Boiler Burner Cover Insulation with Composite Sealing Structure
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Solution Overview
Problem
Conventional burner stones and sealing gaskets in condensing boilers face high failure rates due to fragility, thermal shock, and chemical solubility issues in harsh environments, leading to reduced protection and efficiency.
Innovation Solution
A burner cover insulation device comprising a heat-resistant inorganic fibrous cover layer, a support layer for mechanical strength, and a filling material for thermal insulation, connected with a sealing element to combine insulation and sealing functions, using mechanically bonded fibres without binders for enhanced durability and thermal shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vermiculite burner stone is used for insulation, then thermal insulation is provided, but the structure becomes fragile and fails under thermal shock
Solution Approach 1:
The patent uses a composite structure consisting of an inner layer of heat-resistant ceramic fibres and an outer layer of steel mesh. This composite material combines the thermal insulation properties of ceramic fibres with the mechanical strength and thermal shock resistance of steel mesh, resolving the contradiction between providing thermal insulation and maintaining structural strength under thermal shock conditions.
2Temperature
If inorganic fibre burner stone is used, then high temperature resistance is achieved, but the fibres dissolve in condensate
Solution Approach 1:
The steel mesh acts as an intermediary protective layer between the ceramic fibres and the condensate environment. The mesh provides a barrier that prevents direct contact between the hygroscopic ceramic fibres and the damp condensate, thereby preventing dissolution while maintaining the high temperature resistance of the fibres.
Solution Approach 2:
The steel mesh functions as a flexible protective shell that encloses the ceramic fibre insulation. This thin film structure provides protection against moisture and chemical degradation from condensate while allowing the underlying insulating material to maintain its thermal performance at high temperatures.
3Reliability
If sealing gasket is used to seal the cover plate, then sealing is provided, but the gasket deteriorates under high temperature
Solution Approach 1:
The steel mesh serves as an intermediary protective layer between the sealing gasket and the high-temperature environment. By positioning the mesh between the gasket and the hot gases, it shields the gasket from direct thermal exposure, thereby extending the gasket's service life while maintaining effective sealing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides improved mechanical strength, thermal insulation, and durability, reducing maintenance costs and the risk of debris contamination, while maintaining effective sealing and insulation performance in high-temperature, damp environments.
Implementation Method 1
a cover layer (102) comprising a heat resistant inorganic fibrous material, which has the function to protect the filling material from the heat produced by a burner
Implementation Method 2
In between the cover layer (102) and the support layer (103), the insulating layers (104, 104') are provided
Data Source
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AI summary
A burner cover insulation device for shielding a burner cover from a boiler burner. The insulation device includes a cover layer comprising a heat resistant inorganic fibrous material and having a first outer peripheral edge; a support layer providing mechanical strength to the device and having a second outer peripheral edge that at least extends to the outer peripheral edge of the cover layer; and a filling material forming an insulating layer between the cover layer and the support layer. A through hole extends through the cover layer and the support layer. The invention furthermore relates to a method for manufacturing such a device.