Abstract
A refractory block configured to surround an outlet modifies, within a refractory vessel, the flow of molten metal passing through the outlet. The block takes the form of a base through which a main orifice passes, and a wall extending upwards around the periphery of the base. Structural features that may be included in the block include a circumferential lip around the exterior of the wall, an interior volume in which the radius decreases downwardly towards the main orifice in a plurality of steps, and flow openings in the wall that are configured to induce swirling in the flow pattern in the interior volume of the block.
Claims
1. A block for controlling flow from a refractory vessel, comprising: a) a base disposed around a casting channel having a primary axis, the base having a base upper surface and a base lower surface, the base upper surface having a base upper surface circumference; b) a wall extending from the circumference of the upper surface of the base, the wall having a wall upper surface; wherein, from: a) a first design feature, wherein the wall comprises a circumferential external surface having a top and a bottom, and wherein the block further comprises a wall circumferential lip extending radially outwardly from the circumferential external surface of the wall; b) a second design feature, wherein the wall comprises a circumferential internal surface having a top and a bottom, and wherein the block further comprises an internal fin extending inwardly from the circumferential inner surface of the wall; c) a third design feature, wherein the wall comprises a circumferential internal surface having a top and a bottom, wherein the wall circumferential internal surface comprises a plurality of steps, and wherein the wall circumferential internal surface has a radius with respect to the casting channel primary axis that decreases towards the bottom of the wall circumferential internal surface; d) a fourth design feature, wherein the wall comprises a circumferential external surface having a top and a bottom, wherein the wall comprises a circumferential internal surface having a top and a bottom, wherein the wall comprises at least one entrance flow opening extending from the wall circumferential external surface to the wall circumferential internal surface; e) a fifth design feature, wherein the wall comprises a plurality of barriers extending upwardly from the circumference of the base upper surface, and wherein each barrier is circumferentially adjacent on each side to another barrier to form a pair; the block comprises a design feature selected from the group consisting of: the third design feature, wherein the plurality of steps is located at a level above the level of the upper surface of the base; the fourth design feature, wherein the at least one entrance flow opening extends upwardly to the wall upper surface, wherein the at least one entrance flow opening comprises a major axis in a horizontal plane, and wherein the block further comprises at least one deflector extending upwardly from the base upper surface and disposed between the at least one entrance flow opening and the primary axis of the casting channel; and the fifth design feature, wherein each pair of circumferentially adjacent barriers defines an entrance flow opening, and wherein each entrance flow opening comprises a central vertical plane, wherein the block comprises at least one deflector extending upwardly from the base upper surface and disposed between an entrance flow opening and the primary casting axis of the casting channel, and wherein the at least one deflector comprises an angled facet in a facet plane facing the central plane of the entrance flow opening, wherein the central vertical plane of the entrance flow opening intersects the facet plane of the deflector, and wherein the intersection of the central vertical plane of the entrance flow opening with the facet plane has an angle from and including 91 degrees to and including 179 degrees.
2. The block of claim 1, wherein the block comprises the fourth design feature.
3. The block of claim 2, wherein the at least one deflector comprises an angled facet facing the major axis of the at least one entrance flow opening in the horizontal plane, wherein a major axis of the at least one entrance flow opening intersects the angled facet of the deflector, and wherein an intersection of the major axis of the at least one entrance flow opening with the angled facet of the deflector has an angle, in the horizontal plane, from and including 91 degrees to and including 179 degrees.
4. The block of claim 2, wherein the major axis of the at least one entrance flow opening in the horizontal plane does not intersect the primary axis of the casting channel.
5. The block of claim 2, wherein the at least one deflector is in communication with the circumferential internal surface of the wall.
6. The block of claim 5, wherein the circumferential internal surface of the wall is concave with respect to the primary axis of the casting channel, wherein the at least one deflector comprises a surface that is in communication with the circumferential internal surface of the wall, and wherein the deflector surface that is in communication with the circumferential internal surface of the wall is convex with respect to the primary axis of the casting channel.
7. The block of claim 1, wherein the block comprises the fifth design feature.
8. The block of claim 6, wherein the at least one entrance flow opening is located above the wall circumferential lip.
9. The block of claim 1, wherein the block comprises the third design feature.
10. The block of claim 9, wherein the wall comprises a circumferential external surface having a top and a bottom, and wherein the block further comprises a wall circumferential lip extending radially outwardly from the circumferential external surface of the wall.
