Abstract: The tunnel kiln establishes multiple kiln car train paths by a pedestal which upwardly projects from the kiln's foundation. Aprons which depend from the kiln cars and extend transversely between laterally adjacent pedestals (or a pedestal and a side wall of the tunnel) thus effectively form a seal thereat so that the undercar cooling techniques may be employed in multitrain tunnel kilns.

Abstract: Intensive undercar cooling is achieved in the latter portion of a tunnel kiln by (a) a continuous undercar longitudinal cooling air flow or (b) by transverse undercar sub-chambers in which heat exchangers are used to set up local cooling connection currents within each sub-chamber. Air flows in the undercar channel are substantially prevented in the heat-up zone and up to about the middle of the firing zone. Pressure equalization is permitted with respect to the firing chamber thereabove but very little air will actually pass therebetween in the sensitive heat-up zone because there is no other substantial air passageway leading into or out of the sub-chambers formed by aprons depending from the kiln cars.

Abstract: Transverse sub-chambers are defined beneath a train of kiln cars. Pressure equalization is permitted with respect to the firing chamber thereabove but very little air will actually pass therebetween because there is no other substantial air passageway leading into or out of the sub-chamber. Rather, heat exchange cooling apparatus is employed in each sub-chamber so as to set up convention air currents within the sub-chamber to cool the underside of the kiln car. The heat exchanger units in different sub-chambers are preferably individually controllable so as to provide a controllable degree of undercar cooling as a function of location along the tunnel kiln.

Abstract: A tunnel dryer and method for drying unfired bricks or similar objects in which the tunnel comprises exhaust means for exhausting heated gases within the tunnel, partition means disposed in the drying space of the tunnel consisting of at least one vertically adjustable partition positioned upstream of the exhaust means, and means for positioning the vertically adjustable partition at an intermediate level within the drying space of the tunnel to define an effective drying zone for the unfired bricks.

Abstract: The invention relates to a method and apparatus for efficiently cutting clay columns. The apparatus employs at least two supporting conveyors with one positioned downstream from the other and spaced apart a predetermined distance defining a gap therebetween. Each conveyor is wide enough to handle any desired column length so that no changes thereof are necessary when the size of the cut length changes. The conveyors or the end rollers thereof adjacent the gap are arranged to move horizontally thereby causing the gap to move. The cutting mechanism moves vertically and is operated in a coordinated fashion with movement of the gap following the point of intersection of at least one cutting wire with the conveyor plane so that clay columns are conveyed and cut simultaneously. Material adhering to the cutting wire(s) is automatically cleaned therefrom during cutting.

Abstract: An improved process and apparatus for forming layers of bricks in which rows within the layer can have the same or differing orientations. The bricks are conveyed in closed or substantially closed rows along a first conveyor. Two other conveyor systems are fed therefrom. On one of these two other conveyor systems, bricks are moved initially to a displacement device and spread apart in a direction longitudinally of the row and are thereafter transferred downstream to form, on a conveyor, a layer or partial layer. When partial layers are formed, that partial layer can be supplemented by transferring a layer of rows of bricks from a preparatory layer formed on the other conveyor system. When such bricks are transferred from the preparatory layer, they are simultaneously rotated through 90.degree. prior to their being deposited to complete the partial layer.

Abstract: Method and apparatus for cutting extruded split tile columns in a quick, efficient manner that reduces the possibility of damage and effectively doubles cutting speed. The apparatus cuts the moving split tile column as it moves away from the extruder and includes oppositely mounted, freely movable cutting discs which roll through and cut that split tile column when moved vertically therethrough. Cutting occurs on both up and down strokes with the cutting apparatus being moved relative to the moving column to a predetermined amount to a new cutting position after each stroke. The discs can be mounted in the same plane, arranged 90.degree. to the column's moving direction positioned so as to just touch each other or the discs can be in two separate and slightly offset planes so that the discs can overlap.

