Method for repairing glass furnace

Abstract

The invention relates to a method for repairing a region (30) to be repaired, which extends on a lower surface (29) of a side wall (22, 26) of a housing of a glass furnace (10), the method comprises the steps of: a) installing an inner template (32) to form a mould (36) around the area to be repaired, the inner template comprising flexible textile elements (50) and reinforcing elements (52) intended to reinforce the inner template; b) filling the mould with a repair product (41) until a working configuration is reached, in which step a) the textile element is rigidly attached to the furnace and the textile element is shaped so as to exert, in the working configuration, a force (R) on the reinforcing element opposite the thrust (P) exerted by the repair product on the reinforcing element.

Description

Technical Field

[0001] This invention relates to a method for repairing glass furnaces. The invention also relates to a template for performing this method. Background Technology

[0002] [ Figure 1 A schematic half-cross-section of the glass furnace 10 is shown. The tank 12, the metal structure 14, and the superstructure 16 can be seen in particular.

[0003] The trough 12 for containing molten glass includes vertical sidewalls 22 and a base plate 24. The sidewalls 22 typically include sidewall blocks that extend to the upper edge 25 over the entire height of the trough. The base plate of the trough defines a generally horizontal bottom, while the generally vertical sidewalls surround the bottom.

[0004] The term "superstructure" 16 of a glass furnace is generally used to refer to the component that covers the furnace pool and encloses the outer shell. Superstructure 16 typically includes bricks with noses (if present), walls, and arches. Superstructure 16 does not contact the molten glass. Superstructure 16 typically includes an intermediate layer 18, sidewalls 26, and a vault 28 at its base, with the intermediate layer 18 resting on a metal structure and the sidewalls 26 resting on the intermediate layer. In a gas furnace, burners (not shown) are arranged in the sidewalls 26. The intermediate layer 18 includes noses 20 ("gap bricks"), preferably formed by noses 20 ("gap bricks").

[0005] The tank and the superstructure together form the outer shell of the furnace.

[0006] In the remainder of the specification, unless otherwise stated, the term “sidewall” refers to the sidewall 22 of the tank and / or the sidewall 26 of the superstructure. The sidewall defines the inner surface of the shell, or “inner arch” 29, and the surface opposite the inner arch, referred to as the “outer arch” 31. The sidewall typically includes not only the refractory bricks defining the inner arch, but also the insulators and / or cladding components and / or metal base structure surrounding these bricks.

[0007] The “interior” of the furnace is defined by the inner arch 29.

[0008] Molten glass, vapors, and condensates are highly corrosive. Refractory components will suffer severe erosion.

[0009] The refractory components used are typically in block or plate form, and are either molten and cast or obtained through sintering. Their selection depends on their placement to withstand localized stresses and ensure a satisfactory service life for the furnace. Selection guidelines also include avoiding defects that render the glass unusable, which would reduce production output.

[0010] To extend the lifespan of the furnace, repairs are required by the glass manufacturer.

[0011] Repairs can be performed after the glass is removed and the furnace has cooled. Then, a person can enter the furnace to perform the repairs. Alternatively, the repairs can be "hot" repairs, preferably at temperatures above 300°C, in which case a person cannot enter the furnace.

[0012] Repair involves filling the empty spaces created by furnace erosion with repair products; that is, fixing the repair products to the areas initially occupied by refractory material that have disappeared due to erosion. This area is referred to as the "area to be repaired".

[0013] The area to be repaired 30 is particularly likely due to erosion of the sidewalls 22 of the tank and / or the sidewalls 26 of the superstructure. To repair the sidewalls, it is necessary to hold the repair product in place to prevent it from flowing due to gravity. This problem is generally not present in the repair of the base plate.

[0014] The area to be repaired sometimes penetrates the furnace shell, creating fluid communication between the furnace's interior and exterior. Such penetrations, in particular, can lead to leaks of molten glass in the bath. These leaks are dangerous and can cause furnace shutdowns.

[0015] To repair a hot melt furnace, as shown in EP 0739 861, a template is typically manufactured to create a mold using one or more refractory components. This mold is capable of holding the repaired product in place until it hardens. Thus, the area to be repaired is partially defined by one or more refractory components of the furnace and partially by the template.

[0016] The template has a portion inside the furnace where erosion has occurred. When erosion results in a channel penetrating the furnace shell, the template may also include a portion outside the furnace to prevent repair products from escaping. The outer portion of the template is typically a veneer. For clarity, the terms "internal template" and "external template" refer to the portions of the template inside and outside the furnace, respectively.

[0017] [ Figure 2 An example of a conventional internal template 32i is shown. The template includes three adjacent panels 351, 352 and 353, which are held in place by metal clamps 39, wedge bricks 43 and cooling pipes 45.

[0018] "Hot" repair is a repair performed at temperatures typically above 300°C. Therefore, hot repair requires only a limited temperature reduction (called "quenching"), or even no temperature reduction at all, which significantly reduces the duration of furnace operation interruptions. However, introducing the template element into the furnace can cause it to degrade under thermal shock.

[0019] Furthermore, especially for hot repair, the interior of the furnace is not easily accessible, making it difficult to fabricate internal templates for certain areas to be repaired. In particular, introducing internal template elements may require creating channels through the furnace shell. Additionally, no operator can enter the furnace during hot repair. Therefore, sometimes the internal template must be installed at a distance from the area to be repaired. Consequently, the size and weight of the internal template elements significantly slow down the template fabrication process.

[0020] These limitations also make it very difficult to manufacture complex-shaped internal templates, especially when the area to be repaired protrudes into the furnace.

[0021] After the mold is installed, the mold is typically filled with repair product using a pump. During heat repair, the repair product experiences a sudden increase in temperature upon entering the mold, which in particular reduces its flowability. Therefore, it is difficult to fill the mold evenly.

[0022] Typically, for heat repairs, the internal template is made of metal and cooled by water circulation. Once the repaired product has hardened, the internal template must be removed, as the metal will bubble when it comes into contact with the molten glass.

[0023] After the repaired product has hardened, the template is removed to make room for the reconstructed refractory components. However, if the original shape of the metal template is complex, it often makes it impossible to reconstruct the original shape. Then, during an operation called "tempering," the temperature can be increased to restart the furnace.

[0024] EP 0739 861 B1 describes examples of methods for thermal repair glass furnaces, particularly troughs.

[0025] JP03-140793 discloses an internal template for repairing blast furnace sidewalls. The template consists of a vertical plate rigidly attached to the wall to be repaired via a horizontal bar. A bag is suspended from the bar and then filled with the repair product. The use of the bag advantageously prevents leakage into the blast furnace interior.

[0026] However, the rods must be securely fixed to the wall and pass through it. Therefore, the installation of the template takes a long time and affects the structure of the blast furnace.

[0027] These rods must also be sized to hold the board in place and must be precisely attached to the board and the wall to be repaired.

[0028] Solutions for repairing glass furnaces are still needed that address the aforementioned problems, particularly allowing for rapid furnace rebuilding without compromising the quality of the glass produced.

[0029] This invention aims to at least partially satisfy this need. Summary of the Invention

[0030] This invention relates to a method for repairing an area extending on the inner arched surface of a side wall of a glass furnace shell, the method comprising the following steps: a) Install an internal template to create a mold around the area to be repaired. The internal template includes or may even consist of flexible textile elements and reinforcing elements designed to strengthen the internal template. b) Fill the mold with the repair product until the working configuration is achieved.

[0031] According to a key aspect of the invention, in step a), the textile element is rigidly attached to the furnace, preferably outside the furnace shell, preferably on the outer arch of the sidewall, and the textile element is shaped such that, in the working configuration and during step b), a force opposite to the thrust applied to the reinforcing element by the repair product is applied to the reinforcing element.

[0032] Therefore, the textile element causes the reinforcing element to resist the thrust exerted on the repair product toward the interior of the furnace.

[0033] As will be seen in more detail in the remainder of the instruction manual, the installation of the internal template can be advantageously simplified by having the textile elements absorb at least partially, and preferably entirely, the thrust of the repair product. This is particularly useful for heat repair. It can also limit or even eliminate the use of rigid fasteners between the furnace and the reinforcing elements.

[0034] According to another key aspect of the invention, in step a), the reinforcing element and / or the textile element, preferably at least the textile element, preferably only the textile element, is rigidly attached to the surface of the inner arch of the sidewall of the furnace, which is different from the furnace shell, preferably rigidly attached to the outer arch of the sidewall of the shell.

[0035] As will be seen in more detail in the remainder of the instructions, the attachment on the outside of the inner arch prevents any damage to the inner arch during the installation of the inner formwork. Attaching on the outside of the inner arch is also much simpler to implement than attaching on the inner arch, especially during heat repair.

[0036] According to another key aspect of the invention, the textile element comprises or is composed of knitted fabric.

[0037] As will be seen in more detail in the remainder of the instruction manual, the use of knitted fabrics has proven particularly suitable for creating textile elements of complex shapes with minimal seams.

[0038] According to another key aspect of the invention, the textile element (preferably in the form of a bag) includes a portion that contacts the inner arch of the wall to be repaired in the working configuration, said portion being permeable to the repair product. As will be seen in more detail in the remainder of the specification, this permeability allows contact between the repair product and the inner arch of the wall to be repaired, and, upon curing, allows the repair product to adhere well to the inner arch of the wall to be repaired.

[0039] Preferably, the textile element is in the form of a bag having a first large surface, referred to as the "back side," that contacts the inner arched surface of the wall to be repaired in the working configuration, and the portion through which the repair product is permeable includes at least the back side.

[0040] Preferably, the bag includes a second large side, referred to as the "front side," which is opposite to the first large side and exposed to the interior of the furnace. The bag preferably includes a portion through which the repair product cannot pass, and this portion that is either through or "sealed" over the repair product includes at least the front side.

