roller 313a to the inner periphery of the roller 313b and operates 15; as a guide to guide the outer surface of the current! Pine tree. Thus, the rollers 313 and 313a give the clay load an initial compression and feed the flow downward, and the rollers 313, 313b give a second and subsequent compression. king and feed the power horizontally. Additional opposed-20 'rollers (not shown) may form subsequent stages which cooperate with rollers 313, 313a, 313b to extend the tray. to form, compress and feed as a rectangular belt 320 of indefinite or continuous length which is horizontally fed to a receiving slide plate 317a disposed outwardly at the top periphery of the roll 313b. Hence, driven rollers 318 feed the belt 320 | the horizontal oven 325 through the opening or entrance gate 309! ; in the front or input end 326 so that it then extends out | emerges as a hot cellular product from outlet I30 | or port 360 in the outlet end 327 of the furnace 235.

The cistern 310 takes a pre-mixed raw or; I green charge formed from a mixture of clay, | ! water and carbonaceous material as described above.

II The cistern 410 has identical end walls 411, 35i side walls 413, rollers 413, 413a, 413b, 419, a curved plate 417, a sliding plate 417a, and a heater 428 for delivering a compact horizontal belt 420 of green clay load, equal to and above band 320.

; The belt 320 is then fed to an 8020249

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-24- i! Cover zone where glaze or engobe is sprayed onto the top surface of belt 320 through a nozzle assembly 329 with a horizontal manifold 329a spaced a number from; bearing down-facing nozzles 329b. On-5; of the emerging belt 320 there is another nozzle; assembly 329c with a group of nozzles 329d driven by a transversely extending divider piece 329e. The nozzles 329d provide a separating or! release agent on the bottom surface and optionally the side surfaces 10 of the belt 320. The release agent preferably consists of; a sludge formed from coarse, high temperature resistant, refractory clay and water and sufficiently liquid I | is to pass through nozzles 329d. The mouthpiece together-I | sets 429 and 429c, which are similar to the nozzle assemblies 329, 329c, are provided for the belt 420. From- there, the power driven rollers 318 and 418 feed the belts 329, 420 through ports 309, 409 into oven 325. Horizon- i! Tonal force driven rollers 335 take up belt 320: and horizontal power driven rollers 435 take up belt 420 20! on. The top circumferences of rollers 335 and 435 also form! wide horizontal conveyors feeding the belts 320 and 420 j at uniform speeds through the furnace 325, where the rollers 335, 435 are driven as shown in FIGS. 11 and 12.

According to the present embodiment, the i | J oven 325 provided with a number of horizontally arranged j; muffle plates 330a, 330b, 330c, 330d over the furnace 325 i; ! j divide entire length into a number alternately at a distance i | placed combustion chambers and muffle chambers, the '30s; combustion chambers extending in the longitudinal direction! rooms 347a, 347b and 347c. The upper chamber 347a is located i! so above the top band 420; the intermediate chamber 347b i lies between the top rollers 435 and the bottom rollers 335 i 1 I | and the lower chamber 347c is below rollers 335. Target 35; of the combustion chambers 347a, 347b and 347c is the tires! 320 and 420 from the combustion gases so that the | tires are in a reducing or neutral atmosphere, i> | at least during the period when the temperature of the j-I bands is above about 445 ^ C.

8020249 -25 j The muffle plates 330a and 330b thus form between

| a tubular top muffle chamber 431 and the plates; 330c and 330d the lower muffle chamber 331 in which the rollers I

j 435 and 335 and bands 420 and 320 are in place. The guide 5; or muffle plates 330a and 330c slope slightly so that the last portion of chambers 331, 431 gradually widens toward the outlet ports 360 and 460 and the corresponding de- The chambers of chambers 347a and 347b gradually narrow towards the end of 327.

The muffle plates 330a, 330b, 330c, 330d are preferably formed from molten silica plates which are temperature-sensitive. oven rats allow 325 to about 1483 ° C. Om! To prepare these stoving plates, the silica load must be provided with a silica or sand glaze before the oven 525 along the top surface and then after baking, the glaze thus formed must be formed from the foamed residual product. sawed off. A sequence of molten silica plates transversely lateral to lateral in the oven each form of the muffle plates 330a, 330b, 330c, 20! 330d. When installed, the plates should initially be heated to about 1260 ° C. At that temperature: | The plates will slowly de-glaze to form cristobalite crystals that have less tendency to sag at higher temperatures. After that, the higher temperatures up to about 1483 ° C can be used.

j Rollers 335 and 435 protrude through the side walls | 344 from the oven 325 and the end portions thereof are shown : supported by wheels or rollers 370a, 370b, 370c and driven | through belts 372 as described above for the fronts. ongoing implementation.

Staggered fuel nozzles 340a disposed in approximately the last half direct an ignited air gas mixture transversely across the upper chamber; I i! j 347a to heat it, while similarly staggered 35; nozzles 340b and 340c do the same for the control panel or! ; intermediate chambers 347b resp. 347c. Air lines 300: supply air through branch lines 301 to nozzles 340a! 340b, 340c, while gas or oil lines 302 and branch lines I; gene 303 supply the fuel thereto.

8020249> \ -26- ι! At the inlet end of the oven 325, an exhaust assembly or means similar to the exhaust assembly of Figure 1 is provided. It comprises a motor 52 which, via a belt 53, drives a fan 41 for discharging the 5 products of combustion from the discharge ends of chambers 347a, 347b, 347c through ports 348a, 348b, 348c, and manifolds | pieces 349 and to deliver them through the exhaust strut | stone 354.

| As can be seen in Fig. 13c, the bands 10: 320a and 420a are swollen or formed into cells after being swollen. i! i passed under the glaze applicators 363 and 463 and thence to the annealing furnace or cooling furnace 380, the successive The following rooms are equipped with air systems 419a, 419b,! 419c, 419d wherein the cooling oven is equal to the cooling oven 80. 15; So it turns out that the combustion gases

j I

are formed in the rear end of the interior of the furnace by burning fuel through nozzles 340a, 340b, 340c fed forward to the front end of; furnace 325 and discharged therefrom while the countercurrent charges move therewith. The entering cargo tires.

