Heat insulation block unit, heat insulation wall, heat insulation block unit production method, and heat insulation block construction method

Abstract

To provide a heat insulation block unit which can provide an easier repair work in a repair work for heat insulation walls in a heating furnace in which a steel shell is present, particularly, in a repair work for the heat insulation wall on the ceiling side of the heating furnace.SOLUTION: A heat insulation block unit comprises plural heat insulation blocks each provided with a laminated inorganic fiber aggregate mat and a block fixing bracket on the side in contact with a furnace wall, and comprises connection units for connecting the block fixing brackets in the plural heat insulation blocks each other.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an insulating block unit, an insulating wall, a method for manufacturing an insulating block unit, and a method for installing an insulating block. [Background technology]

[0002] Conventionally, heat-resistant concrete called castable concrete has been used to form an insulating wall on the inner surface of the furnace shell of a heating furnace, etc. In recent years, in consideration of the ease of construction of the insulating wall and the insulating properties of the formed insulating wall, insulating materials made of inorganic fibers, which have fire resistance and insulating properties, have been used to line the insulating wall instead of castable concrete.

[0003] Methods for forming insulating walls using insulating material made of inorganic fibers include the paper lining method, in which inorganic fiber mats are stacked parallel to the furnace shell (steel surface) and secured with studs installed perpendicular to the furnace shell; the stack lining method (also known as the H-anchor method), in which inorganic fiber mats are stacked perpendicular to the furnace shell and secured with fixing brackets installed perpendicular to the furnace shell and rods that are fixed to these fixing brackets and pass through the inorganic fiber mats parallel to the furnace shell; and the module method (e.g., Patent Document 1), in which inorganic fiber mats are formed into blocks and an insulating block made by attaching an insulating block fixing bracket (hereinafter sometimes referred to as a "block fixing bracket") to one surface of the block is attached to the insulating block via the block fixing bracket, etc. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2011-226771 Summary of the Invention [Problem to be solved by the invention]

[0005] Of these, the stack lining method has the advantages of low manufacturing costs and quick construction, but because the inorganic fiber mat is pierced with rods, which support the inorganic fiber mat at points, there is a problem that the fixing brackets cannot fully support the inorganic fiber mat, causing problems such as the inorganic fiber mat falling from the furnace shell (especially the ceiling) or gaps forming between the inorganic fiber mat and the furnace shell.In addition, the position where the skewer is inserted into the inorganic fiber mat at the construction site is left to the contractor, and this position can be off, resulting in poor construction accuracy.

[0006] Furthermore, the modular method involves attaching pre-prepared insulation blocks to the furnace shell at the construction site, which improves workability. However, the installation process requires a great deal of time to attach the numerous insulation blocks one by one, and there was a need to reduce this workload, particularly when installing on the ceiling, which is a heavy workload, or when installing under harsh, humid and hot conditions.

[0007] As an alternative method, a prefabricated construction method is known in which the steel shell is cut at the location where the insulation block is to be attached, a prefabricated panel of the same shape is prepared with the insulation block already attached to the steel shell, and the panel is then attached to the cut location of the steel shell.

[0008] However, the above-mentioned prefabricated construction method requires the work of cutting the steel shell and the work of welding the steel shell of the panel to the existing steel shell, resulting in a large-scale construction work. Furthermore, gas pipes and the like are installed on the ceiling side of the heating furnace, and from a safety perspective, it is not desirable to perform welding work on the ceiling side. Furthermore, the insulation panel including the steel shell is heavy, so it cannot be lifted with a simple chain block, and the lifting work becomes large-scale.

[0009] Based on the above, an object of the present invention is to provide an insulating block unit, an insulating wall, a method for manufacturing an insulating block unit, and a method for installing insulating blocks that can provide easier repair work when repairing insulating walls in a heating furnace that has a steel shell, particularly when repairing insulating walls on the ceiling side of the heating furnace. [Means for solving the problem]

[0010] As a result of extensive research aimed at solving the above problems, the present inventors have discovered the following. -By connecting multiple insulation blocks with a connecting unit of a specific structure to form an insulation block unit comprising multiple insulation blocks, it has become possible to install insulation blocks in a simple manner. This construction method eliminates the need to cut the existing steel shell. Unlike prefabricated panels with steel skin and insulation blocks, insulation block units are light in weight, so they can be lifted using a simple chain block. By adjusting the number of insulation blocks to be combined and the way they are combined, insulation block units of various shapes and sizes can be formed, making it possible to accommodate repair areas of various shapes and sizes. - It is possible to check the areas of the insulation wall that need repair at the construction site and adjust the size and shape of the insulation block unit to fit those areas, allowing for flexible response according to on-site needs.

