Insulation block unit, insulation wall, manufacturing method of insulation block unit, and construction method of insulation block

Abstract

To provide an insulating block unit that can facilitate easier repair work in repair work of an insulating wall in a heating furnace having an iron shell, particularly in repair work of an insulating wall on the ceiling side of the heating furnace. [Solution] An insulating block unit comprising a plurality of insulating blocks each having a mat of stacked inorganic fiber aggregate and a block fixing metal fitting on the side in contact with the furnace wall, and a connecting unit that connects the block fixing metal fittings in the plurality of insulating blocks to each other.

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 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 workability of the insulating wall and the insulating properties of the formed insulating wall, insulating materials made of inorganic fibers having fire resistance and insulating properties have been used to line the inside instead of castable.

[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 (iron skin surface) and fixed with studs set perpendicular to the furnace shell; the stack lining method (so-called H-anchor method), in which inorganic fiber mats are stacked perpendicular to the furnace shell and fixed with a fixing bracket fixed perpendicular to the furnace shell and a rod fixed to this fixing bracket and passing through the inorganic fiber mat 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 blocks is attached to the insulating block via a block fixing bracket to a stud set perpendicular to the furnace shell. [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 advantage 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. Also, at the construction site, the position where the skewer is inserted into the inorganic fiber mat is left to the contractor, and this position can shift, resulting in poor construction accuracy.

[0006] In addition, the modular method involves attaching prefabricated insulation blocks to the furnace shell at the construction site, which improves workability. However, during installation, a great deal of time is spent attaching a large number of insulation blocks one by one, and there was a need to reduce this workload, particularly in installation work on the ceiling, which is a heavy workload, or in installation work under harsh hot and humid 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 prefabricated construction method requires cutting the steel shell and welding the steel shell of the panel to the existing steel shell, which makes the construction work large-scale. In addition, gas pipes and the like are installed on the ceiling side of the heating furnace, and from the viewpoint of safety, it is not preferable to perform welding work on the ceiling side in particular. Furthermore, since the insulation panel including the steel shell is heavy, it cannot be lifted by 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 constructing insulating blocks that can provide easier repair work in repair work of insulating walls in a heating furnace where an iron shell is present, particularly in repair work of insulating walls on the ceiling side of a heating furnace. [Means for solving the problem]

[0010] As a result of extensive investigations aimed at solving the above problems, the present inventors have discovered the following. By combining multiple insulation blocks with connecting units of a specific structure to form an insulation block unit that comprises multiple insulation blocks, it has become possible to install the insulation blocks in a simple manner. This construction method eliminates the need to cut the existing steel shell. Unlike prefabricated panels that have steel skin and insulation blocks, insulation block units are light in weight, so they can be hoisted 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 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 metal fitting for fixing the block on the side in contact with the furnace wall; A connecting unit is provided to connect the block fixing metal fittings in the plurality of insulation blocks to each other. Insulation block unit.

[0012] [2] The insulating block unit 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 as described in [1] or [2], wherein the block fixing metal fittings are 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 fitting and the connecting unit are integrated together.

[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 an insulating block unit according to any one of [1] to [5].

[0017] [7] 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 in contact with the furnace wall; A step of determining the number and combination method of the insulation blocks according to the area in which the insulation blocks are to be installed; a step of connecting the block fixing fittings of the plurality of insulation blocks with a connecting unit in accordance with the determination; A method for manufacturing an insulating block unit comprising:

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

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

[0020]

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

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

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

[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. In addition, 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 of "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 ranges specified by the present invention, they are included in the equivalent range of the present invention as long as they have the same action and effect as those within the numerical range.

[0024] <Thermal insulation block unit 100> As shown in Figure 1(a) showing the state before connection and in Figure 1(b) showing 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 block fixing fittings 12 in the insulating blocks to each other.