! ί; I 320 and 420 are thus gradually dried and then preheated and then melted and cells formed as they are moved through the oven.

| In the fourth embodiment shown in FIGS. 18a and 18b, a rectangular oven 525 has parallel side-by-side freely rotating rollers 535 and driven rollers 536. The rollers 535 take a run-up face! : or platform 510 stores a load 520 carried in an i> I! tray or pan 521. This pan 521 is covered by a back and forth 1 30; weighing hydraulic cylinder 522 through an entrance opening 509; pushed into the front wall 526 into the combustion chamber 531 of the oven 525. The pan 521 is received on the roller table formed by horizontal free-rotating rollers 521 and is ; moved thereon by being pushed by successive 135i the similar pans 521 with their charges 520, while the

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| These pans are passed successively through the cylinder 522 into the oven 525.

j: The oven 525 is heated by burners (not shown!) as in the previous versions and the combustion 8020249 -27-

I I

! Icing products are discharged through a fan 551 through a chimneys 554, the extraction taking place through the exhaust peaks 548. Thus, the pan 521 eventually reaches the | rollers 536 at the outlet end inside the oven 525 that at 5! drive the pan through the momentarily opened exhaust port or opening 560 (which is aligned with the opening 509) when the vertically sliding door 561

i I

! The oven 525 is lifted by a cylinder 562 in the position shown in broken lines in FIG. 18B.

10 A motor (not shown) drives through an i | All rollers 536 in one direction of operating drive so that | | some resistance to supply along the rollers 536 is neglected | thirteen. This creates a back pressure that the side by side! ! pans 521 mounted tandem on rollers 535 and 536 against i! 15! keep together.

j A swiveling finger or link arm 563 which is i! connected to the switch 564 as shown in Fig. i 18b acts as an electrical motor control means (not; 1 shown) of the rollers 536 and the cylinder 562 so that the i 20; door 561 is opened when arm 563 faces door 560 | 1 is moved by the cellular load 520a and the rollers | 536 thereafter are operated to finish a tray 521 from the oven 525! to feed. Then the door 561 is closed and a next cycle can begin.

25; Fuel nozzles (not shown), however, similar to nozzles 40 and 340a, 340b, 340c, heat oven 525. A tray or pans such as pan 620 of i; fig. 19 can be used if the pans like the pan i! : 520 or the pans such as the tray or pans 720 shown in fig. 20,! 30! 21 and 22 are shown can be used as the follow-I; pans such as pan 520. Indeed pans 620

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i and 720 are mixed together.

; Referring in particular to Fig. 19-

i I

| In the sections with the trays or pans 620, a pair of opposed end segments 521 and a number of intermediate segments 622. The segments 622 are each channel-shaped parts with; flat rectangular base plates 623 and upright opposite spaced parallel spaced | rectangular side plates 624 protruding from opposite i _ ................. .............. ........... _ .....................: 8 0 2 0 2 4 9 -28-

i I

[I the edges of the bottom plate 623. 1 I The end sections are also channel-shaped parts with] rectangular base plate 625 and side plates 626. One end is closed by a rectangular end plate 627.

5 | In use, sections 624 and 625 are assembled by simply being edge to edge! places on the platform 510 to form a pan 620 that is closed on its sides and bottom. The silica charge of! coarse sand, water and carbonaceous material are removed with the 10 | hand packed or pounded in pan 620 and cylinder 522 | is used to put each pan 620 in the oven consecutively! to push.

J The panels or plates 623, 624, 625, 626, and 627 j are formed from plates of refractory material, i.e., S15; pressed carbon such as fine coke or charcoal granules. Pitch I or tar can be used as a binder for the coke or.

| charcoal and as an adhesive to attach the appropriate edges to each other! to connect.

; j | When the sand melts in the furnace 525, the charge holds the segments or sections 622, 623 together until | ! the charge after melting and forming into cells has cooled. The molten silica can be cooled quite quickly and does not require annealing. A cooling oven is therefore not necessary. From j! internal rollers 566 forward of the rollers 536 deliver the 25i silica to an area where it cools and the sections 621 and

J

| 622 are removed for reuse.

| Referring to Figs. 20, 21 and 22, one! second embodiment of the segmented or in sections | distributed pan "720 a plurality of abutting faces of rectangular intermediate bottom plates 723 and end plates 723a each having a pressed or packed straight prismatic or 1) rectangular block 724 of silica load. A conventional press (not shown) ) can be used to compress each block 724 Ii I on its associated base plate 723 or 723a, 35 or the blocks can be pressed separately and then placed on the base The outer or side ends 725 of the Block 724 must terminate inwardly from the end edges 726 of the bottom plate 723. The sides 727 of each block 723 must terminate in line with the side edges 729. The outer edges! 8020249

V

-29- ί 1 I! ! 729a of the terminal blocks 724a must terminate inwardly of the outer edges 729a or end plates 726a.

I [When the plates 723, 723a are assembled I have peripheral parts on which elongated spaced 5i. parallel side bars 730 and spaced parallel transverse end bars 731 are included which form elements of a detachable rim that rests on but is not secured to plates 723, 723a as shown in FIG. The bars 730 extend the length of the adjacent el-; 10; plates 723 and 723a placed together and bars 731! ! move inwardly from the ends of the bars 730.

| i '| When the pan 720 is assembled the | [separate blocks 723 and 723a against each other. These blocks 723 and 723a fuse when the silica charge 15; formed by blocks 723, 723a melts and forms cells 4 as it passes through oven 525.

