# US 11,027,456 B2 · Ceramic composite > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,027,456 B2 - Document ID: US11027456B2 - Status: Granted - Kind: B2 - Application number: 15/773,451 - Filed: 2016-11-04 - Published: 2018-11-15 - Granted: 2021-06-08 - Earliest claimed: 2015-11-05 - Assignees: Shildan, Inc. - Applicants: Shildan, Inc. - Inventors: Moshe Steinmetz - Web page: https://patentgrep.com/patent/US11027456B2 ## CPC - B28B 11/243: {Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence)} - B28B 1/002: {assembled from preformed elements} - B28B 3/20: wherein the material is extruded {(extrusion moulding of plastics B29C48/00)} - B28B 11/044: {with glaze or engobe or enamel or varnish} - C04B 33/32: Burning methods - C04B 35/628: Coating the powders {or the macroscopic reinforcing agents} - F27B 9/028: {Multi-chamber type furnaces, (F27B9/029 takes precedence)} - F27B 9/2407: {the conveyor being constituted by rollers (roller hearth furnace)} - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - F27B: FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS ## Abstract A composite ceramic element and method of firing clay or ceramic elements in a roller kiln, comprising the steps of passing a first ceramic element on rollers through the roller kiln, passing a second ceramic element on rollers through the roller kiln, and mating and securing the first and second ceramic elements together after passing each said ceramic element through the roller kiln. ## Claims ### Claim 1 A method of firing clay or ceramic elements in a roller kiln, comprising the steps of separately extruding a pair of first and second ceramic elements to each have a plurality of protruding plateaus and adjacent recesses, with said protruding plateaus each in the shape of a substantially rectangular parallelepiped and adjacent recesses substantially in the same shape, passing the first ceramic element on rollers through the roller kiln, passing the second ceramic element on rollers through the roller kiln, and mating and securing the first and second ceramic elements together by interlocking the respective plateaus and recesses, after passing each said ceramic element through the roller kiln, such that a lateral edge defined by said interlocking plateaus and recesses being substantially flat, and said elements defining top, bottom, front, back and lateral surfaces when interlocked, with said front and back surfaces being substantially flat and parallel to one another, and said lateral surfaces being substantially flat and parallel to one another, to define a noncircular shape when said elements are interlocked. ### Claim 2 (depends on 1) The method of claim 1, wherein the first and second ceramic elements are secured together along surfaces that rested against the rollers when passing through the roller kiln. ### Claim 3 (depends on 2) The method of claim 2, comprising the additional step of glazing at least one surface of the first and second ceramic elements before being secured together. ### Claim 4 (depends on 3) The method of claim 3, wherein opposite surfaces are glazed of the first and second ceramic elements before being secured together. ### Claim 5 (depends on 4) The method of claim 4, wherein each said surface of the first and second ceramic elements being glazed is opposite the surface of the respective first and second ceramic element that rested against the rollers when passing through the roller kiln. ### Claim 6 (depends on 1) The method of claim 1, wherein the first and second ceramic elements are secured together to form a joint therebetween. ### Claim 7 (depends on 1) The method of claim 1, wherein the first and second ceramic elements are each secured together by the steps of inserting an inner tube in an opening along a respective ceramic element, positioning an end plate against a lateral edge of said first and second ceramic elements, and inserting fastening devices through openings in the end plate and into the inner tubes situated in the respective openings in the first and second ceramic elements. ### Claim 8 (depends on 7) The method of claim 7, wherein the fastening devices are screws. ### Claim 9 (depends on 1) The method of claim 1, wherein the edges of the first and second ceramic elements are machined or cut with a tool after extrusion and prior to and/or after firing. ### Claim 10 A pair of clay or ceramic elements configured to mate and be secured together by interlocking in complementary fashion after being individually passed on rollers through a kiln, said elements each comprising a plurality of protruding plateaus each in the shape of a substantially rectangular parallelepiped and adjacent recesses substantially in the same shape, said elements configured to mate with respective plateaus and recesses of the other element when interlocking with one another, a lateral edge defined by said interlocking plateaus and recesses being substantially flat, and said elements defining top, bottom, front, back and lateral surfaces when interlocked, with said front and back