[0041] The method according to the invention may further include one or more of the following optional and preferred features: - During steps a) and b), the area to be repaired is exposed to temperatures above 300°C; - During step a), the textile element is rigidly attached to the outside of the furnace shell, preferably on the outer arch surface of the side wall; - During step b), a bag defined by a textile element is filled with the repair product, at least a portion of the bag being sealed to the repair product, the sealed portion preferably including at least one front of the bag; - The bag includes a portion through which the repair product can pass, which preferably includes at least one rear end of the bag, which extends against and in contact with the wall to be repaired in the working configuration. - The textile element defines at least one bag, and in step a), a reinforcing element (preferably in the form of a plate) is introduced into the bag or attached to the front of the bag facing the interior of the furnace, the bag may (or may not) seal the repair product; - The bag defined by the textile elements is divided into multiple compartments, and in step a), a reinforcing element (preferably in the form of a plate) is introduced into one or more of the compartments, and / or in step b), one or more of the compartments (preferably all of the compartments) are filled with a repair product, the compartments preferably being impermeable to the repair product; - The textile element is made of a material selected from ceramics, metals, organic materials and mixtures thereof, preferably ceramics; - The textile element defines at least one connector, and in step a), the connector is attached to the reinforcing element (preferably in the form of a plate), preferably to the lower end of the reinforcing element, and is arranged to extend partially outside the furnace, so that a tensile force is applied to the connector from outside the furnace to hold the reinforcing element in place; - The knitted fabric comprises the repetition of basic units, at least a portion of which are at least partially closed by at least one thread called a sealing thread. The basic unit is defined as a minimum rectangular pattern which forms 70% or more of the surface of the knitted fabric by repetition. The remaining portion of the surface of the knitted fabric may be occupied, in particular, by specific stitches common in knitted fabrics, such as increases (single or double needles), decreases (single or double needles), increases and decreases, selvedges, nets, or lockstitches. - More than 30% of the total surface area of ​​the basic unit is sealed by the at least one sealing line; - By quantity, more than 40%, preferably more than 90%, of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 30% of the total surface area of ​​the at least partially enclosed basic units; - By quantity, more than 30% of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 50%, preferably more than 70%, of the total surface area of ​​the at least partially enclosed basic units; - By quantity, more than 90% of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 70% of the total surface area of ​​the at least partially enclosed basic units; - Knitted fabrics are made of materials selected from ceramics, metals, organic materials and mixtures thereof, preferably ceramics; - The repetition of the basic unit allows more than 85%, preferably more than 97%, of the surface of the knitted fabric to be covered; - The ceramic knitted fabric accounts for more than 5% and less than 25% of the weight of the textile element; - The sealing lines are oriented parallel to each other; and / or - Sealing line, preferably each sealing line is made of a material selected from ceramics, organic products and mixtures thereof, preferably made of ceramic; - The knitted fabric includes knitting yarn containing more than 95% oxide by weight, preferably consisting of knitting yarn containing more than 95% oxide by weight; - Sealing line, preferably each sealing line contains more than 95% oxide by weight; - The reinforcing elements are made of ceramic matrix composites and / or the textile elements are made of ceramic, and the entire internal template is preferably made of ceramic; - The reinforcing element has the shape of a plate, grid, frame, or rod; - In step a), the reinforcing element is detachably attached to the textile element; - Reinforcing elements are attached to the textile elements to be positioned in a predetermined location in the working configuration; - The method includes sintering after step b) and step 5) of introducing the repaired product into the mold in step b). - The obtained sintered repair product is composed of multiple components, and the content of any component in the sintered repair product is greater than 5%. - The content of any component in the sintered repair product differs from the content of the component in the reinforcing element by less than 20%, and / or - The content of any component in the sintered repair product differs from the content of the component in the area of ​​the furnace defined as the area to be repaired by less than 20%, and / or - The content of any component in the sintered repair product differs from the content of the component in the textile element by less than 20%, and the content is expressed as a weight percentage based on oxides. - The internal template is discarded in the area to be repaired after the repair, that is, the internal template is not removed before the furnace resumes operation; - Reinforcing components: - Made of ceramic matrix composites, and / or - Includes through holes and / or recesses, said through holes and / or recesses being arranged to be filled with repair product during step b), and / or - It has the shape of a flat or non-flat plate with a thickness greater than 3 mm and less than 50 mm, preferably to form the bottom of the bag defined by textile elements; - The internal template includes multiple reinforcing elements that are arranged in a working configuration such that after the repair product hardens, the repaired wall has the same shape as it was initially (i.e. before erosion). - The internal template includes an accessory for holding the reinforcing element in the working configuration, the accessory preferably being made of ceramic matrix composite material, and when the reinforcing element is made of the same ceramic matrix composite material, the ceramic matrix composite material of the accessory may be the same as or different from that of the reinforcing element. - Ceramic matrix composites for reinforcing components and / or the accessories: - It is sintered, and / or - For more than 90% of its mass, it is composed of oxides, and / or - Contains more than 20% and less than 80% of fibers by volume, and / or - Contains fibers that contain more than 90% oxides by weight and / or are arranged in the form of textiles, and / or - Contains a matrix that comprises more than 90% oxide by weight, and / or - Contains a matrix comprising Al2O3 and / or SiO2 and / or ZrO2 and / or Cr2O3, and / or - It has a total content of SiO2 + Al2O3 + ZrO2 + Cr2O3 greater than 80% by weight percentage of oxides.

[0042] In a particularly preferred embodiment, the internal template includes: - A textile element (preferably made of ceramic material) in the form of a bag, the bag including a back, a front, two sides, and a bottom, the back extending abutting against and in contact with the wall to be repaired in the working configuration, the front exposed toward the interior of the furnace, the two sides connecting the sides of the front and back, the bag preferably including an excessive length (preferably in the form of a connector, preferably a strip), the excessive length being attached to the outside of the housing in step a); and - A single reinforcing element attached to the bag, preferably made of CMC, preferably in the form of one or more plates or one or more rods, the plates being rigidly attached to each other, preferably perforated, and the rods being rigidly attached to each other, preferably in the form of I or III (the upper and lower ends of three vertical rods are rigidly connected by horizontal upper and lower rods respectively), or - A set of reinforcing elements, attached to the bag and including: - A first reinforcing element, preferably made of CMC, preferably in the form of a plate (preferably perforated) or a mesh, is attached to the textile element to reinforce the front, and is preferably arranged in a groove defined by the textile element. - A second reinforcing element, preferably made of CMC, preferably in the form of a plate (preferably perforated) or a rod or an assembly of rods (the rod preferably in the form of an I), is attached to the textile element to reinforce the sides of the bag; or - Multiple reinforcing elements, each reinforcing element (preferably made of CMC) in the working configuration in the form of a U-shaped frame and attached to the textile element, such that the web of the U reinforces the front, and the two branches of the U reinforce the two sides respectively. The reinforcing elements in the form of a U-shaped frame are preferably horizontal and one stacked on top of the other. The web of the U-shaped frame arranged at the highest point is preferably attached to a connector, the other ends of which are attached to the sidewalls, preferably to the outside of the housing.

[0043] Of course, optional or non-optional features of the main aspects of the present invention can be combined, provided that they are technically compatible.

[0044] The present invention also relates to an internal template for implementing the method according to the invention.

[0045] The present invention also relates to a glass melting furnace comprising an internal template according to the invention and / or at least one area repaired according to the method of the invention. Attached Figure Description

[0046] Other features and advantages of the invention will also become apparent upon review of the following description and with reference to the accompanying drawings, wherein: - [ Figure 1 As described in the preface, Figure 1 The diagram schematically shows a half-cross-section of a glass furnace before erosion. - [ Figure 2 ] [ Figure 2 This illustrates an example of a standard template. - [ Figure 3 ] [ Figure 3 The method according to the present invention is illustrated schematically. - [ Figure 4 ] [ Figure 4 An example of a reinforcing element with through holes in the form of a plate is shown; - [ Figure 5 ] [ Figure 5 An example of a knitted fabric structure that can be used as a textile element is shown schematically; - [ Figure 6 ] [ Figure 6 ]Schematic illustration [ Figure 5 The knitted fabric shown in the image; - [ Figure 7 ] [ Figure 7 An example of a knitted fabric with incorporating reinforcing yarns that can be used as textile elements is shown schematically; - [ Figure 8 ] [ Figure 8 ]Schematic illustration [ Figure 7 The structure of knitted fabrics; - [ Figure 9 ] [ Figure 9 [This shows] Figure 7 A magnified view of the knitted fabric, which in particular makes it possible to describe the surfaces S1 and S2 that allow for the calculation of closure; - [ Figure 10 ] [ Figure 10 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 11 ] [ Figure 11 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 12 ] [ Figure 12 [This schematically illustrates various examples of templates according to the invention in working configurations;] - [ Figure 13 ] [ Figure 13 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 14 ] [ Figure 14 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 15 ] [ Figure 15 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 16 ] [ Figure 16 An example of a template according to the invention in a working configuration is shown schematically; - [ Figure 17 ] [ Figure 17 An example of a template according to the invention in a working configuration is shown schematically.

[0047] In different accompanying drawings, the same reference numerals are used to denote the same or similar components. Detailed Implementation

[0048] definition

[0049] The “template” is part of the “mold” into which the repair product is introduced.

[0050] This is created by assembling one or more "template elements" and positioning one or more assembled template elements. The portion of the mold defined by the template is fitted with a portion of the inner surface of the furnace and / or a portion of the inner arched surface (inner surface) of the wall, extending from the textile element to form the mold. During the filling process, the relative positions of the different template elements may change under the thrust applied by the repair product. The "working configuration" is the shape the template takes at the end of the filling.

[0051] The template element includes one, preferably multiple, reinforcing elements, and one, preferably multiple, textile elements. In addition to the template element, the template may also include "accessories" for assembling and securing the template element, and which do not come into contact with the product being repaired during the repair process. Unlike accessories, the template element is a component that comes into contact with the product being repaired during the repair process.

[0052] “Textile” is a combination of fibers (optionally yarns), especially yarns.

[0053] A "fiber" is a filament whose length is greater than five times its equivalent diameter. The "equivalent diameter" of a fiber is the diameter of a disk with the same surface area as its cross-section at its midpoint.

[0054] In textiles, fibers can be assembled in a disordered manner, such as in the form of felt or paper, or along one or more preferred directions, preferably in the form of threads, which themselves are preferably in the form of one or more fabrics. The threads of textiles can be: - "Single thread" refers to a combination of fibers that comprises more than 10 and preferably fewer than 500,000 fibers in cross-section and whose length is greater than 5 times their diameter. - "Assembled thread" is a combination of single threads, which preferably includes more than 2 and more preferably less than 500 single threads in cross-section.

[0055] Textiles can be particularly: - Organized structures of fibers and / or threads (single or combined), particularly knitted or woven fabrics, or - A random structure of fibers and / or threads (single or combined threads) and / or fibers not bonded into threads, the random structure being, for example, paper or felt, but a random structure is not preferred.

[0056] The fabrics for CMCs and textile elements are preferably organized.

[0057] “Fabric” consists of a network of parallel warp threads and weft threads that run laterally through the network.

[0058] "Knitted fabric" consists of a network of threads in the form of loops, which may be reinforced by one or more groups of threads that extend substantially parallel to each other and are driven into the loops.

[0059] A "loop yarn" is a thread that makes up all or part of the stitches in a knitted fabric. A knitted fabric can include a single loop yarn, especially when the fabric is manufactured using a weft knitting method. A knitted fabric can also include multiple loop yarns, especially when the fabric is manufactured using a warp knitting technique.

[0060] A set of sealing threads that are oriented in essentially the same direction is a set of "one-way" threads.

[0061] A "ply" consists of a set of parallel lines.

[0062] "Web" is a woven or nonwoven textile, such as knitted fabric, that defines a surface without openings through which a repair product can penetrate. Preferably, the gaps between the threads or fibers constituting the web do not form such openings, thus the web can constitute a barrier that prevents the repair product from penetrating.

[0063] A "net" is a woven or nonwoven textile, such as a knitted one, which, unlike a web, includes openings that allow the product to be repaired. The total surface area of ​​these openings may be greater than 5%, greater than 10%, greater than 30%, greater than 60%, greater than 90%, or greater than 95% of the surface area of ​​the web (that is, including the surface area of ​​the openings) defined by its perimeter.

[0064] Textiles can have the shape of a "bag". A bag defines a cavity, especially a cavity for containing one or more reinforcing elements and / or repair products. Bags can be formed, in particular, from yarn and / or net.