As shown in Fig. 22, vertical guides.

freely rotating rollers 580 spaced at intervals | are arranged within the oven 525 the pans such as the pan | 720 through the oven 525, the rollers 580 being a significant The outward movement of the side bars 730 and the bars 731 prevent significant inward movement.

i i The. elements namely plates 723, 723a and bars 730, 731 can be taken off quite easily from | the monolithic rectangular product after it has been formed into cells, melted and then cooled.

! Thus, a small press (not shown) can be used to produce a very long cellular molten silica product.

| The trays 620 and 720 are cheap and consumable! ! ; bar. Therefore, one, two or three times i use is expected to be all they can withstand. Since they consist of carbonaceous material or carbon, they can be digested by oxygen and water vapor. They thus function to obtain a reducing state around the load and when the hot trays and loads are discharged to the outside air, they can be digested by the surrounding air.

| 8020249 \ -30- I I The fact that the bins are consumable allows the burning of fuel such as gas * oil or solid fuels * I * wood or coal, inside the furnace for, | generating combustion products such as water vapor. These 5; combustion products are digested by reaction with the carbon from the bins.

! In any of the embodiments where a clay load [or a silica load is used and if the furnace 25, 225, i 325 or 525 is approximately 12 m long, the speed of the feed through the furnace must be such that the load is approximately i ten . minutes in the oven for up to about sixty minutes, depending on the thickness of the load. Thus, a 9 mm thick load J should be moved at about 60 cm per minute to stay in the oven for twenty minutes, while a 5 cm thick 15; load should move about 30 cm per minute.

j The distance between the rollers in the oven should be i; j are that a significant sag is prevented, in! especially after the charge has melted and is in a relatively viscous state. In the last part of the oven 120! therefore, care should be taken to ensure that the rollers are spaced at a center distance of I 1 less than about 12.5 cm. This will also vary with the thickness of the load. If the load is thin; i | so about 9 mm the rollers with their centers should be about | 37.5 mm apart, and if the load is 25 cm thick, for example 12.5 cm, the rollers should be approximately one

J

i spaced 10 cm apart.

! In the oven before the point or zone | in which the melting takes place, the tires are sufficient! self-supporting so that the rollers can be spaced approximately 30 cm to 60 cm apart.

| 1; The loads supported on plates or in trays do not have this sag problem since the carbon plates are rigid enough to provide support.

I However, the reels must be sufficient in number to make a Seg-35; pan pan always by supporting two or more rolls.

Closer-mounted rollers interrupt the conti | nuance of the vertical wall entirely or leave very thin; ! refractory wall columns and / or lining between the rollers „, J 0 2 0 2 4 9 • v

I

-31-; left with little play around the rollers.

With conventional refractories, it is difficult to maintain the wall support above the rollers due to movement and shear due to 5; thermal expansion, especially in multi - furnaces i decks and muffle furnaces. For this reason, the furnace is constructed of: molten silica, as a rule, in every part exposed; at no more than about 1483 ° C, and support wall sections I on the cold sides. Breaking solid or cemented layers 10! not down due to different expansion.

It is to be noted that at the usual high temperatures in the hot zone, the molten silica tends to deglaze over time and convert to | | cristobalite, which has a crack-forming thermal expansion I 15 below about 316 ° C. The ovens normally become months! kept in operation for a long time at the full temperature and in this case and in many other operations it is easy to keep the devitrified parts by a small fire above 316 ° C.

! 1 i 1 Processes.

ί!

i I

From the foregoing description the operation or process of the device will be clear. A load which can be satisfactorily processed into a foam form mig or swollen clay product consists of 100 parts by weight ! clay, about 6 to about 15 parts by weight of water and 25 parts; about 1/20 to about 2 parts by weight of available carbon substance in carbonaceous material. I call this a moist clay load or mixture.

| i! The clays which I have found useful as a raw material include surface clays, 30; "ball clays", kaolin, clay shale and ben tonite. Other | clayey materials are useful for my process, the] essential property is the small outer particle size of the material and the ability to sinter to a | impermeable mass. Clays and clay materials, which have an average particle size of less than 1 micron, are therefore particularly suitable in my process. These clays are found in nature in the form of rock, they must are ground to a 0! ''? · ;;? Λ.Γ 8020249 -32-! ....... Γ "'.............. ..... ........ .............. ...........................; ; : granular form, which passes through a 6 mesh sieve.

There are innumerable organic or carbon substances! compounds useful as the carbonaceous | i i i material in my process. However, they must be soluble in water and carbonize when heated. Therefore, sugar or sodium lignite (Orzan A) is quite useful if! the carbonaceous material.

j It is recalled that as organic | materials are present in the clay itself, soluble carbon-10i dust-containing material is used in a lesser amount so that the total of the naturally occurring carbonaceous material and the added available carbon | amounts to about 2 parts per 100 parts clay.

1 Another load that can be handled 15 | to a foamy molten mineral composed of silica, carbonaceous material and water.

j A useful raw silica material is sedi! ! mental quartzite, which occurs in solid form in nature; | ! with an average crystallite diameter of about 10 microns and less, preferably between 5 and 10 microns and | : a negligible amount of intergranular material ; | contains. A preferred raw silica material contains: ! at least 99% SiO 2 on an oxide base. Such a. rough | : silica material can be found, for example, in Arkansas, i25! Illinois and California and has the following typical chemistries.