Abstract: Bricks (or other block-like articles) are automatically selectively set either "edgewise" or "flatwise" onto a platform such as a kiln car. The operational mode can be conveniently and automatically programmed to change from edge setting to flat setting and vice versa so that, for example, a hack of uncured bricks can be formed of flats (layers) alternating between edge and flat set as may be desired for subsequent curing operations in a kiln. In the flat setting mode, groups of bricks are turned by 90.degree. before they are grouped and transferred as a layer of "flat" oriented bricks for hacking. In the edge setting mode, such bricks are grouped and transferred as a layer of "edge" oriented bricks onto a hack. Special techniques are employed to facilitate changes between these two modes of operation.

Abstract: Apparatus is disclosed for individually and independently controlling the distribution of powdered solid fuel to each of a plurality of individual burners. A plurality of fuel outlet ports respectively and individually corresponding to individual ones of the plural burners are aligned with and spaced from a respectively corresponding plurality of air outlet ports. The air oulet ports are individually and controllably supplied with pressurized air while a supply of powdered solid fuel is fed into the spaces between the fuel outlet ports and the air outlet ports. In the preferred embodiment, a baffle is disposed between each pair of respectively corresponding fuel outlet and air outlet ports.

Abstract: Both method and apparatus are disclosed for controlling the distribution of powdered solid fuel to one or more burners. The powdered solid fuel is caused to pass downwardly through an air current passing from an air inlet to one or more outlet ports. The total rate at which fuel is distributed is controlled by the rate at which air is supplied to the air inlet. In addition, each outlet port is provided with an individual adjustment for controlling the relative rates at which fuel is supplied through the various individual outlet ports. The construction of the distributor is such that the system may be controlled to distribute fuel continuously or in successive controlled impulses while at the same time controlling both the total amount of distributed fuel as well as the relative amounts of fuel distributed in the various outlet lines to the burners.

Abstract: A series of moving articles (brick or slug-sized) is supplied to an accumulating apparatus adapted to engage the articles so as to slow their further movement thereby causing them to accumulate in a closed up formation. A sensor detects the accumulation of a predetermined length comprising at least one such article on the accumulating apparatus whereupon a control signal is generated causing a clamping or transfer control means to temporarily prevent further supply of the articles onto the accumulating apparatus and a further conveyor is caused to cooperate with the accumulating apparatus to transport the thus separated predetermined lengths of articles onto a push-off station. Here, the predetermined length is pushed onto other apparatus for accumulating the predetermined lengths into flats of bricks, facing those bricks into double layered flats, grouping the double layered flats, gripping and stacking them such as, for instance, in hacking freshly cut bricks for firing in a kiln.

Abstract: Method for more uniformly blending a layered stack of bricks having a central core section of lesser hardness and lighter color than in a surrounding outer shell section. The bricks are first unloaded from a hack into layers which include a corresponding core section and surrounding shell section. Thereafter, the bricks in each alternate layer are rearranged by placing bricks from the normally occurring core section areas into the normally occurring shell section areas and vice versa. Then the layers of bricks (both rearranged and unaltered) are restacked. The resulting stack will be blended such that when each "slice" of the stack is strapped into a packaged group of bricks, the resulting packaged groups will have approximately equal numbers of bricks having differing degrees of hardness and color.

Abstract: Apparatus and method for more uniformly blending a layered stack of bricks having a central core section of lesser hardness and lighter color than in a surrounding outer shell section. The bricks are first unloaded from a hack into layers which include a corresponding core section and surrounding shell section. Thereafter, the bricks in each alternate layer are rearranged by placing bricks from the normally occurring core section areas into the normally occurring shell section areas and vice versa. Then the layers of bricks (both rearranged and unaltered) are restacked. The resulting stack will be blended such that when each "slice" of the stack is strapped into a packaged group of bricks, the resulting packaged groups will have approximately equal numbers of bricks having differing degrees of hardness and color.