[0065] In textile elements, the textile is flexible, especially since it is not reinforced by a ceramic matrix. This flexibility typically allows the textile element to be folded or rolled up on itself, preferably by hand, and preferably without the use of machinery.

[0066] A "tie" is typically longer than twice its width. Ties can be, in particular, in the form of thin ropes, thick ropes, strips, or cables. In one embodiment, each tie, preferably every tie, is rigidly attached to at least one reinforcing element, particularly a plate made of CMC, during its manufacture. Thus, the tie is integrated into the reinforcing element, avoiding the need for additional fastening components. In another embodiment, the tie is combined with the reinforcing element.

[0067] The reinforcing element is rigid, preferably self-supporting, meaning it maintains its shape when operating at ambient temperature. Preferably, the shape of the reinforcing element remains substantially unchanged during the filling and repair process. Multiple reinforcing elements can be interconnected via hinges. Two components rigidly attached to each other to reinforce the internal template constitute a single reinforcing element.

[0068] Each reinforcing element is preferably made of CMC.

[0069] The term “ceramic matrix composite” or “CMC” is often used to refer to ceramics made of ceramic textiles reinforced with a ceramic matrix.

[0070] In CMC, textiles typically make up 20% to 80% of the CMC volume, with the remaining to 100% being the matrix.

[0071] Generally speaking, when referring to a volume percentage relative to an object (e.g., CMC (e.g., the percentage of fiber) or the matrix of CMC (as mentioned in the previous sentence)), the volume being considered is the volume of the object defined by its outer surface, that is, it includes the empty space inside the object.

[0072] The term "ceramic" is intended to refer to a product that is neither metallic nor organic. In the context of this invention, carbon is considered a ceramic product.

[0073] "SiAlON" is a nitrogen oxide of at least the elements Si, Al, and N, and in particular a compound that satisfies one of the following formulas: - Si x Al y O u N v ,in: - x Greater than or equal to 0, greater than 0.05, greater than 0.1, or greater than 0.2, and less than or equal to 1, less than or equal to 0.8, or less than or equal to 0.4. - y Greater than or equal to 0, or greater than 0.1, greater than 0.3, or greater than 0.5, and less than or equal to 1. - u Greater than 0, greater than 0.1, or greater than 0.2, and less than or equal to 1, or less than or equal to 0.7. - v Greater than 0, greater than 0.1, greater than 0.2, or greater than 0.5, or greater than 0.7, and less than or equal to 1. - x + y >0, x , y , u andv It is the stoichiometric index, normalized relative to the highest index, which is equal to 1. - Me x Si 12-(m+n) Al (m+n) O n N 16-n Where 0 ≤ x ≤ 2, and Me is a cation selected from lanthanides, Fe, Y, Ca, Li, and mixtures thereof, 0 ≤ m ≤ 12, 0 ≤ n ≤ 12 and 0 < n + m ≤ 12. Based on this molecular formula, SiAlON is usually called "α'-SiAlON" or "SiAlON-α'".

[0074] A "channel" is a hole that runs through the outer shell of the furnace, thus connecting the inside and outside of the furnace.

[0075] The “equivalent diameter” of a surface is the diameter of a disk that has the same area as the surface.

[0076] Dry granular mixtures are traditionally referred to as "unprocessed products".

[0077] Products “made of a certain material” or “containing a certain material” should be understood to mean products whose quality is composed of more than 95%, more than 98%, preferably substantially 100% of said material.

[0078] The term "refractory material" is used to refer to materials with a melting point above 1500°C. This definition is commonly used by those skilled in the art and is found in G. Aliprandi's "..." published in Septima Paris in 1979. Matériaux réfractaires et cé ramiques techniques The work also provides examples of refractory materials, particularly oxides, carbides, and nitrides, on pages 297 to 301.

[0079] The term "glass transition temperature" for glass should be understood as the temperature at which the glass changes from a solid state to a viscous state. The glass transition temperature can be determined using differential thermal analysis (DTA). The glass transition temperature is when the glass has a temperature substantially equal to 10°C. 12 The viscosity in Pa.s is measured at temperature. Glass is generally considered "solid" at temperatures below its glass transition temperature.

[0080] The term "thermal adhesive" is used to describe a component that has a melting point above 600°C and, upon curing under decreasing temperature, is able to bind mixed particles together.

[0081] The term "maximum size" is used to refer to the 99.5th percentile (D) of the powder. 99.5 This percentile corresponds to the 99.5% weight percentage on the cumulative particle size distribution curve of the powder particles, with particle sizes classified in ascending order. Particle size distribution and maximum size can be determined using a laser particle size analyzer. A suitable laser particle size analyzer is the Horiba Partica LA-950.

[0082] The term "impurity" is used to refer to unavoidable components that are unintentionally and necessarily introduced with the raw materials, or that arise from reactions with these components. Impurities are not necessary components, but only acceptable ones. Preferably, the amount of impurities is less than 2%, less than 1%, less than 0.5%, or even substantially zero.

[0083] Unless otherwise stated, "repair product" refers to the product before it cures. It is preferably self-cast, meaning it can diffuse under its own weight and fill the mold without causing segregation.

[0084] The term "thermally self-cast" refers to a repair product that can diffuse and fill a mold solely by its own weight without segregation within a temperature range of 300°C to 1550°C. Segregation is considered to have occurred when the cast surface of the product obtained after placing and sintering the repair product has a milky appearance extending more than 3 mm or deeper from the cast surface. This milky surface layer can be easily exposed by sawing in a plane perpendicular to the cast surface after the product has dried or sintered.

[0085] AZS products are preferred electrofused products, with their main components being alumina (Al₂O₃), zirconium oxide (ZrO₂), and silicon dioxide (SiO₂). In other words, alumina, zirconium oxide, and silicon dioxide are the components with the highest mass content. These products are ideally suited for manufacturing glass furnaces. More specifically, current AZS products are primarily used in areas that come into contact with molten glass, and also in the upper structure of glass furnaces. AZS products specifically include those sold by Saint-Gobain SEFPRO, such as ER-1681, ER-1685, or ER-1711.

[0086] When referring to ZrO2 or zirconium oxide, both ZrO2 and trace amounts of HfO2 must be included. In fact, during the melting process, small amounts of HfO2, chemically inseparable from ZrO2 and possessing similar properties, are always naturally present in the zirconium oxide source, typically at a content of less than 2%. Therefore, hafnium oxide is not considered an impurity. The HfO2 content in AZS particles is preferably less than 5%, less than 3%, and less than 2%.

[0087] Unless otherwise stated, all percentages are based on weight percentages of oxides. The mass content of elements is expressed in the form of the most stable oxide.

[0088] If, in a working configuration, any translation of the reinforcing element exceeding 20 cm, other than vertical upward movement, cannot be accomplished without displacement or deformation of the textile element, then the reinforcing element is "attached" to the textile element, and vice versa. Fixation can be rigid, in which case movement of the reinforcing element cannot be achieved without movement or deformation of the textile element. For example, if the reinforcing element is placed within a shell defined by the textile element, then the fixation can be non-rigid.

[0089] The attachment of the textile element to the furnace is rigid because there is at least one contact point between the textile element and the furnace at which they are rigidly fixed relative to each other. Examples of rigid fasteners include adhesive bonding, attachment by means of knotting, or fasteners wrapped around pins or bars, particularly for securing textile elements to the furnace.

[0090] Preferably, the textile element is rigidly attached to the reinforcing element by at least two points, preferably at least three points, which may be aligned or misaligned.

[0091] Unless otherwise stated, attachment may be rigid or non-rigid. Attachment between two parts may be direct, meaning the two parts are in contact with each other in the attachment area, or attachment between two parts may be indirect.

[0092] "Including", "containing", or "having" should be interpreted in a non-restrictive manner.

[0093] Detailed description

[0094] A template is used, in a working configuration, to fill with repair products to repair the walls of a glassmaking furnace, particularly the sidewalls of the furnace's trough. The template comprises flexible textile elements and reinforcing elements for shaping the repair products.

[0095] Textile components

[0096] Flexible textile elements are deformable. Therefore, they are advantageously facilitated in the furnace, for example, in a wound form, and then deformed to achieve the desired shape. The deformability of the textile elements also facilitates their transport. Reinforcing elements form a frame, which preferably works in conjunction with the textile elements, so that the repair product takes on the desired shape in the working configuration.

[0097] According to a key aspect of the invention, the inner template is configured such that, in the working configuration of the inner template, the textile element is rigidly attached to the furnace, preferably to the wall to be repaired, and in contact with the reinforcing element to at least partially, preferably completely, absorb the thrust exerted on the inner template by the repair product. In other words, the textile element attached to the furnace can resist the force exerted on the reinforcing element by the repair product. The textile element participates in holding the reinforcing element in place.

[0098] Advantageously, the textile element limits, or even eliminates, the need for specific fasteners (such as metal rods) to secure the reinforcing element relative to the wall to be repaired. This facilitates the installation of the internal template.

[0099] Preferably, the reinforcing element is held in the working configuration without being rigidly attached to the furnace, particularly the wall to be repaired. In particular, the reinforcing element may be held in the working configuration by means of only one or more textile elements.

[0100] Preferably, the textile element is attached to the wall to be repaired (i.e., the sidewall of the casing), preferably directly, without using intermediate components (i.e., the textile element contacts the wall to be repaired in the attachment area). Using textile elements provides a variety of possibilities for attaching the internal template to the wall to be repaired. In particular, the flexibility of the textile element allows for easy positioning, especially in easily accessible areas, without damaging the inner arched surface of the wall to be repaired.

[0101] Attaching reinforcing elements to the textile element allows the textile element to participate in the positioning of the reinforcing element when the textile element is in the working configuration and preferably rigidly attached to the wall to be repaired. Preferably, the rigid or non-rigid fixation of the reinforcing element to the textile element is adjusted such that when the textile element is in the working configuration, the reinforcing element, preferably each reinforcing element, has a predetermined position. This greatly simplifies the installation of the internal template, which is particularly advantageous for heat repair.

[0102] Preferably, the textile element is attached to the wall to be repaired and holds the reinforcing element in place before the repair product is filled into the internal template. Preferably, the textile element is configured to resist the thrust exerted on the reinforcing element by the repair product during the filling process.

[0103] Preferably, the textile element is shaped to hold the repaired product, and in particular to prevent the repaired product from leaking into the furnace.

[0104] According to a key aspect of the invention, the textile element is shaped to partially extend outside the outer casing in a working configuration. The portion of the textile element outside the interior space of the furnace, or the "excess length," can be used to retain the textile element against forces applied by the repair product.

[0105] This embodiment is particularly advantageous when the textile element has, at least partially, the shape of a bag (which defines an upper opening for introducing the repair product into the bag). When laid flat, the length of the bag can be greater than the height of the wall to be repaired.

[0106] The excessive length can extend across all or part of the width of the textile element, particularly across all or part of the width of the bag (the dimension of the open side of the bag, which, in the working configuration, is supported on the wall to be repaired). The excessive length is preferably in the form of one or more connectors, preferably in the form of a strip. The excessive length preferably has a length greater than 40 cm, greater than 70 cm, greater than 100 cm, and / or less than 500 cm, and / or a width greater than 1 cm, preferably greater than 3 cm, and / or less than 30 cm, preferably less than 20 cm, preferably less than 10 cm. This simplifies the attachment operation after the excessive length has left the furnace shell.