[0011] Based on the above, the present inventors have completed the following invention. [1] A plurality of insulating blocks each having a laminated inorganic fiber aggregate mat and a block fixing metal fitting on the side in contact with the furnace wall; a connecting unit that connects the block fixing metal fittings of the plurality of heat insulating blocks to each other; Insulation block unit.

[0012] [2] An insulating block unit as described in [1], wherein the block fixing metal fittings are plate-shaped bodies extending in the stacking direction of the inorganic fiber aggregate mat in the insulating block, and the connecting units are members that connect the block fixing metal fittings to each other.

[0013] [3] An insulating block unit described in [1] or [2], wherein the block fixing hardware is a member formed by combining, in a cross shape, a plate-like body extending in the stacking direction of the inorganic fiber aggregate mat in the insulating block and a plate-like body extending in a direction perpendicular to the stacking direction.

[0014] [4] The heat insulating block unit according to any one of [1] to [3], wherein the block fixing metal fittings and the connecting unit are integrated.

[0015] [5] The heat insulating block unit according to any one of [1] to [4], wherein the inorganic fiber aggregate mat is formed by folding one long mat.

[0016] [6] An insulating wall comprising the insulating block unit according to any one of [1] to [5].

[0017] [7] A step of preparing a plurality of insulating blocks each having a mat of laminated inorganic fiber aggregate and a metal fitting for fixing the block on the side contacting the furnace wall; A step of determining the number and combination of the heat insulating blocks according to the area where the heat insulating blocks are to be installed; a step of connecting the block fixing metal fittings of the plurality of insulation blocks with connecting units in accordance with the determination; A method for manufacturing an insulating block unit, comprising:

[0018] [8] A method for manufacturing an insulating block unit according to [7], in which the block fixing fittings and the connecting unit are integrated.

[0019] [9] A method for manufacturing an insulating block unit described in [7] or [8], wherein in the step of preparing a plurality of the insulating blocks, a mat of the inorganic fiber aggregate is prepared by folding one long mat.

[0020]

[10] A method for constructing an insulating block, comprising a step of installing an insulating block unit manufactured by the method for manufacturing an insulating block unit according to any one of [7] to [9] in a furnace shell. [Effects of the Invention]

[0021] According to the insulating block unit of the present invention, it is possible to provide a simpler repair work for the insulating wall in a heating furnace having an iron shell, particularly for the insulating wall on the ceiling side of the heating furnace. [Brief explanation of the drawings]

[0022] [Figure 1] 1(a) is a schematic diagram showing how a heat insulating block 10 is connected to a connection unit 20. FIG. [Figure 2] Fig. 2(a) is a perspective view of the heat insulating block 10. Fig. 2(b) is a conceptual diagram of the manufacturing process of the heat insulating block 10. [Figure 3] FIG. 3 is a schematic cross-sectional view of the block fixing metal fitting 12. As shown in FIG. [Figure 4] Fig. 4(a) is a perspective view of the connecting unit 20. Fig. 4(b) is a cross-sectional view showing the connecting unit 20 and the block fixing metal fitting 12 in a connected state. Fig. 4(c) is a cross-sectional view showing another form of the connecting unit 20 and the block fixing metal fitting 12 in a connected state. [Figure 5] Fig. 5(a) is a schematic diagram showing a state in which the block fixing metal fittings 12 and the connecting unit 20 are integrated together. Fig. 5(b) is a schematic diagram showing another form in which the block fixing metal fittings 12 and the connecting unit 20 are integrated together. Fig. 5(c) is a schematic diagram showing the connection of the heat insulating blocks 10 together when a member in which the block fixing metal fittings 12 and the connecting unit 20 are integrated together is used. [Figure 6] FIG. 6 is a schematic diagram showing the state when the heat insulating block unit 100 is installed in the furnace shell. DETAILED DESCRIPTION OF THE INVENTION

