Heat insulating block for partition wall, partition wall, heating furnace, and method for manufacturing partition wall

Abstract

Provided is a heat insulating block for a partition wall. The heat insulating block uses a mat of inorganic fiber aggregate, is easy to install on a furnace ceiling, does not require dismantling of an existing structure, or can minimize the extent of dismantling of the existing structure, and can be easily installed even if a pair of structures are formed on the furnace ceiling.　The heat insulating block for a partition wall is provided with a laminated inorganic fiber aggregate mat. The heat insulating block includes a block fixing metal fitting on a surface facing a ceiling of a heating furnace, and further includes a support member engageable with the block fixing metal fitting and engageable with a pair of structures on the ceiling of the heating furnace. The support member is configured to be switchable between a state in which the entire support member is positioned between the pair of structures and a state in which a portion of the support member extends outside a gap between the pair of structures.

Description

Insulating block for partition wall, partition wall, heating furnace, and method for manufacturing partition wall

[0001] The present invention relates to an insulating block for a partition wall, a partition wall, a heating furnace, and a method for manufacturing a partition wall.

[0002] Generally, industrial furnaces are divided into continuous and batch-type furnaces. Continuous heat treatment furnaces, which continuously heat treat large volumes of steel, have large internal volumes and long furnace lengths. Therefore, partitions are often installed inside the furnace for various purposes, such as preheating, heating, soaking, and cooling the steel, or increasing the residence time of hot air inside the furnace to improve thermal efficiency. One example of such a partition is a dry partition.

[0003] A known dry partition wall structure for industrial furnaces is one that consists of a heat-resistant block with a support bracket attached to one longitudinal end of a ceramic fiber blanket molded body, and a receiving member that is provided on the furnace shell ceiling and can engage with the support bracket (Patent Document 1).

[0004] Patent No. 3398534

[0005] However, with the technology of Patent Document 1, the working space on the heating furnace ceiling is limited by hanging hardware and support beams, making it difficult to perform detailed work such as fastening bolts between the receiving member and the support metal fittings of the heat-resistant block.

[0006] Furthermore, unless the holes in the receiving member are drilled with high precision and the receiving member is accurately welded to the existing ceiling structure, there is a problem in that the bolts of the support bracket and the holes in the receiving member will not be aligned when the heat-resistant block is attached.

[0007] On the other hand, it is also possible to fasten the support member to the bolts in advance and then fix the support member to the ceiling beams etc. later, but the ceiling space is limited and it is necessary to lift the partition wall from inside the furnace for construction, which is difficult for the following two reasons.

[0008] (1) Figure 1 shows a cross-sectional view of the ceiling of a heating furnace in the furnace width direction. Multiple hanging fittings 14 are hung from ceiling beams 12, and ceiling refractory material 16 is formed around the hanging fittings 14. For example, as shown in the figure, a support member 18 is welded to the top of the hanging fittings 14. A method in which the support member 18 and bolts are fastened in advance and a heat-resistant block is inserted from below has the problem that the support member 18 and the hanging fittings 14 interfere with each other, making insertion impossible.

[0009] (2) Figure 2 shows a cross-sectional view of the ceiling portion of a heating furnace in the furnace length direction. A plurality of hanging fittings 14 are hung from ceiling beams 12, and ceiling refractory material 16 is formed around the hanging fittings 14. In this case, a receiving member 18 is, for example, welded to the ceiling beams 12. In order to insert a heat-resistant block from below with the receiving member 18 and bolts fastened in advance, it is necessary to dismantle the ceiling refractory material 16 in the furnace length direction over the length of this receiving member 18, which poses a problem of large-scale dismantling work.

[0010] As shown in FIG. 3 , a pair of structures 19 (four structures 19 are shown in FIG. 3 , but any two adjacent structures 19 form a pair of structures 19) are installed on existing structures (e.g., beams 12) at the location where the ceiling of the heating furnace is being demolished, and support members are then fixed to the pair of structures 19. The distance between the pair of structures 19 may be narrower than the ceiling-side surface of the heat-resistant block. In this configuration, if the support members and bolts are fastened and the heat-resistant block is inserted from below, interference occurs between the support members and the pair of structures 19, making insertion impossible. In FIG. 3 , the direction extending from the lower left to the upper right is the furnace width direction, and the direction extending from the lower right to the upper left is the furnace length direction. One side wall 17 in the furnace width direction is shown, but the other side wall is omitted.

[0011] In view of the above, an object of the present invention is to provide an insulating partition wall block using an inorganic fiber aggregate mat, which can be easily installed on the furnace ceiling and does not require dismantling of the existing structure or can minimize the extent of dismantling of the existing structure. Another object of the present invention is to provide an insulating partition wall block that can be easily installed inside the furnace even when a pair of structures for installing the insulating partition wall block are formed on the furnace ceiling and the space is further restricted by the pair of structures.

[0012] As a result of extensive research aimed at solving the above problems, the present inventors have discovered the following.

[0013] By pre-engaging the block fixing hardware installed on the ceiling side of the insulation block with the support members fixed to a pair of ceiling structures, the work of engaging the support members with the block fixing hardware is eliminated during the installation work of the insulation block.

[0014] When the support members are fixed to a pair of ceiling structures, by positioning the support members entirely between the pair of structures before the insulation block is installed, preferably by making the support members sized to fit within the ceiling-side surface of the insulation block, the insulation block can be installed in a predetermined location without dismantling the existing structure on the furnace ceiling, or while minimizing the dismantling of the existing structure, without interfering with the pair of structures. Furthermore, after the insulation block is installed in a predetermined position, by switching the support members to a state in which they extend outside the pair of structures, preferably outside the ceiling-side surface of the insulation block, the insulation block can be suspended from the ceiling and its vertical position can be fixed.

[0015] Based on the above, the inventors have completed the following invention: [1] A heat insulating block for a partition wall comprising a mat of laminated inorganic fiber aggregates, wherein a block fixing fitting is provided on the ceiling side of the heating furnace, and further comprises a support member that is engageable with the block fixing fitting and engageable with a pair of structures on the ceiling of the heating furnace, wherein the support member is configured to be switchable between a state in which the entire member is located between the pair of structures and a state in which a part of the member extends outward between the pair of structures.

[0016] [2] The inner surfaces of the pair of structures are each positioned at a location substantially coinciding with the edge of the ceiling-side surface, or outside the ceiling-side surface, and the support member is configured to be switchable between a state in which it is housed inside the ceiling-side surface and a state in which it extends outside the ceiling-side surface, as described in [1].

[0017] [3] The insulating block for a partition wall according to [1], wherein the inner surfaces of the pair of structures are each positioned on the inside of the ceiling-side surface, and the support member is configured to be switchable between a state in which it is located between the pair of structures and a state in which it extends outward between the pair of structures while being housed on the inside of the ceiling-side surface.

[0018] [4] The insulating block for a partition wall according to any one of [1] to [3], wherein the support member is rotatably engaged with a shaft extending from the block fixing fitting toward the ceiling of the heating furnace, and the support member is configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outward between the pair of structures by rotating about the shaft.

[0019] [5] An insulating block for partition walls described in any of [1] to [3], wherein the support member comprises a fixed support member connected to an axis extending from the block fixing fitting toward the ceiling of the heating furnace, and at least one movable support member connected to the fixed support member, the movable support member being rotatably engaged with another axis extending from the fixed support member toward the ceiling of the heating furnace, and the movable support member being configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outside the space between the pair of structures by rotating around the other axis.