[0107] The textile element includes one or more excessively long portions, preferably in the form of a connector, preferably in the form of a strip, preferably more than 2 and / or less than 100, preferably less than 50, preferably less than 10 excessively long portions.

[0108] By any channel created for this purpose, or preferably a pre-existing channel, preferably through a vent, especially a burner vent, or through an observation block set up for observing the interior of the furnace during operation, the excessively long portion may pass through the side wall, preferably outside the area to be repaired.

[0109] The connector, preferably the strap, can extend to a height below the bag opening in the working configuration. This allows for a favorable reduction in the bag's weight and size.

[0110] However, preferably, the connectors and preferred strips do not extend to the bottom of the bag, that is, on one side of the wall to be repaired, the bag is raised, preferably by more than 20 cm, which limits the risk of the repair product leaking through the bottom of the bag.

[0111] The textile element preferably defines the bag, and is preferably in the following shape: - Bags, preferably bags having a generally parallelepiped shape in a working configuration, and / or sails and / or nets, or - Strip.

[0112] In one embodiment, the textile element defines several bags, each bag for containing a respective reinforcing element, preferably in the form of a plate.

[0113] Preferably, when the template is filled with the repair product, the textile element is sealed by the repair product. Preferably, the textile element is a tulle, at least a portion of which is sealed by the repair product and shaped to form an interface between the furnace interior and the repair product at the end of the filling process in the working configuration.

[0114] The sealing portion covers more than 1%, more than 10%, more than 30%, more than 50%, more than 70%, more than 90%, or even 100% of the portion of the inner template that is in contact with the interior of the furnace in the working configuration.

[0115] The textile element is preferably made of a material selected from ceramics, metals, organic materials, and mixtures thereof. Preferably, the textile element is made of ceramic, especially for heat repair.

[0116] Preferably, the textile element is made of a material containing more than 95%, preferably more than 97%, more than 98%, more than 99%, and more than 99.5% oxide by weight. The textile element is preferably made of a material that can withstand temperatures above 800°C, preferably above 1000°C, preferably made of ceramic material, and more preferably made of alumina and / or silica and / or E-glass.

[0117] The textile element is preferably made of fibrous material.

[0118] Textile components can be woven or nonwoven.

[0119] Knitted fabrics

[0120] According to a key aspect of the invention, the textile element is at least partially, preferably entirely, made of knitted fabric.

[0121] Knitting allows for the creation of various shapes without the need for stitching. This results in better control over the absorption of forces applied to the repair product, while reducing manufacturing costs.

[0122] Knitted fabrics are preferably made of materials selected from ceramics, metals, organic materials, and mixtures thereof. Preferably, knitted fabrics are made of ceramics, especially for heat repair. Otherwise, knitted fabrics may be made of metals or organic materials.

[0123] Knitted fabrics consist of repetitions of basic units, at least a portion of which is preferably at least partially enclosed by at least one thread called a sealing thread. A basic unit is defined as a minimum rectangular pattern that forms 70% or more of the surface of the knitted fabric through repetition.

[0124] The inventors have discovered that knitted fabrics in which the basic unit is at least partially enclosed by at least one thread called a sealing thread are particularly suitable for the present invention. In particular, this prevents the knitted fabric from penetrating the repair product.

[0125] Preferably, by quantity, more than 40%, more than 50%, more than 60%, more than 70%, more than 80%, more than 90%, more than 95%, and more than 100% of the basic units of the knitted fabric are at least partially sealed by sealing lines, more preferably by a set of sealing lines, and more preferably by unidirectional sealing lines.

[0126] Preferably, the sealing line or all of the sealing lines together enclose more than 30% of the total surface area of ​​the at least partially enclosed basic unit.

[0127] In particular, the sealing line or all of the sealing lines preferably together enclose more than 40%, more than 50%, more than 60%, more than 70%, and more than 80% of the total surface area of ​​the at least partially enclosed basic unit.

[0128] Preferably, by quantity, more than 40%, preferably more than 50%, preferably more than 60%, preferably more than 70%, preferably more than 80%, preferably more than 90%, preferably more than 95%, preferably substantially 100% of the knitted fabric basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, preferably by unidirectional sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 30%, preferably more than 40%, preferably more than 50%, preferably more than 60%, preferably more than 70%, preferably more than 80% of the total surface area of ​​the at least partially enclosed basic units.

[0129] Ceramic knitted fabrics preferably include mesh threads selected from the following: - One or more coil wires comprising, by weight, more than 95%, preferably more than 97%, more than 98%, more than 99%, more than 99.5% oxide. - One or more coil wires comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, and preferably more than 99.5% carbide by weight. - One or more coil wires containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% boride by weight. - One or more coil wires comprising, by weight, greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, preferably greater than 99.5% nitride. - One or more coil wires containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% carbon by weight. - and the mixture of the coil wires.

[0130] Ceramic knitted fabrics include, preferably, a selection of, loop yarns from the following: one or more loop yarns containing, by weight, more than 95%, more preferably more than 97%, more preferably more than 98%, more preferably more than 99%, more preferably more than 99.5% oxide.

[0131] Preferably, the coil wire comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, and preferably more than 99.5% by weight of oxide is selected from: - One or more such lines: comprising more than 95%, preferably more than 97%, more preferably more than 98%, more preferably more than 99%, more preferably more than 99.5% oxides by weight, and having the following chemical analysis: by weight percentage, SiO2 + Al2O3 + ZrO2 > 50%, preferably SiO2 + Al2O3 + ZrO2 > 60%, or even SiO2 + Al2O3 + ZrO2 > 70%, even SiO2 + Al2O3 + ZrO2 > 80%, even SiO2 + Al2O3 + ZrO2 > 90%, - One or more such lines: comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% by weight of oxides, and having a chemical analysis showing that, by weight percentage, SiO2 > 70%, preferably SiO2 > 80%, preferably SiO2 > 90%, or even SiO2 > 99%, - One or more such lines: comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% by weight of oxides, and having the following chemical analysis: by weight percentage, Al2O3 > 65%, preferably Al2O3 > 70%, or even Al2O3 > 80%, or even Al2O3 > 90%, or even Al2O3 > 95%, - and its mixtures.

[0132] More preferably, at least a portion, preferably, of the one or more coil wires are: - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% alumina by weight, and / or - One or more such lines: comprising more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably comprising more than 95%, preferably more than 98% amorphous silica, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% mullite by weight, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% mullite and corundum by weight, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% glass by weight, preferably washed glass.

[0133] Preferably, the one or more coil wires comprising more than 95%, preferably more than 97%, more than 98%, more than 99%, and more than 99.5% carbide by weight are: - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, and preferably substantially 100% silicon carbide by weight. - One or more such wires: which contain more than 95%, preferably more than 98%, preferably more than 99%, and preferably substantially 100% boron carbide by weight. - and its mixtures.

[0134] Preferably, the one or more coil wires comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% by weight of nitride are one or more such wires comprising more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silicon nitride by weight of silicon nitride.

[0135] Preferably, the mass per unit length of the one or more coil wires is greater than 20 g / km, more preferably greater than 25 g / km, more preferably greater than 30 g / km, and more preferably less than 300 g / km, more preferably less than 250 g / km, and more preferably less than 200 g / km. The mass per unit length expressed in g / km is usually referred to as "tex".

[0136] Preferably, the basis weight of the knitted fabric is greater than 50 g / m². 2 Preferably greater than 100 g / m 2 And preferably less than 300 g / m 2 Preferably less than 200 g / m 2 .

[0137] Preferably, the row density of the knitted fabric is 2 to 5 rows per centimeter, and the column density is 1 to 3 columns per centimeter.

[0138] Preferably, the repetition of the basic unit can cover more than 80%, preferably more than 85%, preferably more than 90%, preferably more than 92%, preferably more than 94%, preferably more than 95%, preferably more than 97%, preferably more than 99% of the surface of the knitted fabric, with the remaining portion occupied by specific stitches common in knitted fabrics, such as increases (single or double needles), decreases (single or double needles), increases and decreases, selvedges, nets, or lockstitches.

[0139] The knitted fabrics are preferably selected from plain knit fabrics, double rib knit fabrics, bubble knit fabrics, rib knit fabrics, English rib knit fabrics, 1x1 rib knit fabrics, satin knit fabrics and Chamius crepe satin knit fabrics.

[0140] Textile elements may include several different knitted fabrics connected together, that is, having different basic units, and the knitted fabrics may in particular be selected from the list above.

[0141] Sealing thread

[0142] Preferably, the sealing line, and more preferably each sealing line is a single line or a combination of lines.

[0143] The sealing line can be a force line, a floating line, or a one-way line, with a one-way line being preferred.

[0144] Preferably, the sealing line, and more preferably each sealing line is a unidirectional line.

[0145] Preferably, the sealing wires are different from the coil wires.

[0146] Preferably, the mass per unit length of the sealing line is greater than 100 tex, more preferably greater than 300 tex, more preferably greater than 500 tex, more preferably greater than 600 tex, and more preferably less than 3000 tex, more preferably less than 2000 tex, and more preferably less than 1500 tex.

[0147] Preferably, the sealing thread, preferably each sealing thread, is inserted into the loop of the closed basic unit of the knitted fabric, preferably by deposition and fixation in the loop, rather than being carried by the loop.

[0148] The number of sealing lines enclosing the basic unit depends on the surface area of ​​the basic unit and the mass per unit length of the sealing line. Preferably, the sealing lines are oriented parallel to each other, and more preferably oriented in the direction of the row or column of the stitches.

[0149] In one embodiment, the sealing thread, preferably each sealing thread, is made of the same material as the loop thread of the knitted fabric.

[0150] In one embodiment, the sealing thread, preferably each sealing thread, is made of a material different from the material of the loop yarn of the knitted fabric.

[0151] The sealing line, preferably each sealing line, is made of a material selected from ceramics (especially for heat repair), metal products, organic products, and mixtures thereof. Preferably, the sealing line, preferably each sealing line, is made of ceramic material.

[0152] In a preferred embodiment, the sealing line, preferably each sealing line, is selected from: - Lines containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, and preferably more than 99.5% oxides by weight. - Lines containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, and preferably more than 99.5% carbides by weight. - Lines containing greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, and preferably greater than 99.5% by weight of borides. - Lines containing nitrides of greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, and preferably greater than 99.5% by weight. - Lines containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% carbon by weight. - and the mixture of the lines.

[0153] Preferably, each sealing line contains more than 95%, more preferably more than 97%, more preferably more than 98%, more preferably more than 99%, more preferably more than 99.5% oxide by weight.

