US3100677A - Method of making refractory brick - Google Patents
Method of making refractory brick Download PDFInfo
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- US3100677A US3100677A US829342A US82934259A US3100677A US 3100677 A US3100677 A US 3100677A US 829342 A US829342 A US 829342A US 82934259 A US82934259 A US 82934259A US 3100677 A US3100677 A US 3100677A
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Links
- 239000011449 brick Substances 0.000 title claims description 118
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 229910052751 metal Inorganic materials 0.000 claims description 60
- 239000002184 metal Substances 0.000 claims description 60
- 239000011822 basic refractory Substances 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 5
- 230000001066 destructive effect Effects 0.000 claims description 4
- 239000011819 refractory material Substances 0.000 claims description 4
- 230000006835 compression Effects 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 3
- 238000001881 scanning electron acoustic microscopy Methods 0.000 claims 1
- 238000000034 method Methods 0.000 description 32
- 239000000203 mixture Substances 0.000 description 23
- 125000006850 spacer group Chemical group 0.000 description 12
- 230000008569 process Effects 0.000 description 10
- 229910000831 Steel Inorganic materials 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000007787 solid Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000003517 fume Substances 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000035939 shock Effects 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 229910001629 magnesium chloride Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical compound [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0018—Producing metal-clad stones, such as oven stones
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/04—Casings; Linings; Walls; Roofs characterised by the form, e.g. shape of the bricks or blocks used
- F27D1/06—Composite bricks or blocks, e.g. panels, modules
- F27D1/08—Bricks or blocks with internal reinforcement or metal backing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/123—Repress
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49879—Spaced wall tube or receptacle
Definitions
- the present invention relates to a novel method for metal encasing refractory brick for use in the construction of various parts of furnaces, and to a novel metal cased refractory brick made by said method.
- the brick are widely used in metallurgical furnaces, and, in particular, in the basic open-hearth furnace used for making steel.
- ThQbIlCk usually is encased on four sides with the ends uncased, however, less than four sides may be cased and the ends also may be cased.
- the purpose of the external plates on the brick is primarily to provide a bonding medium between adjoining brick, which tends to make the furnace structure more resistant to the effect of thermal shock and the attacks of slags and furnace fumes in service.
- the metal plates tend to oxidize and melt in service, fusing adjoining brick into a more or less monolithic structure on the surface facing the interior of the furnace. At the same time the metal plate further back into the furnace wall retains its integrity, thus providing support to the furnace wall during the life of the furnace structure.
- the brick without external plates are more subject to thermal shock and to sheeting due to changes in structure resulting from attack by slags and fumes than are brick with external plates.
- One method is to press the brick mix into a channel previously inserted into the press cavity, thus forming a metal case on three sides of the brick. The fourth side can then be left free of a metal casing, or a metal casing can be applied through pressure from the upper plunger of the press. In this latter case, the applied metal plate has projections which anchor it to the brick.
- Another method which is used is to attach the metal plates toany or all sides of the brick by means of adhesives.
- Another method is to use a channel of the proper size and to force the channel apart, insert the previously formed brick into the channel, and then to allow the channel to assume its normal position so that it is held to the brick by its spring. This method may be used in conjunction with adhesives.
- Another recent method of preparing cased brick is to form a refractory brick in a normal manner and then place two U-shaped channels over the brick from opposite faces in a manner that the legs of the channels overlap. The overlapping legs are then spot welded together to form a brick with a double thickness of metal on each side.
- the principal method used to place the internal plates in the brick is an adaptation of the method hereinbefore 3 ,l00-,677 Patented Aug. 13, 1963 described for forming the brick into a channel previously inserted into the press cavity.
- a second channel of smaller cross-section but the same length and approximately the same height is placed inside the channel forming the outside casing for the brick.
- the brick is then pressed, simultaneously forming both the outside metal casing on three sides and the two internal plates.
- a T-shaped metal form is used in place of the smaller channel.
- the fourth side can be externally plated as described.
- Another method which is used to provide the internal plates is to press smaller brick and combine two or three of them into a composite with separating plates to form a full-size brick with both internal and external plates. Another method is to saw a full-size brick into two or three smaller brick and combine these into a composite brick with separating plates to form a full-size brick with internal and external plates. Another recent method is to prefabricate a box of the same external dimensions as the brick which is to be formed. This box is made up of the two side members and the end members but with no top and bottom members. Inside the box one or two plates: of similar size to the side members are fastened so as to divide the width of the box into two or three equal parts.
- a brick is formed having metal plates on the ends and sides and with one or two internal plates inside the brick. External plates may then be fastened to the remainingtwo free faces of the brick by means of adhesives or by welding to the other metal faces.
- a further object is to provide a novel method of forming a metal cased refractory brick which includes the steps of inserting the refractory mix in a container and forming the container into a brick of the same perimeter :as the container but having less volume, thereby compressing the refractory mix.
- Another object is to provide a cased refractory brick having a continuous meta casing. 1
- Still another object of the present invention is to provide a method of forming a metal cased refractory brick, having internal plates. Another object is to provide a casedrefractory brick having internal plates and a continuous metal casing.