[0020] [6] An insulating block for partition walls described in any of [1] to [3], wherein the support member comprises a fixed support member connected to an axis extending from the block fixing fitting toward the ceiling of the heating furnace, and at least one movable support member connected to the fixed support member, and the movable support member is configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outside the space between the pair of structures by sliding relative to the fixed support member.

[0021] [7] The insulating block for a partition wall according to any one of [1] to [6], wherein the support member engages with the pair of structures to be suspended from the pair of structures. [8] A partition wall comprising a plurality of insulating blocks for a partition wall according to any one of [1] to [7], arranged in the furnace width direction. [9] A heating furnace comprising the partition wall according to [8].

[0022]

[10] A method for manufacturing a partition wall inside a heating furnace by suspending an insulating block for a partition wall described in any one of [1] to [7] from the pair of structures on the ceiling of the heating furnace, the method comprising: a step of inserting the support member between the pair of structures while the support member is positioned between the pair of structures; and a step of engaging the support member with the pair of structures by switching the support member to a state in which it extends outward from between the pair of structures after the inserting step.

[0023] The partition wall insulating block of the present invention is easy to install on the furnace ceiling and does not require dismantling of the existing structure, or the extent of dismantling of the existing structure can be minimized. In particular, it is easy to install because it does not require hole alignment on the furnace ceiling or fastening with nuts. Furthermore, even if a pair of structures for installing the partition wall insulating block are formed on the furnace ceiling, and the installation space is further limited by the pair of structures, the installation of the insulating block inside the furnace can be facilitated.

[0024] FIG. 1 is a cross-sectional view of the ceiling of a conventional heating furnace in the width direction. FIG. 2 is a cross-sectional view of the ceiling of a conventional heating furnace in the length direction. FIG. 3 is a schematic diagram of the ceiling of a heating furnace in which a pair of structures 19 for installing partition wall insulation blocks are formed on the furnace ceiling. FIG. 4 is a perspective view of an insulating block for partition walls 100 of the present invention. FIGS. 5(a) and 5(b) are views of the insulating block for partition walls 100 of FIG. 4 as viewed from the Z1 direction, showing the positional relationship between the support member 20 and the pair of structures 19. FIG. 6 is a schematic diagram showing a partially exploded insulating block precursor 30. FIGS. 7(a) to 7(b) are schematic diagrams showing other embodiments 20B to 20C of the support member 20, with the folds of the inorganic fiber aggregate mat 32 omitted. FIGS. 8(a) to 8(c) are schematic diagrams showing other embodiments 20D to 20F of the support member 20, with the folds of the inorganic fiber aggregate mat 32 omitted. 9(a) and 9(b) are schematic diagrams showing other embodiments 20G to 20H of the support member 20, with the folds of the inorganic fiber aggregate mat 32 omitted. FIG. 10 is a schematic diagram showing another embodiment 20I of the support member 20, with the folds of the inorganic fiber aggregate mat 32 omitted. FIG. 11(a) is a diagram of the support member 20B viewed from the ceiling side with the surface P1 facing the ceiling, and is a schematic diagram showing the entire support member 20B positioned between a pair of structures 19. FIG. 11(b) is a schematic diagram of a state in which a portion of the support member 20B extends outward from the gap between the pair of structures 19. FIG. 11(c) is another schematic diagram of the entire support member 20B positioned between the pair of structures 19. FIG. 12(a) is a schematic diagram of the support member 20B viewed from the ceiling side with the surface P1 facing the ceiling. FIG. 12(b) is a schematic diagram showing the support member 20B rotated about the axis 38. Fig. 12(c) is a schematic diagram showing a state in which the support member 20B has been further rotated about the shaft 38. Fig. 13(a) is a schematic diagram showing the support member 20D as viewed from the ceiling side with the surface P1 facing the ceiling, and showing a state in which the entire support member 20D is positioned between the pair of structures 19. Fig. 13(b) is a schematic diagram showing a state in which a part of the support member 20D extends outward from between the pair of structures 19. Fig. 14(a) is a schematic diagram showing the support member 20D as viewed from the ceiling side with the surface P1 facing the ceiling.Fig. 14(b) is a schematic diagram of another support member 20D as viewed from the ceiling side with the surface P1 facing the ceiling. Fig. 14(c) is a conceptual diagram of another support member 20D as viewed from the ceiling side with the surface P1 facing the ceiling.

[0025] Below, we will explain an insulating block for partition walls, a partition wall, a heating furnace, and a method for manufacturing a partition wall as examples of embodiments of the present invention. However, the scope of the present invention is not limited to the embodiments described below. Note that the notation "a to b" indicating a numerical range means "a or more and b or less" unless otherwise specified, and also encompasses 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 range specified by the present invention, they are considered to be within the equivalent range of the present invention as long as they have the same functional effects as those within the numerical range.

[0026] <Insulating block for partition wall> Figure 4 shows a perspective view of one embodiment 100 of the insulating block for partition wall of the present invention.

[0027] The partition wall insulation block 100 of the present invention comprises a mat 32 of laminated inorganic fiber aggregate, a block fixing metal fitting 34 provided on the surface P1 facing the ceiling of the heating furnace, and a support member 20 (20A) engageable with the block fixing metal fitting 34 and engageable with an existing structure on the ceiling of the heating furnace. The support member 20 (20A) is configured to be switchable between a state in which its entirety is positioned between a pair of structures 19 formed on the ceiling of the heating furnace and a state in which a portion of it extends outside the pair of structures.

[0028] When the inner surfaces of the pair of structures 19 are positioned so as to substantially coincide with the edge of the ceiling-side surface P1 or are positioned outside the ceiling-side surface P1 (in the case of the positional relationship between surface P1 and the pair of structures 19 in Figures 12 and 14, which will be described later), it is preferable that the support member 20 be configured so as to be switchable between a state in which it is stored inside the ceiling-side surface P1 and a state in which it extends outside the ceiling-side surface P1. This configuration further improves the ease of insertion (construction) between existing structures.

[0029] When the inner surfaces of the pair of structures 19 are each positioned inside the ceiling-side surface P1 (in the case of the positional relationship between surface P1 and the pair of structures 19 in Figures 11 and 13, which will be described later), it is preferable that the support member 20 be configured to be switchable between a state in which it is located between the pair of structures 19 and a state in which it extends outward between the pair of structures 19 while stored inside the ceiling-side surface P1.

[0030] (Pair of Structures 19) The pair of structures 19 formed on the ceiling of the heating furnace described above are structures that are installed in addition to existing structures, such as beams 12, on the ceiling of the heating furnace where a partition wall is to be formed. They are fixed by connecting one end and the other end of the structures to the existing structures, such as beams. The existing structures, such as beams 12, may also be used as the pair of structures 19. The pair of structures 19 may be a pair of linear elongated members, as shown in FIG. 3 , and the cross-sectional shape of the elongated members is not particularly limited. An example of the cross-sectional shape of the elongated members is a quadrilateral, specifically a rectangular cross-section as shown in the figure. For example, the elongated members may be solid rectangular cross-section members or hollow rectangular cross-section members. Furthermore, the linear elongated members may be elongated plate members, elongated members such as beams 12 in FIG. 3 whose cross-section includes a surface connecting the upper and lower surfaces and their approximate center, or elongated members whose cross-section is a quadrilateral with one side removed. Furthermore, the concept of the pair of structures 19 in the present invention includes not only the pair of additionally installed structures 19 described above, but also a pair of existing structures, or a combination of one additional structure 19 and the other existing structure. The pair of structures 19 may extend in the furnace width direction or in the furnace length direction. From the viewpoint of installing partition walls, it is preferable that the pair of structures 19 extend in the furnace width direction in terms of workability.

