Pottery kiln system

Abstract

A sustainable pottery kiln system for firing pottery, consisting of: a raised platform, mounted 30 cm above the ground and 150 cm wide, serving as the oven floor and providing a stable base for the goods during firing; a chamber comprising a combustion chamber and a chamber wall, wherein the combustion chamber includes a front door for loading the pots and wherein the chamber wall is constructed of circular brick layers in a head-bond pattern; a heat source with a domed entrance that has a central gap at the top, the domed entrance serving both as a chimney and as access to the combustion chamber; a horseshoe-shaped shelf that divides the oven chamber and is created by stacking bricks in three layers; a dome that is mounted on the cornice and matches the top of the arched entrance, and whose shape is created by the layering of the bricks; a rectangular air duct that allows for the intake of fresh air and the extraction of heat and smoke; and a chimney that is connected to the combustion chamber via the flue and is located behind the stove.

Description

AREA OF INVENTION

[0001] The present disclosure relates to a sustainable pottery kiln system, which is a cost-effective, gas-fired cross-draft design and is manufactured from locally sourced materials. More specifically, the present invention relates to a sustainable pottery kiln system for firing pottery. BACKGROUND OF THE INVENTION

[0002] Modern ceramic kilns typically use expensive refractory bricks or ceramic fiber mats, materials that can pose a financial barrier for traditional potters. Furthermore, ceramic fiber mats present health risks, as prolonged contact with them can lead to respiratory and other health problems in potters. Both refractory bricks and ceramic mats act as insulation due to their air pockets, with smaller air pockets providing better insulation. In this invention, insulation is achieved by inserting a ceramic fiber mat between two brick walls, creating an effective barrier that maintains high internal temperatures and is suitable for firing earthenware pottery at up to 1000°C.

[0003] Traditional kilns in rural pottery communities typically use wood, sawdust, dry leaves, or cow dung as fuel, which presents several challenges. These fuels require complex storage, are susceptible to weathering, and incur transportation costs when purchased in bulk. Furthermore, burning these fuels produces smoke, soot, and other harmful byproducts, exposing potters to respiratory and other health risks. Maintaining a consistent firing temperature often requires potters to remain near the kiln, resulting in prolonged exposure to these pollutants. Therefore, there is an urgent need for an affordable gas-powered kiln that eliminates the health risks associated with these traditional fuels.

[0004] This invention addresses these problems by introducing an affordable gas-fired kiln constructed from fired bricks and clay. The kiln's design ensures an efficient and reliable firing process, achieving high temperatures quickly and evenly. This reduces the likelihood of pots breaking during the heating and cooling phases. By minimizing the use of hazardous materials and utilizing clean energy, this kiln represents a significant advancement in safe, efficient, and environmentally friendly kiln technology for traditional potters. SUMMARY OF THE INVENTION

[0005] This disclosure relates to a sustainable pottery kiln system for firing pottery. This invention focuses on the use of commonly available materials such as fired brick and clay to construct an affordable and accessible kiln for potters. In this way, the invention provides a sustainable, cost-effective solution that minimizes environmental impact and reduces the health risks associated with conventional kiln fuels. The kiln's design promotes the use of clean energy and more efficient firing, meeting both environmental and user safety objectives. The kiln features a cylindrical structure, which improves heat distribution and efficiency. In contrast, cubic or cuboid kilns often suffer from "cold spots" in their corners, where heat does not reach sufficiently, preventing uniform temperatures throughout the firing chamber.The cylindrical design of this invention eliminates these dead zones and ensures that the entire chamber reaches the required firing temperature, making it suitable for efficient earthenware production. Furthermore, the kiln features a domed roof that allows for even heat distribution throughout the chamber. Unlike flat-topped kilns, which often develop cold spots, a dome allows for better heat convection, thus improving airflow and heat circulation within the kiln. This domed structure is not only more stable than a conventional arch but also maximizes internal heat distribution, making it ideal for a circular kiln design. The result is an innovative, user-friendly earthenware kiln that enables efficient, uniform firing with minimal environmental impact.By eliminating the usual inefficiencies of conventional kilns, this invention sets a new standard for the design and functionality of pottery kilns, combining practicality, safety and environmental compatibility.

