Document mpGvb894yREGE0EBoO9KnxGNb

FILE NAME: Ferro Engineering (FER) DATE: 1967 Oct 17 DOC#: FER006 DOCUMENT DESCRIPTION: Amended US Patent - FERROBOARD ADDRESS O N IV T H E C O M M IS S IO N E R O F P A TE N TS TR A D E M A R K E X A M IN IN G O P E R A TIO N W A S H IN G TO N . D .C .. 0 2 *1 U.S. D EPA R TM EN T O F C O M M E R C E paten t o ffic e WASHINGTON Paper No. A ll com m unicatione respecting th is a p p lic a tio n should give the s e ria l numbert date o l HI* ing, and name o f the e p p lic e n t. Yount, Flynn & Tarolli 1111 Leader Bldg. Cleveland, Ohio I4J4-III4. L_ 1 Mailed: 8 Ser. No.: 2 8 2 7 1 3 Filed: Oct. 17, 1967 Applicant: Oglebay Norton -j Company Mark: FERROBOARD The changes hereinafter sp ecified have been made in the above identified application in accordance with the provisions of Order Number 5316 of November 2d,.1964, which reads ' in part a s lo l l o w s : Obvious informalities in the application, including the classification of goods or s e r v ic e s , may be corrected but said correction must be in the form of an amendment in writing, approved by the examiner, entered in the file and made a part of the record. If the changes set forth below are not satisfactory to the applicant, appropriate amendment may he submitted under the provisions of Rule 2.74, provided the printing of the registra tion has not been commenced at the time .such amendment is approved. . The application has been amended as follows: ' Since applicant's goods are properly classified in'Class 2 3 , the class number in this application has been changed accordingly. RMBerman:atb --557-3273 P O L ` 108 <I214-G4> USCOMM-DC 7 7 8 3 - PG5 4 P - IN THE UNITED STATES PATENT OFFICE Application of OGLEBAY NORTON COMPAN For Trademark FERROBOARD Serial No. Filed October 17, 1967 l / Dlv. I Cleveland, Ohio October 10, 1968 Hon. Commissioner of Patents Washington, D. C. 20231 Sir: In response to the Office Action of July 17, 1968, applicant encloses a copy of United States Patent No. 3,373,047 which relates to the Insulating panels made and sold by applicant under the mark FERROBOARD, This patent explains the commercial use of the panels. With respect to the identification of the gocds, they are identified in accordance with terminology which is utilized in the trade. As will be apparent from the patent, applicant's panels are used to Insulate molten steel at the top of an Ingot mold from a container therefor or from the ingot mold. II Ferro Engineering" at the bottom of the specimens submitted with the application Indicates the Ferro Engineering Division of Oglebay Norton Company. Oglebay Norton Company, applicant herein, operates its hot topping division under the trade name Ferro Engineering. The phrase "Ferro Engineering" constitutes not only the trade name of applicant but a house trademark. Respectfully submitted, YOUNT, FLYNN & TAROLLI Attorneys for Applicant JHY:lk (216) 621-2234 r March 12, 1968 H. D. SHEETS ET AL MATERIAL FOR HOT TOP' Filed Oct. 6, 1964 3,373,047 m l FIG. I U k\ '1 v; I; INVENTOR. HERBERT 0. SHEETS gyJOHN W LENNON rrfg , ti&Q.st/*-*Cr f*! & United States Patent Office Pa LenteJ Ma3r,,3172,3,10346.73 1 2 3.373,047 MATERIAL 'OK HOT TOP Herbert D. Sheets ami John W. Lennon, (mlnmbus, Ohio, assignors, by mesne assignments, lo GgJcbny Norton Companv, Cleveland, Ohio, a corporation or Delaware 5 Filed Get. <5, 1064, Ser. No. 401,944 5 Claims. (Cl. 106--33.1) The present invention relates to a refractory material for use in hot topping and, more particularly, to a hot 10 top refractory panel or board which contacts the molten metal being poured into the mold with which the hot lop is associated. Known hot top structures and specifically hot top insulating panels or boards have been constructed of a 15 material including organic and inorganic fibrous materials tit combination with a granular refractory material and binder. These known insulating panels or boards when contacted by moltcn'mciai generate gases which, at least in part, bubble through the molten metal and cause, what 20 has.bcen termed, "boiling" of the metal. This boiling may cause splashing of the metal and sparks which create a hazard to the pouring crew. Moreover, hydrogen and oxygen may be picked up by the sinkhead metal causing harmful metallurgical effects therein. 25 The present invention is directed to the solution of this boding problem. It has been found that by eliminat ing or drastically reducing the amount of organic fibrous material in the insulating panel and utilizing an asbestos fiber having a low water content in the material constitut- 30 ing the panel, boiling of the molten metal is greatly reduced. Furthermore, the use of an asbestos material having a low water content permits the use of a relatively fine granular filler material which provides a panel hav ing good insulating properties. 