[0031] (Relationship between the support member 20 and the pair of structures 19) Figures 5(a) and (b) show the partition wall insulation block 100 of Figure 4 viewed from the Z1 direction. Figures 5(a) and (b) show the state in which the support member 20 of the partition wall insulation block 100 is inserted between the pair of structures 19. Figure 5(a) shows the state in which the entire support member 20 is positioned between the pair of structures 19, while Figure 5(b) shows the state in which a part of the support member 20 extends outward from between the pair of structures 19.

[0032] In the above, "between a pair of structures 19" means between a line L1 extending vertically along the inner surface 19P1 of each of the pair of structures 19 and a line L2 extending vertically along the inner surface 19P2 in Figures 5(a) and 5(b).

[0033] 5(a), when the entire support member 20 is positioned between the pair of structures 19, that is, when the entire support member 20 is positioned between the line L1 and the line L2, the partition wall insulation block 100 is lifted from below and the support member 20 is passed between the pair of structures 19. As a result, the support member 20 is positioned above the pair of structures 20, and the laminated inorganic fiber aggregate mat 32 and the block fixing hardware 34 are positioned below the pair of structures 19.

[0034] 5(a) above, by switching to a state in which a portion of the support member 20 extends outward between the pair of structures 19, i.e., the state shown in FIG. 5(b), the support member 20 and the pair of structures 19 are engaged, and the partition wall insulation block 100 is installed in a state in which it is suspended from the pair of structures 19. In FIGS. 5(a) and 5(b), the inner surfaces 19P1 and 19P2 of the pair of structures 19 are arranged inside the ceiling-side surface P1, but the inner surfaces 19P1 and 19P2 may also be arranged outside the ceiling-side surface P1.

[0035] (Laminated inorganic fiber aggregate mat 32) The insulating block 100 for partition walls of the present invention is composed of a laminated inorganic fiber aggregate mat 32, block solidification metal fittings 34, and support member 20 (20A).In the following, in this specification, the combination of the laminated inorganic fiber aggregate mat 32 and block solidification metal fittings 34 will be referred to as the insulating block precursor 30.

[0036] The inorganic fibers forming the laminated inorganic fiber aggregate mat 32 are not particularly limited, but examples include single or composite fibers of silica, alumina / silica, and zirconia, spinel, titania, and calcia containing these. 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. Alumina / silica fibers with an alumina ratio of 70 to 80 mass% and a silica ratio of 30 to 20 mass% are particularly preferred. Since the present invention relates to a heat insulating block precursor 30 that is long in the vertical direction, if the tensile strength of the inorganic fiber aggregate mat 32 is low, it may tear under its own weight and fall. From this perspective, the alumina / silica-based fibers, particularly polycrystalline alumina / silica-based fibers, which have high tensile strength at high temperatures, are preferred.

[0037] As the inorganic fiber aggregate mat 32, a mat (needle blanket) in which a needling process has been 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 improving heat resistance and durability.

[0038] The bulk density of the inorganic fiber aggregate mat 32 is not particularly limited, but from the viewpoint of the heat resistance and strength of the formed heat insulating block precursor 30, it is preferably 85 kg / m ３ ~150 kg / m ３ is preferred, and 90 kg / m ３ ~140 kg / m ３ is more preferable.

[0039] The thickness of the inorganic fiber aggregate mat 32 is selected appropriately, 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, there is a problem that it is difficult to maintain the shape of the heat insulating block precursor 30 when folded.

[0040] The size of the inorganic fiber aggregate mat 32 is not particularly limited and can be cut to an appropriate size depending on the size of the desired insulation block precursor 30. However, it is preferable that the inorganic fiber aggregate mat 32 constituting the partition wall insulation block 100 of the present invention is used by stacking multiple long mats folded in half, as shown in Figure 4. In this case, the inorganic fiber aggregate mat 32 has a length twice the height of the partition wall to be formed.

[0041] (Size of the insulation block precursor 30) The size of the insulation block precursor 30 is not particularly limited as long as it can ensure the insulating effect as a partition wall and does not interfere with the ease of installation, which is a feature of the present invention. However, the length in the furnace length direction (Y direction in Figure 4) is preferably 200 mm to 400 mm, and more preferably 250 mm to 350 mm. By setting the length at or above the lower limit, the insulating effect as a partition wall can be fully exhibited. Furthermore, by setting the length at or below the upper limit, the weight of the insulation block precursor 30 can be prevented from becoming excessive, improving installation ease.

[0042] The length of the insulation block precursor 30 in the furnace width direction (X direction in Figure 4) is preferably 200 mm to 400 mm, more preferably 250 mm to 350 mm. By setting the length at or above the lower limit, the number of insulation block precursors 30 required to form the partition wall can be made appropriate, improving workability. Furthermore, by ensuring sufficient repulsive force between the insulation block precursors 30, the insulation block precursors 30 can withstand the wind pressure inside the furnace. Furthermore, by setting the length at or below the upper limit, the insulation block precursors 30 do not become excessively heavy, improving workability.

[0043] The height of the heat insulating block precursor 30 (directions perpendicular to the X and Y directions in FIG. 4 ) can be set arbitrarily and is appropriately selected depending on the desired height of the partition wall. For example, it is preferably set to 1000 mm or more and 2000 mm or less.

[0044] (Method of folding the inorganic fiber aggregate mat 32) The method of folding the inorganic fiber aggregate mat 32 is not particularly limited, as long as there are folds on the surface of the insulation block precursor 30 that will be installed on the furnace shell (surface P1 on which the block fixing bracket 34 is installed in Figure 4). From the perspective of firmly fixing the partition wall insulation block 100 to the ceiling, it is preferable that there are at least two folds, and more preferably four or more folds, on the surface P1 of the insulation block precursor 30 that will be installed on the ceiling. The upper limit of the number of folds depends on the size of the insulation block precursor 30, but is preferably 10 or less, and more preferably 8 or less. In the embodiment shown in Figure 4, eight folds are formed on the surface of the insulation block precursor 30 that will be installed on the ceiling.

[0045] A preferred method of folding the inorganic fiber aggregate mat 32 is to fold a long mat in half, align the folds on the surface P1 that will be installed on the ceiling, and stack multiple mats together, as shown in Figure 4 (eight long mats folded in half are stacked on top of each other in Figure 4).

[0046] Alternatively, one long mat may be folded zigzag, or multiple long mats folded zigzag may be combined together, but since workability deteriorates when the mat is too long, the preferred method is to stack multiple long mats folded in half as shown in Figure 4.

[0047] Furthermore, as described above, as long as a predetermined number of folds are formed on the surface P1 that will be installed on the ceiling, it is acceptable to mix in some of the flat, unfolded long mats.