: chemical analysis: i i

! table I. I

"i! Per cent. | SiCh 99.2

i i Z

• 30. Fe2 ° 3 0.10! ! A1o0q 0.14! CaO 0.05! ! Tio2 ο, οι! MgO 0.0335; alkali-containing material 0.27 combustion loss 0.20 i j, i In practice, the quartzite material [is finely ground after removal from the mine, so that it passes through 8020249

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-33- I! a sieve of about 6 mesh. As a purer form of | ! silica is desirable, silica powder obtained by grinding quartzite sand or gravel must be used! uses. The addition of colloidal silica has been improved. tert the surface of the quartzite, as will be done below are being explained.

The charge is made up of 1000 parts: silica and about 1/2 part to about 4 parts available! carbon in soluble carbonaceous material and sufficient 10! mix water to ensure full distribution! of the soluble carbonaceous material and the colloids. The silica, if it is present. Therefore, about 1: 50 to about 100 parts of water is recommended. The silica loading; i- i must be placed on plates which are passed end to end through the oven 25 instead of belts 20, 120.

| Yet another form of raw silica material! is diatomaceous earth, which is a very porous form of the silica: and foams quite easily. However, it is not a pure form of silica, and its poor resistance to acids compromises its utility.

| i When processing the clay load or i silica load, the load is packed using I '! from a low ™ printing press or rollers, such as rollers 13 and 19.

i; The clay charge is extruded into the belts 20, 120.

25 | However, the silica loading can pass carrier plates or carriers 200; [its bottom face, require.

| The carrier plate 200 is consumable and if J a carrier plate is used it is made in the same j: I press in which the load is packed. The plate 200 i 30! is made from a binder and carbon material.

| It is preferably composed of a binder and carbonaceous material, such as pitch and fine coke or pitch.

I; and coal dust, such as is used in the processing of carbon dioxide. The plate 200 is manufactured on an aluminum 135! ^ oil plate or other separating means 201 in the press 202,! | not so that it sticks to the heated plate 203. The aluminum 1 1020249 will melt in the furnace 25 and burn. If desired! .

silica sand, which in purity corresponds to the silica of: the interior are placed on the top surface of the silicone loading (without blowing agents to produce a -34-] 1 ............ .... ...... ...... ...... ............................ ........... ~ ......'......! II glaze to form.

! When the molten glassy cellular • i | ! silica has melted and there the successive silica loads! i i i in the room 32 abut as they become! 1 a plate 5! passed through the chamber 32, the silica of -700 melts to the I silica of the following, so that the through the silica in the oven | 25 formed tape will gradually form one whole.

| It should be noted that the plates 200 should be | are removed from the molten silica band once the 10 1 cellular molten silica has cooled.

I When the load enters the oven ΐ ^ | 25, regardless of whether it is a silica load or a clay load, | subjected to a temperature of about 3.16 ° C and gradually subjected to rising temperatures, so that the 15j charge, when it reaches the end of its movement in the chamber | 31 is subjected to ambient temperatures Which are about 28 ° C to about 111 ° C lower than the temperature of the gases from the combustion zone or chamber 32.

The charge then enters the combustion chamber 32, where the temperature is kept, for example, as follows: for surface clay charges and bentonite charges 1093 ° C to 1260 ° C. For other clay loads 1150 ° C to 1705 ° C. In front of ! silica loads J.650 ° C to 1815 ° C.

In any case, the temperature and turbulence, which determine the heat transfer properties, must be such that no more than about 83 ° C temperature | y difference is between the surface temperature of the load

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| and the lowest temperature in the interior of the load.

i! S! Although the baking time and temperatures vary '! ! 'I30 | for every raw material and every thickness of the final! | product I have found in the application of Californian clays, which were mined - near yan Corona, that roofing sheet, weighing 25 ^ 37.5 mm thick and weighing about 5 kg per m2, can be made by the load about 30 heat for 15 minutes y66r and then bake for about 3Q minutes at a temperature in the combustion zone or chamber 32 yan

! O

i about YY.72 C.

ji Sintering of the charge usually takes place when the charge is approximately 56 ° C to about 40 278 ° C below the melting point of the clay or silica in the 0 '' 7 '': /: 8020249 s -35- ί ! I i charge. Sintering can therefore largely take place in: the preheating chamber 31.

In the chamber or combustion zone 32 the; charge gradually, while the formation of cells takes place 5! and on exiting chamber 32, it has gone up! ! foamed or cellular raw material has a density of i! 3 2 ί I 128 kg per m to about 1600 kg per m and a glassy i j. I cellular structure of usually not connected! ; standing cells.

When good results are obtained, 98% of the cells have a diameter of less than 2 mm and in many cases less than 1 mm. This fine cell structure! gives evenly thin cell walls, which provide easy 1 | manufacturing.

15 | If the raw material is silica, so that one! foamed molten silica product is manufactured, it is not necessary to feed the product to the cooling oven 80. In! | Instead, it should be cooled quickly to about 1093 ° C and then as soon as it is convenient. .

20 With all other materials, the product must! are fed to the cooling oven 80 and gradually therein; cooled. For best results, the annealing curve j for each product should be determined experimentally. In producing the roof tiles from Corona clay, as described above; I 25 ί, gives a curve equal to that of 6 mm thick plate-! glass good results.