[0154] Preferably, the sealing line contains more than 95%, preferably more than 97%, more than 98%, more than 99%, and more than 99.5% oxide by weight; preferably, each sealing line is: - A line comprising, by weight, greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, preferably greater than 99.5% of oxides, and having the following chemical analysis: by weight percentage, SiO2 + Al2O3 + ZrO2 > 50%, preferably SiO2 + Al2O3 + ZrO2 > 60%, or even SiO2 + Al2O3 + ZrO2 > 70%, and also having the following chemical analysis: SiO2 + Al2O3 + ZrO2 > 80%, or SiO2 + Al2O3 + ZrO2 > 90%, and / or - A line comprising, by weight, greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, preferably greater than 99.5% of oxides, and having the following chemical analysis: by weight percentage, SiO2 > 70%, preferably SiO2 > 80%, preferably SiO2 > 90%, or even SiO2 > 99%, and / or - A line comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% by weight of oxides, and having a chemical analysis of Al2O3 > 65%, preferably Al2O3 > 70%, or even Al2O3 > 80%, or even Al2O3 > 90%, or even Al2O3 > 95% by weight percentage.

[0155] More preferably, at least a portion, preferably, of the one or more sealing lines are: - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% alumina by weight, and / or - One or more such lines: comprising more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably comprising more than 95%, preferably more than 98% amorphous silica, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% mullite by weight, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% mullite and corundum by weight, and / or - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% glass by weight, preferably washed glass.

[0156] Preferably, the sealing line comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, and preferably more than 99.5% by weight of carbide is: - One or more such lines: which contain more than 95%, preferably more than 98%, preferably more than 99%, and preferably substantially 100% silicon carbide by weight. - One or more such wires: which contain more than 95%, preferably more than 98%, preferably more than 99%, and preferably substantially 100% boron carbide by weight. - and its mixtures.

[0157] Preferably, the one or more sealing lines comprising more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% by weight of nitride are one or more such lines comprising more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silicon nitride by weight of silicon nitride.

[0158] In a first preferred embodiment, one or more loops of the knitted fabric are made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% oxide by weight, and the sealing thread, preferably each sealing thread, is made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% oxide by weight.

[0159] Preferably, in this first embodiment: - One or more loops of the knitted fabric contain more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably more than 95%, preferably more than 98% amorphous silica, and the sealing thread, preferably each sealing thread, contains more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% amorphous silica; - One or more loops of the knitted fabric contain more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% amorphous silica by weight, and the sealing thread, preferably each sealing thread, contains more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% glass by weight, preferably washed glass; - One or more loops of the knitted fabric contain more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% amorphous silica by weight, and the sealing thread, preferably each sealing thread, contains more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% alumina by weight. - One or more loops of the knitted fabric contain more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, preferably more than 95%, preferably more than 98% amorphous silica, and the sealing thread, preferably each sealing thread, contains more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% mullite by weight.

[0160] In the second embodiment, one or more loops of the knitted fabric are made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% silicon carbide by weight, and the sealing thread, preferably each sealing thread, is made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% silicon carbide by weight.

[0161] Preferably, in this second embodiment, one or more loops of the knitted fabric contain more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silicon nitride by weight, and the sealing thread, preferably each sealing thread, contains more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silicon nitride by weight.

[0162] In a third embodiment, one or more loops of the knitted fabric are made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% oxide by weight, and the sealing thread, preferably each sealing thread, is made of a material containing more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, preferably more than 99.5% carbide by weight.

[0163] Preferably, in this third embodiment, one or more loops of the knitted fabric contain more than 90%, preferably more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silica by weight, and preferably more than 90%, preferably more than 95%, preferably more than 98% amorphous silica, and the sealing thread, preferably each sealing thread, contains more than 95%, preferably more than 98%, preferably more than 99%, preferably substantially 100% silicon carbide by weight.

[0164] Knitted textile elements can be manufactured according to techniques known in the prior art. In particular, it can be manufactured by simultaneously knitting multiple loops and / or multiple sealing threads. The stitches of the knitted fabric can therefore be formed by multiple loops. Alternatively, multiple sealing threads can be introduced into the knitted fabric. All combinations are possible, such as multiple loops with a single sealing thread, multiple sealing threads with a single loop, or multiple loops with multiple sealing threads.

[0165] Preferably, the textile element comprises multiple layers of knitted fabric, preferably consisting of multiple layers of knitted fabric, wherein at least one layer of knitted fabric is a knitted fabric containing a sealing line, and the above features may optionally be applied to the knitted fabric.

[0166] When a textile element comprises or is composed of multiple knitted fabrics, a set of sealing threads is preferably a set of unidirectional threads, preferably arranged in layers.

[0167] In one embodiment, the textile element is made using a plurality of bags inserted into each other. Preferably, each bag is made of knitted fabric. Preferably, each bag includes a set of sealing threads, preferably unidirectional threads, more preferably unidirectional threads in different directions from one bag to another, and preferably unidirectional threads in a 90° direction from one bag to another.

[0168] Introducing at least one sealing thread into the basic unit of a knitted fabric can be advantageously done using a conventional knitting machine.

[0169] Reinforcing elements

[0170] The reinforcing elements are preferably selected from solid plates or perforated plates, closed frames, such as rectangular frames, preferably open frames, preferably L-shaped or U-shaped frames, and rods.

[0171] Preferably, the template includes reinforcing elements, such as reinforcing elements in the form of rods, which preferably extend substantially in a vertical plane in the working configuration, preferably not along the edges of the template to avoid forming sharp edges, and preferably extend over the entire height of the template. The ends of the vertical rods may be rigidly attached to the ends of the horizontal rods to define the reinforcing elements in the form of one or more frames, preferably open frames, or even cages.

[0172] In one embodiment, at least one reinforcing element, or even each reinforcing element, extends substantially horizontally in the working configuration, preferably substantially parallel or perpendicular to the wall to be repaired. Such reinforcing elements extending perpendicularly to the wall to be repaired can be used in particular to separate at least a portion of the textile element from the wall to be repaired, for example, to provide an opening for introducing the repair product.

[0173] Preferably, the reinforcing element has a flat or non-flat shape, preferably a flat plate of the template, with a plate thickness greater than 3 mm, preferably greater than 8 mm and / or less than 50 mm, preferably less than 40 mm, preferably less than 30 mm, preferably less than 20 mm, and preferably less than 15 mm.

[0174] In a preferred embodiment, the area of ​​the template plate is greater than 500 cm². 2 and / or less than 1 m 2 .

[0175] The template plate can be a plate that is substantially parallel to the wall to be repaired in the furnace, or a plate that is perpendicular to the wall to be repaired in the furnace, especially at the end of the area to be repaired.

[0176] The template is preferably attached to the bag, yarn, or net of the textile element, preferably rigidly attached.

[0177] In one embodiment, at least one connector, preferably a strip, preferably multiple connectors, preferably multiple strips, made of textile, is fixed to a reinforcing element (e.g., a plate or frame of a template, preferably an open frame), preferably by adhesive bonding or by integrating it into the reinforcing element during its manufacture, particularly when the reinforcing element is made of CMC. For example, at least two connectors, preferably two strips, are attachable to the top of the template plate, and at least two connectors, preferably two strips, are attachable to the bottom of the template plate. Connectors, preferably strips, are attachable to the outside of the housing for holding the reinforcing element in place, particularly for holding the template plate.

[0178] In one embodiment, the template plate is attached inside the bag.

[0179] In a preferred embodiment, the template plate is disposed inside the bag without being rigidly attached to the textile elements. Preferably, the shape of the bag is substantially the same as the shape of the template plate, which allows the template plate to be effectively secured. The bag can be replaced in a substantially equivalent manner by a strip at least partially surrounding the template plate.

[0180] Specifically, one or more template panels can be fixed to bags, canvas, netting, or one or more strips. The resulting assembly can be deformed to facilitate its introduction into the furnace, where it is then unfolded to achieve a working configuration. The textile elements restrict the relative positions of the template panels to each other, which greatly facilitates unfolding.

[0181] A similar result can be achieved by equipping the textile element with a component for hooking the template, for example by providing the textile element with multiple bags, each bag for holding its own template plate.

[0182] The internal template preferably includes a "bottom" reinforcing element, which is substantially parallel to the furnace bottom in the working configuration and preferably configured to impose a predefined shape of reinforcing element on the lower part of the template in the working configuration.

[0183] The bottom reinforcing element preferably has the shape of a plate, frame, or rod, with the shape of a rod being preferred, especially when the textile element is a sail.

[0184] The bottom reinforcing element is preferably resting against the furnace bottom in the working configuration. Advantageously, the bottom reinforcing element helps to position the template relative to the wall to be repaired. The bottom reinforcing element is preferably attached to or placed on the bottom of a bag or sleeve defined by a textile element, preferably on the bottom of a bag defined by a textile element.

[0185] In one embodiment, at least one reinforcing element, or even each reinforcing element, extends parallel to the wall to be repaired in the working configuration, preferably horizontally or vertically.

[0186] In one embodiment, at least one reinforcing element, preferably a bottom reinforcing element, includes a through hole and / or a groove, such as […]. Figure 4 As shown in the diagram. During step b), filling these holes and grooves with the repair product facilitates better template fixation, reduces the temperature gradient of the repair product during the sintering step, and facilitates manipulation of the reinforcing element by reducing its mass. Preferably, the average equivalent diameter of these holes is greater than 8 mm and more preferably less than 350 mm, and even more preferably less than 300 mm.

[0187] In one embodiment, the reinforcing element is in the form of a mesh, with holes preferably evenly distributed, and the total surface area of ​​the holes accounts for more than 10%, preferably more than 15%, and preferably less than 80%, and preferably less than 70% of the surface area of ​​the reinforcing element defined by its perimeter (i.e., the surface of the mold that participates in defining the area around the area to be repaired (the surface area of ​​the holes and the surface area of ​​the mesh material)).

[0188] The provision of through-holes and / or grooves can be achieved by any technique known to those skilled in the art. In particular, through-holes can be formed by drilling or waterjet cutting, for example on ceramics, preferably ceramics in the form of CMC obtained after sintering. In CMCs, through-holes and / or grooves can also be formed on textiles (preferably woven fabrics) and then coated with a slurry.

[0189] The reinforcing element is preferably attached to the textile element so as to have limited mobility or even remain in place relative to the textile element during the introduction of the template into the furnace and / or during the filling of the template.

[0190] The reinforcing element may be attached to the textile element, preferably sewn, and preferably with holes provided in the reinforcing element for this purpose; or the reinforcing element may be bonded to the textile element, integrated into the textile element, particularly when the reinforcing element is made of CMC; or the reinforcing element may be covered by the textile element, for example, placed in a sleeve or bag defined by the textile element; or the reinforcing element may be inserted into the thickness of the textile element. Fixation may be provided through one or more fixing points, preferably at least three fixing points, and / or through one or more fixing lines, or even through a fixing surface, for example having a diameter greater than 5 cm. 2 The fixed surface area.

[0191] Preferably, the reinforcing element is detachable, meaning it can be removed from the textile element without damaging the template, such as the adhesive dots or stitching. Preferably, the reinforcing element can be removed by hand, preferably without tools, and preferably reversibly.

[0192] The detachable design allows for adjustable formwork. The template can be easily adapted, especially to the area of ​​the wall to be repaired.