[0048] There is no particular limitation on the bulk density of the heat insulating block precursor 30, but it is preferably 96 kg / m ３ ~160 kg / m ３ Preferably, 100 kg / m ３ ~140 kg / m ３More preferably, the lower limit is 128 kg / m ３ The above is even more preferable. It is preferable that the folded inorganic fiber aggregate mat 32 constituting the heat insulating block precursor 30 is ultimately in a compressed state. In other words, it is preferable to compress the folded inorganic fiber aggregate mat 32 with the beam 36 (described later) inserted and fixed.

[0049] 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 precursor 30. Furthermore, from the viewpoint of preventing deformation of the beam 36, the upper limit is preferably 40% or less, and more preferably 30% or less. Note that, by increasing the compression ratio, the bulk density of the insulating block precursor 30 increases, and the heat resistance of the insulating block precursor 30 improves.

[0050] The heat insulating block precursor 30 can be compressed and its shape can be maintained by sewing it with an alumina rope or the like. Furthermore, the bulk density of the heat insulating block precursor 30 can be increased by folding and stacking the inorganic fiber aggregate mat 32, compressing it by pressing down both sides of the compressed surface with pressure plates such as plywood or metal plates (not shown), and fixing it with a band (not shown). The compressed state can also be maintained with only the band without using pressure plates.

[0051] After construction, the partition wall insulating blocks 100 can be released from compression by cutting the bands, and the partition wall insulating blocks 100 can be tightly attached to each other and fixed inside the furnace.

[0052] (Block fixing metal fittings 34) A block fixing metal fitting 34 is attached to the surface P1 of the heat insulating block precursor 30 that contacts the furnace shell. A shaft 38 such as a bolt or stud is attached to the block fixing metal fitting 34 by screwing or the like, and a support member 20, which will be described later, is engaged with this shaft 38. The shaft 38 such as a bolt or stud may be connected to the block fixing metal fitting 34 by welding.

[0053] Figure 6 shows a schematic diagram of a portion of the heat insulating block precursor 30 in disassembled form (a schematic diagram showing the manufacturing process of the heat insulating block precursor 30). The shape of the block fixing fitting 34 is a plate-like body extending in the lamination direction of the inorganic fiber aggregate mat 32, as shown in Figures 4 and 6. From the viewpoint of providing strength, it is preferable to have a U-shaped cross-section, or it may have a flange.

[0054] As shown in Figure 4, a shaft 38 such as a bolt or stud is connected to the block fixing fitting 34 in the center of the inorganic fiber aggregate mat 32 in the stacking direction, and it is preferable that a hole with a screw or screw groove is formed for connecting the shaft 38. However, if the shaft 38 such as a stud is connected by welding, a screw or hole is not necessarily required, and for example, a recess for erecting the shaft 38 may be formed.

[0055] The block fixing metal fitting 34 is formed with a plurality of slits 342 into which the blades 362 of the beam 36 are inserted.

[0056] From the viewpoint of strength and heat resistance, the material of the block fixing metal fittings 34 is preferably heat-resistant stainless steel such as SUS310S or SUS304.

[0057] (Method for Manufacturing the Heat Insulating Block Precursor 30) Hereinafter, an example of a method for manufacturing the heat insulating block precursor 30 will be described.

[0058] First, a mat 32 of inorganic fiber aggregate having the desired width and length is cut out. As shown in Figure 6, this cut-out mat 32 of inorganic fiber aggregate is folded in half, and a beam 36 is attached to the inside of the fold. At that time, it is attached so that the blade 362 of the beam 36 protrudes from the ceiling side surface P1 of the heat insulating block precursor 30 to be formed.

[0059] The beam 36 has the function of fixing the block fixing bracket 34 and the laminated inorganic fiber aggregate mat 32. It is inserted into the folded portion of the inorganic fiber aggregate mat 32, and the blade 362 of the beam 36 penetrates the mat 32 and protrudes towards the ceiling side of the heat insulating block precursor 30, and as will be explained later, this blade is fixed to the block fixing bracket 34.

[0060] Furthermore, the beam 36 is inserted into the mat 32 of laminated inorganic fiber aggregate and is positioned on the ceiling side when installed on a ceiling, so that damage due to heat can be suppressed.

[0061] Although Figure 6 shows only one mat 32 of inorganic fiber aggregate folded in half, when manufacturing the insulating block precursor 30 shown in Figure 4, for example, a total of eight similar mats 32 of inorganic fiber aggregate folded in half are connected to the block fixing hardware 34 via beams 36.

[0062] The number of beams 36 is not particularly limited as long as the block fixing fittings 34 can be attached, but it is preferable to have four or more beams from the viewpoint of joint strength. The material of the beams 36 is not particularly limited as long as it can exhibit heat resistance when used in the furnace, but examples include SUS310S and SUS304. The shape of the beams 36 is not particularly limited as long as it can fix the folded inorganic fiber aggregate mat 32 and the block fixing fittings 34, but an example is a shape in which a triangular blade is welded to a round bar as shown in the figure.

[0063] Furthermore, if the inorganic fiber aggregate mat 32 is not folded in a zigzag pattern or in half, but rather plate-shaped inorganic fiber aggregate mats 32 are stacked to form a heat insulating block precursor, the beam 36 cannot be used to fix the block fixing bracket 34 to the inorganic fiber aggregate mat 32. In this case, a horizontal skewer with a support bracket welded to it is passed through the stacked plate-shaped inorganic fiber aggregate mat 32. The present invention does not exclude the use of such a horizontal skewer, but from the viewpoint of durability, it is preferable to fix the block fixing bracket 34 to the inorganic fiber aggregate mat 32 using the beam 36 described above.

[0064] Generally, an inorganic fiber aggregate mat 32 installed on a furnace wall is fixed to the furnace wall by its own resilience. However, in the partition wall insulation block 100 of the present invention, the block fixing fitting 34 has the role of suspending and fixing the partition wall insulation block 30 from the ceiling, in addition to the resilience of the mat.

[0065] The partition wall formed with the insulating partition block 100 of the present invention has a gap on the underside for passing steel plates or the like, and is not supported from the furnace floor. Therefore, to prevent downward sliding, it is necessary to fix the vertical position by hanging it from the ceiling in addition to relying on the repulsive force of the inorganic fiber aggregate mat 32 itself. Block fixing hardware 34 is used for this purpose, together with the support member 20 described later.

[0066] The block fixing fitting 34 is preferably made of a material that can suppress damage caused by heat inside the furnace, and is preferably made of heat-resistant stainless steel such as SUS310S or SUS304. The same applies to the material of the shaft 38.

[0067] The sides of the insulation block precursor 30 are then pressed down with similarly sized pressing plates, and the laminated inorganic fiber aggregate mat 32 is compressed to a predetermined thickness in the stacking direction using a compression packing machine or the like via the pressing plates, and then fixed with bands. The bands are used to compress and fix the insulation block precursor 30 to a predetermined size. There are no particular restrictions on the material of the bands as long as they perform this function, but for example, polypropylene (PP) bands, polyethylene (PE) bands, iron bands, etc. can be used.

[0068] The pressure plates are attached to the sides of the insulation block precursor 30 and serve to protect the insulation block precursor 30 when it is compressed by the bands. When the insulation block precursor 30 is actually installed in a furnace, the bands are cut and the pressure plates are removed. The material of the pressure plates is not particularly limited and can be selected as appropriate from plywood, wood, iron, plastic, cardboard, etc. The shape of the pressure plates is not particularly limited, but is selected to match the shape of the side of the insulation block precursor 30. The size of the pressure plates is not particularly specified, but it is preferable that they are slightly smaller than the size of the insulation block precursor 30.

