Method of manufacturing a grate

Claim 1

A method of manufacturing a grate for support of a combustible solid comprising the following steps: (a) mixing a kaolin-type clay with about 10.4 percent of its weight of water; (b) adding gradually stainless steel needles having the dimension of about 0.010 inches by 0.022 inches by 1 inch in the amount of 11/2 percent of the weight of kaolin-type clay; (c) mixing the resulting material thoroughly for about 5 minutes; (d) pouring the mixture into prepared molds while vibrating for proper consistency; (e) allowing the molds to stand at ambient temperature for about 15 hours to harden; (f) drilling alternate rows of perpendicular and non-perpendicular through holes having a diameter of 1/4 inch on 2 inch centers, the non-perpendicular through holes forming an angle of 15 degrees in the longitudinal direction with respect to a perpendicular; (g) placing the drilled product in a curing oven at 100 degrees F.; (h) increasing the oven temperature at a rate of 50 degrees per hour until the oven temperature reaches 1000 degrees F.; (i) maintaining the oven temperature at 1000 degrees F. for about 8 hours; (j) increasing the oven temperature 100 degrees per hour until the oven temperature reaches 2000 degrees F.; and (k) decreasing the oven temperature gradually to an ambient temperature.

Claim 2

A method of manufacturing a grate for support of a combustible solid comprising the following steps: (a) mixing a kaolin-type clay with about 10.4 percent of its weight of water; (b) adding gradually stainless steel needles having the dimension of about 0.010 inches by 0.022 inches by 1 inch in the amount of 11/2 percent of the weight of kaolin-type clay; (c) mixing the resulting material thoroughly for about 5 minutes; (d) pouring the mixture into prepared molds while vibrating for proper consistency; (e) allowing the molds to stand at ambient temperature for about 15 hours to harden; (f) drilling alternate rows of perpendicular and non-perpendicular through holes having a diameter of 1/4 inch on 2 inch centers, the non-perpendicular through holes forming an angle of 15 degrees in the longitudinal direction with respect to a perpendicular; (g) placing the drilled product in a curing oven at 100 degrees F.; (h) increasing the oven temperature at a rate of 50 degrees per hour until the oven temperature reaches 1000 degrees F.; (i) maintaining the oven temperature at 1000 degrees F. for about 8 hours; (j) increasing the oven temperature 100 degrees per hour until the oven temperature reaches 2000 degrees F.; and (k) decreasing the oven temperature gradually to an ambient temperature.

Claim 3

A method of manufacturing a grate for support of combustible solids comprising the following steps: (a) mixing a kaolin-based clay with water; (b) adding to the mixture metallic needles approximately one inch in length; (c) pouring the clay and metallic needle mixture into a prepared mold; (d) allowing the mold to harden; (e) drilling holes through the hardened molded mixture; and (f) curing the drilled product at elevated temperatures.

Claim 4

A method of manufacturing a grate for support of combustible solids comprising the following steps: (a) mixing a kaolin-based clay with water; (b) adding to the mixture metallic needles approximately one inch in length; (c) pouring the clay and metallic needle mixture into a prepared mold; (d) allowing the mold to harden; (e) drilling holes through the hardened molded mixture; and (f) curing the drilled product at elevated temperatures.