surfaces being substantially flat and parallel to one another, and said lateral surfaces being substantially flat and parallel to one another, to define a noncircular shape when said elements are interlocked. ### Claim 11 (depends on 10) The elements of claim 10, wherein at least one surface is glazed after the elements are secured together. ### Claim 12 (depends on 11) The elements of claim 11, wherein two opposite surfaces are glazed after the elements are secured together. ### Claim 13 (depends on 10) The elements of claim 10, wherein each said element comprises at least one opening, and additionally comprising an inner tube positioned in at least one of the openings of each said element, an end plate against a lateral edge of said elements, and fastening devices for securing the end plate to the elements through the inner tubes situated in the respective openings in the elements. ### Claim 14 (depends on 13) The elements of claim 13, wherein the fastening devices are screws. ### Claim 15 (depends on 10) The elements of claim 10, wherein the elements form a joint therebetween when secured together. ### Claim 16 (depends on 15) The elements of claim 15, wherein the joint is formed at perpendicular edges of the elements. ### Claim 17 (depends on 15) The elements of claim 15, wherein the joint is formed at opposite lateral edges of the elements. ### Claim 18 (depends on 15) The elements of claim 15, wherein the joint is formed at corners on the same side of the elements. ### Claim 19 (depends on 10) The elements of claim 10 having convex opposite surfaces when secured together. ### Claim 20 (depends on 10) The elements of claim 10 having substantially V-shaped opposite surfaces when secured together. ### Claim 21 (depends on 10) The elements of claim 10 having rippled or corrugated opposite surfaces when secured together. ### Claim 22 (depends on 16) The elements of claim 16, wherein each said element comprises two plateaus each in the shape of a substantially rectangular parallelepiped and having an opening therethrough, and a protruding edge in the shape of a substantially rectangular parallelepiped along one side thereof. ### Claim 23 A pair of clay or ceramic elements configured to mate and be secured together in complementary fashion after being individually passed on rollers through a kiln, wherein the elements form a joint therebetween when secured together, which is formed at opposite lateral edges or corners on the same side of the elements, or the elements each have asymmetrically inclined surfaces opposite surfaces configured to mate with one another, one of said elements comprises four plateaus each in the shape of a substantially rectangular parallelepiped and having an opening therethrough, and the other of said elements comprises three plateaus each in the shape of a substantially rectangular parallelepiped and having an opening therethrough, and two protruding edges each in the shape of a substantially rectangular parallelepiped along opposite sides thereof. ### Claim 24 A pair of clay or ceramic elements configured to mate and be secured together in complementary fashion after being individually passed on rollers through a kiln, wherein the elements have convex, substantially V-shaped or rippled or corrugated opposite surfaces when secured together, one of said elements comprises four plateaus each in the shape of a substantially rectangular parallelepiped and having an opening therethrough, and the other of said elements comprises three plateaus each in the shape of a substantially rectangular parallelepiped and having an opening therethrough, and two protruding edges each in the shape of a substantially rectangular parallelepiped along opposite sides thereof. ### Claim 25 (depends on 10) The elements of claim 10, wherein the elements each have asymmetrically inclined surfaces opposite surfaces configured to mate with one another. ### Claim 26 (depends on 13) The elements of claim 13, wherein said opening is provided through one of the plateaus. ### Claim 27 (depends on 26) The elements of claim 26, wherein said elements each comprise a protruding edge along one side thereof and extending in the direction of said opening, and said protruding edges extending to different length from one another in a direction perpendicular to the opening. ### Claim 28 A pair of clay or ceramic elements configured to mate and be secured together by interlocking in complementary fashion after being individually passed on rollers through a kiln, said elements each comprising a plurality of protruding plateaus each in the shape of a substantially rectangular parallelepiped and adjacent recesses substantially in the same shape, said elements configured to mate with respective plateaus and recesses of the other element when interlocking with one another, and a lateral edge defined by said interlocking plateaus and recesses being substantially flat, wherein said elements each comprise a protruding edge along one side thereof, and said protruding edges extending to different length from one another.