[0006] This disclosure is intended to provide a sustainable pottery kiln system for firing pottery. The system comprises: a raised platform positioned 30 cm above the ground and 150 cm wide, serving as the kiln floor and providing a stable base for ware during firing; a chamber comprising a firing chamber and a chamber wall, the firing chamber including a front door for loading pots and the chamber wall constructed of circular brick courses in a head-bond pattern; a heat source with an arched entrance featuring a central gap at the height of the arch, the arched entrance serving as both a chimney and an access point to the firing chamber; and a horseshoe-shaped shelf dividing the kiln chamber, created by stacking bricks in three layers.a dome positioned on top of the shelf and coinciding with the top of the arched entrance, the shape of which is created by the layering of bricks; a rectangular flue duct that allows fresh air to be drawn in and heat and smoke to be expelled; and a chimney connected to the combustion chamber by the flue duct and located behind the stove.

[0007] One objective of this disclosure is a sustainable pottery kiln system for pottery making.

[0008] Another objective of this disclosure is to provide a furnace system with an innovative cylindrical shape paired with a domed top that eliminates cold spots and promotes uniform heat transfer in the combustion chamber.

[0009] Another objective of this disclosure is to provide a unique furnace system in which the chamber door and chimney are integrated into a single arched entrance.

[0010] Another objective of this disclosure is to provide a pottery kiln system with a double-shell structure that ensures excellent insulation.

[0011] To further clarify the advantages and features of the present disclosure, a more detailed description of the invention is given with reference to specific embodiments thereof, which are illustrated in the accompanying drawings. It should be noted that these drawings represent only typical embodiments of the invention and are therefore not to be considered as limiting its scope. The invention is described and explained with additional details and information with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE FIGURES

[0012] These and other features, aspects, and benefits of this disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which identical symbols consistently represent identical parts. The following applies: Fig. Figures 1 to 7 show different views of the proposed sustainable pottery kiln system according to an embodiment of the present disclosure. Fig. Figure 8 shows a block diagram of the proposed pottery kiln system according to an embodiment of the present disclosure.

[0013] Furthermore, those skilled in the art will recognize that elements in the drawings are presented for the sake of simplicity and are not necessarily drawn to scale. For example, the flowcharts illustrate the method by outlining the main steps to enhance understanding of aspects of this disclosure. Additionally, with regard to the design of the device, one or more components of the device may be represented in the drawings by conventional symbols, and the drawings may show only the specific details relevant to understanding the embodiments of this disclosure, so as not to clutter the drawings with details that are readily apparent to those skilled in the art who benefit from the description herein. DETAILED DESCRIPTION:

[0014] To facilitate understanding of the principles of the invention, reference is now made to the embodiment illustrated in the drawings, which is described in specific language. However, it is clear that this is not intended to limit the scope of the invention, since such changes and further modifications of the illustrated system and such further applications of the principles of the invention as they are shown therein are considered as would normally occur to a person skilled in the art in the field to which the invention relates.

[0015] It is clear to the person skilled in the art that the preceding general description and the following detailed description are exemplary and explanatory of the invention and are not intended as a limitation of it.

[0016] References in this specification to “an aspect”, “another aspect”, or similar formulations mean that a particular feature, structure, or property described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, occurrences of the phrase “in one embodiment”, “in another embodiment”, and similar formulations in this specification may all refer to the same embodiment, but need not.