35 Accordingly, the principal object of the present inven tion is the provision of a new and improved hot top_ structure constructed of a material which generates a minimum amount of gases when contacted by molten metal and, thus, greatly minimizes the amount of boil- 40 ing of the molten metal and which has good insulating properties, strength, and flexibility. Another object of the present invention is the provi sion of a new and improved hot top insulating panel or board wherein the panel is made of a material contain- 45 ing an asbestos having a low.water content and which generates a relatively small amount of gas . when con tacted by molten metal and wherein the material con tains little, if any, organic fibrous material.- A further object of the present invention is the pro- 50 vision of a new and improved hot top insulating panel or board made of a material containing amositc asbestos, a relatively fine granular refractory filler, and a suitable binder which provides an insulating panel or board hav ing good heat-insulating properties, sufficient strength 50 and flexibility, and from which a minimum amount of gas is generated when the board is contacted by molten metal. . A stilt further object of the present invention is the provision of a new and improved hot top insulating board 00 comprised of 79-90 parts by weight of a granular refrac tory filler, 5-10 parts by weight of an organic binder, and 5-10 parts by weight of an asbestos having a water content of less than 6%. Still another object of the present invention is the pro- 05 vision of a new and improved hot top insulating board comprised of 79-90 parts by weight of 200 mesh silica sand, 5-10 parts by weight of an organic binder, 5-10 parts by weight of amositc asbestos, and about 1 part by weight of an organic fibrous material. 70 Further objects and advantages of the present inven tion will be apparent to those skilled in the art to which the invention relates from the following detailed descrip tion of the preferred embodiment thereof made with reference to the accompanying drawings forming a part of this specification and in which: FIG. 1 is a side clcvational view of a hot top, partly in section, and embodying the present invention; FIG. 2 is a sectional view of a modified hot top em bodying the present invention; and FIG. 3 is a sectional view of still another hot top em bodying the present invention. The present invention provides an improved hot top structure and, particularly, an improved hot top panel or board for use in a hot top. As is well known, hot tops are utilized in association with ingot molds for maintain ing a mass of molten metal above the ingot mold so as to feed the shrinkage cavity as the nictal in the mold cools. Hot tops arc supported on the upper end of the ingot mold and have a central opening through which molten metal is poured into the mold. The molten metal also is poured so as to fill or substantially fill the hot top. The hot top is constructed of suitable insulating struc ture so as to maintain some of the metal in the hot top in a molten state, so as to feed the shrinkage cavity as the metal in the mold solidifies. Hot tops are formed of different constructions and, by way of example, a preferred embodiment of the present invention is illustrated in FIG. 1 which shows a hot top 10 supported in the upper end of an ingot mold 11. The hot top 10 has a central opening therethrough through which molten metal is poured into the ingot mold, and the hot top, as noted above, maintains a mass of molten metal above the ingot mold I I to feed the shrinkage cavity as the metal in the mold solidifies. The hot top 10 includes a metal casing 12 which is conventional in construction and includes an upper section 13 and a lower section 14, which arc suitably secured together. In the illustrated hot top, the metal casing 12 has a lining 17. The lining 17 comprises a hard, dense high temperature firebrick or equivalent castable refractory whose purpose is to form a lining or backup support for the insulating refractory panels. The lining is thus a semi-permanent lining capable of being reused for a number of pouring operations. , An insulating panel means overlies the lining 17 in the embodiment shown in FIG. 1 and comprises a plurality of individual insulating panels or boards 25 suitably posi tioned in the hot top overlying the lining 17 which backs up the panels 25 and provides support for the panels. The upper end of the pancis 25 are substantially flush with the upper side of the upper canopy 26 of the metal casing 12, while the lower ends of the panels 25 are' supported in a recessed portion 27 of a bottom ring 2S. When the molten meta! is poured through the central opening in the hot top, the molten metal contacts the in sulating pancis 25. When the insulating pancis containing considerable quantities of organic fibrous materials of the known prior art are contacted by the molten metal, the materials in the panels generate gases which bubble through the molten metal causing "boiling" of the molten metal. According to the present invention, the insulating refractory pancis are constructed of a material which minimizes the generation of gases when contacted by molten metal and which, thus, minimizes the boiling of the molten metal. The material of which the panels are made includes a granular refractory filler, a binder, and an inorganic, fibrous asbestos form material having a relatively low combined water content. The granular refractory filler preferably comprises a relatively