11. The block of claim 10, wherein the wall circumferential lip is displaced from the bottom of the circumferential external surface of the wall, and wherein a lip shielded volume is defined beneath the wall circumferential lip and exterior to the circumferential external surface of the wall.
12. The block of claim 10, wherein the wall circumferential lip is displaced from the top of the circumferential external surface of the wall.
13. The block of claim 9, wherein the block further comprises an internal fin extending inwardly from the circumferential inner surface of the wall.
14. The block of claim 10, wherein the block further comprises an internal fin extending inwardly from the circumferential inner surface of the wall.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) The invention will now be described with reference to the attached drawings in which
(2) FIG. 1 is a perspective drawing of a refractory element configured as a block;
(3) FIG. 2 is a perspective drawing of a refractory element having an outward lip located between the top and bottom of a circumferential wall;
(4) FIG. 3 is a cross-section of a perspective representation of a refractory element having an outward lip located between the top and bottom of a circumferential wall;
(5) FIG. 4 is a vertical cross-section of a refractory element having an outward lip located between the top and bottom of a circumferential wall;
(6) FIG. 5 is a perspective representation of a refractory element having an outward lip located between the top and bottom of a circumferential wall, and two internal fins;
(7) FIG. 6 is a perspective representation of a refractory element having an outward lip located between the top and bottom of a circumferential wall, and four internal fins;
(8) FIG. 7 is a perspective representation of a refractory element having a circumferential wall stepped interior surface and two internal fins;
(9) FIG. 8 is a perspective representation of a refractory element having a circumferential wall stepped interior surface and four internal fins;
(10) FIG. 9 is a perspective representation of a refractory element having a circumferential wall stepped interior surface and six internal fins;
(11) FIG. 10 is a cross-section representation of a refractory element having an outward lip located between the top and bottom of a circumferential wall, and a circumferential wall stepped interior surface;
(12) FIG. 11 is a perspective representation of a refractory element having an outward lip located between the top and bottom of a circumferential wall, and a circumferential wall stepped interior surface;
(13) FIG. 12 is a cross-section of a perspective view of a refractory element having an outward lip located between the top and bottom of a circumferential wall, a circumferential wall stepped interior surface, and angled entrance flow openings;
(14) FIG. 13 is a perspective view of a refractory element having an outward lip located between the top and bottom of a circumferential wall, a circumferential wall stepped interior surface, and six angled entrance flow openings;
(15) FIG. 14 is a top view of a refractory element having an outward lip located between the top and bottom of a circumferential wall, a circumferential wall stepped interior surface, and six angled entrance flow openings;
(16) FIG. 15 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element;
(17) FIG. 16 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element;
(18) FIG. 17 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element;
(19) FIG. 18 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element, the flow directors being in direct communication with the interior of the circumferential wall;
(20) FIG. 17 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element, the flow directors being in direct communication with the interior of the circumferential wall;
(21) FIG. 18 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element, the flow directors being in direct communication with the interior of the circumferential wall;
(22) FIG. 19 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings, and flow directors between the entrance flow openings and the major vertical axis of the element, the flow directors being in direct communication with the interior of the circumferential wall;
(23) FIG. 20 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings in which the intersections of the opening bottom and the opening wall are beveled or rounded, and flow directors protruding inwardly from the circumferential wall between the entrance flow openings and the major vertical axis of the element;
(24) FIG. 21 is a top view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings in which the intersections of the opening bottom and the opening wall are beveled or rounded, and flow directors protruding inwardly from the circumferential wall between the entrance flow openings and the major vertical axis of the element;
(25) FIG. 22 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall, entrance flow openings in which the intersections of the opening bottom and the opening wall are beveled or rounded, and flow directors protruding inwardly from the circumferential wall between the entrance flow openings and the major vertical axis of the element;
(26) FIG. 23 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall between the top and bottom of the circumferential wall, entrance flow openings in which the intersections of the opening bottom and the opening wall are beveled or rounded, and flow directors protruding inwardly from the circumferential wall between the entrance flow openings and the major vertical axis of the element;
(27) FIG. 24 is a perspective view of a refractory element having an outward lip extending outwardly from a circumferential wall between the top and bottom of the circumferential wall, entrance flow openings in which the intersections of the opening bottom and the opening wall are beveled or rounded, and flow directors protruding inwardly from the circumferential wall between the entrance flow openings and the major vertical axis of the element;
(28) FIG. 25 is a top view of a refractory element in which the circumferential wall takes the form of a plurality of cylinders; and
(29) FIG. 26 is a perspective view of a refractory element in which the circumferential wall takes the form of a plurality of cylinders.
