KILN FURNITURE KITS AND PARTS OF KITS FOR DEFORMATION AND BREAKAGE FREE HIGH TEMPERATURE TREATMENT OF PRODUCTS, AND USE THEREOF

Abstract

The present invention relates to kiln furniture kits for supporting ceramic products, such as for example sanitary ware, during high temperature processes in a kiln. The invention further relates to rolling element holders as part of the kiln furniture kits according to the present invention for deformation and breakage free firing or drying of ceramic products.

Claims

1. A rolling element holder for use in high temperature treatment of ceramic products, the holder comprising: a sheet-like base element with one or more perforations or wells formed therein wherein the perforations or wells are sized to hold one or more rolling elements.

2. The rolling element holder according to claim 1, wherein the holder comprises a material selected from the group consisting of standard silicate, alumina, silico-aluminate, carbide and mixtures thereof.

3. The rolling element holder according to claim 1, wherein the perforations or wells are arranged in a regular pattern.

4. The rolling element holder according to according to claim 1, wherein the perforations or wells have a substantially ular cross-section.

5. A kiln furniture kit for use in drying and/or firing ceramic products, comprising one or more rolling element holders, one or more rolling elements, and one or more spacers configured to burn without residue in a firing and/or drying process.

6. The kiln furniture kit according to claim 5, further comprising: a base batt and one or more supporting segments, wherein the one or more rolling element holders comprise perforations configured to hold the one or more rolling elements.

7. The kiln furniture kit according to claim 5 further comprising: one or more supporting segments and a base wherein the rolling element holder and the base forms an integral part, and wherein the holder comprises wells or perforations configured to hold one or more rolling elements.

8. The kiln furniture kit according to claim 5, further comprising: a base batt, wherein: the rolling element holder is configured to support ceramic products to be fired, the rolling element holder comprises one or more wells formed on a lower surface of the rolling element holder, and the one or more wells on the lower surface of the rolling element holder are configured to be placed over one or more rolling elements sitting on the base batt.

9. The kiln furniture kit according to claim 5, wherein the one or more rolling elements are selected from balls or rollers.

10. The kiln furniture kit according to claim 5, wherein the rolling elements comprise a material selected from the group consisting of alumina, silico aluminates, carbides, nitrides, zirconia, SiC and mixtures thereof.

11. The kiln furniture kit according to claim 5, wherein the one or more spacers is configured: to maintain the other elements of the kiln furniture in place prior to a firing and/or drying process, and to disintegrate or shrink during a firing and/or drying process to allow the other elements of the kit to freely move.

12. The kiln furniture kit according to claim 5, wherein the base batt comprises limiting elements on its edges selected from the group consisting of a rim, pins, nibs, and a mixture of nibs and pins, and wherein the limiting elements comprise the same material as the base batt.

13. A kiln furniture kit according to claim 5, wherein the said base batt comprises a material selected from the group consisting of standard silicate, alumina, silico-aluminate, carbide, and mixtures thereof.

14. The kiln furniture kit according to claim 6, wherein the one or more supporting segments are coated by a material comprising alumina, silico-aluminate, silica, magnesia, or mixtures thereof.

15-19. (canceled)

20. The rolling element holder according to claim 1, wherein the perforations or wells have a substantially rectangular cross-section.

21. The rolling element holder according to claim 21, wherein the substantially rectangular perforations or wells have rounded corners.

22. A kiln furniture kit for use in drying and/or firing ceramic products, comprising a rolling element holder comprising a well; and a rolling element within the well, wherein the rolling element holder comprises a material selected from the group consisting of standard silicate, alumina, silico-aluminate, carbide, and mixtures thereof.

23. The kiln furniture kit of claim 22, wherein the rolling element holder further comprises a perforation that passes through the rolling element holder.

24. The kiln furniture kit of claim 22, wherein: the rolling element holder comprises a plurality of wells, the kiln furniture kit comprises a plurality of rolling elements, and each of the plurality of rolling elements is within one of the plurality of wells.

25. The kiln furniture kit of claim 22, wherein the rolling element holder further comprises a perforation that passes through the rolling element holder.

Description

SHORT DESCRIPTION OF THE FIGURES

[0028] The invention will be further illustrated by reference to the following figures:

[0029] FIG. 1 shows a sanitary ware product placed on a single-use shrinkage base as presented in the state of the art;

[0030] FIG. 2 shows a rolling element holder 3 with rolling elements 2 inside of perforations 4 and comprises perforations 4 and recesses 5 that are not used for rolling elements decreasing the weight of the rolling element holder;

[0031] FIG. 3 shows on the left side a kiln furniture kit in its assembled state, and on the right side the parts of the same kiln furniture kit, comprising a base batt 8, a rolling element holder 3 containing balls as rolling elements inside perforations 4, supporting segments 7 and spacers 6;

[0032] FIG. 4 shows two base batts comprising two different types of limiters, on the left side a continuous rim 9 may stop the movement of the rolling element holder 3 or the rolling elements; on the right side a base batt 8 with nibs 10 is presented as an alternative;

[0033] FIG. 5 shows supporting segments 7 having limiting elements which are configured to stop the movement of the shrinking ceramic product through a rim 9 or nibs 10; a supporting segment may contain recesses and/or perforations 5 to decrease the weight of the supporting segment.