[0069] Thereafter, the block fixing metal fittings 34 are attached to the blades 362 of the beams 36 protruding from the inorganic fiber aggregate mat 32. For example, the block fixing metal fittings 34 can be fixed to the beams 36 by passing the blades 362 of the beams 36 through slits 342 provided in the block fixing metal fittings 34, bending the blades 362, and fastening them with welding or screws.

[0070] (Support member 20 that can engage with a pair of structures 19 on the ceiling of the heating furnace) In addition to the above-mentioned insulating block precursor 30, the insulating block 100 for partition walls of the present invention is equipped with support members 20 (20A to 20I) that can engage with the block fixing fittings 34 of the precursor 30 and can engage with a pair of structures on the ceiling of the heating furnace.

[0071] The support member 20 (20A) is configured to be switchable between a state in which the entire support member 20 (20A) is positioned between the pair of structures and a state in which a portion of the support member 20 (20A) extends outside the gap between the pair of structures.

[0072] As shown in FIG. 4, the support member 20 (20A) may include a fixed support member 22A fixed to a shaft 38 extending from the block fixing bracket 34 toward the ceiling of the heating furnace, and at least one movable support member 24A1, 24A2 connected to the fixed support member 22A. The fixed support member 22A may extend in the furnace width direction (X direction) or the furnace length direction (Y direction). The extension direction of the fixed support member 22A can be adjusted appropriately depending on the extension direction of the pair of structures 19.

[0073] The movable support members 24A1, 24A2 are rotatably engaged with another axis extending from the fixed support member 22A toward the ceiling of the heating furnace, and by rotating the movable support members 24A1, 24A2 around the other axis, they are configured to be able to switch between a state in which the entire member is positioned between a pair of structures 19 and a state in which it extends outside the pair of structures 19, and preferably, are configured to be able to switch between a state in which it is stored inside the plane P1 and a state in which it extends outside the plane P1.

[0074] In the support member 20 (20A) of FIG. 4, two movable support members 24A1 and 24A2 are connected to both ends of a fixed support member 22A extending in the X direction.

[0075] In Figure 4, the movable support member 24A1 on the left is shown in a closed state, and the movable support member 24A2 on the right is shown in an open state. When both of these movable support members 24A1 and 24A2 are closed, it corresponds to "the state in which the entire support member 20A is located between the pair of structures 19," and when both are open, it corresponds to "the state in which a part of the support member 20A extends outward between the pair of structures 19." Furthermore, when both of the movable support members 24A1 and 24A2 are closed, it corresponds to the state in which the support member 20A is housed inside the surface P1, as described above, and when both are open, it corresponds to the state in which the support member 20A extends outward outside the surface P1, as described above.

[0076] As will be explained in detail later, when the inner surfaces of the pair of structures 19 are each positioned inside the ceiling surface P1, the partition wall insulation block 100 is inserted between the pair of ceiling structures 19 with the entire support member 20 (20A) positioned between the pair of structures. After insertion, by switching a part of the support member 20A to extend outward between the pair of structures 19, the support member 20A and the pair of ceiling structures 19 can be engaged. This allows the partition wall insulation block 100 to be suspended from the ceiling and its vertical position to be fixed. Furthermore, when the inner surfaces of the pair of structures 19 are each positioned approximately to coincide with the edge of the ceiling surface P1, or outside the ceiling surface P1, it is preferable to insert the partition wall insulation block 100 between the pair of ceiling structures 19 with the support member 20 housed inside the ceiling surface P1. This improves the ease of insertion of the partition wall insulation block 100.

[0077] In the support member 20 (20A) of the embodiment shown in Fig. 4, the fixed support member 22A and the movable support members 24A1, 24A2 are both formed of L-shaped steel. These L-shaped steels are connected to each other with bolts and nuts, and the movable support members 24A1, 24A2 are rotatable about the bolts as axes (separate axes extending toward the ceiling of the heating furnace). Note that the method (connection mode) of connecting the fixed support member 22A and the movable support members 24A1, 24A2 is not limited as long as they can be rotatably connected in this manner.

[0078] The fixed support member 22A and the shaft 38 are connected with a nut. They are basically fixed, but may be configured to be able to rotate slightly when force is applied. By configuring the fixed support member 22A to be rotatable, it is possible to avoid obstacles when inserting the partition wall insulation block 100 between a pair of ceiling structures 19.

[0079] The support member 20 (20A) is preferably formed from L-shaped steel, U-shaped steel, or C-shaped steel as described above in order to provide the strength necessary to withstand the structure of suspending the insulation block 100, but it may also be formed from flat plate steel if the required strength can be achieved by increasing the thickness of the material forming the support member 20, for example.

[0080] As the material for the support member 20 (20A) is installed outside the furnace, SS material or the like is acceptable, but if the temperature inside the furnace is high and the temperature outside the furnace is high, or if corrosion of the support member 20 needs to be prevented, it is preferable to construct it from heat-resistant stainless steel such as SUS310S or SUS304.

[0081] Furthermore, the size of the support member 20 (20A) should be such that it can be switched between a state in which "its entirety is located between the pair of structural elements 19" and a state in which "a part of it extends outward between the pair of structural elements 19". For example, in the case of the support member 20A shown in Figure 4, when the movable support members 24A1 and 24A2 are folded (closed), and the surface P1 is facing the ceiling of the heating furnace, the entire support member 20A should be located between the pair of structural elements 19, and it is possible to have various shapes and sizes. In a preferred configuration, the size of the support member 20 (20A) should be such that it can be switched between a state in which "it is housed inside the surface P1" and a state in which "it extends outward from the surface P1". For example, in the case of the support member 20A shown in Figure 4, when the movable support members 24A1 and 24A2 are folded (closed), and the surface P1 is facing the ceiling of the heating furnace, the entire support member 20A should be housed inside the surface P1. Various shapes and sizes are possible.

[0082] The length of the elongated fixed support member 22A is preferably 80% to 120% of the distance W1 between the pair of structures 19, more preferably 90% to 100%, and more preferably 90% to 95%, meaning the length of the fixed support member 22A is preferably about 5 to 10% less than the distance L1 between the pair of structures. Furthermore, in a preferred embodiment, the length of the elongated fixed support member 22A is preferably 80% to 120% of the length of the surface P1 of the heat-insulating block in the X direction, more preferably 90% to 100%, and particularly preferably 100%, meaning the length of the fixed support member 22A and the length of the surface P1 of the heat-insulating block in the X direction are the same.

[0083] The fixed support member 22A preferably has a width of 20 to 60 mm. Its length depends on the distance W1 between the pair of structures or the size of the ceiling-side surface P1 of the heat-insulating block 100, but if it is too long, deformation may occur due to thermal expansion, so it is preferable to keep it at 500 mm or less. The thickness of the fixed support member 22A is preferably 3 to 5 mm.

[0084] Furthermore, it is preferable that the length of the movable support members 24A1 and 24A2 be 80% or more and 120% or less of half the length of the surface P1 of the insulating block in the Y direction, and it is more preferable that it be 90% or more and 110% or less, and it is particularly preferable that it be 100%, that is, the length of the movable support members 24A1 and 24A2 be the same as half the length of the surface P1 of the insulating block 30 in the Y direction.