DETAILED DESCRIPTION OF THE INVENTION
(30) FIG. 1 is a cross-section representation of certain components of a refractory element 10 of the present invention, showing their geometric relationship. Refractory element 10 contains a base 12, which is depicted as being cylindrical in shape, and having a main orifice 13 which passes through the base from a base upper surface 14 to a base lower surface 15. A wall 16 extends upwardly from base upper surface 14. Wall 16 is disposed around the periphery of base 12. The wall has a wall interior surface 17, a wall upper surface 18 and a wall exterior surface 19. A wall circumferential lip 20 extends outwardly from wall 16. The wall circumferential lip 20 has a wall circumferential lip upper surface 22, a wall circumferential lip lower surface 24, and a wall circumferential lip exterior surface 25. In the representation in FIG. 1, wall upper surface 18 and wall circumferential upper surface 22 are coplanar. Shielded volume 26 is the volume located below the wall circumferential lower surface 24. Operating shielded height 28 is the distance between base upper surface 14 and wall circumferential lip lower surface 24. Operating shielded volume 30 is the volume located below the wall circumferential lip lower surface 24 between the plane of base upper surface 14 and the plane of wall circumferential lip lower surface 24. Internal height 32 is the distance between base upper surface 14 and wall upper surface 18. Wall circumferential lip protrusion distance 34 is the distance between wall exterior surface 19 and the farthest radial extent of wall circumferential lip 20. Shielded height 36 is the distance between the plane of base lower surface 15 and the plane of wall circumferential lip lower surface 24. An interior volume 37 is partly defined by wall interior surface 17 and base upper surface 14.
(31) FIG. 2 depicts a refractory element 10 having an outwardly-extending wall circumferential lip located between the top and bottom of a circumferential wall. The element has a base 12 through which main orifice 13 passes vertically. Wall 16 extends upwardly from base upper surface 14 of base 12. The wall has a wall upper surface 18. Wall circumferential lip 20 extends radially outward from wall 16. The wall circumferential lip 20 has a wall circumferential lip upper surface 22. In the representation in FIG. 2, wall upper surface 18 and wall circumferential lip upper surface 22 occupy different horizontal planes. The plane of the wall circumferential lip lower surface 24 is located above the plane of the base upper surface 14 and above the plane of the base lower surface 15.
(32) FIG. 3 depicts a refractory element 10 having an outwardly-extending wall circumferential lip 20 located between the top and bottom of a circumferential wall. The element has a base 12 through which main orifice 13 passes vertically. Wall 16 extends upwardly from base upper surface 14 of base 12. The wall has a wall upper surface 18. Wall circumferential lip 20 extends radially outward from wall 16. The wall circumferential lip 20 has a wall circumferential lip upper surface 22 and a wall circumferential lip lower surface 24. In the representation in FIG. 3, wall upper surface 18 and wall circumferential lip upper surface 22 occupy different horizontal planes. The plane of the wall circumferential lip lower surface 24 is located above the plane of the base upper surface 14 and above the plane of the base lower surface 15. Height H is the distance between base upper surface 14 and wall upper surface 18, and is equivalent to internal height 32. Height h is the distance between the plane of base upper surface 14 and the plane of wall circumferential lip lower surface 24, and is equivalent to operating shielded height 28. The radial outward extent of wall circumferential lip 22 from wall exterior surface 19, indicated as p, is equivalent to lip horizontal protrusion distance 34.