[0034] FIG. 6 shows a rolling element holder acting as a supporting element 11 that may be used when the shrinkage of the ceramic product is relatively small during high temperature treatment; the rolling element holder acting as a supporting element 11 is placed over a base batt 8 and rolling elements 2 which ensure the movement during shrinkage, while spacers 6 may keep the kiln furniture elements in place during loading of the product;

[0035] FIG. 7 shows an example of a large sanitary ware piece which requires the use of a plurality of kiln furniture elements to allow movement during the high temperature process.

DETAILED DESCRIPTION OF THE INVENTION

[0036] The present invention according to the appended claims provides a rolling element holder 3 and kiln furniture kits for supporting ceramic products during high temperature treatment, such as firing or drying, and their use. The ceramic products to be fired may be sanitary ware.

[0037] The present invention provides kiln furniture kits which may comprise a rolling element holder as part of a kiln furniture kit to provide deformation free firing or drying of shaped ceramic products as an improvement over the state of the art. FIG. 1 illustrates a shrinking base 1 with a ceramic product placed onto the base according to the state of the art. The ceramic product will shrink together with the shrinking base during firing or drying avoiding deformation of the ceramic product. The shrinking base is not re-usable and is disposed as ceramic waste after firing or drying.

[0038] A rolling element holder may be part of a kiln furniture kit for use in high temperature treatment of ceramic products. The rolling element holder 3, as shown on the left side of FIG. 2, comprises a sheet-like base element and may be part of a kiln furniture kit. The rolling element holder 3, as shown in FIG. 2, is configured to hold one or more rolling elements 2, such as for example balls, inside of perforations 4 having round cross-sections. The rolling element holder 3 thereby having a smaller height than said rolling elements 2 which may carry supporting segments on which the ceramic products to be fired are placed. Undergoing shrinkage during the firing or drying process, the ceramic product may move on the supporting segment. This movement is supported by balls which may also move together with the ceramic product. The rolling element holder may be pushed as a consequence by the rolling elements in the direction of shrinkage avoiding deformation or breakage of the ceramic product. The rolling element holder, as shown in FIG. 2, may also comprise unused perforations and/or wells 4 or perforations and/or recesses 5 to decrease the weight of the rolling element holder 3 and/or facilitate air circulation.

[0039] In a different embodiment, as shown on the right side of FIG. 2, the rolling element holder 3 according to the present invention may also comprise rollers as rolling elements 2. The perforations of the rolling element holder in this case have a substantially rectangular cross-section 4 inside which rollers are placed. The rollers carry then supporting segments on which the ceramic product to be fired is loaded. Undergoing shrinkage, the contracting movement of the ceramic product is supported by the rollers which may move together with the ceramic product in the direction of shrinkage avoiding the deformation of the ceramic product. The rolling element holder, as shown in FIG. 2, may also comprise unused perforations and/or wells 4 or perforations and/or recesses 5 to decrease the weight of the rolling element holder 3 and facilitate air circulation.

[0040] In both said embodiments, the rolling element holder 3 may comprise a suitable ceramic material. The material may be selected from the group consisting of standard silicate, alumina based products, silico-aluminate, or carbide, such as for example cordierite mullite, light cordierite mullite, or SiC, such as for example, infiltrated silicon carbide, recrystallized silicon carbide or nitride bound silicon carbide, or mixtures thereof.

[0041] In both configurations the rolling element holder ensures that the rolling elements are kept in a certain pattern. The pattern may be regular meaning that one rolling element has substantially the same distance to the neighbouring rolling elements. The pattern may be symmetric. In another embodiment the pattern is such that always a group of two perforations have the same distance, between other groups of two perforations might be a greater or smaller distance. The pattern may also have a different symmetry to ensure optimal support of the weight of the supporting segments carrying the ceramic product to be fired.

[0042] The present invention provides kiln furniture kits comprising one or more rolling element holders 3, one or more rolling elements 2, one or more spacers 6 that keep the kit in place during loading of the ceramic article and do not interfere with the movements during the firing or drying process, optionally a base batt 8, and optionally one or more supporting segments.