[0085] Specifically, the width and thickness of the movable support members 24A1 and 24A2 are the same as those of the fixed support member 22A. The length depends on the size of the ceiling-side surface P1 of the insulation block 100, but if it is too long, it may expand due to heat and cause distortion, so it is preferable to keep it 200 mm or less.

[0086] (Other Forms of Support Member 20) Figures 7(a) to 7(b), 8(a) to 8(c), 9(a) to 9(b), and 10 show other forms 20B to 20I of support member 20. Note that in Figures 7 to 9 and 10, the X and Y directions may be omitted, but as in Figure 4, the direction in which block fixing metal fittings 34 extend is the X direction, and the direction perpendicular to the X direction is the Y direction. Also, in Figures 7 to 9 and 10, the folds of inorganic fiber aggregate mat 32 are omitted.

[0087] 7(a) shows a configuration in which an L-shaped steel support member 20B is rotatably engaged with a shaft 38. In this configuration, the support member 20B is composed of a single member (the L-shaped steel in the drawing). The length Lb of the support member 20B is sufficient to position it between the pair of structures 19, and it is preferable that it can be stored in the ceiling-side surface P1 of the insulation block 100.

[0088] This configuration reduces the number of parts, thereby lowering costs. Also, because there is only one pivot point (i.e., one hole formed in the support member), it is possible to prevent a decrease in strength, which could be a cause of damage during installation or operation.

[0089] Figure 11 shows the partition wall insulation block 100 having the support member 20B. It shows the plane P1 as viewed from the ceiling side. In the state shown in Figure 11(a), the entire support member 20B is positioned between the pair of structures 19. Therefore, by lifting the partition wall insulation block 100 from below, the support member 20B can be passed between the pair of structures 19 and positioned on the ceiling side of the pair of structures 19.

[0090] Figure 11(b) shows the state in which the support member 20B is rotated around the axis 38 in the above state, switching to a state in which the support member 20B extends outside the pair of structures 19. In this state, the support member 20B is engaged with the pair of structures 19. Therefore, the partition wall insulation block is suspended from the pair of structures 19. In this example, in order to suspend the partition wall insulation block from the pair of structures 19, it is not necessary to pass the inorganic fiber aggregate mat 32 between the pair of structures 19. This shortens the travel distance of the inorganic fiber aggregate mat 32, improving workability.

[0091] In addition, the length Lb of the support member 20B needs to be longer than W1 in order to engage with a pair of structures 19, and is preferably 110% or more of W1, more preferably 120% or more of W1, and even more preferably 130% or more of W1.

[0092] Furthermore, in order to avoid the presence of existing structures or the like in the Y direction, it is preferable that the length Lb of the support member 20B be equal to or less than the length of the diagonal line between the points where the inner surfaces 19P1, 19P2 of the pair of structures 19 intersect with the ceiling-side surface P1, as shown in Fig. 11(c) . Note that, when the length of W1 is unknown during the design of the support member 20B, it is preferable that the length Lb of the support member 20B be equal to or less than the length of the surface P1 in the Y direction, as shown in Fig. 11(a) .

[0093] Figure 12 shows a view from plane P1 when W1 is approximately the same as the length of plane P1 in the X direction. When the length Lb of support member 20B is the same as the diagonal of plane P1, as shown in Figure 12(a), rotating support member 20B around axis 38 (not shown) causes the end of support member 20B to extend outside plane P1, as shown in Figure 8(b). Further rotation causes the end of support member 20B to extend further outside plane P1, as shown in Figure 8(c). This extended portion can be engaged with a pair of structures 19 or an existing ceiling structure.

[0094] From this perspective, it is preferable that the length Lb of the support member 20B be 95% or more and 100% or less of the diagonal length of the ceiling side surface P1 of the insulation block precursor 30, with the lower limit being more preferably 98% or more, and it is most preferable that it be 100%, i.e., the length Lb of the fixed support member 22B is the same as the diagonal length of the surface P1.

[0095] 7(b) shows a support member 20C in a configuration in which two support members 20C1 and 20C2 are rotatably engaged with shafts 38. In the illustrated configuration, one support member 20C1 is formed of an L-shaped steel beam, and the other support member 20C2 is formed of flat steel plate. However, both support members may be made of L-shaped steel beams and stacked upside down (with the upright piece of the upper L-shaped steel beam facing upward and the upright piece of the lower L-shaped steel beam facing downward), or both may be made of flat steel plate as long as strength is maintained. In this configuration, 20C1 and 20C2 can be rotated in different directions, which allows for more efficient avoidance of obstacles when being inserted between a pair of ceiling structures 19.

[0096] The length Lc of the support members 20C1 and 20C2 (the length from the axis 38 to the end of the support members 20C1 and 20C2) corresponds to half the length of the support member 20B. In addition, when the distance W1 between the pair of structures 19 is approximately the same as the length of the plane P1 in the X direction, it corresponds to half the length of the diagonal of the insulation block 100. 7B, when the support members 20C1 and 20C2 are positioned diagonally on the surface P1 of the insulation block 100, the entire support members 20C1 and 20C2 are positioned between the pair of structures 19, preferably inside the surface P1. Rotating the support members 20C1 and 20C2 from this position so that they extend in the X direction corresponds to a state in which a portion of the support members 20C1 and 20C2 extends outside the space between the pair of structures 19, preferably outside the surface P1. As described below, by setting the length Lc of the support members 20C1 and 20C2 to be less than half the diagonal length of the insulation block 100, the support members 20C1 and 20C2 can be positioned inside the surface P1 even when they are not positioned diagonally on the surface P1.

[0097] It is preferable that the length Lc of the support members 20C1, 20C2 be 95% or more and 100% or less of 1 / 2 the diagonal length of the ceiling side surface P1 of the insulation block precursor 30, and a lower limit of 98% or more is more preferable, and it is most preferable that it be 100%, that is, that the length Lc of the support members 20C1, 20C2 is equal to 1 / 2 the diagonal length of the ceiling side surface P1 of the insulation block precursor 30, in order to maximize the length of the extended portion.

[0098] 8(a) shows a support member 20D in which the fixed support member 22A of the form in FIG. 4 is turned upside down (the upright piece of the L-shaped steel is facing downward) and a member 22D is fixed to a shaft 38. If the support member 20D can be switched between a state in which the entirety is positioned between the pair of structures 19 and a state in which a portion of the support member extends outward from the pair of structures 19, preferably between a state in which the support member is housed inside the plane P1 and a state in which the portion extends outward from the plane P1, the orientation of the L-shaped steel constituting the fixed support member 22D may be changed upside down, or a similar support member may be formed by changing the L-shaped steel to a U-shaped steel or a C-shaped steel.

[0099] In this configuration, there are no restrictions on the rotation direction of the movable support members 24D1, 24D2, so obstacles can be avoided more efficiently when inserting the insulation block 100 between the pair of structures 19 or the existing ceiling structure. For example, as shown in Figure 13 (a) from the view of plane P1, when the movable support members 24D1, 24D2 are folded, the entire support member 20D is positioned between the pair of structures 19. Therefore, by lifting the partition wall insulation block from below, the support member 20D can be passed between the pair of structures 19 and positioned on the ceiling side of the pair of structures 19.

[0100] 13(b) shows a state in which the movable support members 24D1, 24D2 are rotated in the above state to switch to a state in which at least a portion of the movable support members 24D1, 24D2 extends outside the pair of structures 19. In this state, the support member 20D is engaged with the pair of structures 19. Therefore, the partition wall insulating block is suspended from the pair of structures 19.