(33) FIG. 4 depicts a refractory element 10 having an outwardly-extending wall circumferential lip 20 located between the top and bottom of a circumferential wall. The element has a base 12 through which main orifice 13 passes vertically. Wall 16 extends upwardly from the base upper surface of base 12. The wall has a wall interior surface 17 and a wall upper surface 18. Wall circumferential lip 20 extends radially outward from wall 16. The wall circumferential lip 20 has a wall circumferential lip lower surface 24. In the representation in FIG. 4, interior maximum horizontal dimension 38 represents the maximum straight-line distance in a horizontal plane between one portion of wall interior surface 17 and another portion of wall interior surface 17, and is also designated as 2L or 2L. Main orifice central axis 40 passes longitudinally, or vertically, through the main orifice 13. Element wall interior elevation angle 42 is described as the angle formed at the vertex of the intersection of a first line between (a) the intersection of wall interior surface 17 and wall upper surface 18 and (b) a point in the plane of base upper surface 14 displaced by a distance 44 (designated as WDD) towards (a) from main orifice central axis 40, and a second line formed by the vertical projection of the first line on the plane of base upper surface 14. WDD 44 may have a value of 15 mm. WDD may also represent the minimum radius of main orifice 13. Lip lower surface elevation angle 46 is described as the angle formed at the vertex of the intersection of a first line extending between (a) the intersection of the wall circumferential lip external surface 25 and wall circumferential lip lower surface 24, and (b) a point in the plane of base upper surface 14 displaced by a distance 48 (designated as LDD) towards (a) from main orifice central axis 40, and a second line formed by the vertical projection of the first line on the plane of upper base surface 14. LDD may have a value of 50 mm, or may have the value of the radius of main orifice 13 at its intersection with base upper surface 14, or may have the value of the minimum radius of main orifice 13.
(34) In certain embodiments of the invention, element wall interior elevation angle 42 may have nonzero values less than 60 degrees, in the range from 60 degrees to 5 degrees, from 60 degrees to 10 degrees, from 60 degrees to 20 degrees, from 50 degrees to 5 degrees, from 50 degrees to 10 degrees, or from 50 degrees to 20 degrees.
(35) In certain embodiments of the invention, lip lower surface elevation angle 46 may have values in the range from 10 degrees to 80 degrees, 15 degrees to 80 degrees, 10 degrees to 60 degrees, 10 degrees to 50 degrees, or 10 degrees to 45 degrees.
(36) In certain embodiments of the invention, internal height 32 (H) may be related to L (half the length of interior horizontal maximum dimension 38) by the relationship
Htan(10)+LDD<L<Htan(70)+WDD
(37) 2L is the largest internal horizontal dimension of the inventive device. For a device having a cylindrical exterior, 2L represents the diameter, but the device may also have a square, rectangular, octagonal, triangular or other polygonal interior, or an oval interior.
(38) Stopper volume 50 represents a volume of the interior of the device that may be occupied by a stopper in use. In the configuration shown, the stopper rod takes the form of a cylindrical solid with a hemispherical solid joined to the cylindrical solid by contact of respective circular surfaces.
(39) FIG. 5 depicts an embodiment of refractory element or block 10 in which a pair of internal fins 52 extend inwardly into the interior volume from wall interior surface 17. Internal fins 52 cooperate with a stopper occupying stopper volume 50 to reduce the formation of vortices in the interior volume of block 10. Wall circumferential lip 20 is displaced below the plane of the wall upper surface 18, is displaced above the plane of the base lower surface, and is displaced above the plane of the base upper surface. In various embodiments a block of the present invention may contain 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 internal fins.
(40) FIG. 6 depicts an embodiment of refractory element or block 10 in which four internal fins 52 extend inwardly into the interior volume from wall interior surface 17. Internal fins 52 cooperate with a stopper occupying stopper volume 50 to reduce the formation of vortices in the interior volume of block 10. Wall circumferential lip 20 is disposed so that the plane of wall circumferential lip upper surface 22 is below the plane of the wall upper surface 18, and the plane of the wall circumferential lip lower surface is above the plane of the base lower surface, and above the plane of the base upper surface. In this embodiment, all molten metal must flow above wall circumferential lip upper surface 22 and above wall upper surface 18 to exit through the main orifice. Wall upper surface 18 is the uppermost portion or level of block 10.
(41) FIG. 7 depicts an embodiment of refractory element or block 10 in which two internal fins 52 extend inwardly into the interior volume. The depicted embodiment contains three internal steps 54 formed in the face of the wall interior surface. The steps may be formed from right angles, obtuse angles, or may take the form of discrete bumps. In certain embodiments, a plurality of steps is required. In this embodiment, the wall circumferential lip upper surface 22 of wall circumferential lip 20 occupies the same plane as does the wall upper surface 18.
(42) FIG. 8 depicts an embodiment of refractory element or block 10 in which four internal fins 52 extend inwardly into the interior volume. The depicted embodiment contains four levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through the main orifice to minimize deposition. The upper surface 22 of wall circumferential lip 20 is displaced downwardly from the plane of wall upper surface 18 of wall 16. The lower surface of the wall circumferential lip is displaced upwards from the base lower surface. In this embodiment, all molten metal must flow above wall circumferential lip upper surface 22 and above wall upper surface 18 to exit through the main orifice. Wall upper surface 18 is the uppermost portion or level of block 10. In various embodiments a block of the present invention may contain 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or 16 levels of internal steps 54.