[0043] A specific embodiment of a kiln furniture kit according to the present invention is shown in FIG. 3 and comprises a base batt 8, one or more supporting segments 7, one or more rolling elements 2, one or more rolling element holders 3 and one or more spacers 6. The elements of the kit may move in the direction of shrinkage on the base batt 8. The base batt is shown in more detail in FIG. 4 having limiting elements on its edges selected from the group consisting of rim, nibs, pins or a mixture of pins and nibs, preventing the one or more rolling elements to move over the edges of the base batt 8. The limiting elements may comprise or consist of the same material as the base batt 8. On the base batt 8 one or more rolling element holders 3 may be placed comprising rolling elements 2 in perforations. On the rolling elements 2 one or more supporting segments 7 may be placed carrying ceramic products to be fired. In between the one or more rolling elements spacers 6 may be placed to keep the holders in an initial position. The spacers may comprise a material suitable for the firing or drying process, such as for example Styrofoam. After starting the firing or drying process, a spacer comprising Styrofoam may burn without a residue allowing the supporting elements to move freely in the direction of shrinkage. The kiln furniture kit, as shown in FIG. 3, comprises one or more balls as rolling elements 2 and one or more rolling element holders 3 having perforations with round cross-sections. In another embodiment of the kiln furniture kit, the kit comprises one or more rollers as rolling elements 2 and one or more rolling element holders 3 having perforations with rectangular cross-sections. A rectangular cross-section means two-longer sides are adjacent to two shorter sides. A short side is always connected to two longer sides. The corners may be rounded, but the sides are substantially perpendicular to each other. The one or more rolling element holders 3 and the base batt 8 according to this specific kiln furniture kit may comprise perforations and/or wells to decrease the weight of the kiln furniture kit. During the firing or drying process the ceramic product may shrink due various mechanisms such as the loss of water, mineral dihydroxylation, or densification. To avoid that the contracting movement of the ceramic product may deform or destroy the ceramic product the supporting elements may move together with the contraction movement of the ceramic product avoiding tensions.

[0044] Another kiln furniture according to the present invention may comprise an integral part formed by a rolling element holder and a base. This sheet-like base element may comprise wells that may be in a regular or irregular pattern. The wells may be configured to hold one or more rolling elements inside the wells allowing the rolling elements to move in the direction of shrinkage during the firing or drying process. The one or more supporting elements are placed on the rolling elements carrying the ceramic product to be fired. If the ceramic product undergoes shrinkage, the contraction of the ceramic product may move the one or more supporting segments on the one or more rolling elements in the direction of shrinkage. The movement of the one or more rolling elements may be limited by the size of the wells in which the rolling elements are placed.

[0045] Another specific kiln furniture kit according to the present invention may comprise a rolling element holder acting as a supporting element 11, as shown in FIG. 6, a base batt 8, one or more rolling elements 2 and one or more spacers 6. The upper side of said rolling element holder acting as a supporting element 11 is configured to carry ceramic products to be fired. The bottom side of said rolling element holder acting as a supporting element 11 may be configured to be placed over one or more rolling elements 2 inside wells. This sheet-like base element may be kept in its initial position by spacers 6 which configured to disintegrate or shrink during the firing or drying process allowing the supporting elements to move freely in the direction of shrinkage. The spacers may comprise a material suitable for the firing or drying process, such as for example Styrofoam which burns without residue. The base batt 8 may have limiting elements on its edges selected from the group consisting of rim 9, nibs 10, pins or a mixture of pins and nibs, preventing the one or more rolling elements to move over the edges of the base batt 1. The limiting elements may comprise or consist of the same material as the base batt 8. The said rolling element holder acting as a supporting element 11 may comprise unused wells that may decrease the weight of the piece.

[0046] The rolling elements used in the specific kiln furniture kits may comprise rollers and/or balls comprising a suitable material. A suitable material may be selected from the group consisting of alumina based products, silico-aluminates, carbides, nitrides, zirconia, such as for example dense cordierite, high alumina, doped zirconia, or SiC, such as for example infiltrated silicon carbide, recrystallized silicon carbide or nitride bound silicon carbide, or mixtures thereof.

[0047] Spacers may be used to keep the supporting elements of the kiln furniture kits in their respective initial position during loading of the ceramic product to be fired onto the kiln furniture kit in an assembled state. The spacers may disintegrate or shrink allowing the supporting elements to move freely during the firing or drying process.

[0048] The base batt 8 may be used in a kiln furniture kit according to the present invention. The base batt may comprise a material selected from the group consisting of standard silicate, alumina, silico-aluminate, carbide such as for example cordierite mullite, light cordierite mullite, high alumina, SiC, silicon infiltrated silicon carbide, recrystallized silicon carbide or nitride bound silicon carbide, or mixtures thereof. The base batt of the kiln furniture may carry the parts of the kiln furniture kit moving in the direction of shrinkage.

[0049] In an embodiment according to the present invention a kiln furniture kit may be used for firing or drying sanitary ware and/or high shrinkage ceramic products.

[0050] According to the present invention, a kiln furniture can be assembled from any part of the invention according to the requirements of the ceramic product to be fired an industrial kiln.

[0051] In case of a heavy ceramic product needs to be fired, it is possible to place the heavy item, such as for example bath tubs or shower trays, on a plurality of kiln furniture kits and use the plurality of kiln furniture kits to support only one ceramic product. Such an assembly is illustrated in FIG. 7, opening up the possibility to fire such heavy high shrinkage ceramic products free of deformation avoiding expensive and unnecessary rejections or low quality ceramic products.

LIST OF REFERENCE NUMERALS

[0052] 1. Shrinking base [0053] 2. Rolling element [0054] 3. Rolling element holder [0055] 4. Unused perforation [0056] 5. Recess and/or perforation for weight reduction [0057] 6. Spacer [0058] 7. Supporting segment [0059] 8. base batt [0060] 9. rim [0061] 10. nibs [0062] 11. integral part