US2230309A - Ceramic product - Google Patents

Description

Feb. 4, 1941. A G. w. REED 2,230,309

CERAMIC PRODUCT Filed .June 4, 193e j; Elf/E4.

40 'f eZf y E y a0 "'25 @e .5444 y INVENTOR Bm gordon Zdjed l ATTORNEYS.

' Patented Feb. 4, 1941 UNITED STATES PATENT OFFICE Claims.

The present invention relates to the manufacture of ceramic construction units.

More particularly the present invention relates to the production of relatively vitreous units, such as building tiles, adapted for use in structures where a high degree of impermeability is desirable. Building units of this character are conventionally formed and fburned in a kiln, the desired degree of vitrication of the product 0 being dependent in large measure on careful control of the burning operation. The instant tiles being normally of prismatic shape, when packed into a kiln for burning, provide a relatively dense packing and, as a result, do not thoroughly ventilate during the heating operation, It is, accordingly, necessary, in order to maintain the desired uniformity and control of temperature, that themass be heated in the kiln over a.rel atvely great length of time. So also this prod- 20 uct, in spite of slow and careful cooling, is, when made in the conventional manner described above, characterized by a great per cent of breakage since the Aproduct is relatively susceptible to destruction'under adverse heat conditions.

The present invention more particularly contemplates the production of vitreous ceramic units of the above character by first providing a mass of suitable plastic material in the form of an element comprising a central aperture 30 having a shape corresponding to the shape of a plurality of the ultimate units, but wherein the units are joined by integral connecting portions along opposite side edges and which may be broken apart to provide improved mortar adhering surfaces.

Unitary elements of this character may be readily stacked in the kiln to provide complete ventilation of the kiln packing so that heating will be rendered substantially uniform throughout the mass. As a result of this arrangement, the time of heating and cooling may, not only be sharply reduced, but the waste or loss due t0 breakage substantially eliminated.

Prior attempts to provide a process of this type have in general resulted in final tile units having surfaces unsuitable for assembly into a structure having the desired degree of impermeability. It is important to note that the usual mortars -0 employed to join the individual units in the iinished structure are relatively porous and free from any substantial degree of impermeability. Thus, unless the individual tiles are maintained within reasonable limits, the sanitary and moisture-retaining character of the resulting struc- (Cl. 'I2-37) ture is lessened and the real purpose of lusing such tiles is defeated.

One type of tile, 'resulting from the attempts to provide adequate ventilation during burning, has been formed with sometimes jagged and irregular projecting portions located at or in the vicinity ol the surfaces to be mortared and thus prevented proper tting and alinement of the units. Thesev projecting portions, moreover, have resulted in an inordinately large spacing between adjacent tiles so that an undesired amount of permeable mortar surface is exposed.

It is, accordingly, an object of the present invention to obviate the above discussed difficulties and to provide an element adapted to be burned while completely ventilated and which at the same time may be readily broken apart after burning'to provide individual tiles free from undesired surface projections and adapted to be properly alined in the nished structure and to be assembled closely with a mortar joint of minimum extent.

A further object of the present invention is to provide a process of manufacturing tile as well as an intermediate tile forming unit of the above character comprising a series of tile sections corresponding in form to the nished tile construction units, being integrally joined and being adapted to be readily broken apart to provide units having a desired uniform and symmetrical configuration and being free from'- irregular or projecting portions which would tend to enlarge the adjacentmortar joint.-

Another object of the present invention is to provide a process and product as abovel wherein the .integrally formed tile sections are arranged in generally polygonal order and joined along side edges by readily breakable means adapted to be broken interiorly of the normal plane 0f said side surface whereby the broken surfaces are ultimately formed interiorly of the normal outer confines of the tile in order to permit close abutment of the units in the finished structure.

An additional object of the present invention is to provide a ceramic construction unit and particularly a construction unit of the highly vitreous type having roughened, broken edges for interlocking with mortar to provide an improved mortar joint but wherein the roughened or broken surfaces are positioned interiorly of the outer side plane of the unit whereby to permit assembly with narrow mortar joints.