[0023] Hereinafter, an insulating block unit, an insulating wall, and a method for manufacturing an insulating block unit will be described as an example of an embodiment of the present invention. However, the scope of the present invention is not limited to the embodiment described below. Unless otherwise specified, the description "a to b" indicating a numerical range means "a or more and b or less," and also includes the meanings "preferably greater than a" and "preferably smaller than b." Furthermore, even if the upper and lower limits of the numerical ranges in this specification are slightly outside the numerical range specified by the present invention, they are considered to be included in the equivalent range of the present invention as long as they have the same functional effects as those within the numerical range.

[0024] <Insulating block unit 100> As shown in Figure 1(a) in the state before connection and in Figure 1(b) in the state after connection, the insulating block unit 100 of the present invention comprises a plurality of specified insulating blocks 10 and a connecting unit 20 that connects the block fixing fittings 12 in the insulating blocks to each other.

[0025] (Insulation Block 10) As shown in Figure 2(a) as an oblique view of the insulating block 10 and in Figure 2(b) as a conceptual diagram of the manufacturing process of the insulating block 10, the insulating block 10 has a mat 11 of folded inorganic fiber aggregate and a block fixing metal fitting 12 on the side that contacts the furnace shell.

[0026] Folded inorganic fiber aggregate mat 11 The inorganic fibers forming the folded inorganic fiber aggregate mat 11 are not particularly limited, and examples thereof include single or composite fibers of silica, alumina / silica, and zirconia, spinel, titania, and calcia containing these. Among these, alumina / silica fibers, particularly polycrystalline alumina / silica fibers, are particularly preferred in terms of heat resistance, fiber strength (toughness), and safety. Alumina / silica fibers having an alumina ratio of 70 to 80% by mass and a silica ratio of 30 to 20% by mass are particularly preferred.

[0027] As the inorganic fiber aggregate mat 11, a mat (needle blanket) in which a needling process is applied to an aggregate of inorganic fibers that does not substantially contain fibers with a diameter of 3 μm or less is preferred, in order to ensure safety while increasing heat resistance and durability. The bulk density of the inorganic fiber aggregate mat 11 is not particularly limited, but from the viewpoint of the heat resistance and strength of the resulting heat insulating block 10, it is preferred that the bulk density be 85 kg / m 3 ~150kg / m 3 is preferred, and 90 kg / m 3 ~140kg / m 3 is more preferable. The thickness of the inorganic fiber aggregate mat 11 is appropriately selected, but is preferably 10 to 30 mm, more preferably 12.5 to 27 mm, from the viewpoints of workability and strength. If the thickness is too thin, work becomes time-consuming, and if the thickness is too thick, it becomes difficult to maintain the structure when folded. The size of the inorganic fiber aggregate mat 11 is not particularly limited, and can be cut into an appropriate size depending on the desired size of the heat insulating block.

[0028] ·Folding method of inorganic fiber aggregate mat 11 The method of folding the inorganic fiber aggregate mat 11 is not particularly limited, as long as there are folds on the surface of the insulating block 10 that will be installed in the furnace shell (surface P1 on which the block fixing bracket 12 is installed in Figure 2(a)). From the perspective of firmly fixing the insulating block 10 to the furnace shell, it is preferable that there are at least two folds on the surface P1 of the insulating block 10 that will be installed in the furnace shell, and four or more folds are more preferable. The upper limit on the number of folds depends on the size of the insulating block 10, but is preferably 10 or less, and more preferably 8 or less. In the embodiment shown in Figure 2(a), five folds are formed on the surface P1 of the insulating block 10 that will be installed in the furnace shell.

[0029] The method of folding the inorganic fiber aggregate mat 11 may be to fold one long mat zigzag as shown in Figure 2(b), or to combine multiple long mats zigzag folded together, or to prepare multiple mats folded in half and assemble them with the folds aligned on the side P1.