(43) FIG. 9 depicts an embodiment of refractory element or block 10 in which six internal fins 52 extend inwardly into the interior volume. The depicted embodiment contains four levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through the main orifice to minimize deposition. The upper surface 22 of wall circumferential lip 20 is displaced downwardly from the plane of wall upper surface 18 of wall 16. The lower surface of the wall circumferential lip is displaced upwards from the base lower surface. In this embodiment, all molten metal must flow above wall circumferential lip upper surface 22 and above wall upper surface 18 to exit through the main orifice. Wall upper surface 18 is the uppermost portion or level of block 10.
(44) FIG. 10 depicts an embodiment of refractory element or block 10 containing a plurality of levels of internal steps 54 formed in the face of the wall interior surface. Tangent line 55 is a line tangent to the surfaces of the nose of a stopper occupying stopper volume 50 and the seat of this stopper in the interior volume of block 10. In various embodiments of the invention, the tangent line intersects an internal step 54, a plurality of internal steps 54, or at least three internal steps 54. All of internal steps 54 are located at a level above the level of base upper surface 14. Base upper surface 14 is at the same level as the entrance of the tundish to mold casting channel where block 10 is used in a tundish. In such a configuration, the tundish to mold casting channel starts at the level of surface 14 or below. A step or a plurality of steps 54 is present in a block of the present invention; this configuration is distinguished from the use of a single step in the seat of a tundish to mold casting channel.
(45) FIG. 11 depicts an embodiment of refractory element or block 10 containing a plurality of levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through main orifice 13 to minimize deposition. Wall circumferential lip 20 is displaced below the plane of the wall upper surface 18, and is displaced from the plane of base lower surface 15.
(46) FIG. 12 depicts an embodiment of refractory element or block 10 containing a plurality of levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through main orifice 13 to minimize deposition. A wall circumferential lip 20 extends horizontally and outwardly from the exterior of the wall of block 10. Entrance flow openings 56 have, at their entrances, a lower surface equivalent to wall circumferential lip upper surface 22. Entrance flow openings 56 are defined, in the horizontal plane, by surfaces of adjacent internal fins 52. Entrance flow openings 56 are in fluid communication with the interior of the device or block, and direct flow onto internal steps 54. Entrance flow openings 56 are flared inwardly in the horizontal plane. In certain embodiments, entrance flow openings 56 have a wall having an initial vertical surface 57 contained in a plane that does not intersect stopper volume 50. This geometry maximizes flow rotation around the stopper.
(47) FIG. 13 depicts an embodiment of refractory element or block 10 containing a plurality of levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through the main orifice to minimize deposition. A wall circumferential lip 20 extends horizontally and outwardly from the exterior of the wall of block 10. Entrance flow openings 56 have, at their entrances, a lower surface equivalent to wall circumferential lip upper surface 22. Entrance flow openings 56 are defined, in the horizontal plane, by surfaces of adjacent internal fins 52. Entrance flow openings 56 are in fluid communication with the interior volume 37 of the device or block, and direct flow onto internal steps 54. Entrance flow openings 56 are flared inwardly in the horizontal plane. In certain embodiments, entrance flow openings 56 have a wall having an initial vertical surface 57 contained in a plane that does not intersect stopper volume 50. This geometry maximizes flow rotation around the stopper. In this embodiment, entrance flow openings 56 have an outer wall 58 having an entrance flow opening outer wall concave section 59. In certain embodiments, the angle formed by the entrance flow opening outer wall concave section 59 is in the range from 90 degrees to 160 degrees, from 190 degrees to 150 degrees, from 90 degrees to 140 degrees, from 90 degrees to 130 degrees, from 90 degrees to 120 degrees, from 90 degrees to 110 degrees, from 100 degrees to 160 degrees, from 100 degrees to 150 degrees, from 100 degrees to 140 degrees, from 100 degrees to 130 degrees, from 100 degrees to 120 degrees, or from 100 degrees to 110 degrees.