[0193] The template preferably includes multiple reinforcing elements, such as reinforcing elements in the form of rods or frames, preferably arranged at fixed intervals, preferably arranged substantially horizontally at the height of the template, for example, spaced more than 10 cm and / or less than 50 cm, preferably less than 40 cm apart. The textile elements preferably include bags to which the reinforcing elements are attached. The rods can form reinforcing elements in the form of frames, preferably open, or form a mesh that is combined with textile elements forming the interface between the interior of the furnace (i.e., the space defined by the furnace shell) and the repair product, such as a mesh in the form of yarn, so as to achieve the board function of a conventional template (holding the repair product by imposing a predefined surface (e.g., a basic plane) on the repair product), while providing great flexibility when installed in the working configuration.

[0194] The reinforcing element is preferably made of a material that can withstand temperatures above 1000°C, and more preferably a material that can withstand temperatures above 1200°C.

[0195] The reinforcing element is preferably made of ceramic, preferably made of oxide, and preferably, the total content of SiO2+Al2O3+ZrO2+Cr2O3 is greater than 80%, preferably greater than 90%, and more preferably greater than 95% based on the weight percentage of the oxide.

[0196] CMC

[0197] The reinforcing elements are preferably made of ceramic matrix composites (CMC). Using ceramic reinforcing elements (especially in the form of CMC) advantageously allows for the manufacture of templates that do not require cooling. Therefore, the template can be lighter (especially if manufactured using thin sheets). Furthermore, due to the absence of cooling, the installation of such internal templates is very fast.

[0198] Furthermore, ceramics, especially those in the form of CMC, do not substantially alter the quality of the manufactured glass when in contact with molten glass or corrosive vapors present in the furnace, thus eliminating the need to remove the internal mold at the end of the repair. This advantageously allows for particularly rapid reuse of the furnace without affecting the quality of the glass, especially the number of defects within it.

[0199] Finally, the internal template can have complex shapes.

[0200] In addition, ceramics, especially CMC-type ceramics: - Its light weight makes it easier to handle. - It easily adapts to complex geometries, allowing for precise adaptation to the construction of the area to be repaired.

[0201] In addition, CMC is well-suited to withstand thermal shock, which allows for thermal repair without causing the reinforcing elements to degrade when introduced into the furnace.

[0202] CMC manufacturing can be carried out by any conventional method, especially including the following steps: i) Applying a slurry to or within textiles that can form a ceramic matrix after consolidation; ii) Shape the textile before or after step i); iii) Preferably by drying and / or sintering, more preferably by sintering, the preform obtained after the foregoing steps is solidified to form the matrix and obtain CMC.

[0203] In step i), the textiles may specifically take the form of: sheets (e.g., sheets consisting of threads that extend substantially parallel to each other (the threads are referred to as “unidirectional threads”), knitted fabrics, woven fabrics (i.e., woven textiles), or stacks of one or more sheets and / or knitted fabrics and / or woven fabrics.

[0204] The textiles preferably take the form of felt, or woven fabric, or sheet, or a stack of one or more felts and / or one or more sheets and / or one or more woven fabrics. The stacking of woven fabrics and / or sheets can be carried out in such a way that the threads of the various woven fabrics or sheets extend substantially in the same direction, or in two, three, four, five or six different directions, depending particularly on the desired mechanical properties.

[0205] Preferably, at least a portion, preferably all, of the fibers in the textile, optionally combined in the form of single and / or combined yarns, are made of ceramic fibers, preferably containing more than 95%, more than 97%, more than 98%, more than 99%, more than 99.5% oxide by weight.

[0206] Preferably, all fibers have the same composition.

[0207] The sizing agent can be applied to or into the textile, for example, by impregnation. The stacking can be carried out by pressing or under vacuum, preferably after impregnation.

[0208] The manufacture of slurries is well known to those skilled in the art. Slurries are typically suspensions, such as water-based or organic solvent suspensions, which contain: - Ceramic particles and / or ceramic particle precursors (i.e., compounds that transform into ceramic particles during CMC manufacturing, particularly during curing and especially during sintering), and - Optional dispersants, plasticizers, lubricants and / or temporary binders.

[0209] The composition of the slurry, the size distribution of the ceramic particles or ceramic precursors, and the mineral fillers in the slurry are all adapted to the type of fiber and the molding technology. For example, the slurry can be applied to or into textiles by soaking, injection, infiltration, or deposition at ambient temperature or higher, at atmospheric pressure or higher, particularly by direct lamination.

[0210] Preferably, the ceramic particles are particles containing more than 95%, preferably more than 97%, more preferably more than 98%, more preferably more than 99%, more preferably more than 99.5% by mass of oxides.

[0211] In step ii), the obtained textile is shaped, preferably by impregnation with a sizing agent. The desired shape is preferably the final shape of the CMC. However, in one embodiment, the shape can be modified after the matrix has hardened, for example by machining or deformation.

[0212] In step iii), consolidation is preferably carried out by sintering.

[0213] Those skilled in the art know how to adjust the parameters of the selected method for manufacturing CMC, particularly how to determine the particle size of the raw materials, the water content during the molding process, and the sintering temperature (if the ceramic is sintered).

[0214] Preferably, the reinforcing element is made of ceramic. - The ceramic, preferably in the form of CMC, is sintered; and / or - The ceramic, preferably in the form of CMC, is composed of oxides for more than 90%, more than 95%, more than 98%, more than 99%, and more than 99.5% of its weight. This advantageously improves the compatibility of the ceramic (especially in the form of CMC) with molten glass during normal furnace operation.

[0215] Preferably, in the ceramic (preferably in the form of CMC), the total content of SiO2+Al2O3+ZrO2+Cr2O3, based on the weight percentage of oxides, is preferably greater than 80%, preferably greater than 90%, and preferably greater than 95%.

[0216] More preferably, - The CMC comprises more than 20% and less than 80% by volume fibers, with the remainder consisting of a matrix, and / or - The fibers of the CMC contain more than 90%, preferably more than 99%, preferably 100% oxides by weight, preferably composed of oxides, and / or - The fibers of the CMC are arranged in the form of textiles (preferably fabrics), and / or - The matrix of the CMC contains more than 90%, preferably more than 99%, preferably 100% oxide by weight, and / or - The matrix of the CMC contains Al2O3 and / or SiO2 and / or ZrO2 and / or Cr2O3, and / or - In the matrix of the CMC, the total content of SiO2+Al2O3+ZrO2+Cr2O3, based on the weight percentage of oxides, is preferably greater than 80%, preferably greater than 90%, and preferably greater than 95%.

[0217] appendix

[0218] In addition to textile elements and reinforcing elements, the internal template may also include accessories, preferably fastening elements for securing the textile elements to the furnace.

[0219] The template may include attachments made of ceramic (preferably CMC ceramic), and the template elements and attachments are preferably not cooled, in particular not by water cooling.

[0220] Hot Repair

[0221] [ Figure 3 The method according to the invention shown in the figure is preferably used for thermal repair of glass furnace areas.

[0222] In one embodiment, particularly for repairing a tank that initially contained a bath of molten glass in contact with the area to be repaired, the repair method includes the following steps: 1) If the area to be repaired is at least partially defined by the surface of the furnace pool in contact with the molten glass bath, then at least partially the molten glass is discharged from the pool to expose the area to be repaired; 2) Optionally, but preferably, the area to be repaired is rinsed to remove glass residue; 3) Reduce the temperature inside the furnace to above 300°C, preferably above 400°C, preferably above 500°C, preferably above 600°C, preferably above 700°C, preferably above 800°C, preferably above 900°C and preferably below 1500°C, or even below 1450°C or 1400°C. 4) The method of the present invention is further characterized by the following steps: placing the repair product according to steps a) and b); 5) Raise and maintain the furnace temperature between 900°C and 1400°C to sinter the repaired product; 6) The present invention relates to introducing a glass composition to be melted into a bath and raising the temperature of the furnace to an operating temperature that causes the composition to melt.

[0223] In one embodiment, the repair product used in step b) comprises a thermal adhesive, and in step 3), the temperature inside the furnace is reduced to a temperature at which the thermal adhesive is not in a solid state. Specifically, when the thermal adhesive is glass, the temperature inside the furnace is reduced to a temperature still above the glass transition temperature of the glass. The glass is preferably selected to have a glass transition temperature between 600°C and 1350°C, more preferably between 900°C and 1350°C, more preferably between 1000°C and 1300°C, and more preferably between 1150°C and 1250°C.

[0224] In step 4), the template is installed by assembling the template components.

[0225] In step a), the installation of the internal template is difficult due to its inaccessibility.

[0226] Flexible textile elements can be advantageously deformable in order to facilitate their introduction into the furnace.

[0227] Optionally, standard attachments can be used to reinforce the template elements and keep them in the working configuration.

[0228] In step b), the mold defining the area to be repaired is filled with the repair product, preferably by casting.

[0229] Repair products

[0230] The repair product can be a conventional repair product and can be prepared using any known technology.

[0231] Preferably, the repair product is the result of wetting an unshaped product. The wetting can be performed using any known technique, such as in a mixer. Those skilled in the art know how to determine the amount of solvent (preferably water) used to wet the unshaped product and obtain the repair product.

[0232] Unfinished products can be particularly: - Repairing thermal coatings AZS, alumina, or Chrom50, especially when the area to be repaired is located on the wall of a furnace bath, or - Repairing thermally coated molten silica when the area to be repaired is located in an arched section.

[0233] These unfinished products were sold by Saint-Gobain Sefpro.

[0234] Preferably, the maximum particle size of the repaired product or equivalent unshaped product is less than 10 mm, more preferably less than 8 mm, and more preferably less than 6 mm.

[0235] The particle size distribution of the repaired product or equivalent unshaped product is preferably determined such that the repaired product is self-cast under thermal conditions.

[0236] Preferably, the repair product is selected such that its chemical analysis is close to that of the furnace material defining the area to be repaired, and preferably, the content of any component in the repair product differs from the content of the component in the material by less than 10%.

[0237] For example, if the area to be repaired is defined by one or more refractory blocks made of AZS (alumina-zirconia-silica) products, the unshaped product used to manufacture the repair product is preferably a repair heat-coating AZS product, depending on the location of the area to be repaired in the glass furnace. If the area to be repaired is defined by one or more refractory blocks made of AZS-chromium products, the unshaped product used to manufacture the repair product is preferably a repair heat-coating Chrom50. Finally, if the area to be repaired is defined by one or more refractory blocks made of silica products, the unshaped product used to manufacture the repair product is preferably a repair heat-coating fused silica.

[0238] The repair product can be brought to the area to be repaired using any technique known to those skilled in the art. If the area to be repaired is difficult to access, one or more channels can be provided from the outside to the inside of the furnace, such as channels formed by drilling. These channels advantageously enable the introduction of components for conveying the repair product to the area to be repaired, such as cooling pipes or nozzles.

[0239] In one embodiment, the repair product is pumped by a pump that generates an intake pressure preferably less than or equal to 180 bar, and is preferably delivered to the area to be repaired via a water-cooled pipe or nozzle.

[0240] Throughout step b), the area to be repaired is preferably maintained at a temperature above 300°C, preferably above 400°C, preferably above 500°C, preferably above 600°C, preferably above 700°C, preferably above 800°C, preferably above 900°C, and / or preferably below 1550°C, preferably below 1500°C.

[0241] In step 5), (which is optional), particularly if the method includes step 3), the furnace is maintained at a temperature of 900°C to 1400°C, preferably 1250°C to 1400°C, preferably 1300°C to 1400°C, in order to sinter the repaired product, preferably for a duration of more than 8 hours, preferably more than 10 hours, and preferably less than 15 hours.