[0030] There is no particular limitation on the bulk density of the insulating block 10, but it is preferably 96 kg / m 3 ~160kg / m 3 is preferred, and 100 kg / m 3 ~140kg / m 3 It is preferable that the folded inorganic fiber aggregate mat 11 constituting the insulating block 10 is ultimately in a compressed state. In other words, it is preferable that the folded inorganic fiber aggregate mat 11 is compressed with the beam 14, which will be described later, inserted and fixed in place.

[0031] The compression ratio is preferably 10% or more, more preferably 15% or more, and even more preferably 20% or more, from the viewpoint of improving the heat resistance and durability of the insulating block 10. Furthermore, from the viewpoint of preventing deformation of the beam 14, the upper limit is preferably 40% or less. Note that by increasing the compression ratio, the bulk density of the insulating block 10 increases, improving the heat resistance of the insulating block 10.

[0032] The insulation block 10 can be compressed and its structure maintained by stitching with alumina rope or the like. The bulk density of the insulation block 10 can also be increased by folding and stacking the inorganic fiber aggregate mat 11, compressing it by pressing down both sides of the compressed surface with pressure plates 16 such as plywood or metal plates, and securing it with bands 18. While Fig. 2(a) shows a configuration in which the compression is maintained by bands 18 and pressure plates 16, the compressed state can also be maintained by bands 18 alone, without using pressure plates 16.

[0033] After installation, the bands 18 are cut to release the compression of the insulating blocks 10, allowing the insulating blocks 10 to be tightly attached to each other and fixed to the furnace shell. 1(b), when forming the insulation block unit 100, the band 18a surrounding the side surfaces of the insulation block 10 (the other four surfaces excluding the surface P1 facing the furnace shell and the surface facing it) may be cut off. This is because, after installation in the furnace shell, the band 18a will be buried between the insulation blocks 10, making cutting it difficult.

[0034] In addition, the band 18b that surrounds the furnace shell side surface P1 of the insulating block 10 and the opposing surface so as to be in contact with it is exposed to the inside of the furnace even after installation in the furnace shell and can be cut and removed, so the band 18b can be cut and removed after installation in the furnace shell.

[0035] 12 block fixing brackets A block fixing bracket 12 can be attached to the surface P1 of the insulation block 10 that contacts the furnace shell. An insulation block unit 100 comprising multiple insulation blocks 10 can be installed in the furnace shell by connecting the block fixing bracket 12 to a stud provided on the furnace shell (for example, by inserting the stud provided on the furnace shell into a hole 122 provided in the block fixing bracket 12 and fastening it with a nut from the side of the inorganic fiber aggregate mat 11 on the back surface of the block fixing bracket 12). Alternatively, an insulation block unit 100 comprising multiple insulation blocks 10 can be installed in the furnace shell by welding a stud to the block fixing bracket 12, passing the stud through a hole formed in the furnace shell, and fastening it with a nut or the like from outside the furnace.

[0036] The block fixing hardware 12 may be a plate-like body extending in the stacking direction of the folded inorganic fiber aggregate mat 11 as shown in Figure 2(a) (hereinafter, this may be referred to as an "I-shaped block fixing hardware"), but is preferably a member (hereinafter, this may be referred to as a "cross-shaped block fixing hardware") that combines a plate-like body extending in the stacking direction of the folded inorganic fiber aggregate mat 11 and a plate-like body extending in a direction perpendicular to the stacking direction as shown in Figure 1(a).

[0037] When I-shaped block fixing fittings are used, the I-shaped block fixing fittings can be connected to each other with a connecting unit 20 described below to form an insulating block unit 100 having insulating blocks 10 lined up in a row. In this case, the number of connected blocks is not particularly limited, but from the viewpoint of ease of handling, it is preferable to connect 2 to 6 blocks.

[0038] When cross-shaped block fixing hardware is used, the cross-shaped block fixing hardware can be connected vertically and horizontally using connecting units 20 described below, thereby connecting the insulating blocks 10 in a 3x3 arrangement, for example, as shown in FIG. 1(a) to form an insulating block unit 100. The number of connections is not particularly limited in this case, but from the standpoint of ease of handling, examples of connection patterns include 2x2, 3x3, 4x4, 2x3, 2x4, 3x4, 2x5, 3x5, and 3x6. Of these, 2x3, 2x4, 3x3, 4x4, and 3x6 connection patterns are preferred.