[0017] The terms "includes," "comprehensive," or other variations thereof are intended to cover non-exclusive inclusion, so that a process or method that includes a list of steps may include not only those steps but also other steps not expressly listed or inherent in such process or method. Likewise, one or more devices, subsystems, elements, structures, or components preceded by "includes...a" do not, without further limitations, exclude the existence of other devices, subsystems, elements, structures, components, or additional devices, subsystems, elements, structures, or components.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as they are generally understood by a person skilled in the art in the field to which this invention belongs. The system, methods, and examples provided herein are for illustrative purposes only and are not to be understood as limiting.

[0019] Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0020] The present invention presents a pottery kiln system which, through its advanced design features, is specifically developed for maximum energy efficiency and firing consistency. This kiln system has an innovative cylindrical shape with a dome that prevents cold spots and enables uniform heat transfer in the firing chamber, thereby ensuring a safe and reliable firing process for earthenware.

[0021] A unique aspect of this kiln system is the integration of the chamber door and chimney into a single arched entrance. Potters load the pots through this arched door, which can then be partially closed with bricks to make room for the gas burner. This design reduces the overall size of the kiln while allowing a direct fire path, which can be divided in different directions by placing a small wall in front of the burner. This configuration optimizes fire distribution and improves the evenness and reliability of the firing process.

[0022] The double-walled structure of the furnace system provides excellent insulation. The inner wall consists of bricks laid horizontally in a head-bond pattern, with the shorter brick sides facing outwards. A 2.5 cm thick ceramic fiber layer is then laid over the inner wall, followed by a 2.5 cm wide air gap enclosed by a second brick wall. This multi-layered insulation reduces heat loss and ensures safety by keeping hot surfaces away from direct contact with users.

[0023] Proper chimney construction is essential for effective operation. The chimney's cross-section corresponds to that of the burner opening, ensuring a balanced air supply and exhaust. The stove's 226 cm high chimney is located behind the stove and begins precisely at the rear of the combustion chamber wall. This height creates the necessary draft to draw in air for efficient combustion, enabling a consistent temperature rise and maintaining optimal burning conditions.

[0024] Unlike traditional kilns where pots are stacked directly on top of each other, increasing the risk of damage to the lower pots, this kiln system features a fixed, horseshoe-shaped shelf. This shelf divides the chamber into two levels, allowing pots to be placed on it in a way that reduces the weight of the lower pots and minimizes the risk of breakage. This arrangement provides potters with an organized and efficient loading system and improves the overall functionality and durability of the kiln.

[0025] The attached Fig. Figures 1 to 8 show a gas kiln made of standard bricks and clay, highlighting its double-walled dome structure with a single chimney. This kiln design prioritizes user safety and improves firing efficiency, making it suitable for both local potters and studios. The kiln's volume is approximately 1050 liters and is optimized to meet the needs of potters of varying sizes.

[0026] The volume of this kiln is 1050 liters, which is the average size for local potters and large for studio potters. Volume of the dual spherical segment = Vhemisphere + Vcylinder Volume of gas oven=πR2(2R3+H)

[0027] Here, R is the radius of the cylinder and the hemisphere, and H is the height of the cylinder.

[0028] The hemisphere and cylinder have a radius of 50 cm, and the cylinder has a height of 100 cm. Using the formula above, the total volume of the oven is calculated as follows: VGaskiln≅1050L 20,500 Indian rupees (224.79 euros = 244 dollars) are needed to build a gas oven with a volume of 1050 liters. If the same oven were built with firebricks, the cost would be three to four times higher.

[0029] In the Fig. Figures 1 through 7 show various views, including top, bottom, left, right, front, back, and a perspective view. The system comprises a platform, a chamber, a heat source or arched entrance, a shelf, a dome, and a chimney.

[0030] The chamber wall consists of a first layer of 23 cm thick brickwork. The chamber wall is additionally insulated with a 2-inch thick ceramic fiber ceiling, followed by a 1-inch thick air gap, then a second 11 cm thick brick wall, and finally a 2-inch thick layer of cement for added strength and watertightness.

