Flexible Ceramic Fibre Shield for Boiler Frame Heat Protection
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Solution Overview
Problem
Existing thermal radiation and conduction shields for boiler and furnace openings face issues with short lifespan due to brittle materials, high manufacturing costs, and inefficient heat transfer prevention, particularly when subjected to high temperatures and mechanical stress during shutdowns.
Innovation Solution
A shield composed of high-temperature-resistant, flexible ceramic fibre sheets with stainless steel support elements and clamping systems, allowing for a tight seal and adaptation to various opening shapes, ensuring durability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-fibre fabric pouch stuffed with ceramic fibre is used, then thermal insulation is provided, but the shield has short life-cycle due to brittle materials breaking during displacement
Solution Approach 1:
The patent changes the physical state and mechanical properties of the insulating material from brittle (glass-fibre fabric) to flexible and elastic (flexible ceramic fibre sheets). This parameter change allows the shield to withstand mechanical displacement during shutdowns without breaking, directly resolving the contradiction between reliability and strength.
Solution Approach 2:
The patent creates a composite structure combining flexible ceramic fibre sheets with stainless steel support elements and clamping systems. This composite material approach provides both the thermal insulation properties needed and the mechanical strength required to resist displacement stresses, eliminating the short life-cycle problem.
2Reliability
If shield is manufactured from castable by mould casting, then thermal insulation is achieved, but manufacturing costs increase due to individual mould requirements
Solution Approach 1:
The patent segments the shield into modular components: flexible ceramic fibre sheets, stainless steel support elements, and clamping systems. This segmentation allows for standardized manufacturing of components that can be assembled together, eliminating the need for expensive individual moulds while maintaining thermal insulation performance.
Solution Approach 2:
The patent changes the manufacturing approach from mould casting to assembling pre-fabricated flexible sheets and metal components. This parameter change in the manufacturing process eliminates mould-related costs while preserving the thermal insulation function through the flexible ceramic fibre material.
3Ease of operation
If shield is dimensioned smaller than opening for castable manufacturing, then installation is facilitated, but heat transfer to frame occurs due to loose fit
Solution Approach 1:
The patent uses flexible ceramic fibre sheets that can be cut and shaped to precisely fit the opening dimensions. This flexibility allows the shield to create a tight seal that prevents heat transfer to the frame, while still being easy to install by cutting the sheets to the required size and shape.
Solution Approach 2:
The patent introduces dynamic adaptability through the flexible sheets and clamping system, allowing the shield to be adjusted and sealed tightly against the opening. This dynamic fit eliminates the heat transfer problem while maintaining installation ease, as the flexible material can be easily cut and positioned.
4Ease of repair
If repeated displacement during shutdowns occurs, then shield removal for maintenance is enabled, but mechanical stress causes shield failure
Solution Approach 1:
The patent fundamentally changes the mechanical parameters of the insulating material from brittle to flexible and elastic. This parameter change enables the shield to withstand repeated displacement during shutdowns and maintenance operations without failing, directly resolving the contradiction between ease of repair and reliability.
Solution Approach 2:
The composite structure combining flexible ceramic fibre sheets with stainless steel support elements creates a mechanically durable assembly that can be repeatedly installed and removed. The flexible nature of the ceramic fibre sheets prevents damage during handling, while the steel elements provide structural integrity.
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 shield provides reliable, long-lasting thermal insulation with resistance to high temperatures and mechanical stress, maintaining a tight seal to prevent heat transfer, thus reducing operational costs and improving durability.
Implementation Method 1
the shield is employed in said openings in order to prevent conduction of heat through the protective face block from the firebox to those frame constructions of the apparatus
Implementation Method 2
said sheets (3) and said support elements (4) are held tightly against each other by said clamping elements (5)
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to providing a thermal radiation and conduction shield suitable for mounting on the rear side of a protective face block placed on an opening, such as a manhole, in the refractory ceramic lining of a boiler, furnace, or like apparatus. The shield is employed in said opening in order to prevent conduction of heat through the protective face block from the firebox to those frame constructions of the apparatus that are not manufactured from heat-resistant materials. Since the material of the protective face block is typically a refractory, high-density ceramic material of very high thermal conductivity, the operating temperature of the hot side of the shield is practically equal to that of the firebox. Consequently, the backing insulation of the shield must provide effective thermal insulation as well as good resistance to high temperatures. A third prerequisite is resistance to mechanical stress under practical operating conditions.