[0025] (Insulation Block 10) As shown in Figure 2(a) which is an oblique view of an insulating block 10, and in Figure 2(b) which is a conceptual diagram of a manufacturing process for 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, zirconia containing these, spinel, titania, and calcia. Among these, alumina / silica-based fibers, particularly polycrystalline alumina / silica-based fibers, are particularly preferred in terms of heat resistance, fiber strength (toughness), and safety. In particular, alumina / silica fibers having an alumina ratio of 70 to 80% by mass and a silica ratio of 30 to 20% by mass are 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 preferable, for the reason of increasing heat resistance and durability while ensuring safety. 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 preferably 85 kg / m 3 ~150kg / m 3 is preferred, and 90 kg / m 3 ~140kg / m 3 is more preferred. 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 is time-consuming, and if the thickness is too thick, there is a problem that it is 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 a suitable size according to 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, so long as there are folds on the surface of the insulation block 10 that will be installed in the furnace shell (surface P1 on which the block fixing metal fittings 12 are installed in Figure 2(a)). From the viewpoint of firmly fixing the insulation block 10 to the furnace shell, it is preferable that there are at least two folds on the surface P1 of the insulation block 10 that will be installed in the furnace shell, and more preferably four or more folds. The upper limit on the number of folds depends on the size of the insulation 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 insulation block 10 that will be installed in the furnace shell.

[0029] The method of folding the inorganic fiber aggregate mat 11 may be, as shown in Figure 2(b), by folding one long mat in a zigzag fashion, or by combining multiple long mats in a zigzag fashion, or by preparing multiple mats folded in half and combining them with the folds aligned on the side P1.

[0030] There is no particular restriction 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 insulation block 10 is finally in a compressed state. In other words, it is preferable that the folded inorganic fiber aggregate mat 11 is compressed in a state in which a beam 14, which will be described later, is inserted and fixed.

[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. Moreover, the upper limit is preferably 40% or less, from the viewpoint of preventing deformation of the beam 14. Note that by increasing the compression ratio, the bulk density of the insulating block 10 increases, and the heat resistance of the insulating block 10 improves.

[0032] The insulation block 10 can be compressed and its structure can be maintained by sewing with an 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 both sides of the compressed surface with pressure plates 16 such as plywood or metal plates, and fixing with bands 18. In Fig. 2(a), a form in which the compression is maintained by the bands 18 and pressure plates 16 is shown, but the compressed state can also be maintained by the bands 18 alone without using the pressure plates 16.

[0033] After installation, the bands 18 of each insulation block 10 can be cut to release the compression, bring the insulation blocks 10 into close contact with each other, and fix them to the furnace shell. As shown in Fig. 1(b), when forming the insulation block unit 100, the band 18a surrounding the side surfaces of the insulation block 10 (four surfaces excluding the surface P1 on the furnace shell side and the surface facing it) may be cut off. This is because after installation in the furnace shell, the band 18a will be embedded between the insulation blocks 10, making cutting it difficult.

[0034] In addition, the band 18b which surrounds and contacts the furnace shell side surface P1 of the insulation block 10 and the opposing surface 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 metal fitting 12 can be attached to the surface P1 of the insulation block 10 that contacts the furnace shell. An insulation block unit 100 including multiple insulation blocks 10 is installed in the furnace shell by connecting the block fixing metal fitting 12 to a stud erected on the furnace shell (for example, by inserting the stud erected on the furnace shell into a hole 122 provided in the block fixing metal fitting 12 and fixing with a nut from the side of the inorganic fiber aggregate mat 11 on the back surface of the block fixing metal fitting 12). Alternatively, an insulation block unit 100 including multiple insulation blocks 10 can be installed in the furnace shell by welding a stud to the block fixing metal fitting 12, passing the stud through a hole formed in the furnace shell, and fixing with a nut or the like from the outside of the furnace.

[0036] The block fixing fitting 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 may be referred to as an "I-shaped block fixing fitting"), but is preferably a member formed in a cross shape by combining 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) (hereinafter may be referred to as a "cross-shaped block fixing fitting").

