Monolithic float glass forming chamber and method of construction

Abstract

The present invention is related to a monolithic float glass forming chamber and its method of construction. The forming chamber being of the type that includes a bottom wall; side walls and a roof wall to form an elongated chamber, the elongated chamber including a forming section and a cooling section for a desired thickness and ribbon width of molten glass, wherein each type of wall comprises: a first refractory structure with a mixture of a castable and pumpable refractory material and an insulation material; and a second refractory structure with a castable and pumpable refractory material, the first and second refractory structures being formed at the same construction site.

1 - 16 . (canceled) 
     
     
         17 . A monolithic float glass forming chamber, said forming chamber being of the type that includes a bottom wall; side walls and a roof wall to form an elongated chamber, said elongated chamber including a forming section and a cooling section for a desired thickness and ribbon width of molten glass, wherein each type of wall comprises: a first refractory structure with a mixture of a castable and pumpable refractory material and an insulation material; and a second refractory structure with a castable and pumpable refractory material, said first and second refractory structures are formed on the construction site. 
     
     
         18 . The monolithic float glass forming chamber as claimed in  claim 17 , wherein the first and second refractory structures are carried out by the sol-gel process. 
     
     
         19 . The monolithic float glass forming chamber as claimed in  claim 17 , wherein the mixture of the pumpable and castable material and the insulation material comprises from about 40 to from about 90% of Al 2 0 3  and an additive as carlita, thermolita, perlita, verelite or a mixture of the same. 
     
     
         20 . The monolithic float glass forming chamber as claimed in  claim 17 ,
 wherein the castable and pumpable refractory material comprising from about 40 to about 65% by weight of Al 2 0 3 ; from about 55 to about 30% by weight of Si0 2 ; 3.5% by weight of a mixture of Ti0 2  and Fe 2 0 3  and CaO; and 0.5% by weight of Na 2 0.   
     
     
         21 . The monolithic float glass forming chamber as claimed in  claim 17 , wherein the mixture of the pumpable and castable material and the insulation material comprises from about 40 to about 65% by weight of Al 2 0 3 ; from about 55 to about 30% by weight of Si0 2 ; 3.5% by weight of a mixture of Ti0 2  and Fe 2 0 3  and CaO; and 0.5% by weight of Na 2 0 and an additive as carlita, thermolita, perlita, verelite or a mixture of the same. 
     
     
         22 . The monolithic float glass forming chamber as claimed in  claim 17 , wherein the monolithic float glass forming chamber includes a bottom refractory wall; and, a roof refractory wall. 
     
     
         23 . The monolithic float glass forming chamber as claimed in  claim 22 , wherein the bottom refractory wall comprises:
 a first bottom wall and side walls, said side walls being separated one of the other on two lateral sides of the first bottom wall, said first bottom wall and   side walls being manufactured with a mixture of the castable refractory material and an insulation material on a casing having bottom and side walls; and,   a second bottom wall and second side walls manufactured of the castable refractory material on said first bottom wall.   
     
     
         24 . The monolithic float glass forming chamber as claimed in  claim 23 , wherein the second side walls and second bottom wall includes: a gap between the second side walls and second bottom wall to prevent gases diffusion to cause bubble faults in the glass production. 
     
     
         25 . The monolithic float glass forming chamber as claimed in  claim 23 , further includes metallic anchors which are welded at the bottom and side walls of the casing to maintain fixed the first bottom wall, the first side walls, the second bottom wall and second side walls. 
     
     
         26 . The monolithic float glass forming chamber as claimed in  claim 23 , further includes: a ceramic cushion material placed between said side walls of the casing and the side walls of the first bottom wall to provide a gap for the thermal expansion of the refractory walls at the working temperatures. 
     
     
         27 . The monolithic float glass forming chamber as claimed in  claim 22  wherein the roof refractory wall comprises:
 a first roof refractory wall manufactured of the castable refractory material, said first roof refractory wall including first side walls to each side of the first roof refractory wall; 
 a sheet of metal layer on the upper surface of the first roof refractory wall to prevents diffusion and escape of gases from the float glass forming chamber to the atmosphere; 
 a second roof refractory wall manufactured with a mixture of the castable refractory material and the insulation material, said second roof refractory wall being placed on the upper surface of the sheet of metal layer, said second roof refractory wall including second side walls to each side of the second roof refractory wall; 
 wherein the first roof refractory wall, the sheet of metal layer and the second roof refractory wall includes hollow spaces to install heating or atmosphere supply elements to control the operation of the chamber. 
 
     
     
         28 . The monolithic float glass forming chamber as claimed in  claim 22  wherein the bottom refractory wall; and the roof refractory wall further includes: sealing means between said main bottom refractory wall and the roof refractory wall, to provide access to an internal part of the monolithic float glass forming chamber. 
     
     
         29 . The method for the construction of a monolithic float glass forming chamber as claimed in claim  13 , wherein the roof refractory wall further includes; providing removable sealing means to said roof refractory wall, to provide access to the internal monolithic float bath refractory structure.