- the present invention comprises a process of making cased refractories including the steps of placing a refractory mix into a hollow geometrical shape and formingthat shape into the desired refractory brick.
- the invention further consists in the process hereinafter described and claimed and in the refractory brick made by said process.
- H6. 1 is a perspective view of a sheet before it is formed into the casing for a fire brick
- FIG. 2 is a perspective view of a hollow geometric shape formed in the brick making process
- FIG. 3 is a perspective view of the shape shown in FIG. 2 filled with brick mix and diagrammatically showing a vibratory motion imparted to the filled shape
- FIG. 4 is a perspective view of the shape shownin FIG. 3 with a diagrammatic representation of a brick forming press
- FIG. 5 is a perspective view of a finished brick
- FIG. 6 is a perspective view of a modification of the hollow geometric shape shown in FIG. 2,
- FIG. 7 is an end view of a geometric shape containing a spacer
- FIG. 8 is an end view of the brick formed from the shape shown in FIG. 7,
- FIG. 9 is an end view of a geometric shape having a p modified form of spacer contained therein,
- FIG. 11 is a perspective View of a brick made of a modified form of casing containing perforations in the outer walls, 1
- FIG. 13 is an end view of a geometric shape having another modified form of spacer contained therein,
- FIG. 14 is an end view of the brick formed from the shape shown in FIG. 13, and
- FIG. 15 is a perspective view of the brick shown in FIG. 14.
- a flat sheet or metal plate 19 which preferably is carbon steel or a similar oxidizable metal and is of any predetermined length and width (FIG. 1) is conventionally rolled and the opposite edges joined into a hollow geometric shape 11 (FIG. 2) which has an infinite number of possible dimensions for length, width and height.
- geometric shape is formed into the predetermined cross-section of established-perimeter and shape by usual sheet-metal forming techniques and joined to form a continuous cross-section.
- the cross-section of the hollow shape is shown as circular in FIG. 2 and elliptical in FIG. 6 and can be any suitable cross-section having a perimeter substantially equal to the perimeter of the refractory'brick. 'The important consideration is that the perimeter of the cross-sectionof the shape be substan-v tially equal to the perimeter of the cross-section of the shape to which it will be transformed in the brick-forming operation.
- the metal case may stretch slightly in the brick-forming process if a sufiicient amount of refractory mix is placed in the geometrical shape before it is formed into a brick.
- the perimeter of the final brick is substantially the same as the perimeter of the hollow geometrical shape in all cases.
- the area of the cross-section of the hollow geometric shape be greater than the area of the cross-section of the shape to which it will be transformed in the brick-forming operation. This allows rigid control over the density of the final brick.
- the end joint of the metal sheet 11) can be overlapped as shown in FIG. 2 to form a seam 11a, or it can be butt welded, if desired.
- the hollow geometric shape 11 Following the fabrication of the hollow geometric shape 11 from the metal sheet 10 (FIG. 2), it is filled (FIG. 3) with 'a predetermined amount of a refractory brick mix 12.
- the refractory can be any known refractory, but is preferably a basic refractory.
- the amount of brick mix to be placed into the shape may be measured by weight or by volume with similar final results. [[n addition to'merely filling the shape with brick mix it is necessary to' compact it by means of vibration,
- case 15 having sides 16 and free ends 17.
- the ends 17 can be left open or can have metal caps or plates attached thereto as by welding or gluing.
- a brick '14 is formed of the required volume and density with a continuous metal casing :15 on four sides 16.
- the refractory part 12 of the brick 14 has a greater density since the cross-sectional area and consequently the volume of the metal casing 15 is reduced in the brick-forming process.
- the metal case 15 retains the refractory portion 12 of the brick .14by the stresses set up in the brick-forming process, and cannot be removed without the destruction of the brick.
- the process may be modified to allow the incorporation of internal steel plates 29' in the final brick'14 (FIGS. 710).
- the plates 20 are introduced into the hollow geometric shape '11 prior to filling it with brick mix 12.
- the shape of the internal plates 20 can vary, two possibilities being illustrated in FIG. 7 and FIG. 9. As can be seen, FIG. 7 shows the internal plates 2t? formed in the shape of a cross, while FIG. 9 illustrates the use of plates 24 in the-form of an X.
- Other possible designs include the use of a concentric circle in the original hollow geometric shape, which on final transformation in the pressing operation becomes a small rectangle within a larger rectangle. Another possibility is shown in FIGS.
- a modification of this invention shown in FIG. 11 is to use steel plate which is perforated rather than solid to form the hollow geometric shapes. This produces a brick 14 including a refractory portion 12 (and la metal casing 15 having sides 16 with perforations 21 provided therein.
- Expanded metal can also be used to form the outer metal casing for the brick, and the term perforated is intended to include such casing constructions.
- FIG. 12 shows a modified spacer plate 25 provided with perforations 26 in the flange portions 27.
- This spacer plate also may be made from expanded metal. Either the solid or perforated form of the spacer can be used with all types of casings and refractory mixes.
- the hollow geometric shape v111 which has been filled and compacted with brick mix 12 is then introduced to a brick-forming press (diagrammatically indicated by the arrows 13 in FIG. 4), where the original geometric shape 11 is transformed into the'final brick form 14 (FIG. 5).