As indicated above, when the foamed or cellular clay belts 20 ia, 120a, which are now molten or glassy, enter the cooling oven 80, they are initially cooled fairly quickly in the oven 81 by - i ί | ambient air lining under forced draft against the i I tire surfaces. This lowers the temperature of the tires 20a, 120a to just about the annealing temperature. After that, the products pass through the annealing chambers 82a, 82b, 82c, 35! 82d, where the tires are cooled gradually and then i i | | supplied to the rollers 93, 193 and exit with an allowable temperature to eventually cool on the rollers 93, 193. The speed of the belts or plates through the oven 25 and | the cooling boy 80 is between about 7.5 cm per minute and about 140 cm about 180 cm per minute and the distance from the rollers 36, 136 | ö 2 0 2 4 9 -36- i:

At the discharge end of chamber 32 is about 2.5 cm to 1 about 12.5 cm at the centers.

i i, i The viscosity of the material during the! | g g | icelvörming is between 4.8 x 10 poise and 5.2 x 10 poise and 1 i i 5 "the material does not sag between the rolls.

i [| | From a theoretical point of view, it is known (Norton's "Refractories") that ferrous clays melt at temperatures as much as 111 ° C lower under reducing conditions than under oxidizing conditions. In the manufacture of the clay charge, which forms the belts 20 and 120, I thus incorporate in the clay soluble carbonaceous material and water in such amounts that the solution of carbonaceous material covers all clay particles. When packed under low pressures of 3.5 bar to 70 bar, a wet clay band is thus obtained, which clay is sufficiently loose that moisture is expelled from the mixture during the initial heating and the carbon containing component remains as a very thin coating on all final clay particles. The carbonaceous 120 component, such as sugar, is evenly distributed throughout the | imassa and perfectly mixed with each particle as a coating thereon. Further heating of the clay layer causes that it sintered and cracks may appear in the upper Ivlak at this time.

25 | In the chamber 31, however, the atmosphere has an excess of air or oxygen and therefore has an oxidizing atmosphere. One or more surfaces of belts 20 and 120 are maintained in this oxidizing state from just before melting the belt or plate to delivery to 130 cooler temperatures. The temperature just before the sin "T and during baking is sufficiently high that the cabbage j 1! I dust in the surface area of the load is burned away to | I a limited depth from the surface of the clay. Thus | I becomes a jacket of high melting point material;

I I

35itly. or completely formed around the belt 20 or 120 or the | plate.

In the interior of the charge, however, "reducing conditions are present due to the presence of the organic or carbonaceous material. Under carefully controlled temperature conditions in the combustion chamber

8 02 0 2 4 S

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s; | | 32, bands 20 and 120 will therefore be kept like this that the jacket does not melt or become too tacky to roll over! to run while the main part of this load i; : melts. As the clay melts, the iron oxide in the clay and the carbon may diffuse on the surface of each particle and react with each other to release carbon monoxide or carbon dioxide for the melted viscose clay, thereby inflating the clay to a large number of closed bubbles.

10! If a separating agent or release agent is applied to the bottom surface of the belt 20 or 120, or the bottom and the side surfaces thereof, it is either free or

Separating agent when heating the oven inert than the clay itself and thus does not stick to the surfaces of the rolls. When this release agent or separating agent is applied on three sides, it forms a cradle below and to the sides of belts 20 and 120 around the charge during the period in which | it is foamed or shaped into cells, to be limited, i! I have also found that when cell formation occurs in the combustion chamber, the temperature becomes so. held, that the viscosity of the clay becomes about 5 x 10 j ipoise, the clay is sufficiently tacky to adhere | | to the rollers that support them unless the oxidized | skin or other separating agent is present and yet is sufficiently viscous so that the gas generated by the reaction of the carbonaceous organic material and the iron oxide or similar oxides of the clay causes small bubbles, I; not break out, but expand the clay and form closed cells of essentially equal consistency.

30; By adjusting the carbon content of the clay, the correct amount of gas is formed to obtain the desired density. Moisture adjustment and degree of compression give a clay tape strong enough to pass over the rollers, but not so dense that a long, low temperature drying time is required.

S i The carbon reduction of the iron oxides and other oxygen-rich components in the clay is possible at lower temperatures; however, a significant portion of the reaction is postponed until the charge melts.

It is an essential part of my process that the coal coating is deposited on every small end particle in the interior of the large agglomerated particles of the clay, as mined or ground. Thus, as the clay melts and molecular diffusion becomes faster, the physical decomposition of the iron oxide and carbon takes place over a very short distance and the reaction takes place immediately. This phenomenon acts as a built-in control to produce gas after sintering but immediately upon melting.

i Some porous rocks of compact i | J10 [quartz crystallites are formed with crystallites:> f part- | little ones, which are almost as small as the end particles in clay! [clogs. Diatoms — Earth is also silica with fine end- I size but less pure than the purer sands.

These silicas, such as quartz crystallites or diatomaceous earth 15, have larger specific surfaces than pulverized sand, and therefore larger interfaces. This is another way to say that a thinner layer of carbon covers a smaller depth of silica and thus faster molecular diffusion! due to a shortcut. In some instances, the carbon reacts with the silica to produce silicon carbide, which then reacts with more silica upon further heating. to produce silica fluimonoxide and carbon monoxide, which [the gases are in a silica mass or at a high temperature

Temperature resistant aluminum silicate, such as "ball clay".

Γ 25: In my preferred method of manufacturing ivory to make foamed molten silica with [a purer composition, I add sugar and water to [a small amount of commercial colloidal silica! · I [solution, which is then thoroughly mixed with commercial [30 [silica powder. This gives a dispersion of carbon over a | [much larger area than could otherwise be obtained, even [even by grinding the silica to small particle size.

ij - [i The silica powder has a particle size i! Approximately 15 microns equivalent diameter, while colkxdale 35silica is approximately 1000 times smaller. This means that the area of given mass of colloidal silica has 1000 times the area of the same mass of silica powder. So I use about 2 parts by weight of colloidal silica on 100 parts by weight of silica powder and thereby increase the effective surface area of the silica powder by about 20 times.

8 0 2 0 2 4 ο;. Π · ν: -39-

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I I This increases the area of the interface i | : I! for reaction between the carbon and the silica. So when the charge of silica, colloidal silica and carbon is heated in oven 25, the carbon is distributed fairly evenly across! 5; the silica and when heated the moisture is expelled and! the carbon eventually reacts with the silicon to produce silicon carbide and then the silicon carbide reacts! with silica to produce silica monoxide and carbon monoxide \! I run.