It is furthermore an object of the present. invention to provide a construction element as above having longitudinally recessed side edges,

Fia

a portion of the interior surface of the recess comprising a broken, irregular edge adapted for improved mortar adherence, substantially all of the broken or irregular surface being located within the recess. i s

The present invention additionally contemplates tlie provision of a unitary form' of relatively plastic tile making material comprising la series oi sections corresponding to the shape of the finished tile units and integrally joined together by connecting :or bridging po rtions,-ltho connecting portions so arranged in forr'rrl as to permit limited, angular /movmentof lth'e1sec-- tions joined thereby under theQinucnce v'of .the

elevated temperatures prevailing .in thetkiln;

It is, accordingly, an object of the present fine' vention to provide an element ladapted 'j toibe" burned in the' kiln whereinv any distorting or warping tendencies are caused torac't upontlie.' relatively thin bridging-or connecting portions.v

between the respective tile unit sections so thatthe finished tile units will possess their predetermined, undistorted form. o

A yet further object of the present invention is to provide a process comprising the forming or extrusion of a plastic mass of tile making "materials-into a predetermined section. burning the section while completely ventilatedl-and' thenA breaking the .section apart along predetermined lines of integral juncture to provide ceramic tiles of predetermined, generally prismaticv exterior configuration free fromprojectirig broken surf faces.

Numerous other objects and advantages will l more fully appear during the course and progress of the following specification.

Figure 1 is a sectional view taken vertically and cent-rally through an extrusion machine consti'ucted for the purpose of carrying out the process of the present invention. A

Figure 2 is a detail sectional view taken on the line 2--2- in Figure 1. v

Figure `3 is a perspective view oi the extruded 'Y element or section formed by thernach-ine'in` Figures 1 and 2.

Figure 4 is an end view ol the extrudedelel ment shown in Figure 3 the parts being shown in relatively`separated position after-burnirig and breaking. v .l t

Figure 5 is a perspective view of Aa finished tile embodying the features of the present invention.'

Figure 6 is an end elevational viewjshowing a 1 plurality of the construction units of Figure 5 assembled together through the agency of a. suitable mortar to provide a relatively impermeable' floor structure.

Referring tothe figures of the drawing, wherein the present invention is disclosedmore'in de` tail, Figures 1 and 2 show a machineadapted to extrude a. section suitable fory burning andl the production of construction elements in accordance with the present invention.

'The extrusion device, which is shown more or less diagrammatically in the figures, isl of the auger type comprising a chamber l0 fed with suitable, preferably relatively plastic tile making material through a hopper I2.` .The plastic material in the chamber I0 is fed progressively in the righthand direction. as viewed in. Figure 1, through the l.agency of an auger or spiral' cor'iv veyor I4 mounted on a shaft Iii-and ,journ`alled 'at one end in the bearing I8 supported by the plurality of struts 20 and at the other end in the wall 22. It will be understoodthat the shalt i6 is driven by any suitable means inot shown).

. tions MJ.l of, t e* extruded :that these 'bridging f 'r' connecting The plastic material advancing to the right in Figure 1, passes through the extrusion head or orifice 24, secured to the chamber l0 by fastening means 26.

Attention is directed to the fact the extrusion head, 24 is of generally'rectangular forin and supports centrally tiiermi, throughthei agency of struts 29, av frminglmember or die 28 of similar rectangular',configuration 'so that'theplastic extri'idedr material in e-ilectl passes through a.

space defined by co-axialp'rectangular innerand ejec'truded prodout er limits and, accordinglyuct possesses, the corig'ii-rationj di ajrectangular, tubular section? JIt- ,is rnoreover`, important to 'note .that thevouterportion'ofthe @extrusion head 24 is 'provided with fzifghtfv inwardly vprojecting Aforming'rinexribers-3ll.v Twootthetorniing mem- V bers 30a-'are'mounted-.kin leach'side v'wall f the f member' 24, being rigidlyapositioned as layweldfA ingv in appropriate grooves. The" inwardly projecting reeends of the. members 30 Yare oppovsitely inclined and sharpened as at 32. v

The inner forming member or `die r28.is lprovided with similarly arranged members illv mounted at the four corners thereof and so positioned that theyare aligned ,in the same `plane with the` correspondingfmembers 32. yEachA ofy sharpened; free edge. portion- '36 spacedfa` pre'- 'cletermined distance from1th'einc1in'ed edge ponl tion 32 'ofthe-opposite for'n'inggmernber 30;

It will be obvious. from vthejabove .desririation that the section of plastic material Iproceeding from/the extrusionv head will have :a-'cro's'sfsectional shape, as shown inv Figure 3. Particular attention is directed tothe -fa'ct that the sections of material enclosed' by the forming.platesA or members 3 0 an d 3v4 and' theropposed;'sides'v of the inner and outer forming members j28` correspond to the cross sectional shapeiof the finished construction elernent.

