Kiln modular nanometer insulation wallboard

Abstract

This invention proposes a modular nano-insulation wall panel for kilns, comprising a panel body consisting of an inner layer, a middle layer, and an outer layer from the inside out. Several pre-drilled grooves are formed on the back of the panel body, with the inner diameter of each groove gradually decreasing from the opening to the inside. A frame is fixedly connected to the edge of the back of the panel body, and cross-shaped reinforcing ribs are fixedly connected to the front of the panel body. The advantages of this invention are: significantly improved adhesion of the insulation material; combined with the aerogel composite layer inside the panel body, greatly improved overall thermal resistance; continuous curved pre-drilled seams on the four sides of the panel body, filled with ceramic fiber woven tape layers. These seams can be considered expansion joints, and together with the ceramic fiber woven tape layers, they can seal the contact surfaces between adjacent panels. The design of the pre-drilled seams allows for slight thermal expansion displacement between adjacent panels, while the ceramic fiber woven tape layers maintain elastic sealing even at ultra-high temperatures, exhibiting good weather resistance.

Description

Technical Field

[0001] This utility model relates to the field of kiln insulation wall panel technology, and in particular to a modular nano-insulation wall panel for kilns. Background Technology

[0002] In the field of industrial kilns, thermal insulation wall panels are key structural components for maintaining kiln thermal efficiency and reducing energy consumption. Traditional kiln insulation structures mostly use single refractory brick masonry or composite fiber module splicing, but these methods suffer from the following technical bottlenecks: Insufficient heat loss control is a significant issue. Traditional refractory bricks (such as high-alumina bricks) generally have a thermal conductivity higher than 0.8 W / (m·K). Under operating conditions of 1300℃, the outer wall temperature of the kiln can reach over 200℃, resulting in a heat loss rate as high as 15%-20%. While fiber modules (such as aluminosilicate fiberboard) have a lower thermal conductivity, their compressive strength is insufficient, making them prone to pulverization and detachment under long-term high temperatures, leading to a decline in their thermal insulation performance.

[0003] Due to poor adaptability to thermal expansion, traditional wall panel installation requires leaving a 5-10mm expansion joint, which is filled with ceramic fiber cotton or mortar. However, fiber cotton is prone to carbonization and cracking under long-term high temperatures, while mortar cracks due to thermal shock, leading to the leakage of high-temperature flue gas. This type of sealing failure accounts for more than 40% of kiln maintenance cases. Utility Model Content

[0004] The purpose of this invention is to at least solve one of the aforementioned technical defects.

[0005] Therefore, one objective of this utility model is to propose a modular nano-insulation wall panel for kilns, in order to solve the problems mentioned in the background art and overcome the shortcomings of the existing technology.

[0006] To achieve the above objectives, one embodiment of the present invention provides a modular nano-insulation wall panel for kilns, comprising a panel body, wherein the panel body consists of an inner layer, a middle layer and an outer layer from the inside out; The back of the plate has several reserved grooves, and the inner diameter of the reserved grooves gradually decreases from the opening to the inside. A frame is fixedly connected to the edge of the back of the plate, and a cross-shaped reinforcing rib is fixedly connected to the front of the plate. The plate has pre-drilled holes near its four corners, and the front end of each pre-drilled hole is connected to a countersunk hole. A plug ring is embedded in the countersunk hole; The plate has continuous curved pre-reserved slots on its four sides, and the pre-reserved slots are filled with ceramic fiber woven tape layers.

[0007] Preferably, in any of the above schemes, the inner layer of the plate is a silica brick layer, the middle layer is an aerogel composite layer, and the outer layer is a stainless steel layer.

[0008] The above technical solution is adopted: This wall panel is an insulating wall panel installed on the inner wall of a kiln. The panel body consists of an inner layer, a middle layer and an outer layer from the inside to the outside. The middle layer is an insulating layer and the outer layer is a protective layer and a sealing layer.

[0009] The wall panel installation method is as follows: the back of the wall panel is filled with heat insulation material between it and the inner wall of the kiln. The pre-reserved groove design increases the contact area between the wall panel and this material, which greatly improves the adhesion of the heat insulation material. Combined with the aerogel composite layer inside the panel, the overall thermal resistance of the panel is greatly improved. The wall panels are installed at the pre-drilled holes using chemical bolts or pre-embedded bolts and fasteners. After installation, a plug ring is inserted into the countersunk hole, and the sides of adjacent panels are directly spliced ​​and contacted. The four sides of the panel have continuous curved reserved gaps, which are filled with ceramic fiber woven tape layers. The reserved gaps can be regarded as expansion joints. Together with the ceramic fiber woven tape layers, they can seal the contact surfaces between adjacent panels. The design of the reserved gaps allows for slight thermal expansion displacement between adjacent panels, while the ceramic fiber woven tape layers can still maintain elastic sealing at ultra-high temperatures and have good weather resistance.

