Screen protector insulation kit and process for making same

Abstract

The application provides a screen protection insulation kit, which has a vertical surface structure and a horizontal surface structure which are integrally molded by using multiple layers of materials. The vertical surface structure is an arc-shaped thin wall formed by circumferentially dividing a cylinder, and the horizontal surface structure is a fan ring-shaped thin wall which extends radially and outwardly from the lower end of the vertical surface structure. The vertical surface structure comprises, in sequence, a first mica paper, a second mica paper, a first glass cloth, a first mica plate, a second glass cloth, a third mica paper, and a fourth mica paper, which are attached to each other by high-temperature glue. The horizontal surface structure comprises the first mica paper, the second mica paper, the first glass cloth, the second glass cloth, the third mica paper, and the fourth mica paper of the vertical surface structure, and further comprises a second mica plate and a third mica plate which are stacked between the first glass cloth and the second glass cloth. The application also provides a manufacturing process of the screen protection insulation kit, in which a steel mold is used to mold multiple layers of materials into the screen protection insulation kit.

Description

Technical Field

[0001] This invention relates to the field of high-frequency calcium carbide furnace technology, specifically a protective insulation kit and its manufacturing process. Background Technology

[0002] The high-frequency calcium carbide furnace is the main equipment for producing calcium carbide. Its production principle is to release a high-frequency, high-voltage electric arc through electrodes inside the furnace. The high temperature generated by the electric arc causes coke and calcium oxide to melt and react to produce calcium carbide.

[0003] In existing technologies, electrode protective screens are crucial equipment on high-frequency calcium carbide furnaces. For example... Figure 1 As shown, the electrode protective screen 1 typically consists of several identical protective screen units 11 arranged in a cylindrical structure. Each protective screen unit 11 is a stainless steel body with an internal cooling water circulation unit. The exterior of the electrode protective screen 1 is the furnace cavity of the high-frequency calcium carbide furnace, which experiences high-temperature radiation of thousands of degrees Celsius due to molten calcium carbide. The interior of the electrode protective screen 1 contains internal equipment such as electrodes, contact elements, low-ring flexible hoses, and electrode cylinders. The electrode protective screen 1 provides high-temperature insulation and thermal insulation protection for the internal equipment.

[0004] The applicant's research found that, Figure 1 The electrode protection screen 1 shown has the potential risk that the lower end of the protection unit 11 is easily broken down by an electric arc. Once the lower end of the protection unit 11 is broken down by an electric arc, cooling water will leak into the furnace body, which can easily cause a serious safety accident. Summary of the Invention

[0005] The present invention aims to provide a protective screen insulation kit to provide reliable insulation protection for the lower end of the protective screen unit of the electrode protective screen in the prior art, so as to prevent the arc from breaking down the protective screen unit and causing cooling water to leak into the furnace body and cause a safety accident.

[0006] To achieve the above objectives, the present invention adopts the following technical solution.

[0007] The protective insulation kit has a vertical structure and a horizontal structure made of multiple layers of materials molded and cured into one piece. The vertical structure is an arc-shaped thin wall formed by equally dividing a cylinder around the circumference, and the horizontal structure is a fan-shaped thin wall that extends radially outward from the lower end of the vertical structure.

[0008] Among them, multiple screw through holes are provided radially on the facade structure;

[0009] The facade structure consists of layers of mica paper, mica paper, fiberglass cloth, mica board, fiberglass cloth, mica paper, and mica paper stacked in sequence, with each layer bonded together by high-temperature adhesive.

[0010] The horizontal plane structure comprises a first mica paper, a second mica paper, a first glass fiber cloth, a second glass fiber cloth, a third mica paper and a fourth mica paper, and further comprises a second mica plate and a third mica plate which are stacked between the first glass fiber cloth and the second glass fiber cloth.

[0011] The screen insulation kit is applied to the screen unit of the electrode protection screen in the prior art, and the specific use is as follows:

[0012] The vertical plane structure is matched with the inner wall surface of the screen unit, and the horizontal plane structure is matched with the lower end surface of the screen unit.

[0013] The screen insulation kit is fixed on the screen unit by using screws with insulation protection from the through holes.