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

[0038] When a cross-shaped block fixing metal fitting is used, the cross-shaped block fixing metal fittings can be connected vertically and horizontally with a connecting unit 20 described below, for example, as shown in Fig. 1(a) to connect the insulation blocks 10 in 3 rows and 3 columns to form an insulation block unit 100. In this case, the number of connections is not particularly limited, but from the viewpoint of ease of handling, examples of connection patterns include 2x2, 3x3, 4x4, 2x3, 2x4, 3x4, 2x5, 3x5, and 3x6. Among these, the connection numbers of 2x3, 2x4, 3x3, 4x4, and 3x6 are preferred.

[0039] The shape of the block fixing fitting 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 it has a U-shaped cross section.For example, it may have a cross-sectional shape having an inner flange as shown in 12A in Figure 3(a) or a cross-sectional shape having an outer flange as shown in 12B, but other shapes are acceptable as long as they satisfy the viewpoints of providing a predetermined strength and of connectivity with the connecting unit 20 described later.

[0040] It is preferable that the block fixing hardware 12 has a hole 122 in the center of the lamination direction of the inorganic fiber aggregate mat 11 as shown in FIG. 2(b), or has a stud instead of a hole at the same location as shown in FIG. 1(a). In the cross-shaped block fixing fittings, 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 a 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 fitting 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 insulating block 10 will be described below.

[0043] First, a mat 11 of inorganic fiber aggregate having a desired width and length is cut out. The cut out mat 11 of inorganic fiber aggregate is alternately folded and laminated as shown in Fig. 2(b). Also, as shown in Fig. 2(b), a beam 14 is attached to the inside of the fold of the mat 11 of inorganic fiber aggregate so that the blade is exposed on 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 described later, this blade is fixed to the block fixing metal fitting 12. In addition, since the beam 14 is inserted into the inorganic fiber aggregate mat 11 and is located 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 the block fixing metal fittings 12 can be attached, but from the viewpoint of bonding strength, it is preferable to have 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 of the material 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 of the shape include a round bar with a triangular blade welded to it as shown in the figure.

[0045] In addition, when the inorganic fiber aggregate mat 11 is not folded zigzag but is stacked as a plate-shaped inorganic fiber aggregate mat, the block fixing metal fitting 12 and the inorganic fiber aggregate mat cannot be fixed using the beam 14. In this case, a cross skewer to which a support metal fitting is welded is inserted so as to penetrate the stacked mat. The present invention does not exclude the use of such a cross skewer, but from the viewpoint of durability, it is preferable to fix the block fixing metal fitting 12 and the inorganic fiber aggregate mat 11 using the beam 14.

[0046] Also, as shown in Fig. 2(b), the guide pipes 15 can be attached inside the folds of the inorganic fiber aggregate mat 11. The holes of the guide pipes 15 correspond to the holes 122 of the block fixing metal fittings 12, and serve as guides for fastening nuts from inside the furnace to join the studs provided on the furnace shell to the block fixing metal fittings 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. After the nut fastening, the guide pipes 15 have completed their function and are therefore preferably removed. As described above, the guide pipe 15 is used when a stud is formed in the furnace shell and connected to the block fixing fitting 12. However, in a configuration in which a stud is formed in the block fixing fitting 12 and this stud is passed through a hole formed in the furnace shell to fix the furnace shell and the block fixing fitting 12, the guide pipe 15 is not necessary.

[0047] The material of the guide pipe 15 is not particularly limited, and a metal, cardboard, or plastic cylinder 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. In addition, it is preferable to use nuts made of heat-resistant stainless steel such as SUS310S or SUS304.

[0048] Generally, the inorganic fiber aggregate mat 11 installed on the 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 insulation block 10 to the furnace wall in addition to the repulsive force of the mat. Since the block fixing metal fittings 12 are attached to the furnace wall (iron shell), they are preferably made of a material that can suppress damage caused by heat, and are preferably made of heat-resistant stainless steel such as SUS310S or SUS304.