fine sand such as 200 mesh silica sand, that is, a silica sand substantially all of which passes through a 200 mesh screen. Other granular refractory fillers may also be used, such as diatomaceous earth, magnesia, alumina, or forsterite. The binder may 3,373,047 be of any conventional form and may be a phenolic resin is sufficient lo provide a suitable homogeneous mixture, such as the. resin marketed under the tradename Dure?, generally one-half hour was found to be satisfactory. Phenolic 12.135, an organic resin, or any oilier suitable After mixing, the mixture is formed into panels or and known type of binder. A smalt amount of organic boards by a suitable molding method. The panels arc fibrous material may also be included in the mixture. The molded into the desired shape and thickness for the par organic fibrous material may be either ground wood fiber, cardboard shavings, .or paper palp, or combinations ticular use to which they ate to be pul and arc then dried into self-sustaining panels having substantially parallel thereof. sides. One suitable method of molding is by pouring the The asbestos form material utilized-has a combined mixture onto a screen and pulling a vacuum on the screen water content of less than 6%. Crocidolitc asbestos, 10 to remove the major portion of the water. After the mold t anthrophyllile asbestos, trcmolitc asbestos, or amosito ing of the boards, the boards arc dried. The drying tem asbestos may be usdc, all of which have a combined water peratures and time may vary and must be such so as not content of less than 69o. These materials also have a low to exceed the temperature at which the binder material loss of weight on ignition. Of the above-noted materials, will decompose. Drying by placing the boards in an oven \ amositc asbestos is preferably used due to its fiber strength la at 400 F. for two hours, then reducing the temperature to and availability. Amositc asbestos contains a small amount 300 F. for one hour has been found to be satisfactory. of water, approximately under 6% by weight, and has an In the preparation of the mixture, the amosite asbestos extremely low loss of weight on ignition, as compared absorbs an amount of water, filling the voids or spaces in with other asbestos having a high water content and a the bundlelike fibers of the amosite. When the water is higher loss on ignition. The amosite asbestos used has a 20 removed in the molding and drying of the boards, the 'bundlelike fiber form with voids or spaces therein and an water is removed from these spaces and the spaces or orthorhombic crystal structure. The amosit: asbestos also voids remain providing air pockets throughout the boards. lias sufficient fiber length and tensile strength character These pockets, it is believed, aid in rendering the board istics which provide the hot top panel or board with the a good insulator and provide for removal of gases through desired strength and flexibility. the panel. The table below indicates the,various ingredients which Insulating panels or boards made of the material and comprise the material forming a completed panel or by the method disclosed above may be used in any type board, with the range of parts by weight of the ingredients of hot top, and the hot top of FIG. 1 is an illustration of in the panels, as well as the preferred parts by weight one form of hot top for which the -panels may be used. within the ranger 30 FIG. 2 illustrates a modified form of hot tap structure in which -panels made of the material disclosed above Ingredient Range (T arts Preferred (P arts h y Weight) by W eight) may be embodied. The panels JO, made of the material described hereinabove, are utilized in the hot top shown G r a n u la r R e fra c to ry r t l l o r ................. ........ 70-00 6-87 in FIG. 2 in the same manner as the panels described here B in d e r .................................................................. A sb e sto s h a r i n g less th a n 0% w a t e r ____ O rg an ic F ib ro u s M a t e r i a l . . , , ................... 5-10 5-10 <2 6 33 inabove with respect to FIG. 1. The panels 30 in the hot 8 0-1 top of FIG. 2, however, are backed up, that is, supported by a metal portion 32 of the hot top illustrated. The metal portion 32 is suitably secured with and inlerfilted within As noted above, the use of the above materials in the the upper hot top casing 33 and has a surface 34 against construction of a hot top panel provides a good light 40 which the panels 30 engage. A bottom ring 35 is suitably weight insulating-panel and one which minimizes the supported at the bottom end of the portion 32 of the generation of gases when contacted by the molten metal, hot top and has a recess 36 in which the bottom end of and one which has a relatively low loss of weight when the panel 30 is supported. contacted by molten metal as compared to known panels Another form of the hot top in which panels made of crioanlst.aiTnhinegwceoingshitdelorasbs lfeoqrupaannteitlisesofofthoergaabnoicvef-inboroteuds mmanttec*- 45 tihlleusmtraatteedriainl dFeIsGcr.ib3e. dThheerheiontabtoopveshmowayn bine FeImGb.o3diecdomis ' rial in tests has been found to be 5-6% as compared to prises a plurality of panels 40 which are located in the 11% for such known panels. Moreover, panels con upper end of an ingot mold 41 with the upper ends of structed in accordance with the present invention have the panels substantially flush with the upper end of the none or very little organic fibrous material in the mix, 50 mold 41. The panels, thus, extend down into the ingot and thus greatly reduce or eliminate gases generated by mold 41. The plurality of the panels 40 form the hot the organic fibrous materials. .The insulating ability of the top and arc positioned in the upper end of the ingot mold refractory panel made of the material noted above is quite so as to form a lining at the upper end of the ingot mold good because it includes a relatively fine refractory filler. 