[0242] In step 6), the furnace is restored to normal operation: the glass composition to be melted is introduced into the furnace, and if the method includes step 3), the furnace temperature is increased to restore the furnace to normal operation.

[0243] Example

[0244] To illustrate the present invention, the following non-limiting embodiments are provided.

[0245] Figures 5 to 9 Knitted fabrics that can be used for textile components are shown.

[0246] Figure 5 and Figure 6 The image shows T1, a plain knit weft-knitted fabric made of Quartzel® yarn with a basis weight of 120 g / m². 2 The row density is 3.43 rows per centimeter, the column density is 2.1 columns per centimeter, and the shape is a rectangle with a length of 300 mm and a width of 300 mm. It is manufactured by Saint-Gobain Performance Plastics, and the Quartz® line is numbered C9 33 Z20 QS1318 and sold by Saint-Gobain Quartz.

[0247] [ Figure 5 The structure of this knitted fabric is described in the document.

[0248] [ Figure 6 The figure shows a knitted fabric Tl, where reference numeral 1 indicates Quartzl® yarn, and where the basic unit of the knitted fabric is indicated by a rectangular dashed line S1.

[0249] Figure 7 and Figure 8 Knitted fabric T2 is shown that is identical to knitted fabric T1, but with a sealing line incorporated, as shown. Figure 7 The seal line, indicated by gray line 2, is a wire with reference number Quartzel® C14 640QS1318 sold by Saint-Gobain Quartz. The seal line is deposited in the direction of the coil row, but is not subjected to force in the coil, and the wire is trapped in the coil.

[0250] The total weight of each knitted substrate is equal to 1000 g / m². 2 The loop density is equal to the loop density of the knitted fabric T1, and the yarns are oriented substantially entirely in the same direction (direction of progress), such as [ Figure 7 As shown in the image.

[0251] [ Figure 8 The structure of this knitted fabric is shown in the image.

[0252] The fill rate is the ratio between the area S2 occupied by all Quartzel® fill lines in the basic unit and the area S1 of the aforementioned basic unit, as shown in […]. Figure 9 As shown in the diagram. For knitted fabric T2, it was calculated that 59% of the total area of ​​the basic units was sealed by the sealing thread. In this embodiment, 100% (by quantity) of the basic units were sealed by the thread.

[0253] In particularly advantageous embodiments, such as [ Figure 10 As shown, the internal template 32 includes a textile element 50 and a reinforcing element 52. The textile element 50 is in the form of a bag for containing the repair product and is preferably made of knitted fabric. The reinforcing element 52 is in the form of a plate and is preferably made of CMC and is disposed inside the bag.

[0254] The textile element 50 includes an excessively long portion 54 that is attached to the outside of the housing, preferably on the outer arch surface. It is preferably secured by wrapping (e.g., wrapping around a fastener), by hooking (e.g., hanging on a hook), by adhesive, or by clamping (preferably on the outer arch surface 31).

[0255] The repair product 30 is introduced into the bag through the top opening (wide arrow). The repair product applies a thrust P to the reinforcing element 52, indicated by a horizontal arrow. The reinforcing element resists this thrust P by a reaction force R of the same magnitude opposite to the reinforcing element 52.

[0256] The internal template 32 may optionally include a rod 58 (preferably made of ceramic, more preferably of CMC) or a connector (especially a textile strip, optionally integrated into the textile element for holding in position in contact with the upper part of the plate or bag), thereby resisting the thrust exerted by the repair product into the furnace, i.e., pulling the upper part of the plate or bag toward the inner arch of the wall to be repaired. The rod 58 may also be used to keep the bag open during filling.

[0257] The template may also include wedges, preferably in the form of wedge-shaped bricks 60, for resting against the base plate 24 and against the lower part of the plate, thereby resisting the sliding of the inner portion into the furnace.

[0258] like[ Figure 11 As shown in Figure

[11] , the reinforcing elements can be fixed to the bag in a predetermined position, for example, in an insertion slot, which is preferably of a substantially complementary shape, for example, in the form of a bag. In a non-preferred embodiment, two reinforcing elements are fixed to the bag formed by the textile element 50 in Figure

[11] . These reinforcing elements 521 and 522 are fixed one after the other in the form of plates through insertion slots 621 and 622, respectively.

[0259] [ Figure 12 Various composable implementations are shown: Figure 12 A shows a textile element 50, whose "back" 50a is made of a textile that allows the repair product to pass through before curing. Preferably, the "front" 50b is made of a textile that allows the repair product to pass through before curing, preferably the T1 knitted fabric described above. The side surface 50c, which connects the front and back sides along the vertical edge 63, and the bottom surface 50d, are preferably made of a textile that does not allow the repair product to pass through before curing, preferably the T2 knitted fabric described above. This embodiment allows the repair product to adhere well to the wall to be repaired, preventing leakage into the furnace before curing.

[0260] exist Figure 12 In B, the inner template has a mesh-like reinforcing element that can be attached (preferably rigidly) to the inside or outside of the bag defined by the textile element (as shown), preferably inside.

[0261] exist Figure 12 In embodiment C, the inner template includes reinforcing elements in the form of substantially vertical plates to reinforce the front of the bag exposed to the furnace interior, and for each side of the bag, the inner template also includes three uniformly spaced, stacked reinforcing elements in the form of substantially horizontal rods. In the illustrated embodiment, the rods are located outside the bag, and the plates are located inside the bag defined by the textile elements. However, preferably, the rods are located inside the bag, and the plates are located inside the defined bag.

[0262] exist Figure 12 In D, the internal template includes reinforcing elements in the form of a substantially vertical plate to enhance the front of the bag's exposure to the furnace interior. In the illustrated embodiment, this plate is located outside the bag and is positioned between the horizontal strips 65... h and vertical strip 65 v Within the defined groove, the two ends of the horizontal strip are attached to the bag, and the two ends of the vertical strip are attached to both the horizontal strip and the bag.

[0263] exist Figure 12 In embodiment E, the internal template includes reinforcing elements in the form of substantially vertical plates to reinforce the front of the bag exposed to the furnace interior, and for each side of the bag, the internal template also includes reinforcing elements in the form of substantially vertical plates, substantially perpendicular to the wall to be repaired. In the illustrated embodiment, all reinforcing elements are inside the bag. The textile element includes an excessively long portion in the form of two connectors (preferably strips).

[0264] exist Figure 12 In F, the internal template has a plate-like reinforcing element that can be attached (preferably rigidly) to the inside (as shown) or outside of the bag defined by the textile element, preferably inside. The textile element has an excessively long portion across the entire width of the bag.

[0265] exist Figure 13 In A, the template comprises textile elements in the form of multiple bags 501, 502, each bag containing plates 521, 522, which are arranged adjacent to each other or separated by independent plates 523 (i.e., not arranged in the bags). The independent plates are preferably arranged to be supported on adjacent plates in the working configuration, these adjacent plates being attached (preferably rigidly) to two bags arranged on either side of the independent plates. Preferably, the adjacent plates act as stops to prevent the independent plates from moving into the furnace.

[0266] exist Figure 13 In A, the two side panels are sewn into the bag.

[0267] exist Figure 13 In B, the diagram shows Figure 13 A top view shows two side panels 521 and 522 sewn inside the bag, while a separate panel 523 is placed in the pleats 72 formed by the bags 501 and 502.

[0268] [ Figure 14 The following illustrates a particularly advantageous implementation. The template comprises textile elements (preferably made of knitted fabric) in the form of bags, and reinforcing elements (preferably multiple reinforcing elements in the form of rods) in the form of rods. These rods are preferably interconnected to form one or more reinforcing elements in the form of frames (preferably multiple open frames, preferably in a U-shape opening toward the wall to be repaired).

[0269] Preferably, the frames extend horizontally in the working configuration, and the spacing between them is preferred. d The frame is 10 cm to 30 cm long. Preferably, the frame is attached (preferably detachably) to the bag, and more preferably to the inside of the bag.

[0270] Preferably, at least one frame, and preferably each frame, is also held in place on the textile element, preferably by insertion into a sleeve or by sewing. Preferably, the web of the U-shaped frame arranged at the highest point is attached to a connector forming the excessively long portion 54, the other end of which is attached to a sidewall, preferably to the outside of the housing. More preferably, the web of each other U-shaped frame is attached to the frame above it via a connector 55.

[0271] [ Figure 15 Another particularly advantageous embodiment is shown. The textile element is in the form of a bag that is substantially parallelepiped in the working configuration, equipped with an excessively long portion in the form of a connector for securing it to the outside of the outer shell, preferably to the outer arch surface of the wall to be repaired.

[0272] The internal template includes reinforcing elements in the shape of a III (Roman numeral 3) that reinforce the exposed sides of the bag inside the furnace, and for each side of the bag, the internal template also includes reinforcing elements in the shape of an I, which are substantially vertical and substantially perpendicular to the wall to be repaired. In the illustrated embodiment, all reinforcing elements are located inside the bag. Preferably, the III-shaped reinforcing elements are not connected to the I-shaped reinforcing elements.

[0273] Preferably, the vertical rod does not extend along the edge, which avoids sharp corners.

[0274] The textile element has two excessively long sections in the form of strips.

[0275] The III-shaped reinforcing element can be replaced by a plate (preferably perforated). A bottom reinforcing element (preferably in the form of a rod) may also be present.

[0276] In one implementation, the internal template may include multiple modules, such as [ Figure 15 The modules shown are arranged side-by-side adjacent to each other. However, preferably, the I-shaped reinforcing elements are only arranged on the side surfaces at the side ends of the inner template. In other words, the I-shaped reinforcing elements are not arranged at the interface between two adjacent bags.

[0277] [ Figure 16 The diagram shows an internal template in the form of a compartmentalized bag according to the invention, defining a plurality of compartments separated by partitions 74, which preferably extend substantially vertically.

[0278] Partitions 74 can isolate the compartments they separate from each other, that is, prevent the transfer of repair products between these compartments, or conversely, allow communication between these compartments, that is, allow the transfer of repair products between these other compartments.

[0279] Preferably, the compartments or "walls between compartments" extend substantially vertically, more preferably substantially perpendicular to the side walls. The shape and structure of the compartments are preferably determined to create a solidified body along the lines of force, such that the weight of the repair product imparts a predetermined shape to the template.

[0280] In one embodiment, at least one, preferably each partition, includes and / or constitutes a reinforcing element, which is preferably made of ceramic. One or more reinforcing elements may be attached (preferably rigidly) to the partition.

[0281] Unlike bags or bags arranged side-by-side, the compartments interact to give a predetermined shape in a working configuration. Furthermore, it is not necessary to attach each bag to the furnace, which limits costs. The compartments 74 can ultimately form a mechanically solidified body after hardening.

[0282] In one implementation, such as [ Figure 16 As shown, the textile element includes at least one central compartment 503' and two side compartments 501' and 502' adjacent to the central compartment. Thus, the rigidity of the central compartment can be achieved through the rigidity of the side compartments, especially after the side compartments have been filled with the repaired product. In particular, the front of the central compartment exposed to the furnace interior may not have a reinforcing element, as shown.