[0039] The shape of the block fixing metal fittings 12 is a plate-like body extending in the stacking direction of the inorganic fiber aggregate mat 11, as shown in Figure 2(b), and from the viewpoint of providing strength, it is preferable that the cross section be U-shaped.For example, it may have a cross-sectional shape with an inner flange as shown in 12A in Figure 3(a), or a cross-sectional shape with an outer flange as shown in 12B, but other shapes are also acceptable as long as they satisfy the viewpoints of providing a predetermined strength and of connectivity with the connecting unit 20 described later.

[0040] The block fixing hardware 12 preferably has a hole 122 in the center of the lamination direction of the inorganic fiber aggregate mat 11, as shown in Figure 2(b), or preferably has a stud instead of a hole at the same location, as shown in Figure 1(a). In the cross-shaped block fixing hardware, the method of connecting the plate-like body extending in the stacking direction of the folded inorganic fiber aggregate mat 11 and the plate-like body extending in a direction perpendicular to the stacking direction is not particularly limited, and the two components may be joined by welding, or they may be formed as a single component from the beginning. A slit 124 for inserting the blade 142 of the beam 14 is formed in the plate-like body extending in the lamination direction of the folded inorganic fiber aggregate mat 11.

[0041] From the viewpoint of strength and heat resistance, the material of the block fixing metal fittings 12 is preferably heat-resistant stainless steel such as SUS310S or SUS304.

[0042] (Method of manufacturing the heat insulating block 10) An example of a method for manufacturing the heat insulating block 10 will be described below.

[0043] First, an inorganic fiber aggregate mat 11 having a desired width and length is cut out. The cut inorganic fiber aggregate mat 11 is alternately folded and stacked as shown in Fig. 2(b). Also, as shown in Fig. 2(b), a beam 14 is attached inside the fold of the inorganic fiber aggregate mat 11 so that the blade faces the furnace shell side of the insulation block 10 to be formed. The beam 14 has the function of fixing the block fixing metal fitting 12 and the folded inorganic fiber aggregate mat 11, and as shown in the figure, is inserted into the folded portion of the inorganic fiber aggregate mat 11, and the blade 142 of the beam 14 penetrates the mat 11 and protrudes toward the furnace shell side of the insulation block 10, and as will be explained later, this blade is fixed to the block fixing metal fitting 12. Furthermore, because the beam 14 is inserted into the inorganic fiber aggregate mat 11 and is positioned on the furnace wall side when installed on the furnace wall, damage due to heat can be suppressed.

[0044] The number of beams 14 is not particularly limited as long as it can attach the block fixing metal fittings 12, but from the viewpoint of bonding strength, it is preferably four or more. The material of the beams 14 is not particularly limited as long as it can exhibit heat resistance when used in a furnace, and examples thereof include SUS310S and SUS304. The shape of the beams 14 is not particularly limited as long as it can fix the folded inorganic fiber aggregate mat 11 and the block fixing metal fittings 12, and examples thereof include a shape in which a triangular blade is welded to a round bar as shown in the figure.

[0045] If the inorganic fiber aggregate mat 11 is not folded zigzag but is instead stacked as a plate, the block fixing hardware 12 and the inorganic fiber aggregate mat cannot be fixed using the beam 14. In this case, a cross skewer with a support bracket welded thereto is inserted through the stacked mats. While the present invention does not exclude the use of such a cross skewer, from the standpoint of durability, it is preferable to fix the block fixing hardware 12 and the inorganic fiber aggregate mat 11 using the beam 14.

[0046] 2(b), guide pipes 15 can also be attached inside the folds of the inorganic fiber aggregate mat 11. The holes in the guide pipes 15 correspond to the holes 122 in the block fixing brackets 12, and serve as guides for tightening nuts from inside the furnace to join the studs provided on the furnace shell to the block fixing brackets 12 fixed to the insulation blocks 10. The number of guide pipes 15 in the insulation blocks 10 corresponds to the number of studs corresponding to each insulation block 10. Note that after the nuts have been tightened, the guide pipes 15 should preferably be removed, as their function has been fulfilled. As mentioned above, the guide pipe 15 is used when a stud is formed in the furnace shell and connected to the block fixing bracket 12. However, in a configuration in which a stud is formed in the block fixing bracket 12 and this stud is passed through a hole formed in the furnace shell to fix the furnace shell and the block fixing bracket 12, the guide pipe 15 is not necessary.