[0010] Preferably, in any of the above schemes, the reserved grooves are arranged in a linear array on the back of the plate, and the vertical cross-sectional shape of the reserved grooves is trapezoidal.

[0011] The above technical solution is adopted. The wall panel structure consists of three layers from the inside out: Inner layer: silica brick layer, 15-20mm thick, temperature resistant up to 1600℃; Middle layer: aerogel composite layer, made of nano-aerogel and ceramic fiber, 50-60mm thick, thermal conductivity ≤0.03W / (m·K); Outer layer: 304 stainless steel layer, 2-3mm thick, with sandblasted surface treatment, providing both sealing and mechanical protection functions.

[0012] The pre-reserved grooves are distributed on the back of the panel in a linear array. Each groove has a trapezoidal vertical cross-section, a groove opening width of 20mm, a groove bottom width of 15mm, and a depth of 12mm. The grooves are evenly distributed at 30mm intervals to increase the contact area with the filling insulation material.

[0013] The frame consists of stainless steel rectangular tubes (25×40mm cross-section) welded to the back edge of the plate; the reinforcing ribs are cross-shaped stainless steel strips (15mm wide, 3mm thick) welded to the front of the plate to improve the overall bending strength.

[0014] The pre-drilled holes are located at the four corners of the plate, with a diameter of 12mm and a depth that penetrates the plate. The countersunk holes are used to accommodate ceramic plugs that will be embedded after installation.

[0015] The reserved seams and ceramic fiber woven tape layer are located on the four sides of the plate, forming a continuous wavy shape with a seam width of 1.2cm and a depth that penetrates the middle layer. The ceramic fiber woven tape layer is made of zirconium-containing fiber with a density of 280kg / m³, and is pre-compressed and filled in the reserved seams to form an elastic sealing interface.

[0016] Preferably, in any of the above embodiments, the frame is a stainless steel protrusion welded to the plate, and the reinforcing rib is a stainless steel strip welded to the plate.

[0017] The above technical solution is adopted as follows: The manufacturing method of this wall panel is as follows: lamination molding. The inner layer is made of silica bricks cut into standard sizes (such as 600×400×20mm) and the surface is polished smooth. The middle layer is made of aerogel powder and ceramic fiber mixed in a ratio of 3:7 and cured by molding (pressure 15MPa, temperature 200℃). The outer layer is made of laser-cut stainless steel plate, which is bonded to the middle layer with high-temperature epoxy adhesive and then rolled composite.

[0018] Machining involves using a CNC milling machine to machine a pre-reserved groove on the back of the plate, with a groove wall roughness Ra≤6.3μm; pre-reserved holes and countersunk holes are machined at the four corners of the plate using a stamping process.

[0019] For welding and filling, the frame and reinforcing ribs are fixed by argon arc welding, and the welds are inspected by penetrant testing; the ceramic fiber woven tape layer is injected into the reserved gaps under vacuum and then pressurized to 0.5MPa for dense filling.

[0020] Preferably, in any of the above schemes, the diameter of the countersunk hole used to connect chemical bolts and screws is larger than the diameter of the pre-drilled hole.

[0021] Preferably, of any of the above solutions, the plug ring is made of ceramic, and the width of the reserved slot is 1-1.5cm.

[0022] Compared with the prior art, the advantages and beneficial effects of this utility model are as follows: This modular nano-insulation wall panel for kilns has insulation material filling the space between the back of the panel and the inner wall of the kiln. The pre-reserved groove design increases the contact area between the panel and the material, greatly improving the adhesion of the insulation material. Combined with the aerogel composite layer inside the panel, the overall thermal resistance of the panel is greatly improved and the heat loss is small. The four sides of the panel have continuous curved reserved gaps, which are filled with ceramic fiber woven tape layers. The reserved gaps can be regarded as expansion joints. Together with the ceramic fiber woven tape layers, they can seal the contact surfaces between adjacent panels. The design of the reserved gaps allows for slight thermal expansion displacement between adjacent panels, while the ceramic fiber woven tape layers can still maintain elastic sealing at ultra-high temperatures and have good weather resistance.

[0023] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0024] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a first-view structural schematic diagram of the present invention; Figure 2 This is a structural schematic diagram of the present invention from a second perspective; Figure 3 This is a schematic diagram of the structure of the reserved seam in this utility model; Figure 4 This is a schematic diagram of the layer structure of the plate body of this utility model.