In other words, the extrudedproduct orelement comprises four portions corresponding `in cross sectionalv` size an'd Shape tothe ynished tile, y th'e'sej elements; being l indicated '.by' the reference numeral 38 fand'beinlintegrallyQ joined by borner oriconnecting, portions, @0

bridging f portions of .cmrlistric ed ,'Attentionfiislj particularl in the embodiment shown, c river@ nie uniti-sections 'fsay andthe-aaneen isidejsurinclined` sharpened' forming `portuii'an's '32'.1and 736 I is aresult ofI the 'itlie forming members"34likewise-hasia-inclined,

oThesebridgingremous-arenidictebrthe refr'- I erenc'e aumen-142.1 ,I t'wiilfbe'fnoteqfthat they -arereiativeiythirilo narrow vWiart-.re.spettito' the thicknessjor the adjacent-material.

of the extrusionhead provide,"alongitudinally extending recess' along the tile. sections 38 forv Y accommodating the narrow end ofthe-bridging or connecting portion Q2. 'ly hus", r;the ln'arrc'mor Ythin end of the 'bridging 'portions 42pro`vides a' breaklolf section forseparating'the` tile units,`

as will appear-hereinafter more in'detail.-

I'n accordance with the *present invention, itv is contemplated that the 'extrudedv .Section emanating from v the extrusion device. be severed vcutting.means 4Q? arranged above the top nightl vof theconvfeyor Aand 'adaptedfto 'be-4 actuated .i downwardly at predetermined; intervals. to sever Avfwire.. sawforany .otherl conventional device; n,

' '.-f'lhe ,centra Vdi'eforl fovrmingpzi'nember" 13,' vas clearly.sh'owlf inly Figure V2, is `provided with outt the present invention, it will be noted that substantially none of the projections formed -by the irregularity of the broken surface 64 will extend-v beyond the outery or bounding plane of the side n wallor, irlother words, beyond the planes inv into lengths corresponding to the length of the ilnished tiles. An endless conveyor 48 engages the .extruded length oi; material and serves to convey it continuouslyr 4in the righthand direcshown). 'Cooperating vwith the conveyor 46 is a ltion through the agency `of drive means (noti thev material *into elements of .predetermined length. They 4cutting; means v48' Vmaycmprise a wardlyprojecting' portionsifih; on fitsj; periphery vice improvidedfrwitn grooves-v'io'r serrations 52 )bottom or rear, faceof the yiinsl'ied tile units.y

f Reverting'tothe showingof the extruded and severed element shown inl Figure 3, attention is directed/to the fact that each. of the tile Aunit* sections 38 comprises an outer flat surface 54 each tile are -providedby theaction'ofA the out. [ting vmeans 4 8 hereinbefore described.`

. exercised meanwhile'uto preventbreakage. The]v ,elements maybe. packed into the kilnfin any dels'ired manner -'to-:providerelatively vfreey passage ,cent tile sectionA ,3,8'.; 'The line "ofi breakage, more-v which constitutes the -top or outer surface of the finished tile and resides in an exposed portion in the ultimate tile structure.

The grooved, uted or serrated inner face 56 offeachr of the portions fconstitutesitli'e opposite or lower-face of the tilev and it will be apparent'that the vg-rooves52 vprovide'for increased ymortaradherencein ,reta'ini'ng the tiles in op-v erative. position.' Accordingly, lthe surfaces of the sections 38fexter'idi`ng longitudinally of fthe extruded element and transversely between the surfaces 54- and v56 constitutethe side walls or edges of tliejnish'ed tiles and aredesignated by thenumeral 58. 'It will vbeunderstood from the above disclosures'. lthat; .the end" surfaces 50 `of In proceeding-in accordance withl the present invention, the extrudedl elements are carefully dried and packed in a `suitable kiln, care being along l the*y inner isuri aces corresponding to l the of Athe' kilnJ gases through zthe mass 'of material so thatv heating and .'cooling. may proceed sub-4 stantially-uniformly as to all.. portions thereof'. v, .'I'he generally polygonal arrangement oi' the integrally, joinedti'le sections 3,8 'with the central nue `or l aperture extending longitudinally theref between permits the-kiln; to -be readily packed lin this. manner. :After subjecting thekiln pack- 'ling to the required temperature'for a required length Aof time, `'-,tflive' temperature is, lowered and ing. and separatingv the individualmtiles v.