- the brick 114 includes a refractory portion 12 and a metal weight ofthe final brick is elfected while atthe same 5 time providing the same support to the furnace structure as is provided with non-perforated sheet steel.
- the internal plates have perforations in them,
- the present invention provides a refractory brick and a method of preparing same which achieves all of the objects and advantages sought therefor.
- the present invention further provides a brick having an integral or continuous metal casing on four sides thereof, said casing being formed around the brick during the brick making process so that it becomes in effect an From these exintegral part with the brick, tightly adhering, and resisting any attempt at removal without destruction of the metal case.
- the design of the internal plates in the brick can be varied, and the internal plates also are an integral part of the brick.
- the metal casings and spacers are usually made of low carbon steel, although they can be any ordinary metal or alloy, preferably one which is oxidizable at the temperature encountered in the installation. Stainless steel can also be used.
- the brick mix used is preferably a basic refractory type such as dead burned magnesite or chrome ore or mixtures of chrome ore and magnesia. Any suitable basic refractory mix may be used.
- a binder should be utilized in the brick mix to enable the brick to hold together without kihi firing. Binders such as dextrin, gum ara'bic, sulphite pitch, magnesium sulphate, magnesium chloride, sodium dichroma-te, sodium silicate, etc. are suitable in amounts up to about by weight of the brick.
- a further variation of this invention is to use a hollow geometric shape, the perimeter of whose cross-section is only slightly smaller than the perimeter of the cross-section of the final brick form or shape.
- the final brick-forming operation will act to stretch the met-a1 slightly, resulting in the placement of a residual tensile stress in the metal after the brick is formed, thus providing a more tightly adhering metal case.
- the perimeter of the final brick is still substantially the same as the perimeter of the hollow geometric shape.
- the cross-sectional area and the volume of the brick are still reduced from that of the original geometric shape.
- a method of making a metal cased refractory brick adapted to resist the destructive effects of heat consisting of the steps of forming a tubular geometrical shape having a single longitudinal seam, open ends, continuous sides and an established perimeter from a flat sheet of oxidizable metal, temporarily closing one end of the tubular shape to effectively prevent loss of refractory material during the subsequent filling operation, filling the tubular geometrical shape with a basic refractory mix through an open end thereof, vibrating said metal shape along its length to partially compact the refractory mix within the shape to a sufficient extent to cause it to be self-supporting therein, placing the filled tube into a mold housing side and end walls of the final desired form and in a single compression step applying pressure to the outer surface of said metal shape along its length in a direction perpendicular to the direction of vibration and forming the refractory filled geometrical shape into a metal cased refractory brick having only one fabrication scam in the casing and having uncased ends, said brick being of susbtantially the same
- a method of making a metal cased refractory brick adapted to resist the destructive effects of heat consisting of the steps of forming a tubular geometrical shape having a single longitudinal seam, open ends, continuous sides and an established perimeter from a flat sheet of oxidizable metal, placing a spacer plate within the tubular geometrical shape through an open end thereof, temporarily closing one end of the tubular shape to effectively prevent loss of refractory material during the subsequent filling operation, filling the tubular geometrical shape with a basic refractory mix through an open end thereof, vibrating said metal shape along its length to partially compact the refractory miX Within the shape to a sufficient extent to cause it to be self-supporting therein, placing the filled tube into a mold housing side and end walls of the final desired form and in a single compression step applying pressure to the outer surface of said metal shape along its length in a direction perpendicular to the direction of vibration and forming the refractory filled geometriacl shape into a metal cased refractory brick having only one fabrication
Description
1953 J. M. FRANK ETAL 3,100,677
METHOD OF MAKING REFRACTORY BRICK Filed July 24, 19 59 2 Sheets-Sheet 1 /2 27% K MW 1953 J. M. FlANK EI'AL 3,100,677
METHOD OF MAKING REFRACTORY BRICK Filed July 24, 1959 2 Sheets-Sheet 2 FIG,I4
United States Patent 3,10%,677 METHOD 0F MAKING REFRACTORY BRICK Joseph M. Frank, Neil E. Boyer, and James A. Crookston,
Mexico, Mo., assiguors to A. P. Green Fire Brick Company, Mexico, Mo., a corporation of Missouri Filed July 24, 1959, Ser. No. 829,342 5 Claims. (Cl. 18-59) The present invention relates to a novel method for metal encasing refractory brick for use in the construction of various parts of furnaces, and to a novel metal cased refractory brick made by said method. The brick are widely used in metallurgical furnaces, and, in particular, in the basic open-hearth furnace used for making steel. ThQbIlCk usually is encased on four sides with the ends uncased, however, less than four sides may be cased and the ends also may be cased.
The purpose of the external plates on the brick is primarily to provide a bonding medium between adjoining brick, which tends to make the furnace structure more resistant to the effect of thermal shock and the attacks of slags and furnace fumes in service. The metal plates tend to oxidize and melt in service, fusing adjoining brick into a more or less monolithic structure on the surface facing the interior of the furnace. At the same time the metal plate further back into the furnace wall retains its integrity, thus providing support to the furnace wall during the life of the furnace structure. The brick without external plates are more subject to thermal shock and to sheeting due to changes in structure resulting from attack by slags and fumes than are brick with external plates.