[0014] The screen unit combined with the screen insulation kit is finally assembled into the electrode protection screen, and when the electrode protection screen is used in a high-frequency calcium carbide furnace, the screen insulation kit provides reliable insulation protection for the lower end of the screen unit, and the effect of preventing arc breakdown of the screen unit to cause the cooling water to leak into the furnace body and cause a safety accident is achieved.

[0015] In view of the fact that the lower end surface of the screen unit is the part most easily broken down by arc in the prior art, the screen insulation kit in the above technical solution is provided with the second mica plate and the third mica plate which are stacked between the first glass fiber cloth and the second glass fiber cloth in the horizontal plane structure corresponding to the lower end surface of the screen unit, so that the performance of the lower end surface of the screen unit in preventing arc breakdown is further enhanced.

[0016] In order to obtain the screen insulation kit, the application further provides a manufacturing process of the screen insulation kit, in which a plurality of layers of materials are molded into the screen insulation kit by using a steel mold, and the following steps are adopted:

[0017] S01-Placing a polyester film in the mold cavity of the steel mold;

[0018] S02-Placing a first mica paper on the polyester film, and then applying high-temperature glue on the first mica paper;

[0019] S03-Attaching a second mica paper on the first mica paper, and then applying high-temperature glue on the second mica paper;

[0020] S04-Attaching a first glass fiber cloth on the second mica paper, and then applying high-temperature glue on the first glass fiber cloth;

[0021] S04-Attaching a first mica plate corresponding to the vertical plane structure, a second mica plate corresponding to the horizontal plane structure and a third mica plate on the first glass fiber cloth, and then applying high-temperature glue on the first mica plate, the second mica plate and the third mica plate, respectively;

[0022] S05-attaching the second glass cloth on the first mica plate, the second mica plate and the third mica plate, and then coating high-temperature glue on the second glass cloth;

[0023] S06-attaching the third mica paper on the second glass cloth, and then coating high-temperature glue on the third mica paper;

[0024] S07-attaching the fourth mica paper on the third mica paper;

[0025] S08-laying the polyester film on the fourth mica paper;

[0026] S09-steel mold closing to integrate the first mica paper, the second mica paper, the first glass cloth, the first mica plate, the second mica plate, the third mica plate, the second glass cloth, the third mica paper and the fourth mica paper by mold pressing and curing, and obtaining the blank after demolding;

[0027] S10-cutting and polishing the blank according to the design size of the finished product, and then drilling the screw through hole, thereby obtaining the finished product of the screen insulation kit.

[0028] Compared with the prior art, the beneficial effects of the present application are as follows:

[0029] The most vulnerable part of the screen unit to arc breakdown is provided with reliable insulation protection, which can effectively prevent the arc breakdown of the screen unit from causing the cooling water to leak into the furnace body and causing safety accidents.

[0030] In the following, the present application will be further described in conjunction with the drawings and specific embodiments in the description. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 is a structural schematic diagram of the electrode protection screen involved in the present application.

[0032] Figure 2 is a structural schematic diagram of the screen insulation kit involved in the present application.

[0033] Figure 3 is a sectional view structural schematic diagram of the screen insulation kit involved in the present application.

[0034] Figure 4 is a reference diagram of the use state of the screen insulation kit involved in the present application.

[0035] Figure 5 is a principle diagram of the manufacturing process of the screen insulation kit involved in the present application.

[0036] Figure 6 is a schematic diagram of one kind of coating method of the first mica paper in the manufacturing process of the screen insulation kit involved in the present application.

[0037] Figure 7It is a kind of smearing way schematic diagram of first glass fiber cloth in the manufacturing process of the invention. DETAILED DESCRIPTION

[0038] As shown in Figure 2 and Figure 3 , the shielding insulation kit provided by the invention has a vertical surface structure 21 and a horizontal surface structure 22 which are molded and cured as a whole by using multiple layers of materials, the vertical surface structure 21 is an arc-shaped thin wall formed by circumferentially dividing a cylinder, and the horizontal surface structure 22 is a fan ring-shaped thin wall which is outwardly extended from the lower end of the vertical surface structure 21 in the radial direction;

[0039] Among them, a plurality of screw vias 23 are formed on the vertical surface structure 21 in the radial direction;