Breakage' isreadily accomplished by subjecting upon the variousl portionsfthereofgwill break o apart, Aas clearlyshown in Figure 4. Attention `the burned vit'reous'gprcnliuctv removed for breakv.the vitreous element to` a sharp blow orjar whereis particularly 'directed to the fact that breakage' occurs substantiallyat the'thinnest 4part .of the bridging orl'connectingportion 42, namely, l.sub-

stantially at-ythe p'oi'ntwherz'afitjoins'the adjaoven-will oc'curinteriorlyfof the longitudinally extending side`vr` e'p'ressiorifsv formedzby the inclined interiorly'ofhthe sides ofA each tile .sectionf,'prov'ide' a. recess, which has been, indicated generally lby the .referenced nii'ieral, 62..'.and the breakage ofthe v `tending 'fa-'ces 58 is provided centrally with a longitudinally within this recess. As a result, the jagged, irregular or broken surface resulting from the breakage at this point is in effect interiorly positioned with respect to the final tile and does not project to interfere with the fitting of the individual tiles.

As clearly shown in Figure 5, the present inlvention provides-a construction element which is 4 substantially prismatic in form, having top, end

'and side building surfaces. -The recess 62 exlongitudinally of the `opposite side surby/the reference numeral 6,4.

extending, irregular or broken surface designated which reside the surfaces 58. Thus, when assembled in a Wall or lfloor structure, as shown in VFigure 6, the construction units may be accurately In' .accordancev with the preferred V'embodiment` alined, as shown in the iigure, and positioned as l closely as may be desired to produce a mortar joint 66 of the desired dimensions. As shown in the iigure, the mortar lls the longitudinally ex.

tending recesses 62 and contacts directly with the f irregular, broken surface 64, insuring a substantially perfect degree of mortar' adhesioneven though the vadjacent units may be set relatively closely together. yThe present invention provides a simple and effective ceramic construction unit and process for producing the same which reduces production losses andcostsand results in a iinal product of improved character and quality. j lWhen proceeding in accordance with thei presentl invention, the ladverse effectsof the thermal conductivity of the 'material being; burned is overcome. Clay of the kilnin accordance with one of the prior methods of practice mentioned above, thlstechnical factor is responsible forinordinately slow burning ofthe mass a resulting high fuel cost and a high percentage of cracked units as a result of the socalled cooling cracks which occur when the kiln isy cooled.

In accordance with the present invention it is 'contemplated' that vthe instant flue-shaped extruded units be arranged in the kiln preferably superposed on end so that the gases and heat of y the kiln/will pass freely vertically through the mass to directly heat all parts uniformly. Stresses, such as are normally set up during burningand which tend to warp the elements, are

permitted to `act harmlessly by the bridging or connecting portions 42 which, being located adjacent tl'ie side surfaces of the respective tiles and being relatively thin, absorb all of the twisting strains without transmitting them to the adjacent units. In other words, the relatively thin portion adapted zto bebroken, after burning, in effectl acts as a pivot or hinge and permits relative twisting of the portions to absorb the warpage inherent in .the burning operation.

, The rpresent invention, moreover, provides a highly desired, roughened, irregular inish on the surfaces toi be mortared which insures proper mortar `adhesion: without the necessity of v a protrudingv or projecting burnv It is to be noted lin this connection that the entire mortar receiving periphery o'fthe tile, including the end surfaces 60, has desirable mortar securing properties. The end surfaces 60, being formed by cutting the continuous clay bar, are roughened sufciently to provide slightly ragged faces for the purpose of enhancing this effect. l

While the present invention^has been described as being carried out with the assistance of an extruding machine, it will be understood that vari- Cil ous other forming machines may be employed. The lextruded section forming the vpreferred embodiment of the present disclosure comprises in general four tile unit sections polygonally arranged in a quadrangle and joined by corner members, but it will be understood that various' other specific configurations will come within the scope and intent of the present invention, particularly' those wherein the tile sections are generally polygonally positioned in the integral element.