There are numerous methods used to apply these casings to refractory brick. One method is to press the brick mix into a channel previously inserted into the press cavity, thus forming a metal case on three sides of the brick. The fourth side can then be left free of a metal casing, or a metal casing can be applied through pressure from the upper plunger of the press. In this latter case, the applied metal plate has projections which anchor it to the brick. Another method which is used, is to attach the metal plates toany or all sides of the brick by means of adhesives. Another method is to use a channel of the proper size and to force the channel apart, insert the previously formed brick into the channel, and then to allow the channel to assume its normal position so that it is held to the brick by its spring. This method may be used in conjunction with adhesives.
Another recent method of preparing cased brick is to form a refractory brick in a normal manner and then place two U-shaped channels over the brick from opposite faces in a manner that the legs of the channels overlap. The overlapping legs are then spot welded together to form a brick with a double thickness of metal on each side. 1
In addition to the external plates described above, it is also common practice toplace one or two plates inside the brick. The purpose of this is to provide the brick with even more resistance to the effects of thermal shock and breaking-off or sheeting of the brick in service due to attack by furnace fumes and slags. The internal plates are placed inside the brick in such manner that their long dimensions are perpendicular to the hot-face of the brick as it occurs in service. Thus, the internal plates effectively divide each brick into two or three smaller brick separated by metal plates. By means of these internal plates, the brick are made more resistant to the destructive processes which occur in service than brick having only external plates. p
The principal method used to place the internal plates in the brick is an adaptation of the method hereinbefore 3 ,l00-,677 Patented Aug. 13, 1963 described for forming the brick into a channel previously inserted into the press cavity. In this instance, a second channel of smaller cross-section but the same length and approximately the same height is placed inside the channel forming the outside casing for the brick. The brick is then pressed, simultaneously forming both the outside metal casing on three sides and the two internal plates. To form a single internal plate, a T-shaped metal form is used in place of the smaller channel. The fourth side can be externally plated as described. Another method which is used to provide the internal plates is to press smaller brick and combine two or three of them into a composite with separating plates to form a full-size brick with both internal and external plates. Another method is to saw a full-size brick into two or three smaller brick and combine these into a composite brick with separating plates to form a full-size brick with internal and external plates. Another recent method is to prefabricate a box of the same external dimensions as the brick which is to be formed. This box is made up of the two side members and the end members but with no top and bottom members. Inside the box one or two plates: of similar size to the side members are fastened so as to divide the width of the box into two or three equal parts. Theprefabricated metal box thus described is then placed into the press cavity with the open top and bottom placed so that the action of the press will cause the brick mix to be compacted into the box. Thus on pressing, a brick is formed having metal plates on the ends and sides and with one or two internal plates inside the brick. External plates may then be fastened to the remainingtwo free faces of the brick by means of adhesives or by welding to the other metal faces.
It is an object of the present invention to provide a novel method for forming a refractory brick having its four sides encased with an integral sheet of metal and with the ends uncased.
A further object is to provide a novel method of forming a metal cased refractory brick which includes the steps of inserting the refractory mix in a container and forming the container into a brick of the same perimeter :as the container but having less volume, thereby compressing the refractory mix. Another object is to provide a cased refractory brick having a continuous meta casing. 1
Still another object of the present inventionis to provide a method of forming a metal cased refractory brick, having internal plates. Another object is to provide a casedrefractory brick having internal plates and a continuous metal casing.
These and other objects and advantages will become apparent hereinafter.
The present invention comprises a process of making cased refractories including the steps of placing a refractory mix into a hollow geometrical shape and formingthat shape into the desired refractory brick. The invention further consists in the process hereinafter described and claimed and in the refractory brick made by said process.
H6. 1 is a perspective view of a sheet before it is formed into the casing for a fire brick,
FIG. 2 is a perspective view of a hollow geometric shape formed in the brick making process, 3
FIG. 3 is a perspective view of the shape shown in FIG. 2 filled with brick mix and diagrammatically showing a vibratory motion imparted to the filled shape,
FIG. 4 is a perspective view of the shape shownin FIG. 3 with a diagrammatic representation of a brick forming press,
FIG. 5 is a perspective view of a finished brick,
. 3 7 FIG. 6 is a perspective view of a modification of the hollow geometric shape shown in FIG. 2,
FIG. 7 is an end view of a geometric shape containing a spacer,
FIG. 8 is an end view of the brick formed from the shape shown in FIG. 7,
FIG. 9 is an end view of a geometric shape having a p modified form of spacer contained therein,
.FIG. 10 is an end view of the brick formed from the shape shown in FIG. 9,
FIG. 11 is a perspective View of a brick made of a modified form of casing containing perforations in the outer walls, 1
FIG. 12 is a partially broken perspective view of a modified spacer plate having perforated flanges,
FIG. 13 is an end view of a geometric shape having another modified form of spacer contained therein,
FIG. 14 is an end view of the brick formed from the shape shown in FIG. 13, and
FIG. 15 is a perspective view of the brick shown in FIG. 14.