(48) FIG. 14 is a top view of an embodiment of refractory element or block 10 containing a plurality of levels of internal steps 54 formed in the face of the wall interior surface. Fins 52 and steps 54 cooperate with a stopper occupying stopper volume 50 to minimize the formation of vortices and to produce turbulence in the flow through the main orifice to minimize deposition. A wall circumferential lip 20 extends horizontally and outwardly from the exterior of the wall of block 10. Entrance flow openings 56 have, at their entrances, a lower surface equivalent to wall circumferential lip upper surface 22. Entrance flow openings 56 are defined, in the horizontal plane, by surfaces of adjacent internal fins 52. Entrance flow openings 56 are in fluid communication with the interior volume of the device or block, and direct flow onto internal steps 54. Entrance flow openings 56 are flared inwardly in the horizontal plane. In certain embodiments, entrance flow openings 56 have a wall having an initial vertical surface 57 contained in a plane that does not intersect stopper volume 50. In FIG. 14, the plane containing wall initial vertical surface 57 is indicated by a dotted line that does not intersect stopper occupying volume 50. This geometry maximizes flow rotation around the stopper. In this embodiment, entrance flow openings 56 have an outer wall 58 having an entrance flow opening outer wall concave section 59. Entrance flow opening outer wall concave section 59 redirects inwardly the outer portion of flow through entrance flow opening 56. In this embodiment, the major axis, in the horizontal plane, of entrance flow openings 56 is not collinear with any horizontal radius of the stopper volume. This configuration induces flow rotation within the interior volume of block 10.
(49) FIG. 15 is a top view of an embodiment of block 10 of the invention. In this embodiment, walls extend upwardly from base upper surface 14, and wall upper surface 18 is visible in this view. A wall circumferential lip projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of the stopper volume 50. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. The angle other than a right angle may be in the range from 91 to 179, 95 to 175, 100 to 170, 100 to 160, 100 to 150, 100 to 140, 115 to 155, or 120 to 150. The deflector may also have any other geometry that redirects a flow through an entrance flow opening in a direction circumferential to the horizontal radius of stopper volume 50.
(50) FIG. 16 is a perspective representation of the embodiment of block 10 illustrated in FIG. 15. In this embodiment, walls 16 extend upwardly from base upper surface 14 of base 12; wall inner surface 17, wall upper surface 18 and wall outer surface 19 are visible in this view. Main orifice 13 passes vertically through base 12 between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from wall 16; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of the longitudinal axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening.
(51) FIG. 17 is an additional perspective representation of the embodiment of block 10 illustrated in FIG. 15. In this embodiment, walls 16 extend upwardly from base upper surface 14 of base 12; wall inner surface 17, wall upper surface 18 and wall outer surface 19 are visible in this view. A wall circumferential lip 20 projects outwardly from wall 16; wall circumferential lip upper surface 22 is visible in this view. Wall upper surface 18 and wall circumferential lip upper surface 22 are co-planar. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of the vertical longitudinal axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. The floors of entrance flow openings 56 are flat, and form right angles with the walls of the respective entrance flow openings 56.
(52) FIG. 18 is a top view of an embodiment of block 10 of the invention. In this embodiment, walls extend upwardly from base upper surface 14, and wall upper surface 18 is visible in this view. Main orifice 13 passes vertically through base 12 between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along one line segment that is the vertex of an angle that is acute in the horizontal plane and at along another line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62.
(53) FIG. 19 is a perspective representation of the embodiment of block 10 of the invention shown in FIG. 18. In this embodiment, wall 16 extends upwardly from base upper surface 14, and wall interior surface 17, wall upper surface 18 and wall exterior surface 19 are visible in this view. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along one line segment that is the vertex of an angle that is acute in the horizontal plane and at along another line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62.
(54) FIG. 20 is a top view of an embodiment of block 10 of the invention. In this embodiment, walls extend upwardly from base upper surface 14, and wall upper surface 18 is visible in this view. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along a vertical line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62. In the embodiment shown each deflector 60 also has an intersection with a portion of wall interior surface that is described by a concave curve in the horizontal plane. This curved surface redirects flow near wall interior surface 17 towards the interior volume of block 10. The floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 at rounded corners or radii 64. In other embodiments, the floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 through bevels. Entrance flow opening outlet 65 is the junction of the floor of the entrance flow opening with the base upper surface, and may take the form of a step.