[0047] The material of the guide pipe 15 is not particularly limited, and metal, cardboard, or plastic cylinders can be used. The inner diameter depends on the diameter of the stud and the size of the bolt, but is preferably 10 to 30 mm. Furthermore, it is preferable to use nuts made of heat-resistant stainless steel such as SUS310S or SUS304.

[0048] Generally, an inorganic fiber aggregate mat 11 installed on a furnace wall is fixed to the furnace wall by its own repulsive force, but the block fixing metal fittings 12 are used to firmly fix the insulating block 10 to the furnace wall in addition to the repulsive force of the mat. Because the block fixing metal fittings 12 are attached to the furnace wall (steel shell), they are preferably made of a material that can suppress damage from heat, and are preferably made of heat-resistant stainless steel such as SUS310S or SUS304.

[0049] 2(a), the sides are then held down with similarly sized holding plates 16, and the inorganic fiber aggregate mat 11 is compressed to a predetermined thickness in the lamination direction via the holding plates 16 using a compression packing machine or the like, and fixed with bands 18. The bands 18 are used to compress and fix the insulation block 10 to a predetermined size. There are no particular restrictions on the material of the bands 18 as long as they perform this function, but for example, polypropylene (PP) bands, polyethylene (PE) bands, iron bands, etc. can be used.

[0050] The pressure plates 16 are attached to the sides of the insulation blocks 10 and serve to protect the insulation blocks 10 when they are compressed by the bands 18. After the insulation block unit 100, which includes multiple insulation blocks 10, is installed on the furnace wall, the bands 18 are cut and the pressure plates 16 are removed. The material of the pressure plates 16 is not particularly limited and can be selected as appropriate from plywood, wood, steel, plastic, cardboard, and the like. The shape of the pressure plates 16 is not particularly limited, but is selected to match the shape of the side surfaces of the insulation blocks 10. The size of the pressure plates 16 is not particularly specified, but it is preferable that they be slightly smaller than the size of the insulation blocks 10.

[0051] Thereafter, the block fixing metal fittings 12 are attached to the blades 142 of the beams 14 protruding from the inorganic fiber aggregate mat 11. For example, the block fixing metal fittings 12 can be fixed to the beams 14 by passing the blades 142 of the beams 14 through the slits 124 provided in the block fixing metal fittings 12, bending the blades, and fastening them with welding or screws.

[0052] (20 connection units) The heat insulating block unit 100 of the present invention can be formed by connecting the block fixing metal fittings 12 of the heat insulating blocks 10 together with the connecting units 20. The shape of the connecting unit 20 is not particularly limited as long as it can connect the block fixing fittings 12 together, but for example, it can be an elongated member extending in the same direction as the block fixing fittings 12, as shown in Figure 4(a). From the viewpoint of strength and heat resistance, the material of the connecting unit 20 is preferably heat-resistant stainless steel such as SUS310S or SUS304.

[0053] Furthermore, the connecting unit 20 has a longitudinal cross-sectional shape formed to cover the block fixing fitting 12, as shown in Figures 4(b) and 4(c), in order to connect with the block fixing fitting 12. Figure 4(b) corresponds to the block fixing fitting 12A, and Figure 4(c) corresponds to the block fixing fitting 12B. By using such a cross-sectional shape, it becomes possible to freely adjust the distance between the connecting unit 20 and the block fixing fitting 12 by sliding them while connecting them. Note that the shape shown in Figure 4 is merely an example, and other shapes may be used as long as they have the same function.

[0054] 4(a), adjacent block fixing metal fittings 12 are inserted into the connection unit 20 from both sides of the connection unit 20, and the distance between adjacent block fixing metal fittings 12 inside the connection unit 20 can be freely adjusted. This makes it possible to adjust the distance between the insulating blocks 10 to a desired distance and form an insulating block unit 100.