[0283] [ Figure 17 The diagram shows an internal template according to the invention, in which reinforcing elements 52, in the form of plates, are partially held in place by connectors 77 (preferably in the form of strips). The connectors (preferably strips) are attached to the lower part of the plate and pulled out from the outside of the housing to apply traction, the component of which, R, resists the thrust exerted by the repair product on the plate. It advantageously performs a function equivalent to […]. Figure 1 The wedge-shaped brick 60 shown in the figure serves a purpose, as wedge-shaped bricks are often difficult to place, especially for thermal repairs.

[0284] During the curing process of the repair product, the connector (preferably a strip) is secured to the outside of the housing. After the repair product has hardened, the connector (preferably a strip) is embedded in the hardened repair product.

[0285] Rod 58 is used to prevent the plate from falling into the furnace and into the wall to be repaired. Preferably, rod 58 is used to prevent the plate from falling into the wall to be repaired, and the connector (preferably a strip) attached to the plate is used to prevent the plate from falling into the furnace.

[0286] As is now clearly seen, the present invention provides a template and method for repairing glass furnaces, the method utilizing the template, which: - This makes it easier to introduce template elements into the furnace, especially by folding or winding textile elements; - Allows for quick and easy installation, especially since textile elements can be easily attached to the exterior of the inner arch of the sidewall to be repaired; - Makes it easier to arrange reinforcing elements, especially when the reinforcing elements are attached to textile elements; - Allows for the sacrifice of template elements, that is, keeping the template elements in the furnace after repair, especially since the composition of the ceramic (preferably in the form of CMC) can be selected to be similar to the composition of the repaired product.

[0287] Of course, the present invention is not limited to the embodiments described or shown through illustrative and non-limiting examples.

[0288] In particular, the ceramic composition and / or CMC structure of the various parts of the template and / or accessories may be the same or different.

[0289] Detailed descriptions typically refer to textile elements and reinforcing elements for clarity. However, the inner template may include multiple textile elements and / or multiple reinforcing elements, the above-described optional features of the textile elements and reinforcing elements being optional features applicable to each textile element and each reinforcing element of the inner template, respectively.

[0290] Not all textile elements are necessarily the same and / or used in the same way. For example, an internal template may include multiple textile elements, only a portion of which are attached (preferably rigidly) to the furnace.

[0291] Not all reinforcing elements are necessarily the same and / or used in the same way. For example, an internal template may include multiple reinforcing elements, only a portion of which are attached (preferably rigidly) to the textile element.

[0292] Preferably, the internal template includes at least one textile element and multiple reinforcing elements.

Claims

1. A method for repairing an area (30) to be repaired, the area to be repaired extending on the inner arched surface (29) of the sidewall (22, 26) of the outer shell of a glass furnace (10), the method comprising the steps of: a) Install an internal template (32) to form a mold (36) around the area to be repaired, the internal template including a flexible textile element (50) and a reinforcing element (52) designed to reinforce the internal template. b) Fill the mold with the repair product (41) until the working configuration is achieved; In the method, in step a), the textile element is rigidly attached to the furnace and shaped to apply a force (R) to the reinforcing element in the working configuration opposite to the thrust (P) applied to the reinforcing element by the repair product.

2. The method according to the preceding claim, wherein, During steps a) and b), the area to be repaired is at a temperature above 300°C.

3. The method according to any one of the preceding claims, wherein, In step a), the textile element is rigidly attached to the outside of the outer shell of the furnace, preferably to the outer arch surface of the sidewall (22, 26).

4. The method according to any one of the preceding claims, wherein, In step b), the bag defined by the textile element is filled with the repair product, at least a portion of the bag being sealed to the repair product, and the sealed portion preferably includes at least one front end (50b) of the bag.

5. The method according to any one of the preceding claims, wherein, The textile element defines a bag that is the same as or different from the bag mentioned in claim 4, the bag including a portion through which the repair product can pass, the portion through which the repair product can pass preferably including at least one back (50a) of the bag, which extends abutting against and in contact with the wall to be repaired in the working configuration.

6. The method according to any one of the preceding claims, wherein, In step a), the reinforcing element is introduced into a bag defined by the textile element or attached to the front (50b) of the bag defined by the textile element facing the interior of the furnace, the bag being the same as or different from the bag mentioned in claims 4 and 5.

7. The method according to any one of the preceding two claims, wherein, The textile element defines a bag that is the same as or different from the bag mentioned in claims 4 to 6, divides the bag into multiple compartments, and wherein, in step a), a reinforcing element, preferably in the form of a plate, is introduced into one or more of the compartments, and / or in step b), one or more of the compartments, preferably all of the compartments, are filled with the repair product.

8. The method according to any one of the preceding claims, wherein, The textile element is made of a material selected from ceramics, metals, organic materials and mixtures thereof, preferably ceramics.

9. The method according to any one of the preceding claims, wherein, The textile element includes or is composed of knitted fabric.

10. The method according to the immediately preceding claim, wherein, The knitted fabric comprises the repetition of basic units, at least some of which are at least partially closed by at least one thread called a sealing line. The basic unit is defined as a minimum rectangular pattern, and the basic unit forms 70% or more of the surface of the knitted fabric through its repetition.

11. The method according to the preceding claim, wherein, - More than 30% of the total surface area of ​​the basic unit is enclosed by the at least one sealing line; and / or - By quantity, more than 40%, preferably more than 90%, of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 30% of the total surface area of ​​the at least partially enclosed basic units; and / or - By quantity, more than 30% of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 50%, preferably more than 70%, of the total surface area of ​​the at least partially enclosed basic units; and / or - By quantity, more than 90% of the basic units are at least partially enclosed by sealing lines, preferably by a set of sealing lines, wherein the sealing lines or the set of sealing lines together enclose more than 70% of the total surface area of ​​the at least partially enclosed basic units; and / or - The knitted fabric is made of a material selected from ceramics, metals, organic materials, and mixtures thereof, preferably made of ceramics; and / or - The repetition of the basic unit enables the coverage of more than 85%, preferably more than 97%, of the surface of the knitted fabric; and / or - The ceramic knitted fabric constitutes more than 5% and less than 25% of the mass of the textile element; and / or - The sealing lines are oriented parallel to each other; and / or - The sealing line, preferably each sealing line, is made of a material selected from ceramics, organic products and mixtures thereof, preferably made of ceramics.

12. The method according to the preceding claim, wherein, - The knitted fabric comprises knitting yarn containing more than 95% oxide by weight, preferably consisting of knitting yarn containing more than 95% oxide by weight; and / or - Sealing line, preferably each sealing line contains more than 95% oxide by weight.

13. The method according to any one of the preceding claims, wherein, The reinforcing element is made of ceramic matrix composite material, the textile element is made of ceramic, and the entire internal template (32i) is preferably made of ceramic.

14. The method according to any one of the preceding claims, wherein, The reinforcing element has the shape of a plate, a grid, a frame, or a rod.

15. The method according to any one of the preceding claims, wherein, In step a), the reinforcing element is detachably attached to the textile element.

16. The method according to any one of the preceding claims, wherein, The reinforcing element is attached to the textile element so as to be positioned in a predetermined location under the working configuration.

17. The method according to any one of the preceding claims, comprising sintering after step b), step 5) of introducing the repair product into the mold in step b), wherein the obtained sintered repair product is composed of multiple components, and the content of any component in the sintered repair product is greater than 5%. - The content of any component in the sintered repair product differs from the content of the component in the reinforcing element by less than 20%, and / or - The content of any component in the sintered repair product differs from the content of the component in the area of ​​the furnace defining the area to be repaired by less than 20%, and / or - The content of any component in the sintered repair product differs from the content of the component in the textile element by less than 20%. The content is expressed as a weight percentage based on oxides.

18. The method according to any one of the preceding claims, wherein, The internal template (32i) is discarded in the area to be repaired after the repair.

19. The method according to any one of the preceding claims, wherein, The reinforcing element: - Made of ceramic matrix composites, and / or - Includes through holes and / or grooves, said through holes and / or grooves being arranged to be filled with said repair product during step b), and / or - Having a flat or non-flat plate shape, the plate having a thickness greater than 3 mm and less than 50 mm, preferably forming the bottom of the bag defined by the textile element, and / or - It is detachable.

20. The method according to any one of the preceding claims, wherein, The internal template includes an accessory for holding the reinforcing element in the working configuration. The accessory is made of a ceramic matrix composite material, and when the reinforcing element is made of the same ceramic matrix composite material, the ceramic matrix composite material of the accessory may be the same as or different from that of the reinforcing element.

21. The method according to any one of the preceding two claims, wherein, The ceramic matrix composite material of the reinforcing element, and / or the ceramic matrix composite material of the appendix when the preceding claims apply: - It is sintered, and / or - For more than 90% of its mass, it is composed of oxides, and / or - Contains more than 20% and less than 80% of fibers by volume, and / or - Contains fibers that contain more than 90% oxide by weight and / or are arranged in the form of textiles, and / or - Containing a matrix that comprises more than 90% oxide by weight, and / or - Containing a matrix comprising Al2O3 and / or SiO2 and / or ZrO2 and / or Cr2O3, and / or - It has a total content of SiO2 + Al2O3 + ZrO2 + Cr2O3 greater than 80% by weight percentage of oxides.

22. The method according to any one of the preceding claims, wherein, The internal template includes: - A textile element in the form of a bag, preferably made of ceramic material, the bag comprising a back (50a), a front (50b), two sides (50c), and a bottom (50d), the back extending abutting against and in contact with the wall to be repaired in the working configuration, the front exposed toward the interior of the furnace, the two sides connecting the sides of the front and the back, the bag preferably including an overlength portion (54), the overlength portion preferably in the form of a connector, the overlength portion being attached to the exterior of the housing in step a); and - A single reinforcing element attached to the bag, preferably made of CMC, preferably in the form of one or more plates or one or more rods, the plates being rigidly attached to each other, preferably perforated, and the rods being rigidly attached to each other, preferably in the form of I or III, with the upper and lower ends of three vertical rods rigidly connected by horizontal upper and lower rods respectively; or - A set of reinforcing elements, said set of reinforcing elements being attached to the bag and comprising: - A first reinforcing element, preferably made of CMC, preferably in the form of a plate or mesh, the plate preferably being perforated, the first reinforcing element being attached to the textile element to reinforce the front end (50b), the first reinforcing element preferably being arranged in a groove (621, 622) defined by the textile element, and - A second reinforcing element, preferably made of CMC, preferably in the form of a plate, rod, or rod assembly, wherein the plate is preferably perforated, and the rod is preferably in the form of an I-shape. The second reinforcing element is attached to the textile element to reinforce the side (50c) of the bag; or - Multiple reinforcing elements, each preferably made of CMC, in the working configuration each reinforcing element is in the form of a U-shaped frame and attached to the textile element, such that the web of the U reinforces the front (50b), the two branches of the U reinforce the two sides (50c) respectively, the reinforcing elements in the form of U-shaped frames are preferably horizontal and one stacked on top of the other, the web of the U-shaped frame arranged at the highest point is preferably attached to a connector, the other ends of the connector are attached to the side wall, preferably attached to the outside of the housing.

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