[0040] Among them, the vertical surface structure 21 includes first mica paper 201, second mica paper 202, first glass fiber cloth 203, first mica plate 204, second glass fiber cloth 205, third mica paper 206, and fourth mica paper 207 which are stacked in sequence, and each layer is bonded by high-temperature glue;

[0041] Among them, the horizontal surface structure 22 includes first mica paper 201, second mica paper 202, first glass fiber cloth 203, second glass fiber cloth 205, third mica paper 206, and fourth mica paper 207 which are inherited from the vertical surface structure 21, and also includes second mica plate 208 and third mica plate 209 which are stacked between the first glass fiber cloth 203 and the second glass fiber cloth 205, and each layer is also bonded by high-temperature glue.

[0042] As shown in Figure 4 , the shielding insulation kit in the above technical solution is applied to the shielding unit 11 in the electrode protection screen 1 as shown in Figure 1 , and is inlaid on the inner wall surface of the shielding unit 11 through the vertical surface structure 21, is inlaid on the lower end surface of the shielding unit 11 through the horizontal surface structure 22, and is fixed on the shielding unit 11 through the screw (not shown in the figure) with insulation protection from the screw via 23. Finally, the shielding unit 11 combined with the shielding insulation kit is finally assembled into the electrode protection screen 1. When used in a high-frequency calcium carbide furnace, the shielding insulation kit provides reliable insulation protection for the lower end of the shielding unit 11, and achieves the expected effect of preventing arc breakdown of the shielding unit 11 to cause cooling water to leak into the furnace body and cause safety accidents.

[0043] Especially, since the lower end surface of the shielding unit 11 is the part most easily broken down by arc in the prior art, the shielding insulation kit in the above technical solution is provided with second mica plate 208 and third mica plate 209 which are stacked between the first glass fiber cloth 203 and the second glass fiber cloth 205 in the horizontal surface structure 22 corresponding to the lower end surface of the shielding unit 11, so that the performance of the lower end surface of the shielding unit 11 in preventing arc breakdown is further enhanced.

[0044] In the preferred embodiment, the first glass cloth 203 and the second glass cloth 205 are both alkali-free glass cloths with a thickness of 0.4 mm.

[0045] In the preferred embodiment, the first mica plate 204 is a silicone mica plate with a thickness of 1 mm, and the second mica plate 208 and the third mica plate 209 are both silicone mica plates with a thickness of 2 mm.

[0046] In the preferred embodiment, the first mica paper 201, the second mica paper 202, the third mica paper 206, and the fourth mica paper 207 are all silicone mica papers with a thickness of 0.25 mm.

[0047] On the other hand, in order to obtain the above-mentioned screen protection insulation kit, the present application provides a screen protection insulation kit manufacturing process for molding the screen protection insulation kit by a steel mold 3, as shown in Figure 5 The specific steps are as follows:

[0048] S01 - laying the polyester film 200 in the mold cavity 31 of the steel mold 3;

[0049] S02 - laying the first mica paper 201 on the polyester film, and then applying high-temperature glue on the first mica paper 201;

[0050] S03 - attaching the second mica paper 202 on the first mica paper 201, and then applying high-temperature glue on the second mica paper 202;

[0051] S04 - attaching the first glass cloth 203 on the second mica paper 202, and then applying high-temperature glue on the first glass cloth 203;

[0052] S04 - attaching the first mica plate 204 corresponding to the vertical structure, the second mica plate 208 corresponding to the horizontal structure, and the third mica plate 209 on the first glass cloth 203, and then applying high-temperature glue on the first mica plate 204, the second mica plate 208, and the third mica plate 209, respectively;

[0053] S05 - attaching the second glass cloth 205 on the first mica plate 204, the second mica plate 208, and the third mica plate 209, and then applying high-temperature glue on the second glass cloth 205;

[0054] S06 - attaching the third mica paper 206 on the second glass cloth 205, and then applying high-temperature glue on the third mica paper 206;

[0055] S07 - attaching the fourth mica paper 207 on the third mica paper 206;

[0056] S08 - laying the polyester film 200' on the fourth mica paper 207;

[0057] S09-steel mold 3 is closed to mold and cure the first mica paper 201, the second mica paper 202, the first glass fiber cloth 203, the first mica plate 204, the second mica plate 208, the third mica plate 209, the second glass fiber cloth 205, the third mica paper 206, and the fourth mica paper 207 into one, and after demolding, a blank is obtained;

[0058] S10-the blank is cut and polished according to the design size of the finished product, and then a screw through hole is drilled, and the insulating sleeve kit finished product is obtained.