[0101] Furthermore, when the distance W1 between the pair of structures is approximately the same as the length of the plane P1 in the X direction, as shown in, for example, Figures 14(a) to (c), when the movable support members 24D1, 24D2 are folded and the plane P1 is facing the ceiling of the heating furnace and viewed from the ceiling side, it is sufficient that the entire support member 20D is stored inside the plane P1, and various shapes and sizes such as those shown in Figures 8(a) to (c) can be used.

[0102] Figure 8(b) shows an example in which two block fixing brackets 34A, 34B are installed on the surface P1. In other words, by using a beam with two blades at different positions in the axial direction of the beam 36 shown in Figure 6, the laminated inorganic fiber aggregate mat 32 is fixed by the two block fixing brackets 34A, 34B to form the insulation block precursor 30. In this case, a stronger insulation block precursor 30 is formed. Furthermore, since the partition wall insulation block 100 is supported by two shafts 38A, 38B, the weight of the insulation block precursor 30 is distributed across the two shafts 38A, 38B, allowing the insulation block 100 to be hung from the ceiling more stably and fixed in its vertical position.

[0103] In the support member 20E of the form shown in Figure 8(b), a U-shaped steel 22E having holes at positions corresponding to the two shafts 38A, 38B is fixed to the shafts 38A, 38B with nuts with the open side facing downward. Two L-shaped steels 24E1, 24E2 with one closed end face are then placed vertically on both sides of the U-shaped steel 22E and welded to the two L-shaped steels 24E1, 24E2 with the closed end face facing up. L-shaped steels 26E1, 26E2 are attached to the closed end faces of the L-shaped steels 24E1, 24E2 so that they can rotate around bolts (separate shafts).

[0104] The state in which the L-shaped steels 26E1 and 26E2 are each open along the X direction shown in Figure 8(b) corresponds to "a state in which a part of the support member 20E extends outward from between the pair of structures 19," and preferably corresponds to "a state in which the support member 20E extends outward from the plane P1," and the state in which the L-shaped steels 26E1 and 26E2 are each closed along the Y direction corresponds to "a state in which the entire support member 20E is positioned between the pair of structures 19," and preferably corresponds to "a state in which the support member 20E is housed inside the plane P1." Therefore, Figure 8(b) corresponds to "a state in which a part of the support member 20E extends outward from between the pair of structures 19," and preferably corresponds to "a state in which the support member 20E extends outward from the plane P1."

[0105] 8(b), the L-shaped steels 24E1 and 24E2 are attached to the center of the U-shaped steel 22E in the Y direction, but the positions at which the L-shaped steels 26E1 and 26E2 are supported on different shafts are shifted outward from the center in the X direction by the amount of the U-shaped steel 22E located at the center in the X direction. Therefore, as described above, when opened along the X direction, it is possible to make the ends of the L-shaped steels 26E1 and 26E2 extend outside the plane P1.

[0106] 9(a), when the welding position of L-shaped steel 24G1 to the U-shaped steel is on the front side in the Y direction and the welding position of L-shaped steel 24G2 is on the rear side in the Y direction, L-shaped steel 24G1 and L-shaped steel 24G2 can be set longer than when both are attached to the center of U-shaped steel 22E in the Y direction (configuration 20E), and when L-shaped steel 24G1 and L-shaped steel 24G2 are opened in the X direction, the portions extending outward of the pair of structures 19, preferably the portions extending outward of plane P1, can be made longer. Therefore, attachment is possible even when the distance to the existing structure is great.

[0107] The embodiment shown in FIG. 8C is also an example in which two block fixing metal fittings 34A and 34B are formed on the surface P1 of the heat insulating block precursor 30 facing the ceiling.

[0108] In the form of Figure 8 (c), a U-shaped steel 22F having holes at positions corresponding to the shafts 38A, 38B is fixed to the two shafts 38A, 38B with the open side facing downwards using nuts, and L-shaped steels 24F1, 24F2 are rotatably connected to each of the two shafts 38A, 38B extending from the top surface of this U-shaped steel 22F.

[0109] The state in which the L-shaped steels 24F1 and 24F2 are aligned in the X direction as shown in Figure 8 (c) is "a state in which the entire support member 20F is positioned between a pair of structures 19", preferably "a state in which the support member 20F is stored inside the surface P1", and from this state, the state in which the L-shaped steels 24F1 and 24F2 are rotated so that they are aligned in the Y direction is "a state in which a part of the support member 20E extends outside between the pair of structures 19", preferably "a state in which the support member 20F extends outside the surface P1".

[0110] In comparison with the support member 20E of FIG. 8(b), the support member 20F of this embodiment has the advantage that the members 24E1 and 24E2 can be omitted and no additional shaft is required, thereby improving work efficiency.

[0111] The embodiment shown in FIG. 9( b ) is also an example in which two block fixing metal fittings 34A and 34B are formed on the ceiling side surface P1 of the heat insulating block precursor 30 .

[0112] 9(b), a U-shaped steel 22H having holes at positions corresponding to the shafts 38A and 38B is fixed to the two shafts 38A and 38B with the open side facing downwards using nuts. A flat steel 24H extending in the X direction is welded to the center of the Y direction on the top surface of the U-shaped steel 22H. Movable support members 26H1 and 26H2 are rotatably mounted on shafts (separate shafts) extending toward the ceiling at both ends of the flat steel 24H in the X direction.

[0113] The state in which the L-shaped steels 26H1 and 26H2 are aligned in the X direction as shown in Figure 9 (b) is "a state in which a part of the support member 20H extends outward between the pair of structures 19", preferably "a state in which the support member 20H extends outward from the plane P1", and when the L-shaped steels 26H1 and 26H2 are rotated from this state so that they are aligned in the Y direction, this is "a state in which the entire support member 20H is positioned between the pair of structures 19", preferably "a state in which the support member 20H is stored inside the plane P1".

[0114] In comparison with the support members 20E and 20G, the present embodiment 20H has the advantage that the number of parts can be reduced and the number of welding points can be reduced, thereby improving work efficiency.

[0115] The embodiment of FIG. 10 is also an example in which two block fixing metal fittings 34A, 34B are formed on the surface P1 of the heat insulating block precursor 30 on the ceiling side.

[0116] In the embodiment shown in Figure 10, a U-shaped steel 22I having holes at positions corresponding to the shafts 38A and 38B is fixed to two shafts 38A and 38B with the open side facing downwards using nuts. A flat steel 24I extending in the X direction is welded to the center of the Y direction on the top surface of the U-shaped steel 22I. Movable support members 26I1 and 26I2 are mounted on shafts 27I1 and 27I2 extending toward the ceiling at both ends of the flat steel 24I in the X direction so as to be slidable in the X direction. Grooves 28I1 and 28I2 having a width in the X direction are formed in the movable support members 26I1 and 26I2, and the movable support members 26I1 and 26I2 can slide in the X direction along these grooves.