A flat sheet or metal plate 19 which preferably is carbon steel or a similar oxidizable metal and is of any predetermined length and width (FIG. 1) is conventionally rolled and the opposite edges joined into a hollow geometric shape 11 (FIG. 2) which has an infinite number of possible dimensions for length, width and height. The
hollow. geometric shape is formed into the predetermined cross-section of established-perimeter and shape by usual sheet-metal forming techniques and joined to form a continuous cross-section. The cross-section of the hollow shape is shown as circular in FIG. 2 and elliptical in FIG. 6 and can be any suitable cross-section having a perimeter substantially equal to the perimeter of the refractory'brick. 'The important consideration is that the perimeter of the cross-sectionof the shape be substan-v tially equal to the perimeter of the cross-section of the shape to which it will be transformed in the brick-forming operation. The metal case may stretch slightly in the brick-forming process if a sufiicient amount of refractory mix is placed in the geometrical shape before it is formed into a brick. However, the perimeter of the final brick is substantially the same as the perimeter of the hollow geometrical shape in all cases. In addition, it is an essential feature of the present invention that the area of the cross-section of the hollow geometric shape be greater than the area of the cross-section of the shape to which it will be transformed in the brick-forming operation. This allows rigid control over the density of the final brick. The end joint of the metal sheet 11) can be overlapped as shown in FIG. 2 to form a seam 11a, or it can be butt welded, if desired.
Following the fabrication of the hollow geometric shape 11 from the metal sheet 10 (FIG. 2), it is filled (FIG. 3) with 'a predetermined amount of a refractory brick mix 12. The refractory can be any known refractory, but is preferably a basic refractory. The amount of brick mix to be placed into the shape may be measured by weight or by volume with similar final results. [[n addition to'merely filling the shape with brick mix it is necessary to' compact it by means of vibration,
The process may be modified to allow the incorporation of internal steel plates 29' in the final brick'14 (FIGS. 710). The plates 20 are introduced into the hollow geometric shape '11 prior to filling it with brick mix 12. The shape of the internal plates 20 can vary, two possibilities being illustrated in FIG. 7 and FIG. 9. As can be seen, FIG. 7 shows the internal plates 2t? formed in the shape of a cross, while FIG. 9 illustrates the use of plates 24 in the-form of an X. Other possible designs include the use of a concentric circle in the original hollow geometric shape, which on final transformation in the pressing operation becomes a small rectangle within a larger rectangle. Another possibility is shown in FIGS. 1315 and comprises a corrugated or S shaped plate 30 positioned in the hollow geometric shape 31 so that the final brick forming pressure will act to reduce the distance between corrugations and increase the height of the corrugations. Any design may be used for the internal plates, so long as the plates when introduced into the hollow geometric shape are not longer or wider than the corresponding final brick dimensions. emples, it is apparent that many designs not specifically mentioned in this description could be used which would not, however, depart from the spirit and scope of this invention. V
A modification of this invention shown in FIG. 11 is to use steel plate which is perforated rather than solid to form the hollow geometric shapes. This produces a brick 14 including a refractory portion 12 (and la metal casing 15 having sides 16 with perforations 21 provided therein.
Expanded metal can also be used to form the outer metal casing for the brick, and the term perforated is intended to include such casing constructions.
FIG. 12 shows a modified spacer plate 25 provided with perforations 26 in the flange portions 27. This spacer plate also may be made from expanded metal. Either the solid or perforated form of the spacer can be used with all types of casings and refractory mixes.
By the use of perforated sheet steel or expanded metal as the casing and for the internal plates, a reduction in pressure, or' a combination of these two mechanisms.
' to allow the assembly to be handled with a minimum of loss of brick mix.
The hollow geometric shape v111 which has been filled and compacted with brick mix 12 is then introduced to a brick-forming press (diagrammatically indicated by the arrows 13 in FIG. 4), where the original geometric shape 11 is transformed into the'final brick form 14 (FIG. 5). The brick 114 includes a refractory portion 12 and a metal weight ofthe final brick is elfected while atthe same 5 time providing the same support to the furnace structure as is provided with non-perforated sheet steel. In addition, if the internal plates have perforations in them,
the density of the refractory mix will be more uniform,
since it can fiow through the openingsin the plates from one compartment to another. 7 The use of non-solid oasings and internal plates results in more brick units being available per ton of refractory than .if solid casingstand plates are used.
'Ilhusit is seen that the present invention provides a refractory brick and a method of preparing same which achieves all of the objects and advantages sought therefor. The present invention further provides a brick having an integral or continuous metal casing on four sides thereof, said casing being formed around the brick during the brick making process so that it becomes in effect an From these exintegral part with the brick, tightly adhering, and resisting any attempt at removal without destruction of the metal case.
By reducing the volume of a given geometric shape without substantially changing the perimeter of the crosssection from that of the original shape, it is possible to control the density of the final brick within close limits, and to achieve a very high density in the brick.
The design of the internal plates in the brick can be varied, and the internal plates also are an integral part of the brick.