[0055] 4(a) has recessed notches 22 formed at both ends for connection to studs formed on the block fixing hardware 12. The insulation block 10 and the connection unit 20 can be fixed together by connecting the recessed notches 22 to the studs and fastening them with nuts. In this case, the longitudinal length of the connection unit 20 determines the distance between the insulation blocks, so the distance between the insulation blocks 10 can be adjusted by adjusting the longitudinal length of the connection unit 20.

[0056] Another possible configuration of the connecting unit 20 is one that includes, for example, a sliding portion having a recessed notch 22 and a base portion into which the sliding portion is slidably inserted. In this case, two sliding portions are slidably inserted into both ends of the base portion, and the block fixing hardware 12 is slidably inserted into the sliding portions. Furthermore, by sliding the sliding portions relative to the base portion according to the size of the insulation block 10, one connecting unit 20 can accommodate different sizes of insulation block 10. The sliding portions and the base portion are fixed by welding after size adjustment.

[0057] Another possible embodiment of the connecting unit 20 is one in which a plurality of connecting units 20 are prepared, each with a different distance between a pair of recessed cutouts 22. In this case, by selecting a connecting unit 20 with an appropriate distance between the recessed cutouts 22 depending on the size of the insulating block 10, it is possible to accommodate different sizes of insulating block 10.

[0058] In either of the above cases, even if there are gaps between the insulating blocks 10 in the insulating block unit 100 when the connecting unit 20 is fixed to the insulating block 10, the gaps can be filled by the repulsive force of the inorganic fiber aggregate mat 11 after the band 18 is removed.

[0059] As shown in Figures 5(a) and 5(b), the connecting units 20 and the block fixing fittings 12 may be integrated. As shown in Figure 5(a), one block fixing fitting 12 may be integrated with one connecting unit 20, or as shown in Figure 5(b), one block fixing fitting 12 may be integrated with two connecting units 20, or one block fixing fitting 12 may be integrated with three connecting units 20, or one block fixing fitting 12 may be integrated with four connecting units 20.

[0060] As shown in Figure 5(c), whether or not adjacent block fixing fittings 12 are integrated can be determined based on whether they have connecting units 20. The integration method is not particularly limited, and the block fixing fittings 12 and the connecting units 20, which are separate members, may be connected by welding, or they may be formed as a single member from the beginning.

[0061] <Method of manufacturing the heat insulating block unit 100> Each step of the manufacturing method for the heat insulating block unit 100 will be explained below.

[0062] (Step of preparing a plurality of heat insulating blocks 10) In the step of preparing a plurality of insulating blocks 10, a plurality of insulating blocks 10 are fabricated according to the method described above, and the number of insulating blocks required in the following steps is prepared. A plurality of connecting units are also prepared.

[0063] (Process to determine the number and combination of insulation blocks) The number and shape (combination) of the insulating blocks 10 are determined so as to have the required shape and area according to the shape of the insulating block that needs repair among the insulating blocks already installed in the furnace shell. The number and combination of the insulating blocks 10 are not particularly limited, and they may be squares of various sizes, such as the 3x3 shape shown in Figure 1(a), or rectangular shapes such as 1x3, 2x3, or 2x6. Alternatively, they may have a shape with some corners missing, or a shape with the center missing, and even complex shapes can be accommodated as appropriate.

[0064] (Step of connecting block fixing metal fittings 12 together with connecting units 20) In the case of a connecting unit 20 having the shape shown in Figure 4(a), the insulating blocks 10 can be connected to each other by inserting the block fixing fittings 12 into the connecting unit 20 from both ends and fixing the concave cutouts 22 of the connecting unit 20 to the studs of the block fixing fittings 12. In the case of a connecting unit 20 having the shape shown in Figure 4(a), the distance between the connected insulating blocks 10 is determined by the longitudinal length of the connecting unit 20, but the distance between the connected insulating blocks 10 may also be determined by restricting the sliding of the block fixing fittings 12 between the connecting unit 20 and the block fixing fittings 12, for example, with a stopper provided on the connecting unit 20.

[0065] 1(b), the insulating block unit 100 can be held down on its sides by retaining plates 120 and secured with bands (not shown), thereby maintaining its shape and protecting it from external impacts. The retaining plates 120 can be made of the same material as the retaining plates 16 described above. The retaining plates 120 are removed after the insulating block unit 100 has been installed in the furnace shell, and a pull-out band 130 may be installed to facilitate this removal.