LlO · A cellular glassy molten sili>! | caproduct can also be made from ground silica rock,

i i M

| ! such as quartzite rock or diatomaceous earth around agglomerates! i of less than 6 mm in diameter. These crushed rocks are mixed with colloidal silica sol and a 15 soluble carbon compound, which carbonizes when heated! and it is dissolved in water. The solution will penetrate; ; in the agglomerates and cover the small particles therein.

"The subsequent heating will expel the moisture,: | with the colloidal silica and carbon evenly distributed: 20! remain on the particles. With continued heating, a reaction between the carbon and the available sili ca and between the carbon and the available oxygen causes J to cause cell formation while the silica melts.

[Suitable foam materials can be used According to my invention, nes are produced from supers! flat clams, shales, bentosnuts, diatoms earth and silica. Surface clays and shales, which! _ i are obtained from brick, roof tile and. flower pot factories! California, Georgia and Germany have proved suitable 30 | for my processes. These clays and shales must be ground so that they pass through a sieve .

! I about 6 meshes per 2.5 cm.

| Swelling bentonite from Wyoming and South j Dakota and non-swelling bentonite from Mississippi and Cali | 35! fornie are also useful for producing foamed; I material of the present invention. All these clay! j species (shale and bentonite are referred to as clay) j have been successfully processed in the following way:! ; In subsequent batches, sugar turned 40; and sodium lignite (ORZAN A) dissolved in water, respectively, c 8 0 2 0 2 4 9

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And then the water was mixed with the clay to obtain a wet clay pressing consistency. In some cases, where the clay had a high moisture content, the clay was mixed with drier clay, so that a final moisture content

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5% of 6-15% by weight were obtained. Even when [only 3 or 4% of the total water was added to the [clay, the sugar or sodium lignite. added to this water before the time when it was mixed with the clay.

The various samples of the resulting mixtures were each pressed into cakes in flat molds or two-thirds applied by hand to carrier plates. The pressed i

Icuks were dried before baking. Cakes or looser masses on support plates were pushed separately into a laboratory oven at approximately correct temperatures, which were determined by observing the swelling behavior. The temperatures used were between 1128 ° C and 1236 ° C. There | | was not a clay that did not form cells. I

i 4; I have found that in some 20 clays there are naturally occurring organic materials containing carbon. These organic materials are well distributed in the clay and are not a particular problem, except that there! i j [must be taken into account. Thus, in some cases it is not necessary to add carbonaceous material to the clay. In some cases where an extremely high content of organic material is present in the clays, they must be mixed with other clays so that the resulting charge has about 2 weight percent organic material in the mixture. If more than about 2% ί | Organic material is included in the mixture, excessive inflation and irregularities in the cellular structure will occur. When less inflation or foaming is desired, the organic material in the charge becomes correspondingly less. This can be done by mixing with other clays with low organic content. The resulting | [Foamed or cellular clay will be more uniform and the cell formation will be less dense. When cargoes were produced with all clays, shales, bentonite types i [die. hoyen, impermeable cellular 40 pieces of good uniformity were obtained in all cases, 8020249 v -41- [r .......................... ........... "............ '" ..............' "........ ........

! I except when an excess of organic material in the! | loads were included. A better understanding of my invention I is obtained by reference to the following specific! examples.

i 5; Example I.

| | A clay from Fremont, California (Interlocking ί, ί: Tile Co.,), which passed through a 6 mesh screen, was mixed as follows: _10 '1000 parts clay i 10 parts sucrose! ! i 110 parts of tap water.

j A 30 cm square tile was formed by i; pressing at 7 bar to about 2.5 cm thick.

125: The tile was placed in an atmosphere of; ! 372 ° C for 15 minutes, then in a controlled atmosphere; if the tile was at least virtually sintered without;

r I

burning the carbon from the sugar, while raising the temperature to about 1095 ° C in a reduction 20; atmosphere.

I; The tile was fed on rolls of approximately; 30 cm per minute for 20 minutes in an oven at approx spring 1153 ° C in an oxidizing atmosphere. The roles were for j | this corridor clean and new and the tile passed over it Sun-I 25; be kept still by sticking to the rollers. There was ! | ! no indication of sag between rolls. The tile was | ! expanded to about 40 cm by 40 cm and had a reddish- j tig brown skin due to skin oxidation. The interior | 1 was greenish dark gray and formed into cells to about 13Q; 48Q kg per cubic meter.

! A number of courses were repeated and some courses | other spots of melted clay or glaze of yer peeling I | the experiments were on the reels and started piece-work ! of oxidized skin while the adjacent interior material softened and cells. : yormd.

i ....... i

Jfll 0 2 4 9 i:> -42-! : I Example II.

I Green tiles from example I were painted I I on the bottom and sides with an engobe of rough and smooth! calcines refractory refractory refractory clay 51 after preliminary drying.

j; These tiles were fired as in Example 1 and showed less tendency to cause sticky spots on the rollers, but where a sticky spot was present there was still a tendency for the engobe and oxidized skin that could accumulate until the [transporter became ineffective. The tile expanded sideways to about 40 cm by 40 cm.

I Example III.

! i j A mixture of 60 parts calcined refractory clay 15.1 clay to 40 parts raw refractory clay and 10 parts water J was spread over the bottom of a mold cavity and up! pressed against the sides. The mold was then filled with the clay load from example I and tiles that were otherwise pressed as in example I.

20! These tiles were fired as in Example 1 and formed into cells to approximately the same density. . I 1 1 1 i It was noted that while the tile was expanded sideways I i! Increased to about 40 cm by 40 cm in Examples I and II, the tile of this example expanded more in thickness than sideways.

[1: 1, i! I! Example IV.