As indicated, the metal casings and spacers are usually made of low carbon steel, although they can be any ordinary metal or alloy, preferably one which is oxidizable at the temperature encountered in the installation. Stainless steel can also be used.
The brick mix used is preferably a basic refractory type such as dead burned magnesite or chrome ore or mixtures of chrome ore and magnesia. Any suitable basic refractory mix may be used.
A binder should be utilized in the brick mix to enable the brick to hold together without kihi firing. Binders such as dextrin, gum ara'bic, sulphite pitch, magnesium sulphate, magnesium chloride, sodium dichroma-te, sodium silicate, etc. are suitable in amounts up to about by weight of the brick A further variation of this invention is to use a hollow geometric shape, the perimeter of whose cross-section is only slightly smaller than the perimeter of the cross-section of the final brick form or shape. If a sufiicient amount of refractory mix is retained in the hollow geometric shape, the final brick-forming operation will act to stretch the met-a1 slightly, resulting in the placement of a residual tensile stress in the metal after the brick is formed, thus providing a more tightly adhering metal case. The perimeter of the final brick is still substantially the same as the perimeter of the hollow geometric shape. The cross-sectional area and the volume of the brick are still reduced from that of the original geometric shape.
This invention is intended to cover all changes and modifications of the examples of the invention herein chosen for purposes of the disclosure, which do not constitute departures from the spirit and scope of the invention.
What is claimed is:
1. A method of making a metal cased refractory brick adapted to resist the destructive effects of heat consisting of the steps of forming a tubular geometrical shape having a single longitudinal seam, open ends, continuous sides and an established perimeter from a flat sheet of oxidizable metal, temporarily closing one end of the tubular shape to effectively prevent loss of refractory material during the subsequent filling operation, filling the tubular geometrical shape with a basic refractory mix through an open end thereof, vibrating said metal shape along its length to partially compact the refractory mix within the shape to a sufficient extent to cause it to be self-supporting therein, placing the filled tube into a mold housing side and end walls of the final desired form and in a single compression step applying pressure to the outer surface of said metal shape along its length in a direction perpendicular to the direction of vibration and forming the refractory filled geometrical shape into a metal cased refractory brick having only one fabrication scam in the casing and having uncased ends, said brick being of susbtantially the same perimeter as and of a smaller cross-sectional area and smaller volume than the original geometric shape, said refractory brick having uncased ends and a tightly packed body with a. smooth continuous metal casing integrally associated therewith.
2. A method of making a metal cased refractory brick adapted to resist the destructive effects of heat consisting of the steps of forming a tubular geometrical shape having a single longitudinal seam, open ends, continuous sides and an established perimeter from a flat sheet of oxidizable metal, placing a spacer plate within the tubular geometrical shape through an open end thereof, temporarily closing one end of the tubular shape to effectively prevent loss of refractory material during the subsequent filling operation, filling the tubular geometrical shape with a basic refractory mix through an open end thereof, vibrating said metal shape along its length to partially compact the refractory miX Within the shape to a sufficient extent to cause it to be self-supporting therein, placing the filled tube into a mold housing side and end walls of the final desired form and in a single compression step applying pressure to the outer surface of said metal shape along its length in a direction perpendicular to the direction of vibration and forming the refractory filled geometriacl shape into a metal cased refractory brick having only one fabrication scam in the casing and having uncased ends, said brick being of substantially the same perimeter as and of a smaller cross-sectional area and smaller volume than the original geometric shape, said refractory brick having uncased ends and a tightly packed body with a smooth continuous metal casing integrally associated therewith.
