Ceramic log moulding process

Abstract

The present invention relates to an improved process and partible mold for forming a light-weight synthetic ceramic log for use in natural gas, propane and wood-burning fireplaces and stoves which are both fully-vented and non-vented depending upon the particular design of the heat generating equipment. In the subject process, a flexible porous patterned screen is formed simulating the exterior bark portion of a tree or log having a reverse image. Such screen is designed with both porous and non-porous surface characteristics for mounting as a separate element within the partible mold. The flexible porous patterned screen is mounted within the partible mold having major interior surface areas which are capable of connection to a vacuum source for withdrawing water from a liquid composition containing ceramic fibers to rapidly form the ceramic log within the mold during short periods of vacuum molding. After vacuum extraction of the liquid components of the molding composition containing multiple ceramic fibers, the partible mold is opened and the separable screen and newly-formed log are taken therefrom and separated, following which the synthetic log is dried to increase its structural strength for further handling and processing. The molding composition contains both finely-divided ceramic fibers such as aluminosilicate fibers and a colorant such as iron chromite to produce the ceramic log having a dark colorization. After the log is formed and dried, the log is then subjected to an additional colorizing operation to give its exterior surface areas greater colorization ranging from brown to gray to black depending upon the desired surface characteristics to be obtained.

Dependencies are inferred from the claim text.