[0049] 2(a), the sides are pressed down with pressing plates 16 of similar size, and the inorganic fiber aggregate mat 11 is compressed to a predetermined thickness in the lamination direction via the pressing plates 16 by 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 dimension. There are no particular limitations 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 plate 16 is attached to the side of the insulation block 10 and serves to protect the insulation block 10 when the insulation block 10 is compressed by the band 18. After the insulation block unit 100 including a plurality of insulation blocks 10 is installed on the furnace wall, the band 18 is cut and the pressure plate 18 is removed. The material of the pressure plate 16 is not particularly limited, and can be appropriately selected from plywood, wood, iron, plastic, cardboard, and the like. The shape of the pressure plate 16 is not particularly limited, but is selected according to the shape of the side of the insulation block 10. The size of the pressure plate 16 is not particularly specified, but is preferably slightly smaller than the size of the insulation block 10.

[0051] Thereafter, the block fixing metal fitting 12 is attached to the blade 142 of the beam 14 protruding from the inorganic fiber aggregate mat 11. For example, the block fixing metal fitting 12 can be fixed to the beam 14 by passing the blade 142 of the beam 14 through a slit 124 provided in the block fixing metal fitting 12, bending the blade, and fastening it with welding or screws.

[0052] (Connected unit 20) The insulating block unit 100 of the present invention can be formed by connecting the block fixing metal fittings 12 of the insulating blocks 10 described above with a connecting unit 20. The shape of the connecting unit 20 is not particularly limited as long as it is a shape that can connect the block fixing fittings 12 to each other. 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 connection unit 20 is preferably heat-resistant stainless steel such as SUS310S or SUS304.

[0053] In addition, the connecting unit 20 is formed so that its longitudinal cross-sectional shape covers the block fixing metal fitting 12 as shown in Fig. 4(b)(c) in order to connect with the block fixing metal fitting 12. Fig. 4(b) corresponds to the block fixing metal fitting 12A, and Fig. 4(c) corresponds to the block fixing metal 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 metal fitting 12 by sliding them while connecting them. Note that the shape shown in Fig. 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 connecting unit 20 from both sides of the connecting unit 20, and the distance between adjacent block fixing metal fittings 12 inside the connecting unit 20 can be freely adjusted. This makes it possible to form the insulating block unit 100 by adjusting the distance between the insulating blocks 10 to a desired distance.

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

[0056] As another embodiment of the connecting unit 20, for example, it is possible to have a sliding portion having a concave cutout 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 metal fitting 12 is slidably inserted into the sliding portions. Also, by sliding the sliding portion 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 portion and the base portion are fixed by welding after size adjustment.

[0057] As another embodiment of the connecting unit 20, a plurality of connecting units 20 may be prepared, each having a different distance between a pair of concave cutouts 22. In this case, by selecting a connecting unit 20 having an appropriate distance between the concave cutouts 22 according to the size of the insulation block 10, it is possible to accommodate different sizes of the insulation block 10.

[0058] In any of the above cases, even if there are gaps between the insulating blocks 10 in the insulating block unit 100 at the stage 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 (b), the connecting unit 20 and the block fixing metal fitting 12 may be integrated. As shown in Figure 5(a), one block fixing metal fitting 12 may be integrated with one connecting unit 20, as shown in Figure 5(b), one block fixing metal fitting 12 may be integrated with two connecting units 20, or one block fixing metal fitting 12 may be integrated with three connecting units 20, or one block fixing metal fitting 12 may be integrated with four connecting units 20.

[0060] 5(c), whether or not to integrate them can be determined appropriately depending on whether adjacent block fixing metal fittings 12 have connecting units 20. The integration method is not particularly limited, and the block fixing metal fittings 12 and the connecting units 20, which are separate members, may be connected by welding, or 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 described below.

[0062] (Step of preparing a plurality of 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 above-mentioned method to prepare the number of insulating blocks required in the following step. 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 insulation blocks 10 are determined so as to obtain the required shape and area according to the shape of the insulation block that needs repair among the insulation blocks already installed in the furnace shell. The number and combination of the insulating blocks 10 are not particularly limited, and may be squares of various sizes, such as the 3×3 shape shown in Fig. 1(a), or may be rectangular, for example, 1×3, 2×3, or 2×6. Alternatively, the insulating blocks may have a shape with some corners missing, or a shape with the center missing, and even complex shapes can be handled appropriately.