[0059] The purpose of laying the polyester film 200 and the polyester film 200' in steps S01 and S08 is to protect the mold with the polyester film, facilitate demolding, and also make the surface of the insulating sleeve kit finished product more smooth.

[0060] Preferably, in step S09, the steel mold 3 is kept for 40 minutes after closing.

[0061] Preferably, the mass of the first mica paper 201, the second mica paper 202, the third mica paper 206, and the fourth mica paper 207 accounts for 45% of the total weight of the insulating sleeve kit finished product, the mass of the first glass fiber cloth 203 and the second glass fiber cloth 205 accounts for 20% of the total weight of the insulating sleeve kit finished product, the mass of the first mica plate 204 accounts for 5% of the total weight of the insulating sleeve kit finished product, the mass of the second mica plate 208 and the third mica plate 209 accounts for 20% of the total weight of the insulating sleeve kit finished product, and the mass of the high-temperature glue coated on each layer accounts for 10% of the total weight of the insulating sleeve kit finished product.

[0062] Preferably, in steps S02, S03, S06, and S07, the first mica paper 201, the second mica paper 202, the third mica paper 206, and the fourth mica paper 207 are respectively folded at the junction of the vertical structure and the horizontal structure to be respectively applied to the vertical structure and the horizontal structure after being laid; and the first mica paper 201, the second mica paper 202, the third mica paper 206, and the fourth mica paper 207 respectively fold the area corresponding to the vertical structure into multiple vertical folds to construct the arc matching the vertical structure. For the sake of understanding, the first mica paper 201 is taken as an example to demonstrate the above-mentioned application method in Figure 6

[0063] ​Preferably, in steps S04 and S05, after the first glass fiber cloth 203 and the second glass fiber cloth 205 are laid, the first glass fiber cloth 203 and the second glass fiber cloth 205 are respectively pressed and folded at the junctions of the vertical surface structure and the horizontal surface structure to be respectively applied to the vertical surface structure and the horizontal surface structure; and the first glass fiber cloth 203 and the second glass fiber cloth 205 respectively divide the area corresponding to the horizontal surface structure into a plurality of radially extending strips to match the flatness of the horizontal surface structure; and a cloth strip made of the same material as the first glass fiber cloth 203 and the second glass fiber cloth 205 is also applied to the area corresponding to the horizontal surface structure to shield the gap between the strips. For the convenience of understanding, the above application method is demonstrated by taking the first glass fiber cloth 203 as an example, and a cloth strip 203” made of the same material as the first glass fiber cloth 203 is applied to the area corresponding to the horizontal surface structure to shield the gap between the strips 203’. Figure 7

[0064] The shielding and insulating kit obtained by the shielding and insulating kit manufacturing process provided by the present application is tested multiple times at an ambient temperature of 45-80°C, and the experimental results show that the shielding and insulating kit provides reliable insulation protection for the lower end of the shielding unit and achieves the expected effect of preventing arc breakdown of the shielding unit to cause cooling water to leak into the furnace body and cause a safety accident.

[0065] For those skilled in the art, the protection scope of the present application is not limited to the details of the above exemplary embodiments, and all the changed embodiments within the equivalent meaning and the protection scope of the present application made by those skilled in the art based on the essential features of the present application should be included in the present application without departing from the spirit or basic features of the present application.​