3. The method defined in claim 2 wherein said spacer has a shape.
4. The method defined in claim 2 wherein said spacer has an X shape.
5. The method defined in claim 2 wherein said spacer is corrugated and has an S shape.
References Cited in the file of this patent UNITED STATES PATENTS 1,406,542 Crocker 'Feb. 14, 1922 1,571,087 Jackson Mar. 18, 1930 1,760,861 Parker May 27, 1930 1,846,290 Walter Feb. 23, 1932 2,216,813 Goldschmidt Oct. 8, 1940 2,247,376 Heuer July 1, 1941 2,622,314 Bergan Dec. 23, 1952 2,673,373 Heuer Mar. 30, 1954 2,747,231 Reinhardt May 29, 1956 2,759,256 Bergan Aug. 21, 1956 2,791,116 Heuer May 7, 1957
Claims (1)
1. A METHOD OF MAKING A METAL CASED REFRACTORY BRICK ADAPTED TO RESIST THE DESTRUCTIVE EFFECTS OF HEAT CONSISTING OF THE STEPS OF FORMING A TUBULAR GEOMETRICAL SHAPE HAVING A SINGLE LONGITUDINAL SEAM, OPEN ENDS, CONTINUOUS SIDES AND AN ESTABLISHED PERMETER FROM A FLAT SHEET OF OXIDIZABLE METAL, TEMPORARILY CLOSING ONE END OF THE TUBULAR SSHAPE TO EFFECTIVELY PREVENT LOSS OF REFRACTORY MATERIAL DURING THE SUSEQUENT FILLING OPERATION, FILLING THE TUBULAR GEOMETRICAL SHAPE WITH A BASIC REFRACTORY MIX THROUGH AN OPEN END THEREOF, VIBRATION SAID METAL SHAPE ALONG ITS LENGTH TO PARTIALLY COMPACT THE REFRACTORY MIX WITHIN THE SHAPE TO A SUFFICIENT EXTENT TO CAUSE IT TO BE SELF-SUPPORTING THEREIN, PLACING THE FILLED DESIRED INTO A MOLD HOUSING SIDE AND END WALLS OF THE FINAL DESIRED FORM AND IN A SINGLE COMPRESSION STEP APPLYING PRESSURE TO THE OUTER SURFACE OF SAID METAL SHAPE ALONG ITS LENGTH IN A DIRECTION PERPENDICULAR TO THE DIRECTION OF VIBRATION AND FORMING THE FERACTORY FILLED GEOMETRICAL SHAPE INTO A METAL CASED REFRRACTORY BRICK HAVING ONLY ONE FABRICATION SEAM IN THE CASINGAS AND HAVING UNCEASED ENDS, SAID BRICK BEING OF SUBSTANTIALLY THE SSAME PERMETER AS END OF A SMALLER CROSS-SECTIONAL AREA AND SMALLER VOLUME THAN THE ORIGINAL ENDS AND A TIGHTLY PACKETS BODY WITH A SMOOTH CONCESED ENDS AND A TIGHTLY PACKETS BODY WITH A SMOOTH CONTINUOUS METAL CASING INTEGRALLY ASSOCIATED THEREWITH.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US829342A US3100677A (en) | 1959-07-24 | 1959-07-24 | Method of making refractory brick |
DEA34316A DE1186389B (en) | 1959-07-24 | 1960-03-25 | Metal clad refractory brick and method of making the same |
BE589305A BE589305A (en) | 1959-07-24 | 1960-04-01 | Improvements to refractory bricks. |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US829342A US3100677A (en) | 1959-07-24 | 1959-07-24 | Method of making refractory brick |
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US3100677A true US3100677A (en) | 1963-08-13 |
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US829342A Expired - Lifetime US3100677A (en) | 1959-07-24 | 1959-07-24 | Method of making refractory brick |
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US3213533A (en) * | 1959-07-02 | 1965-10-26 | Steetley Refractory Brick Comp | Method of making metal covered refractory bricks |
US3230682A (en) * | 1960-10-14 | 1966-01-25 | Gen Refractories Co | Basic refractory brick unit |
US3390505A (en) * | 1966-11-28 | 1968-07-02 | Corning Glass Works | Refractory housing |
US3499066A (en) * | 1967-07-19 | 1970-03-03 | Coors Porcelain Co | Method for manufacturing isostatically pressed articles having openings or inserts therein |
US3502755A (en) * | 1968-03-18 | 1970-03-24 | Coors Porcelain Co | Method for forming indentations in isostaticly pressed articles |
US3952402A (en) * | 1971-02-02 | 1976-04-27 | Mero Ag | Composite structural panel and process of making |
US4203188A (en) * | 1974-05-22 | 1980-05-20 | Acieries Reunies De Burbach-Eich-Dudelange S.A. Arbed | Method of producing welding wire constituted by a core of welding powder enclosed by a mantle of metal |
US4698891A (en) * | 1985-04-10 | 1987-10-13 | Ryszard Borys | Separator for insulated window glass |
US4945701A (en) * | 1989-05-16 | 1990-08-07 | Tate Access Floors, Inc. | Composite concrete floor panel |
US5216863A (en) * | 1988-08-15 | 1993-06-08 | Nils Nessa | Formwork comprising a plurality of interconnectable formwork elements |
US5296187A (en) * | 1993-03-23 | 1994-03-22 | Ribbon Technology, Corp. | Methods for manufacturing columnar structures |
US6435471B1 (en) | 1997-10-17 | 2002-08-20 | Francesco Piccone | Modular formwork elements and assembly |
US6569379B2 (en) * | 2001-07-24 | 2003-05-27 | Alcoa Inc. | Ceramic core spacer blocks for high temperature preheat cycles |
US6694692B2 (en) * | 1998-10-16 | 2004-02-24 | Francesco Piccone | Modular formwork elements and assembly |
US20060017204A1 (en) * | 2004-07-23 | 2006-01-26 | Kaufold Roger W | Steel-shelled ceramic spacer block |
US20100050552A1 (en) * | 2007-04-02 | 2010-03-04 | Cfs Concrete Forming Systems Inc. | Methods and apparatus for providing linings on concrete structures |
US20100251657A1 (en) * | 2007-11-09 | 2010-10-07 | Cfs Concrete Forming Systems Inc. A Corporation | Pivotally activated connector components for form-work systems and methods for use of same |