(55) FIG. 21 is a perspective view of the embodiment of block 10 of the invention shown in FIG. 20. In this embodiment, wall 16 extends upwardly from base upper surface 14 of base 12, and wall interior surface 17, wall upper surface 18 and wall exterior surface 19 are visible in this view. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. The wall and the wall circumferential lip are interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along a vertical line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62. In the embodiment shown each deflector 60 also has an intersection with a portion of wall interior surface that is described by a concave curve in the horizontal plane. This curved surface redirects flow near wall interior surface 17 towards the interior volume of block 10. The floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 at rounded corners or radii 64. In other embodiments, the floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 through bevels.
(56) FIG. 22 is a top view of an embodiment of block 10 of the invention. In this embodiment, walls extend upwardly from base upper surface 14, and wall upper surface 18 is visible in this view. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. In this embodiment wall upper surface 18 and wall circumferential lip upper surface 22 are not co-planar; wall circumferential lip upper surface 22 is below the level of wall upper surface 18. A top portion of the wall above wall circumferential lip upper surface 22 is interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along a vertical line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62. In the embodiment shown each deflector 60 also has an intersection with a portion of wall interior surface that is described by a concave curve in the horizontal plane. This curved surface redirects flow near wall interior surface 17 towards the interior volume of block 10. The floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 at rounded corners or radii 64. In other embodiments, the floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 through bevels. Entrance flow opening outlet 65 is located at the junction of the floor of the entrance flow opening with an intermediate entrance flow opening floor level 67, and may take the form of a step. In the illustrated embodiment, the intersections of intermediate entrance opening floor level 67 with angled facet 62 and wall interior surface 17 are in the form of rounded corners or radii 64. Intermediate volume outlet 68 is located at the junction of the floor of intermediate entrance flow opening floor level 67 and base upper surface 14, may be in the form of a step.
(57) FIG. 23 is a perspective view of the embodiment of block 10 of the invention illustrated in FIG. 22. In this embodiment, walls extend upwardly from base upper surface 14, and wall interior surface 17, wall upper surface 18 and wall exterior surface 19 are visible in this view. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from the wall; wall circumferential lip upper surface 22 is visible in this view. In this embodiment wall upper surface 18 and wall circumferential lip upper surface 22 are not co-planar; wall circumferential lip upper surface 22 is below the level of wall upper surface 18. A top portion of wall above wall circumferential lip upper surface 22 is interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along a vertical line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62. In the embodiment shown each deflector 60 also has an intersection with a portion of wall interior surface that is described by a concave curve in the horizontal plane. This curved surface redirects flow near wall interior surface 17 towards the interior volume of block 10. The floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 at rounded corners or radii 64. In other embodiments, the floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 through bevels. Entrance flow opening outlet 65 is located at the junction of the floor of the entrance flow opening with an intermediate entrance flow opening floor level that may be depressed with respect to the floor of the entrance flow opening, and may take the form of a step.
(58) FIG. 24 is an additional perspective view of the embodiment of block 10 of the invention depicted in FIG. 22. In this embodiment, wall 16 extends upwardly from base upper surface 14, and wall interior surface 17, wall upper surface 18 and wall exterior surface 19 are visible in this view. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. A wall circumferential lip 20 projects outwardly from wall 16; wall circumferential lip upper surface 22 is visible in this view. In this embodiment wall upper surface 18 and wall circumferential lip upper surface 22 are not co-planar; wall circumferential lip upper surface 22 is below the level of wall upper surface 18. A top portion of wall 16 above wall circumferential lip upper surface 22 is interrupted circumferentially by entrance flow openings 56. In this embodiment, the major axis, in the horizontal plane, of each entrance flow opening 56 is collinear with a horizontal radius of extending from the central vertical axis of block 10. The major axis in the horizontal plane of each entrance flow opening 56 intersects a deflector 60 extending upwardly from base upper surface 14. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, each deflector 60 is in direct communication with a portion of wall interior surface 17. In the embodiment shown each deflector 60 intersects a portion of wall interior surface along a vertical line segment that is the vertex of an angle that is obtuse in the horizontal plane. The obtuse angle is formed by the intersection of a wall of entrance flow opening 56 with angled facet 62. In the embodiment shown each deflector 60 also has an intersection with a portion of wall interior surface that is described by a concave curve in the horizontal plane. This curved surface redirects flow near wall interior surface 17 towards the interior volume of block 10. The floors of entrance flow openings 56 are horizontal, are co-planar with wall circumferential lip upper surface 22, and meet the walls of entrance flow openings 56 at rounded corners or radii 64. In other embodiments, the floors of entrance flow openings 56 are horizontal and meet the walls of entrance flow openings 56 through bevels. Entrance flow opening outlet 65 is located at the junction of the floor of the entrance flow opening with an intermediate entrance flow opening floor level 67, and takes the form of a step. In the illustrated embodiment, the intersections of intermediate entrance opening floor level 67 with angled facet 62 and wall interior surface 17 are in the form of rounded corners or radii 64. Intermediate volume outlet 68 is located at the junction of the floor of intermediate entrance flow opening floor level 67 and base upper surface 14, and takes the form of a step. Entrance flow opening 56 is in fluid communication with the volume above intermediate entrance floor level 67 by way of entrance flow opening outlet 65; the volume above intermediate entrance floor level 67 is fluid communication with the volume above base upper surface 14 by way of intermediate entrance flow opening outlet 68.