[0117] A state in which the L-shaped steels 26I1, 26I2 are slid inward in the X direction, that is, a state in which the L-shaped steels 26I1, 26I2 are contracted in the X direction, is a state in which the entire support member 20I is positioned between the pair of structures 19, and preferably a state in which the support member 20I is stored inside the plane P1. Furthermore, a state in which the L-shaped steels 26I1, 26I2 are slid outward in the X direction, that is, a state in which the L-shaped steels 26I1, 26I2 are extended in the X direction, is a state in which a part of the support member 20I extends outside the gap between the pair of structures 19, and preferably a state in which the support member 20I extends outside the plane P1.

[0118] <Partition wall and manufacturing method thereof> The manufacturing method for a partition wall of the present invention is a method for manufacturing a partition wall inside a furnace by suspending the above-mentioned partition wall insulating block 100 from the ceiling of the furnace, and includes the steps of inserting the support member 20 between the pair of structures 19 on the ceiling of the heating furnace, with the support member 20 positioned between the pair of structures 19, preferably with the support member 20 stored inside the ceiling-side surface P1 of the partition wall insulating block 100, and after the inserting step, switching the support member 20 to a state in which it extends outside between the pair of structures, preferably to a state in which it extends outside the surface P1, thereby engaging the support member 20 with the pair of structures on the ceiling of the heating furnace.

[0119] A plurality of insulating blocks 100 for partition walls are installed between the side walls of the furnace as described above to manufacture the partition walls.

[0120] Specifically, the partition wall insulating blocks 100 are installed in order from both sides of the heating furnace. When constructing the center part of the furnace wall, a hydraulic jack is used to install the blocks while maintaining a predetermined pitch.

[0121] A typical insulating partition block 100 is 1600 mm high, 300 mm long and 300 mm wide, and relatively heavy. Therefore, during installation, it is preferable to install a winch on the ceiling beam and use it to lift the insulating partition block 100 to the desired position.

[0122] The insulating block 100 for partition walls of the present invention is provided with a support member 20 on the shaft 38, making it easy to attach a winch hook, thereby improving workability.

[0123] As described above, when the partition wall insulation block 100 is lifted to the installation position, the support member 20 is positioned between the pair of structures, preferably stored inside the ceiling side surface P1, and in this state, it passes between the pair of structures on the ceiling and reaches the predetermined position, after which the support member 20 is switched to a state in which it extends outside between the pair of structures, preferably outside the surface P1, and engaged with the pair of structures on the ceiling side.

[0124] To engage with a pair of structures, it is sufficient to fix the upper and lower positions of the partition wall insulation block 100, so it is acceptable to simply hook the extended portion of the support member 20 onto the pair of structures on the ceiling side, or to weld the engagement points.

[0125] In the manufacturing method of the present invention, a method for neatly lining the partition wall insulation blocks 100 in a single horizontal row can be employed by stretching a piece of piano wire or the like in a single horizontal row and then aligning the centers of the partition wall insulation blocks 100. By simply aligning the centers of the partition wall insulation blocks 100 in this way, the support members 20 can be attached to the pair of ceiling-side structures in any desired manner. In other words, even if the movable support members 20 are connected to the pair of structures with a slight misalignment, as long as the centers of the partition wall insulation blocks 100 are aligned, there will be no problems in construction. Therefore, the partition wall manufacturing method of the present invention can be said to be a method that greatly improves workability because it does not require fine adjustments.

[0126] The insulation block 100 is relatively heavy, making installation a large-scale project. Furthermore, the ceiling side is surrounded by a pair of existing structures, making the construction work difficult. From this perspective, the partition wall manufacturing method of the present invention offers the advantage of shortening the construction time and simplifying the work procedure.

[0127] <Heating Furnace> The heating furnace of the present invention includes the partition wall described above. It may include multiple partition walls. The lower part of the partition wall has a gap that allows a steel plate to pass through. The partition wall is firmly fixed in its vertical position by the support member 20 and the block fixing hardware 34 described above. Furthermore, because each partition wall insulating block 100 is installed in a compressed state, it is also fixed in place by the repulsive force of the inorganic fiber aggregate mat 32.

[0128] The partition wall insulating block 100 of the present invention facilitates installation on the furnace ceiling and minimizes the amount of dismantling required for the existing structure. In particular, since there is no need to align holes in the furnace ceiling or fasten nuts, the installation process is easy and can be completed in a shorter time, even in a furnace where the working environment is poor. This contributes greatly to improving workability on-site and ensuring the safety of workers. Furthermore, the same advantages can be achieved even when a pair of structures 19 is installed at the location where the furnace ceiling is dismantled.

[0129] 100: Heat insulating block for partition wall 19: Pair of structures 20, 20A to 20I: Support member 30: Heat insulating block precursor 32: Mat of inorganic fiber aggregate 34: Metal fitting for fixing block 36: Beam 38: Axis P1: Ceiling side surface of heat insulating block precursor

Claims

1. An insulating block for partition walls, comprising a mat of laminated inorganic fiber aggregate, and comprising a block fixing metal fitting on the surface facing the ceiling of a heating furnace, and further comprising a support member that is engageable with the block fixing metal fitting and engageable with a pair of structures on the ceiling of the heating furnace, and the support member is configured to be switchable between a state in which the entire support member is located between the pair of structures and a state in which a part of the support member extends outside the space between the pair of structures.

2. An insulating block for partition walls as described in claim 1, wherein the inner surfaces of the pair of structures are each positioned at a position that approximately coincides with the edge of the ceiling-side surface or is positioned outside the ceiling-side surface, and the support member is configured to be switchable between a state in which it is stored inside the ceiling-side surface and a state in which it extends outside the ceiling-side surface.

3. An insulating block for partition walls as described in claim 1, wherein the inner surfaces of the pair of structures are each positioned inside the ceiling-side surface, and the support member is configured to be switchable between a state in which it is located between the pair of structures and a state in which it extends outward between the pair of structures when stored inside the ceiling-side surface.

4. An insulating block for partition walls as described in claim 1, wherein the support member is rotatably engaged with an axis extending from the block fixing fitting toward the ceiling of the heating furnace, and the support member is configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outside the space between the pair of structures by rotating around the axis.

5. An insulating block for partition walls as described in claim 1, wherein the support member comprises a fixed support member connected to an axis extending from the block fixing fittings toward the ceiling of the heating furnace, and at least one movable support member connected to the fixed support member, the movable support member being rotatably engaged with another axis extending from the fixed support member toward the ceiling of the heating furnace, and the movable support member being configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outside the space between the pair of structures by rotating around the other axis.

6. An insulating block for partition walls as described in claim 1, wherein the support member comprises a fixed support member connected to an axis extending from the block fixing fittings toward the ceiling of the heating furnace, and at least one movable support member connected to the fixed support member, and the movable support member is configured to be able to switch between a state in which it is positioned between the pair of structures and a state in which it extends outside the space between the pair of structures by sliding relative to the fixed support member.

7. The insulating block for a partition wall according to claim 1, wherein the support member is suspended from the pair of structures by engaging with the pair of structures.

8. A partition wall comprising a plurality of insulating blocks for partition walls according to any one of claims 1 to 7 arranged in the furnace width direction.

9. A heating furnace comprising the partition wall according to claim 8.

10. A method for manufacturing a partition wall within a heating furnace by suspending an insulating block for partition walls as set forth in any one of claims 1 to 7 from the pair of structures on the ceiling of the heating furnace, the method comprising the steps of: inserting the support member between the pair of structures while the support member is positioned between the pair of structures; and, after the inserting step, switching the support member to a state in which it extends outward between the pair of structures, thereby engaging the support member with the pair of structures.

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