[0031] The proposed pottery kiln system consists primarily of seven main components that are integral to its design: platform, chamber, dome, heat source, shelf, air vent, and chimney, all positioned on a raised platform for stability and ease of use. Each of these components is described below in relation to… Fig. described.

[0032] Platform: The first component is a platform that serves as the kiln floor, providing a stable base for the ware during firing. The platform is raised 30 cm above the ground and is 150 cm wide. It offers protection from flooding during rain and easy access for loading the pottery.

[0033] Chamber: The second component is the main firing chamber, with a front door for filling the pots. The chamber wall, labeled as such, is a robust, 9-inch-thick barrier of circular brick courses laid in a head-bond pattern. This arrangement includes head-bonded joints filled with broken bricks and bed-bonded joints filled with clay mortar. Small gaps in the wall act as natural insulators, improving heat retention. The chamber wall is further insulated with a 2-inch-thick ceramic fiber blanket, followed by a 1-inch-thick air gap, then a 4-inch-thick second brick wall, and finally a 2-inch-thick layer of cement for added strength and watertightness.

[0034] Heat source (arched entrance): The third component is the arched entrance, which serves both as a chimney and as access to the combustion chamber. The arch, with a 50 x 50 cm opening, was carefully constructed from bricks cut at a 45-degree angle, creating a gap in the center as the arch rises. This design allows for efficient airflow and serves two purposes without increasing the stove's footprint.

[0035] Shelf: The fourth component is a horseshoe-shaped shelf that divides the kiln chamber into two levels. This feature, created by stacking bricks in three layers, allows the pots to be loaded at different heights, thus reducing weight pressure and the risk of breakage. Each layer is gradually pressed 7 cm into the kiln, with the gaps filled with broken bricks for stabilization.

[0036] Dome: The fifth component is the dome, which is built on the base and coincides with the apex of the arch. Using a dome compass with a 100 cm diameter and a 50 cm long handle, bricks are stacked to create the dome shape. A keystone placed in the center seals the dome, ensuring a stable and durable structure that promotes efficient heat circulation.

[0037] Flue: The sixth component is the flue, a rectangular channel measuring 20 x 20 x 68.5 cm. This channel connects the oven chamber to the chimney, draws in fresh air, and facilitates the removal of heat and smoke, contributing to even combustion in the oven.

[0038] Chimney: The final component is the chimney, a 220 cm high structure located behind the stove. The chimney walls are 11 cm thick. The hollow section of the chimney measures 10 x 10 cm. The chimney's height and cross-section correspond to those of the burner opening, ensuring a balanced airflow. This is crucial for maintaining a consistent temperature rise, enabling optimal combustion, and creating an efficient combustion environment within the stove.

[0039] The present invention relates to a pottery kiln system in which a kiln structure is manufactured from readily available materials, in particular fired bricks and clay, and which is intended to provide a cost-effective, accessible, and environmentally friendly solution for local potters. The kiln design minimizes the environmental pollution and health risks associated with traditional fuels through the use of a gas-fired firing process.

[0040] The proposed kiln system incorporates a double-walled structure for optimal insulation; an inner wall of standard fired bricks is covered with a 2.5 cm thick ceramic fiber layer, ensuring excellent insulation while preventing direct contact between potters and ceramic material, thus reducing health risks; a 2.5 cm wide air gap is incorporated between the inner and outer walls, utilizing air as a natural insulating material; an outer wall of 11 cm thick standard fired bricks provides structural support, and a 5 cm thick layer of cement encases the entire kiln, making it watertight and improving its durability.The kiln door functions as both a chimney and a loading door, minimizing the kiln's size and simplifying its structure by eliminating the need for a separate firebox. The design allows the potter access to the firing chamber through the arched door, which can be partially closed with bricks to create a controlled burner opening. The kiln's structure incorporates a multi-tiered loading shelf, including a fixed, 27 cm wide, horseshoe-shaped shelf that divides the kiln's interior into two levels, allowing potters to load ware in two separate sections to avoid direct stacking. A brick-based shelf design is arranged to optimize heat distribution, reduce the risk of breakage, and ensure even firing of the ware.The kiln is gas-fired, significantly reducing smoke and pollution compared to traditional fuels like wood or cow dung, contributing to a cleaner working environment and reducing potters' exposure to harmful emissions. The kiln's structure is designed for intuitive loading and firing, minimizing the health risks associated with prolonged exposure to emissions from conventional fuels. Its robust construction ensures long-term use, making it suitable for future generations of potters, as it is easy to maintain and repair using standard materials readily available within the local pottery community.The use of standard fired bricks and clay allows for cost-effective and straightforward repairs and maintenance, as the materials are readily available within the local pottery community. This ensures easy upkeep and extends the kiln's lifespan.