US20100325984A1 (en) * | 2008-01-21 | 2010-12-30 | Richardson George David | Stay-in-place form systems for form-work edges, windows and other building openings |
US20110123801A1 (en) * | 2009-11-24 | 2011-05-26 | Valenciano Philip F | Intumescent rod |
US20110131914A1 (en) * | 2009-04-27 | 2011-06-09 | Richardson George David | Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete |
US20120175810A1 (en) * | 2011-01-07 | 2012-07-12 | Confluent Surgical, Inc. | Drug Delivery Implants, Systems And Methods For Making |
US8578672B2 (en) | 2010-08-02 | 2013-11-12 | Tremco Incorporated | Intumescent backer rod |
US8793953B2 (en) | 2009-02-18 | 2014-08-05 | Cfs Concrete Forming Systems Inc. | Clip-on connection system for stay-in-place form-work |
US9206614B2 (en) | 2011-11-24 | 2015-12-08 | Cfs Concrete Forming Systems Inc. | Stay-in-place formwork with engaging and abutting connections |
US9273479B2 (en) | 2009-01-07 | 2016-03-01 | Cfs Concrete Forming Systems Inc. | Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete |
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US9441365B2 (en) | 2011-11-24 | 2016-09-13 | Cfs Concrete Forming Systems Inc. | Stay-in-place formwork with anti-deformation panels |
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US3213533A (en) * | 1959-07-02 | 1965-10-26 | Steetley Refractory Brick Comp | Method of making metal covered refractory bricks |
US3230682A (en) * | 1960-10-14 | 1966-01-25 | Gen Refractories Co | Basic refractory brick unit |
US3390505A (en) * | 1966-11-28 | 1968-07-02 | Corning Glass Works | Refractory housing |
US3499066A (en) * | 1967-07-19 | 1970-03-03 | Coors Porcelain Co | Method for manufacturing isostatically pressed articles having openings or inserts therein |
US3502755A (en) * | 1968-03-18 | 1970-03-24 | Coors Porcelain Co | Method for forming indentations in isostaticly pressed articles |
US3952402A (en) * | 1971-02-02 | 1976-04-27 | Mero Ag | Composite structural panel and process of making |
US4203188A (en) * | 1974-05-22 | 1980-05-20 | Acieries Reunies De Burbach-Eich-Dudelange S.A. Arbed | Method of producing welding wire constituted by a core of welding powder enclosed by a mantle of metal |
US4698891A (en) * | 1985-04-10 | 1987-10-13 | Ryszard Borys | Separator for insulated window glass |
US5216863A (en) * | 1988-08-15 | 1993-06-08 | Nils Nessa | Formwork comprising a plurality of interconnectable formwork elements |
US4945701A (en) * | 1989-05-16 | 1990-08-07 | Tate Access Floors, Inc. | Composite concrete floor panel |
US5296187A (en) * | 1993-03-23 | 1994-03-22 | Ribbon Technology, Corp. | Methods for manufacturing columnar structures |
US6435471B1 (en) | 1997-10-17 | 2002-08-20 | Francesco Piccone | Modular formwork elements and assembly |
US6694692B2 (en) * | 1998-10-16 | 2004-02-24 | Francesco Piccone | Modular formwork elements and assembly |
US6569379B2 (en) * | 2001-07-24 | 2003-05-27 | Alcoa Inc. | Ceramic core spacer blocks for high temperature preheat cycles |
US20060017204A1 (en) * | 2004-07-23 | 2006-01-26 | Kaufold Roger W | Steel-shelled ceramic spacer block |
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US9783991B2 (en) | 2013-12-06 | 2017-10-10 | Cfs Concrete Forming Systems Inc. | Structure cladding trim components and methods for fabrication and use of same |
US9982444B2 (en) | 2014-04-04 | 2018-05-29 | Cfs Concrete Forming Systems Inc. | Liquid and gas-impermeable connections for panels of stay-in-place form-work systems |
US10450763B2 (en) | 2014-04-04 | 2019-10-22 | Cfs Concrete Forming Systems Inc. | Liquid and gas-impermeable connections for panels of stay-in-place form-work systems |
US10731333B2 (en) | 2015-12-31 | 2020-08-04 | Cfs Concrete Forming Systems Inc. | Structure-lining apparatus with adjustable width and tool for same |
US11053676B2 (en) | 2015-12-31 | 2021-07-06 | Cfs Concrete Forming Systems Inc. | Structure-lining apparatus with adjustable width and tool for same |
US11499308B2 (en) | 2015-12-31 | 2022-11-15 | Cfs Concrete Forming Systems Inc. | Structure-lining apparatus with adjustable width and tool for same |
US11180915B2 (en) | 2017-04-03 | 2021-11-23 | Cfs Concrete Forming Systems Inc. | Longspan stay-in-place liners |
US11821204B2 (en) | 2017-04-03 | 2023-11-21 | Cfs Concrete Forming Systems Inc. | Longspan stay-in-place liners |
US11512483B2 (en) | 2017-12-22 | 2022-11-29 | Cfs Concrete Forming Systems Inc. | Snap-together standoffs for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures |
US11761220B2 (en) | 2017-12-22 | 2023-09-19 | Cfs Concrete Forming Systems Inc. | Snap-together standoffs for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures |
US11674322B2 (en) | 2019-02-08 | 2023-06-13 | Cfs Concrete Forming Systems Inc. | Retainers for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures |
Also Published As
Publication number | Publication date |
---|---|
BE589305A (en) | 1960-10-03 |
DE1186389B (en) | 1965-01-28 |
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