Claims

1. A screen protection insulation kit characterized in that: it has a vertical surface structure and a horizontal surface structure which are integrally molded by using multi-layer materials, the vertical surface structure is an arc-shaped thin wall formed by circumferentially dividing a cylinder, and the horizontal surface structure is a fan ring-shaped thin wall which is radially outwardly extended from the lower end of the vertical surface structure; a plurality of screw through holes are formed on the vertical surface structure in the radial direction; the vertical surface structure comprises a first mica paper, a second mica paper, a first glass fiber cloth, a first mica plate, a second glass fiber cloth, a third mica paper, and a fourth mica paper which are sequentially stacked, and the layers are bonded by high-temperature glue; the horizontal surface structure comprises the first mica paper, the second mica paper, the first glass fiber cloth, the second glass fiber cloth, the third mica paper, and the fourth mica paper which are inherited from the vertical surface structure, and further comprises a second mica plate and a third mica plate which are stacked between the first glass fiber cloth and the second glass fiber cloth, and the layers are also bonded by high-temperature glue; the first glass fiber cloth and the second glass fiber cloth are both alkali-free glass fiber cloths with a thickness of 0.4 mm; the first mica plate is an organic silicon mica plate with a thickness of 1 mm, and the second mica plate and the third mica plate are both organic silicon mica plates with a thickness of 2 mm; the first mica paper, the second mica paper, the third mica paper, and the fourth mica paper are all organic silicon mica papers with a thickness of 0.25 mm; the manufacturing process of the screen protection insulation kit comprises the following steps: S01 - laying a polyester film in the mold cavity of a steel mold; S02 - laying the first mica paper on the polyester film, and then applying high-temperature glue on the first mica paper; S03 - bonding the second mica paper on the first mica paper, and then applying high-temperature glue on the second mica paper; S04 - bonding the first glass fiber cloth on the second mica paper, and then applying high-temperature glue on the first glass fiber cloth; bonding the first mica plate corresponding to the vertical surface structure, the second mica plate corresponding to the horizontal surface structure, and the third mica plate on the first glass fiber cloth, and then applying high-temperature glue on the first mica plate, the second mica plate, and the third mica plate respectively; S05 - bonding the second glass fiber cloth on the first mica plate, the second mica plate, and the third mica plate, and then applying high-temperature glue on the second glass fiber cloth; S06 - bonding the third mica paper on the second glass fiber cloth, and then applying high-temperature glue on the third mica paper; S07 - bonding the fourth mica paper on the third mica paper; S08 - laying a polyester film on the fourth mica paper; S09 - closing the steel mold to integrally mold the first mica paper, the second mica paper, the first glass fiber cloth, the first mica plate, the second mica plate, the third mica plate, the second glass fiber cloth, the third mica paper, and the fourth mica paper, and then demolding to obtain a blank; in step S09, the steel mold is kept closed for 40 minutes after closing; S10 - cutting and polishing the blank according to the design size of the finished product, and then drilling screw through holes to obtain the screen protection insulation kit finished product. The mass of the first mica paper, the second mica paper, the third mica paper, the fourth mica paper accounts for 45% of the total weight of the finished product of the protective screen insulation kit, the mass of the first glass fiber cloth and the second glass fiber cloth accounts for 20% of the total weight of the finished product of the protective screen insulation kit, the mass of the first mica plate accounts for 5% of the total weight of the finished product of the protective screen insulation kit, the mass of the second mica plate and the third mica plate accounts for 20% of the total weight of the finished product of the protective screen insulation kit, and the mass of the high-temperature glue coated on each layer accounts for 10% of the total weight of the finished product of the protective screen insulation kit; In steps S02, S03, S06 and S07, the first mica paper, the second mica paper, the third mica paper and the fourth mica paper are respectively folded at the junction of the vertical structure and the horizontal structure to be pasted on the vertical structure and the horizontal structure; and the first mica paper, the second mica paper, the third mica paper and the fourth mica paper are respectively folded to form a plurality of vertical folds corresponding to the area of the vertical structure to match the curvature of the vertical structure; In steps S04 and S05, the first glass fiber cloth and the second glass fiber cloth are respectively folded at the junction of the vertical structure and the horizontal structure to be pasted on the vertical structure and the horizontal structure; and the first glass fiber cloth and the second glass fiber cloth are respectively cut into a plurality of radial strips corresponding to the area of the horizontal structure to match the flatness of the horizontal structure; and the same material cloth as the first glass fiber cloth and the second glass fiber cloth is respectively pasted in the area corresponding to the horizontal structure to shield the gap between the strips.

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