(59) FIG. 25 is a top view of an embodiment of block 10 of the invention. In this embodiment, walls extending upwardly from base upper surface 14 take the form of a plurality of cylinders or columnar wall components 70 disposed around the circumference of base upper surface 14. The upper surfaces of columnar wall components 70 represent wall upper surface 18. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. Entrance flow openings 56 are formed by the spaces between adjacent columnar wall components 70. This embodiment makes use of a plurality of columnar wall components 70. For example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 or 24 columnar wall components may be used. Deflectors 60 extend upwardly from base upper surface 14 in the interior volume block 10 between the columnar wall components 70 and the central vertical axis of block 10. A line passing, in the horizontal plane, through the midpoint of an entrance flow opening 56 intersects a corresponding deflector 60. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, deflectors 60 take the form of cylinders or columns with a plurality of angled facets on the radial surfaces.
(60) FIG. 26 is a perspective view of the embodiment of block 10 depicted in FIG. 25. In this embodiment, walls extending upwardly from base upper surface 14 take the form of a plurality of barriers or cylinders or columnar wall components 70 disposed around the circumference of base upper surface 14. The upper surfaces of barriers 70 represent wall upper surface 18. Main orifice 13 passes vertically through the base between base upper surface 14 and the base lower surface. Entrance flow openings 56 are formed by the spaces between adjacent barriers 70. This embodiment makes use of a plurality of barriers 70. Deflectors 60 extend upwardly from base upper surface 14 in the interior volume block 10 between the barriers 70 and the central vertical axis of block 10. A line passing, in the horizontal plane, through the midpoint of an entrance flow opening 56 intersects a corresponding deflector 60. Each deflector 60 comprises, in a direction facing a corresponding entrance flow opening 56, an angled facet 62 having an angle other than a right angle with the major axis, in the horizontal plane, of the corresponding entrance flow opening. In the embodiment depicted, deflectors 60 take the form of cylinders or columns with a plurality of angled facets on the radial surfaces.
(61) Elements of the embodiments of the invention include: 10. Refractory element or block 12. Base 13. Main orifice or exit orifice 14. Base upper surface 15. Base lower surface 16. Wall 17. Wall interior surface 18. Wall upper surface 19. Wall exterior surface 20. Wall circumferential lip 22. Wall circumferential lip upper surface 24. Wall circumferential lip lower surface 25. Wall circumferential lip exterior surface 26. Lip shielded volume 28. Operating shielded height 30. Operating shielded volume 32. Internal height 34. Lip horizontal protrusion distance 36. Lip shielded volume height 37. Interior volume 38. Interior volume maximum horizontal dimension 40. Main orifice central axis 42. Wall upper surface elevation angle 44. WDD (wall elevation angle vertex displacement distance) 46. Lip lower surface elevation angle 48. LDD (lip lower surface elevation angle vertex displacement distance) 50. Stopper volume 52. Internal fin 54. Internal step 55. Tangent line to stopper nose / block seat contact 56. Entrance flow opening 57. Entrance flow opening initial vertical surface 58. Entrance flow opening outer wall 59. Entrance flow opening outer wall concave section 60. Deflector 62. Angled facet 64. Radius or rounded corner 65. Entrance flow opening outlet 67. Intermediate entrance flow opening floor level 68. Intermediate entrance flow opening outlet 70. Barrier
(62) Numerous modifications and variations of the present invention are possible. It is, therefore, to be understood that within the scope of the following claims, the invention may be practiced otherwise than as specifically described.