[0025] In the diagram: 1-plate, 101-inner layer, 102-middle layer, 103-outer layer, 2-reserved groove, 3-frame, 4-reinforcing rib, 5-reserved hole, 6-countersunk hole, 7-plug ring, 8-reserved gap, 9-ceramic fiber braided tape layer. Detailed Implementation

[0026] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0027] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0028] like Figure 1-4 As shown, the modular nano-insulation wall panel of this kiln includes a panel 1, which consists of an inner layer 101, a middle layer 102 and an outer layer 103 from the inside to the outside. The back of the plate 1 has several reserved grooves 2, and the inner diameter of the reserved grooves 2 gradually decreases from the opening to the inside. A frame 3 is fixedly connected to the edge of the back of the plate 1, and a cross-shaped reinforcing rib 4 is fixedly connected to the front of the plate 1. Pre-drilled holes 5 are provided near the four corners of the plate 1, and the front end of the pre-drilled holes 5 is connected to a countersunk hole 6. A stopper ring 7 is inserted into the countersunk hole 6; The four sides of the plate 1 are provided with continuous curved reserved slots 8, and the reserved slots 8 are filled with ceramic fiber woven tape layers 9.

[0029] Example 1: In plate 1, the inner layer 101 is specifically a silica brick layer, the middle layer 102 is specifically an aerogel composite layer, and the outer layer 103 is specifically a stainless steel layer. Pre-drilled grooves 2 are linearly arranged on the back of plate 1, and the vertical cross-sectional shape of the grooves 2 is trapezoidal. The frame 3 is a stainless steel protrusion welded to plate 1, and the reinforcing ribs 4 are stainless steel strips welded to plate 1. Pre-drilled holes 5 are used to connect chemical bolts and screws, and the diameter of the countersunk hole 6 is larger than the diameter of the pre-drilled hole 5. The plug ring 7 is made of ceramic, and the width of the pre-drilled slot 8 is 1-1.5 cm.

[0030] Example 2: This wall panel is an insulating wall panel installed on the inner wall of a kiln. The panel 1 consists of an inner layer 101, a middle layer 102, and an outer layer 103 from the inside out. The middle layer 102 is the insulating layer, and the outer layer 103 is the protective layer and the sealing layer. The wall panel is installed at the reserved holes 5 using chemical bolts or pre-embedded bolts and fasteners. After installation, a plug ring 7 is inserted into the countersunk hole 6, and the sides of adjacent panels 1 are directly spliced ​​and in contact.

[0031] The wall panel structure consists of three layers from the inside out: Inner layer 101: silica brick layer, 15-20mm thick, temperature resistant up to 1600℃; Middle layer 102: aerogel composite layer, made of nano-aerogel and ceramic fiber, 50-60mm thick, thermal conductivity ≤0.03W / (m·K); Outer layer 103: 304 stainless steel layer, 2-3mm thick, with sandblasted surface, providing both sealing and mechanical protection.

[0032] The reserved grooves 2 are distributed on the back of the plate 1 in a linear array. The vertical cross section of each groove is trapezoidal, with a groove opening width of 20mm, a groove bottom width of 15mm, and a depth of 12mm. The groove spacing is equidistantly distributed at 30mm intervals to increase the contact area with the filling insulation material.

[0033] Frame 3 and reinforcing rib 4: Frame 3 is a stainless steel rectangular tube (section 25×40mm) welded to the back edge of plate 1; reinforcing rib 4 is a cross-shaped stainless steel strip (width 15mm, thickness 3mm) welded to the front of plate 1 to improve the overall bending strength.

[0034] The reserved hole 5 and the countersunk hole 6 are located at the four corners of the plate 1, with a diameter of 12mm and a depth that penetrates the plate 1; the countersunk hole 6 is used to accommodate the ceramic plug ring 7 that will be embedded after installation.

[0035] The reserved seam 8 and the ceramic fiber woven tape layer 9 are located on the four sides of the plate 1, in a continuous wavy shape, with a seam width of 1.2cm and a depth that penetrates the middle layer 102; the ceramic fiber woven tape layer 9 is made of zirconium-containing fiber with a density of 280kg / m³, and is pre-compressed and filled in the reserved seam 8 to form an elastic sealing interface.

[0036] Example 3: Manufacturing method of this wall panel: lamination molding, the inner layer 101 is made of silica bricks cut into standard size (such as 600×400×20mm), and the surface is polished smooth; the middle layer 102 is made of aerogel powder and ceramic fiber mixed in a ratio of 3:7, and cured by molding (pressure 15MPa, temperature 200℃); the outer layer 103 is made of laser-cut stainless steel plate, which is bonded to the middle layer 102 with high temperature epoxy adhesive, and then rolled composite.