A separating agent was made by mixing 12 parts of raw refractory clay on 88 parts of silica sand and 10 parts of water. This mixture was used to make the bottom cover of the tile of Examples I and J processed as in Example II. When the tile was passed with this bottom covering, over the rollers during baking, the sand was only pulled off when exposed to a sticky spot, while being exposed until any sticky spots on the rollers were well covered. At next 8 p 2 0 2 4 9 ψ -43- these passages were again able to handle the clay [! load without the load sticking.

j

Example V.

j! ! A tile as in example I was made | 5; with Wyoming bentonite in place of clay and the sugar add-on was reduced to about 2 parts per 1000 parts of bentonite. At a baking temperature of about 1260 ° C, similar results were obtained as in Examples I, II and III.

i; - Example 1.

| ; i: I! | In the bottom of the mold I spread an i! ! ! sheet of aluminum foil and a dry mixture of 2 parts of powder petroleum coke and one part powdery pitch from a foundry supplying company. The mold was then heated by a gas flame to melt the pitch and then it was pressed to make a carbon plate. This procedure was repeated [to make the additional carbon platelets from min- | less than 1.6 mm thick to more than 3.2 mm thick.

The carbon plates were then cooled and loaded with a load of about 20 cm by 20 cm by 2.5 cm by placing a mold on the plate and filling the mold. and stamping by hand.

I! For this Example VI, the batch was Missis [sippi M & D "ball clay" / mixed with sucrose and water as in Example I. The sample was baked on one of the! ; carbon plates, going directly from room temperature in the | ; oyen at about 1538 ° C, where it was held for about 20 minutes fried. The temperature was attempted to obtain good cell formation.

In all the above examples, the cellular samples, which were released from the oven into the cold air, broke into brought pieces due to thermal shock. At I: the end of a corridor some samples were placed in; an annealing cabinet and the cooling rate was set to I 35! to obtain unbreakable samples,! 8 02 0 2 4 9 t -44- r ..... “τ .......'.......'................ .................... .............................. ............................

! Example VII.

i; i j | j This was a repeat of example VI except | ! that ground diatomaceous earth was used instead of the | clay. The temperature was adjusted by observing the 5 | melting and cell formation and was estimated at about 1705 ° C.

! The sucrose addition was about 2 parts per 1000. Good | cell formation was obtained at about 320 kg per m and the | product did not break when it was brought from the oven temperature to cold air.

10 i Example VIII.

! i

I i I

i:! | : The procedure of Example VII was repeated, | i except that porous quartzite rock (see Table I) became I | ground and used instead of the diatomaceous earth.

I The baking temperature was about 1760 ° C. Rapid 15 I cooling was successful and cell formation was good after about i! i Bake for 30 minutes.

i i:

Example IX, i | | The procedure of Examples VII and VIII was followed except that the batch was a purer quartzite silicate 20 L, mainly a purchased 325 mesh silica powder, 99.8%! pure silica.

i i To this batch per 1000 parts was added i] _ ’| ! 4 parts sucrose in 49 parts water and 80 parts silica sol, which | | 30% of the silica sol contained 25 millimicron diameter as colloidal silica.

i I

The baking took place on the carbon plate; about 1760 ° C for about 30 minutes. The monster ! was cooled quickly upon removal from the oven and the carbon of | the plate was cut. Cell formation was good at 1 3 30; density from 288 to 384 kg per m.

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| i · ij: | ! Example X.

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; Samples from approximately 20 surface clays! were collected from California, Georgia and Germany. Al JB ° 2 0 2 49 -45- ί I ........... .................... "...... ......................

These were tested along the lines of Example I with | : addition of more or less to no sugar. All samples j could be successfully formed into cells.

! Six commercial ball clay species and a 5J kaolin species from Georgia were also formed on carbon plates and formed into cells according to the above procedure.

| ! It will be clear to the experts; in this area many variations can be made Ι in the embodiments selected here as an illustration of 110 | the present invention and that the teaching of the equivalents | [may apply in full without the scope of the I | invention as defined by the appended claims

i I

! i leave.

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: j: i j | j j; ]! ι i | ......; 8020249

Claims (9)

