Porous refractory materials

Claim 1

A method of making a porous refractory shape comprising the steps of: impregnating a shaped sponge having pores and a cellular structure with a suspension or dispersion of refractory particles in a liquid; squeezing the sponge to remove excess liquid therefrom; air drying the sponge to remove further liquid therefrom; providing a plate-like supporting base made of a refractory material capable of withstanding repeated changes in temperature with a plurality of individually movable supporting rolling elements on the plate-like supporting base upper surface whereby said rolling elements do not penetrate the pores and contaminate the cellular structure of the sponge and said rolling elements being made from a refractory material capable of withstanding a temperature to which the rolling elements are to be subjected; positioning the air dried sponge on top of the plurality of rolling elements supported on the supporting base to define an assembly; then placing the assembly of the supporting base, the rolling elements on the upper surface, and the air dried sponge supported on the rolling elements within a furnace; and subsequently heating the assembly to a temperature to remove the remaining liquid and the material of the sponge and to further sinter the particles together as the porous refractory shape without development of cracks due to differential rates of expansion and contraction of the assembly.

Claim 2

A method of making a porous refractory shape comprising the steps of: impregnating a shaped sponge having pores and a cellular structure with a suspension or dispersion of refractory particles in a liquid; squeezing the sponge to remove excess liquid therefrom; air drying the sponge to remove further liquid therefrom; providing a plate-like supporting base made of a refractory material capable of withstanding repeated changes in temperature with a plurality of individually movable supporting rolling elements on the plate-like supporting base upper surface whereby said rolling elements do not penetrate the pores and contaminate the cellular structure of the sponge and said rolling elements being made from a refractory material capable of withstanding a temperature to which the rolling elements are to be subjected; positioning the air dried sponge on top of the plurality of rolling elements supported on the supporting base to define an assembly; then placing the assembly of the supporting base, the rolling elements on the upper surface, and the air dried sponge supported on the rolling elements within a furnace; and subsequently heating the assembly to a temperature to remove the remaining liquid and the material of the sponge and to further sinter the particles together as the porous refractory shape without development of cracks due to differential rates of expansion and contraction of the assembly.