[0066] <How to install insulation blocks> (Step of installing the heat insulating block unit 100 in the furnace shell) By installing the above-described heat insulating block unit 100 of the present invention in the furnace shell, it becomes possible to efficiently install the heat insulating blocks 10 in the furnace shell.

[0067] The insulating block unit 100 of the present invention is lighter than conventional insulating block panels with steel shells, so it can be lifted using a chain block and installed on the furnace ceiling in a simple and safe manner. When lifting the insulation block unit 100, for example, as shown in Figure 6, a lifting member (e.g., an eye nut 140) can be attached to the stud 126 on the block fixing bracket 12, and used to lift the unit. Then, the studs 126 are passed through holes provided in the furnace shell, and the studs 126 are fixed with nuts or the like from the outside of the furnace shell, thereby allowing the heat insulating block unit 100 to be installed in the furnace shell. Furthermore, a heat insulating mat 120 may be installed between the furnace shell and the heat insulating block unit 100 to provide heat insulation and further protect the furnace shell.

[0068] <Insulated wall> As described above, an insulating wall is formed by installing the insulating block unit 100 of the present invention in the furnace shell. This eliminates the need to install individual insulating blocks 10 multiple times, as was done in the conventional method, and allows for an insulating wall to be efficiently formed in the furnace shell. The insulating wall may be installed on any wall surface within the heating furnace, such as the ceiling or side of the furnace. In particular, when installing an insulating wall on the furnace ceiling or repairing an insulating wall on the ceiling, lifting the insulating material is essential. Reducing and simplifying the number of lifting operations greatly improves the efficiency of the work. [Industrial Applicability]

[0069] The insulating block unit 100 of the present invention can provide easier repair work for insulating walls in a heating furnace that has an iron shell, particularly for insulating walls on the ceiling side of the heating furnace. [Explanation of symbols]

[0070] 100: Insulation block unit 10: Insulation block 11: Folded inorganic fiber aggregate mat 12: Block fixing hardware 14: Beam 15: Guide pipe 20: Connecting unit

Claims

1. The heat insulating block is provided with a plurality of laminated inorganic fiber aggregate mats and a metal fitting for fixing the block on the side contacting the furnace wall, a connecting unit that connects the block fixing metal fittings of the plurality of heat insulating blocks to each other; Insulation block unit.

2. The insulating block unit according to claim 1, wherein the block fixing metal fittings are plate-shaped bodies extending in the stacking direction of the inorganic fiber aggregate mat in the insulating block, and the connecting unit is a member that connects the block fixing metal fittings to each other.

3. The insulating block unit according to claim 1 or 2, wherein the block fixing hardware is a member formed by combining, in a cross shape, a plate-like body extending in the stacking direction of the inorganic fiber aggregate mat in the insulating block and a plate-like body extending in a direction perpendicular to the stacking direction.

4. The heat insulating block unit according to claim 1 or 2, wherein the block fixing metal fittings and the connecting unit are integrated.

5. 3. The heat insulating block unit according to claim 1, wherein the inorganic fiber aggregate mat is formed by folding one long mat.

6. An insulating wall comprising the insulating block unit according to claim 1 or 2.

7. preparing a plurality of insulating blocks each including a mat of laminated inorganic fiber aggregates and a metal fitting for fixing the block on the side that contacts the furnace wall; A step of determining the number and combination of the heat insulating blocks according to the area where the heat insulating blocks are to be installed; a step of connecting the block fixing metal fittings of the plurality of insulation blocks with connecting units in accordance with the determination; A method for manufacturing an insulating block unit, comprising:

8. The method for manufacturing an insulating block unit according to claim 7 , wherein the block fixing metal fittings and the connecting unit are integrated.

9. 9. The method for manufacturing an insulating block unit according to claim 7, wherein in the step of preparing a plurality of insulating blocks, the inorganic fiber aggregate mats are prepared by folding one long mat.

10. A method for constructing an insulating block, comprising the step of installing an insulating block unit manufactured by the method for manufacturing an insulating block unit according to claim 7 or 8 in a furnace shell.

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