[0041] With reference to Fig.8 The pottery kiln system (100) comprises a raised platform (102) positioned 30 cm above the ground and 150 cm wide, the platform (102) serving as the kiln floor and providing a stable base for wares during firing; a chamber (104) comprising a firing chamber (104a) and a chamber wall (104b), the firing chamber (104a) including a front door for loading pots and the chamber wall (104b) constructed of circular brick courses in a head-bond pattern; a heat source (106) with an arched entrance (106a) having a central gap at the height of the arch, the arched entrance (106a) serving both as a chimney and as an access point to the firing chamber (104a); a horseshoe-shaped shelf (108) dividing the chamber (104) and created by stacking bricks in three layers;a dome (110) positioned on the shelf (108) and corresponding to the top of the arched entrance (106a), the shape of which is formed by the stacking of the bricks; a rectangular draft channel (112) that allows the intake of fresh air and facilitates the extraction of heat and smoke; and a chimney (114) connected to the combustion chamber (104a) by the draft channel (112) and located behind the oven.

[0042] In one embodiment, the chamber wall (104b) is a robust, 23 cm thick barrier consisting of a circular brick layer laid in a butt joint pattern, including head joints filled with crushed brick and bed joints filled with clay mortar, wherein the chamber wall (104b) is additionally insulated with a 2 inch thick ceramic fiber covering, followed by a 1 inch thick air gap, then a second 11 cm thick brick wall layer, and finally a 2 inch thick cement layer for additional strength and watertightness, and wherein the small gaps in the chamber wall provide natural insulation.

[0043] In one embodiment, the heat source (106) comprises a domed entrance (106a) with a 50 x 50 cm opening, constructed from bricks cut at a 45-degree angle and featuring a central gap that forms as the arch rises, enabling efficient airflow and serving a dual purpose without increasing the space required for the oven.

[0044] In one embodiment, the horseshoe-shaped shelf (108) is constructed from three layers of bricks, each layer projecting 7 cm into the oven chamber in stages, the gaps between them being filled with broken bricks for stability, thus enabling the loading of pots at different heights.

[0045] In one embodiment, the dome (110) is constructed using a dome compass with a diameter of 100 cm and a handle of 50 cm, wherein the dome (110) includes a central keystone that closes the dome and ensures structural stability and also promotes efficient heat circulation.

[0046] In one embodiment, the draft duct (112) is a rectangular duct with dimensions of 20 x 20 x 68.5 cm, configured to connect the air circulation chamber (104) to the chimney (114), wherein the chimney (114) has a total height of 220 cm and a wall thickness of 11 cm and includes a hollow section with dimensions of 10 x 10 cm.

[0047] In one embodiment, the height and cross-sectional area of ​​the chimney (114) are configured to match the burner opening in order to ensure a balanced airflow and optimal combustion.

[0048] The proposed pottery kiln system offers several advantages, including: less smoke and pollution compared to conventional kilns, as the proposed kiln is powered by gas instead of traditional fuels such as wood or cow dung; easy loading and firing, thus reducing the health risks associated with prolonged contact with traditional fuels; durability and long-term use, making the kiln suitable for future generations of potters; and low cost, as it is made from standard fired bricks and clay.

