Refractory structural element

Abstract

A refractory structural element is provided that is useful for lining the inner surface of a construct typically used as a kiln or other high temperature system. An element includes a stem portion associated with a flared end block portion whereby the flared end block portion is compatible with other structural elements to form a substantially continuous tiled surface when a plurality of refractory structural elements are laid adjacent to each other. The stem portion optionally has a plurality of protrusions decorated on its outer surface that may serve to adjust heat dissipation from the element.

1 . A refractory structural element comprising:
 a cementitious material in a shape having a stem portion, the stem portion having a first end and a second end, the second end associated with a flared end block portion, said flared end block portion including a face, said face having a cross sectional dimension that is greater than a cross sectional dimension of said stem portion.   
     
     
         2 . The element of  claim 1  wherein the flared end block portion is continuous with the stem portion. 
     
     
         3 . The element of  claim 1  wherein the stem portion has a side decorated with protrusions. 
     
     
         4 . The element of  claim 3  where the protrusions are undulations, spirals, ridges, irregular scores, or a combination thereof. 
     
     
         5 . The element of  claim 1  or  3  further comprising fill material surrounding the stem portion. 
     
     
         6 . The element of  claim 5  wherein said fill material is ceramic fiber, perlite, vermiculite, or combinations thereof. 
     
     
         7 . The element of  claim 1  or  3  wherein the first end of the stem portion includes a flange operable to engage a fastener for securement of the element to a substrate. 
     
     
         8 . The element of  claim 1  or  3  wherein said face is space filling. 
     
     
         9 . The element of  claim 1  or  3  wherein the face is planar or arcuate. 
     
     
         10 . The element of  claim 8  wherein the face is planar, convex arcuate, or concave arcuate. 
     
     
         11 . The element of  claim 1  or  3  wherein said flared end block portion has a first edge contoured with a contour feature, said contour feature shaped to interlock with a complementary feature of a complementary refractory structural element. 
     
     
         12 . The element of  claim 11  wherein said contour feature is shaped as a tongue, groove, pin, or socket. 
     
     
         13 . The element of  claim 11  wherein said element has a second edge with a complementary contour feature. 
     
     
         14 . The element of  claim 1  or  3  wherein said stem portion has a circular or ellipsoidal cross sectional shape. 
     
     
         15 . The element of  claim 1  or  3  wherein said stem portion has a polygonal cross sectional shape. 
     
     
         16 . The element of  claim 1  or  3  wherein said flared end block portion has a plurality of sloped walls, each wall extending from an edge of said flared end portion to the second end of said stem. 
     
     
         17 . The element of  claim 1  or  3  wherein said face has a central point and the thickness of the flared end block portion at said central point is greater than the thickness at an edge of said flared end block portion. 
     
     
         18 . The element of  claim 1  or  3  wherein said cementitious material is a phosphate-bonded cement. 
     
     
         19 . The element of  claim 1  or  3  formed of a cementitious material substantially as described herein. 
     
     
         20 . A refractory structural element substantially as described herein.