41. The panels 40 may be held in the upper,end of the The use of a relatively fine refractory filler provides a ingot mold by suitable clamp members, designated 42, multitude of small air pockets in the panel and provides for better insulation as compared with the use of a coarser which engage the mold 41 and the panels 40 and hold the panels in position in the upper end of the mold. The filler material. While the air pockets arc relatively small, panels 40 may also be held in the upper end of the ingot they are adequate to provide a sufficient porosity so that mold by suitable wedgelike tapered comer panel pieces, any gases generated when the board is contacted by 60 not shown, which may be driven downwardly at the in molten metal flow through the board and not through the got mold corners between adjacent side panel pieces and molten met2j. Moreover, the bundlelike fiber construc wedge the panels 40 into tight contact with the inner tion of the amositc asbestos provides air pockets in the walls of the ingot mold 41 so as to hold the panels se panel which also assist in permitting the gases to escape curely in the upper end of the mold 41, thrIonugphrepthaerinpgantehles. material of which the panels are pref 65 It should be apparent that the preferred embodiment > erably made, the granular refractory filler, amosite as of the present invention has been described in consider able detail and it is to be understood that certain changes, bestos, and binder are mixed together in a suitable manner modifications, and adaptations may be made therein and in a conventional vessel with a suitable amount of water. it is intended to cover all such changes, modifications, t The amount of water may vary; however, 135 to 300 70 and adaptations as are covered by the appended claims. parts by weight has been found satisfactory. The amositc Having described our invention, we claim: asbestos is added to the water first. Thereafter, the binder 1. An insulating structure for use in hot topping and is added to the mixture and, finally, after the amositc adapted to be supported at the upper end of an ingot mold asbestos and binder have been dispersed in the mixture, comprising a body to be supported at the upper end of the the granular refractory filler is added. The mixing time 73 ingot mold, said body having one surface for defining at 3,373,047 5 . least a portion of ait opening through which molten metal is poured into the mold, said one surface being contacted by molten ntetal poured into the mold, and said body at least in part constructed of a mixture consisting essentially of 79-90 pails by weight of granular refractory filler, 5-10 parts by weight of inorganic fibrous asbestos form mate rial having a water content between 0 to 6%, 0 to 2 parts by weight of organic fibrous material, and' 5-10 parts by weight of a binder therefor. 2. An insulating structure as claimed in claim 1 wherein said granular refractory filler comprises 200 mesh silica sand and said mixture contains about 1 pail by weight of organic fibrous material, 3. An insulating structure for use in hot topping and adapted to be supported at the upper end of an ingot mold comprising a hot top insulating board to be supported at the upper end of the ingot meld, said board having a sur face for defining at least a part of an opening through which molten metal is poured into the mold, said surface being contacted by molten metal poured into the mold, and said board at least in part constructed of a material consisting essen tially ^ 79-90 parts by weight of sand, G 5-10 parts by weight of an inorganic fibrous asbestos material having a water content between 0 to (>%, 0 to 2 parts by wc-iglu of organic fibrous material and 5-10 parts by weight of an organic binder, fl 4. An insulating structure as defined in claim 3 wherein said sand comprises 200 mesh silica sand. 5. An insulating structure as defined in claim 3 wherein said asbestos material comprises nmositc asbestos. ];; References Cited UNITED STATES PATEN'I S 1,921,729 8/1933 C harm an___________ 249--201 2,385,500 9/1945 Fasold et a l . ______ 106--38.27 3,072,9S1 1/1963 Davidson ............... 106--38.35 " 3,123,878 3/1964 D avidson................. - 10S--38.2 3,230,056 1/1966 Arant et a h _______ 105--38.22 3,262,165 7/1966 In g h am ......................... 249-- 197 , 0 ALEXANDER H. BRODMERKEL, Primary Examiner. L. B. HAYES, Assistant Examiner. rtw t t w . r