[0064] (Step of connecting block fixing metal fittings 12 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 inside of 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 insulation blocks 10 is determined by the longitudinal length of the connecting unit 20, but the distance between the connected insulation blocks 10 may also be determined by restricting the sliding of the block fixing hardware 12, for example, by a stopper provided on the connecting unit 20 and the block fixing hardware 12.

[0065] 1(b), the heat insulating block unit 100 can be held down on its sides by a retaining plate 120 and fixed with a band (not shown) to maintain its shape and protect it from external impacts. The retaining plate 120 can be made of the same material as the retaining plate 16 described above. The retaining plate 120 is pulled out after the heat insulating block unit 100 is installed in the furnace shell, and a pull-out band 130 may be provided 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 insulating block unit 100 of the present invention in the furnace shell, it becomes possible to efficiently install the insulating blocks 10 in the furnace shell.

[0067] The insulation block unit 100 of the present invention is lighter than conventional insulation block panels with iron shells, so it can be lifted using a chain block and can be installed on the furnace ceiling in a simple and safe manner. When lifting the insulation block unit 100, for example, as shown in FIG. 6, a lifting member (e.g., 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 the holes provided in the furnace shell, and the studs 126 are fixed with nuts or the like from outside the furnace shell, thereby making it possible to install the insulation block unit 100 in the furnace shell. In addition, a heat insulating mat 120 may be placed between the furnace shell and the heat insulating block unit 100 to provide heat insulation and further protect the furnace shell.

[0068] <Thermal insulation wall> As described above, a heat insulating wall is formed by installing the heat insulating block unit 100 of the present invention in the furnace shell. Since this eliminates the need to install the individual heat insulating blocks 10 multiple times as in the conventional method, a heat insulating wall can be efficiently formed in the furnace shell. Here, the insulating wall may be installed on any wall surface in the heating furnace, for example, on the ceiling or side of the furnace. In particular, when installing an insulating wall on the ceiling of the furnace or repairing an insulating wall on the ceiling, lifting the insulating material is essential. Reducing the number of times such lifting work is required and simplifying it will greatly improve 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 having an iron shell, particularly for an insulating wall 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 bracket 14: Beam 15: Guide pipe 20: Connecting unit

Claims

1. The present invention provides a method for manufacturing a heat insulating block, comprising: A connecting unit is provided to connect the block fixing metal fittings in the plurality of insulation blocks to each other, The connecting unit includes a base and a slide portion inserted into both ends of the base, and the base and the slide portion are slidable. Insulation block unit.

2. An insulating block unit as described in claim 1, wherein the sliding portion has a concave notch.

3. 3. The insulation 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 insulation block, and the connecting unit is a member that connects the block fixing metal fittings to each other.

4. 3. The insulation block unit according to claim 1 or 2, wherein the block fixing metal fittings are 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 insulation block and a plate-like body extending in a direction perpendicular to the stacking direction.

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

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

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

8. preparing a plurality of insulating blocks each including a mat of laminated inorganic fiber aggregate and a metal fitting for fixing the block on the side in contact with the furnace wall; A step of determining the number and combination method of the insulation blocks according to the area in which the insulation blocks are to be installed; a step of connecting the block fixing fittings of the plurality of insulation blocks with a connecting unit in accordance with the determination; Equipped with The connecting unit includes a base and a slide portion inserted into both ends of the base, and the base and the slide portion are slidable. A method for manufacturing an insulating block unit.

9. An insulating block unit as described in claim 8, wherein the sliding portion has a concave notch.

10. The method for manufacturing an insulating block unit according to claim 8 or 9, wherein the block fixing metal fitting and the connecting unit are integrated together.

11. The method for manufacturing an insulating block unit according to claim 8 or 9, wherein in the step of preparing a plurality of insulating blocks, the mat of the inorganic fiber aggregate formed by folding one long mat is prepared.

12. A method for constructing an insulation block, comprising a step of installing an insulation block unit manufactured by the method for manufacturing an insulation block unit according to claim 8 or 9 in a furnace shell.

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