, InV accordance with the present invention the corner portions of the extruded unit designated by the numeral 40 are, after burning and separating from the tile units, employed in the construction of decorative floor tile assemblies, particularly wherein impermeability is lnot an im portant factor. It has l been found that the tapered protruding extensions 42, which form the bridging portion in the original unit, may be employed to accurately space these units, both from adjacent units and from the supporting floor. In

other words, Vthe corner elements 40, as shown in Figure 4, are employed in oors, for example, Where it is desired that the mortar joints be of uniform width while at the same time being relatively wide.

Changes may be made in the form, construction and arrangement of the several parts without departing from the spirit or scope of the invenlion, or sacrificing any of its attendant advantages, the form herein described being a preferred .embodiment for the purpose of illustrating the llongitudinally extending, irregular, broken surface occupying a portion of the interior surface of said recesses and adapted to promote mortar adhesion but having substantially all projecting portions thereof positioned below the outer plane of said side surfaces.

2. A ceramic building unit of generally prismatic form having opposite side surfaces, said side surfaces being recessed, said recesses interiorly thereof comprising irregular, jagged surfaces formed by breaking a member integrally joining With a portion of said recesses.

3. A ceramic building unitpf generally prismatic form having opposite side walls, said side walls being provided with longitudinally extending side recesses formed therein, said recesses at a point spaced interiorly of the plane of said side walls comprising .,irregular, jagged surfaces formed by breaking integral portions therefrom and adapted to promote mortar adhesion without providing projecting portions.

4. A building unit having a plurality of surfaces adapted to be juxtaposed to similar surfaces in adjacent building units to form bonded joints, said" surfaces being recessed, irregular, jagged surfaces formed interiorly of said recesses and being so arranged that said irregular 'portions do not extend substantially out of the recesses whereby to provide improvedmortar adhering surfaces without `requiring substantial thickness of mortar joint.

5, A ceramic be assembled with vother similar units to provide a finished wall or floor structure, said unit hav.

wall or floor structure, and having at least onev side portion adapted to receive mortar, said side portion comprising a recess extending inwardly of said side and comprising an irregular broken mortar receving surface within said recess adapted to receive mortar to provide a permanently cemented nal assembly.

'7, Al ceramic building unit adapted to beassembled with other units to vprovide ay finished wall yor oor structure, and having at least one side portion adapted to receive mortar, said side portion comprising a recess formed in said side and comprising an irregular broken mortar receiving surface within said recess adapted to receive mortar to provide a permanently cemented nal assembly, said recess extending 'longitudinally of said side surface and being spaced from the lateral marginal edges of said side surface.

8. A ceramic building unit adapted to be assembled with other units to provide a finished wall or floor structure, and having at least one side portion adapted to receive mortar, saidside portion comprising a recess formed in said Side and comprising an irregular broken mortar 're--y ceiving surface within said recess adapted to receive mortar to provide a permanently cemented final assembly, said recess ext-ending longitudinal- 'ly of said side surface and being spaced from the lateral marginal portions thereof, said ir- -regular broken surface portion being formed longitudinally of said recess andoccupying a.

portion thereof only, the remainder of said re" cess being defined by regular, even surface portions.`

" 9; A ceramic building unit adapted to be assembled with otherunits to provide a finished wall or floor structure, andhaving at least one side portion adapted to receive mortar, said side portion comprising a recess formed in said side and comprising an irregular broken mortar receiving surface within said recess adaptedto receive mortar to provide a permanently cemented final assembly, said recess extendingV longitudinally of said side surface and being spaced from the lateral marginal portions thereof, said Y irregular jagged surface portions extending longitudinally and centrally of said recess and having substantially all the jagged portions thereof positioned interiorly of the planeof said lateral marginal portions.

10. A fired Vtile member having longitudinally extending, opposed, parallel Vside surfaces provided With longitudinally extending, recesses disposed centrally of said side surfaces, a portion of. each recess being defined by a jagged mortar receiving surface spaced from both lateral side margins of said recess and located substantially interiorly of the planes of said'side walls.

GORDON W. REED.

building unit adapted to

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