An apparatus for fireproofing refined raw material comprising: j | (a) a longitudinally arranged oven ! with an entrance end and an outlet end and with openings, which | 5 form a front entrance port and a rear outlet port for raw material which is passed through the interior of this furnace 1; (b) means of transport inside the front; supporting and feeding the raw material from the entrance gate along a prescribed generally straight line; | linear path in the interior of the furnace and out the outlet port; I (c) means for burning fuel in I i the rear part of the interior to bake raw material i: 15 as it passes therethrough; | d) guide plates, which are generally high; horizontally arranged around the interior: to be separated in combustion chambers and a muffle in between ! chamber, the means of transport being arranged in the 2θ | muffle chamber; e) exhaust means at the inlet end of the furnace for discharging the combustion gases from the combustion chamber, whereby the heating gases which are front part of the combustion chambers by the means for 25; fuel burning have been delivered, backwards moving in countercurrent above and below the raw material; | | fl delivery means for delivering the raw material to the entrance. 2. Device according to claim 1, wherein the sleeve plates are formed from juxtaposed; i. i I; molten silica plates. : j -: | j 3 Device according to claim 3, wherein; ! the delivery means comprising a cistern for the raw material, the cistern having in its lower part an opening j351, a pair of opposing compression rollers, which are arranged on sides of the opening to be engineered; to feed the raw material downstream, a third compression roller under one of the opposing compression rollers and guide means to form a surface of the, 1020249 -47- "" ..... "I ..... .......... ....... "...................... .......... .......... .......... ............................ .. ...............................................! :. I conduct current from the other of the opposite | compression rollers to the third compression roller, the opposed [opposite compression rollers compressing the raw material from the hopper] and feeding it in a downward direction 5 | fed stream and the third roll and one of the opposed compression rollers cooperate to form this stream as a band of indeterminate length in a horizontal direction into the j input port. Device as claimed in claim 3, wherein the guide means comprise a curved plate, which concentric I tric with one of the opposite compression rollers. | ! 5. Device according to claim 1, provided! i J of a number of nozzles arranged between the! delivery means and the furnace to put material on the surface of. i! jl5: spray the raw material. The device according to claim 1, wherein | the means for burning fuel a number of gas! or oil burners staggered in the opposite the oven walls. i i '20! 7. Device for supplying raw material as a belt in a horizontal direction comprising: 1 a) a cistern for the raw material,! '! which cistern has an opening in its lower part, a pair of spaced-apart opposing compression rollers, the inner circumferences of which are at opposite ends. '! i opposite sides of the opening are arranged to accommodate! to grasp on opposite sides of the raw material and compress it between and gradually down! i to carry as a stream; i 30 'b) a third compacting roller under one of i | the opposite compression rollers and guide means for conducting a surface of the current from the | others from the opposite compression rollers to the top circumference of the third compression roller; 35i (c) where the opposite compaction the rollers compress the raw material from the cistern and supply it to a stream which becomes downward! | , j lined; and | ; d) wherein the third compression roller and one 40 of the opposing compression rollers cooperate every 8 02 0 2 4 9 i! -48- | j compress and supply current as a band of 1 i | ; indeterminate length In a horizontal direction. 'i i | | 8. Device as claimed in claim 7, wherein the guiding means comprise a curved plate which is concentric with one of the opposite compressors. roll. j! 9. Device according to claim 8, provided]! of end rolls at the ends of the opposite gathering; ! | ; press rolls. JlO '10. Oven for baking refractory crude | material, including: i a) One longitudinal I! Oven with interior space and aligned entrance opening and i i an exit to the oven opening; 15 'b) a roller table in the interior; i l (c) a cylinder at the entrance opening to | | push subsequent pans with load into the pan, so that one | pan next along the roller table to the outlet i! pushes; i20 ί (d) driven discharge rollers within the I I: | ! end section of the oven to the closest to the end ί. : i drain pan from the oven through the outlet opening; and ! 1 (e) means of determining when these i | | the closest to the end of the pan is on the discharge rollers 25. and then to operate these rollers. IJ. Device according to claim 10, in which the driven rollers can rotate freely when they are not are powered. I 12, Bucket for receiving a load, 30. consisting of a number of sections, which are provided with flat; | bottom plates, which are formed of refractory material and which are arranged with their edges lying against each other,: an edge of the flat plates, which edge is provided with edge; elements, which are made of refractory material and of 35! can be removed so that the plates are apart: · 'i! | can be taken. i i '| 3.3. Bucket according to claim 1: 2, wherein the elements consist of longitudinally extending side i; I ί rods, which are themselves. extend over the edge parts of all plai .......: | 40! and end bars over the edges of the end plates. r -49- i | ! 14. Container as claimed in claim 12, wherein the elements consist of upright opposite pairs of plates, which form removable channel parts adjoining the bottom plates and end plates, which close the ends of the channel parts closest to the ends. The tray of claim 12, wherein the refractory material contains carbonaceous material selected from | i | | the group consisting of fine coke and charcoal granules. A tray according to claim 15, wherein a binder 10idel selected from the group consisting of pitch and tar mixed with the carbonaceous material. 17. Container according to claim 12, with a load of sili! in the box. i 1 j; - 18. Container as claimed in claim 12, wherein the bottom plates bear respectively compressed individual blocks of this load, the blocks above the plates lying next to each other. ; 19. Method for manufacturing a cell | Shaped glassy molten silica product, in which silica-20 rock selected from the group consisting of quartzite rock and diatomaceous earth is ground to obtain agglomerates less than 6 mm in diameter, the ground isilica rock is mixed with colloidal silica and one; solution, in which a carbon composition, which carbonizes on heating, is dissolved in water, whereby the solution will penetrate into the agglomerates and the particles from which | these agglomerates will exist, and where the water | The agglomerates are expelled and, when charred, the! i | The hydrocarbon compound remains as a coating on the particles, after which the agglomerates are melted at a temperature, which causes the Me particles of deposited carbon to react with available silicon and oxygen to cause cell formation of the molten silica and then the cells to form. formed silica is cooled. 35: i i! ........ I 8020249 Γ i -v -50-! I Summary q. I ---— j! The device includes a number of extruders (10, J 110) that feed parallel bands (20, 120) of raw material | passing along refractory rollers (35, 135) through subsequent chambers (30,32) in an oven and through a cooling oven (80) to a 5 i cutting zone. The surfaces of the raw material (20, 120)! are covered on three sides with a separating agent and on i! i j the exposed side is glazed or uncovered ; left. The furnace combustion chamber (32) has opposite rows of burners (40) which face opposite sides. ports (42) are directed. The reels (35, 135, 36, 136)! protrude through side walls and are supported on circumferentially or spaced wheels (70a, 70b, 70c). j! Wheels. (73a, 73b) synchronize the rollers. A manifold i (56) connects the combustion chamber (32) to the preheating chamber (30). The process uses a mixture of a small amount of soluble carbonaceous carbon! clay and silica loading material and water to adjust the composition. Clay can be extruded as tapes, which are covered with a separating agent and 20; glaze, then baked, preheated, sintered above 1093 ° C; I * I and annealed. The cellular glassy clay products are i | i then cut. Silica loading with a silica sand surface I | can be pressed with a material to form plates; and then baked in the oven around a cellular glassy; product. Consumable section sections are also described. | I I: j; i; ! i! i: i t; ; 8020249