[0049] The drawings and the preceding description provide examples of embodiments. Those skilled in the art will recognize that one or more of the described elements can be combined to form a single functional element. Alternatively, certain elements can be divided into several functional elements. Elements from one embodiment can be added to another embodiment. For example, the sequences of the processes described herein can be changed and are not limited to the manner described herein. Furthermore, the actions of any flowchart need not be implemented in the sequence shown; nor do all actions necessarily need to be performed. Actions that are not dependent on other actions can also be performed in parallel with the other actions. The scope of embodiments is in no way limited by these specific examples.Numerous variations are possible, whether explicitly stated in the specification or not, such as differences in structure, dimensions, and material use. The range of embodiments is at least as broad as specified in the following claims.

[0050] Advantages, other merits, and problem solutions have been described above in relation to specific embodiments. However, the advantages, merits, problem solutions, and all components that may lead to an advantage or solution occurring or becoming more apparent are not to be construed as a critical, necessary, or essential feature or component of any or all claims. REFERENCES 100 The pottery kiln system includes a raised platform. 102 Elevated Platform 104 One chamber 104a Combustion chamber 104b Chamber wall 106 Heat source 106a Arched Entrance 108 Horseshoe-shaped shelf 110 Dome 112 Design Channel 114 Fireplace

Claims

[1] A sustainable pottery kiln system for firing pottery, consisting of: a raised platform 30 cm above the ground and 150 cm wide, which serves as the kiln floor and provides a stable base for the wares during firing; a chamber comprising a combustion chamber and a chamber wall, the combustion chamber comprising a front door for loading the pots and the chamber wall being constructed from circular brick layers in a head-bond pattern; a heat source having an arched entrance with a central gap at the top, the arched entrance serving both as a chimney and as access to the combustion chamber; a horseshoe-shaped shelf that divides the kiln chamber and is created by stacking bricks in three layers; a dome placed on the cornice and aligned with the top of the arched entrance, the shape of which is created by the layering of the bricks; a rectangular air duct that allows the intake of fresh air and the extraction of heat and smoke; and a chimney connected to the combustion chamber by the flue and located behind the stove. [2] The system of claim 1, wherein the chamber wall is a robust 23 cm thick barrier of a circular brick layer in a butt bond pattern, including butt joints filled with broken brick and bed joints filled with clay mortar, the chamber wall being further insulated with a 2 inch thick ceramic fiber blanket, followed by a 1 inch thick air gap, then a second brick wall layer 11 cm thick and finally a 2 inch thick cement layer for additional strength and water resistance, and the small gaps in the chamber wall provide natural insulation. [3] The system of claim 1, wherein the heat source consists of an arched entrance with an opening of 50 x 50 cm, made of bricks cut at a 45-degree angle and having a central gap formed as the arch rises, allowing efficient airflow and serving a dual purpose without increasing the footprint of the furnace. [4] A system according to claim 1, wherein the horseshoe-shaped shelf is constructed from three layers of bricks, each layer extending gradually 7 cm into the kiln chamber and the gaps between them being filled with broken bricks for stability, thereby enabling loading with pots at different heights. [5] The system of claim 1, wherein the dome is constructed using a dome compass having a diameter of 100 cm and a handle of 50 cm, the dome including a central keystone that closes the dome and ensures structural stability and also promotes efficient heat circulation. [6] System according to claim 1, wherein the draft duct is a rectangular duct with dimensions of 20 x 20 x 68.5 cm, connecting the furnace chamber to the chimney for air circulation, the chimney having a total height of 220 cm and a wall thickness of 11 cm and comprising a hollow section with dimensions of 10 x 10 cm. [7] The system of claim 1, wherein the height and cross-sectional area of ​​the chimney are configured to match the burner opening to ensure balanced airflow and optimal combustion.

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