[0037] Machining: A pre-reserved groove 2 is machined on the back of plate 1 using a CNC milling machine, with a groove wall roughness Ra≤6.3μm; pre-reserved holes 5 and countersunk holes 6 are machined at the four corners of plate 1 by stamping.

[0038] Welding and filling: Frame 3 and reinforcing rib 4 are fixed by argon arc welding, and the weld is inspected by penetrant testing; ceramic fiber woven tape layer 9 is injected into the reserved gap 8 under vacuum and pressurized to 0.5MPa for dense filling.

[0039] The working principle of this utility model is as follows: Pre-treatment of the kiln wall: cleaning the inner wall of the kiln, drilling holes to install M12 chemical bolts, with an exposed bolt length of 40mm.

[0040] Position the wall panel by inserting the chemical bolts into the pre-drilled holes 5 and adjusting the level (error ≤ 2mm / m); use a torque wrench to tighten the nuts to 45N·m to ensure that the panel 1 fits tightly against the kiln wall.

[0041] Filling and sealing: Pour refractory castable (aluminate cement-based) into the pre-reserved groove 2 on the back of the plate 1, fill and scrape the surface smooth; embed ceramic plug ring 7 into countersunk hole 6, and gently tap with a rubber hammer until it is flush with the surface of the plate 1.

[0042] For joint treatment, when adjacent panels 1 are joined together, the ceramic fiber woven tape layer 9 in the reserved joint 8 is compressed and expanded to form a continuous sealing surface; a high-temperature sealant containing nano-alumina is applied to the outside of the joint, and a secondary protective layer is formed after curing.

[0043] Compared with the prior art, the present invention has the following advantages: The modular nano-insulation wall panel for the kiln has insulation material between the back of the wall panel and the inner wall of the kiln. The design of the pre-reserved groove 2 increases the contact area between the wall panel and the material, which greatly improves the adhesion of the insulation material. Combined with the aerogel composite layer inside the panel 1, the overall thermal resistance of the panel 1 is greatly improved. The four sides of the plate 1 are provided with continuous curved reserved gaps 8. The reserved gaps 8 are filled with ceramic fiber woven tape layers 9. The reserved gaps 8 can be regarded as expansion joints. Together with the ceramic fiber woven tape layers 9, they can seal the contact surfaces between adjacent plates 1. The design of the reserved gaps 8 allows for slight thermal expansion displacement between adjacent plates 1, while the ceramic fiber woven tape layers 9 can still maintain elastic sealing under ultra-high temperature and have good weather resistance.

Claims

1. A modular nano-insulation wall panel for kilns, characterized in that, It includes a plate (1), which consists of an inner layer (101), a middle layer (102) and an outer layer (103) from the inside to the outside. The back of the plate (1) is provided with several reserved grooves (2), and the inner diameter of the reserved grooves (2) gradually decreases from the opening to the inside. A frame (3) is fixedly connected to the edge of the back of the plate (1), and a cross-shaped reinforcing rib (4) is fixedly connected to the front of the plate (1). The plate (1) has reserved holes (5) near its four corners, and the front end of the reserved holes (5) is connected to a countersunk hole (6). A plug ring (7) is embedded in the countersunk hole (6); The plate (1) has continuous curved reserved slots (8) on its four sides, and the reserved slots (8) are filled with ceramic fiber woven tape layers (9).

2. The modular nano-insulation wall panel for kilns as described in claim 1, characterized in that: In the plate (1), the inner layer (101) is specifically a silica brick layer, the middle layer (102) is specifically an aerogel composite layer, and the outer layer (103) is specifically a stainless steel layer.

3. The modular nano-insulation wall panel for kilns as described in claim 2, characterized in that: The reserved slots (2) are arranged linearly on the back of the plate (1), and the vertical cross-sectional shape of the reserved slots (2) is trapezoidal.

4. The modular nano-insulation wall panel for kilns as described in claim 3, characterized in that: The frame (3) is a stainless steel protrusion welded to the plate (1), and the reinforcing rib (4) is a stainless steel strip welded to the plate (1).

5. The modular nano-insulation wall panel for kilns as described in claim 4, characterized in that: The reserved hole (5) is used to connect chemical bolts and screws, and the diameter of the countersunk hole (6) is larger than the diameter of the reserved hole (5).

6. The modular nano-insulation wall panel for kilns as described in claim 5, characterized in that: The plug ring (7) is made of ceramic, and the width of the reserved slot (8) is 1-1.5cm.

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