Insulating Concrete Shell With Low-Thermal-Bridge Anchoring
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Solution Overview
Problem
Conventional insulating concrete shells for heat treatment furnaces suffer from high thermal conductivity due to numerous anchors and water contamination during the casting process, compromising mechanical stability and insulation efficiency.
Innovation Solution
The insulating concrete shell design features two bent sheet metal strips connected by wires, with a recess for a ceramic fibre mat insertion post-curing, and uses grid-like wire anchors to minimize thermal conductivity while maintaining stability, achieved by embedding wires in the concrete and inserting the fibre mat after casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If numerous anchors are welded to the sheet metal to ensure mechanical stability, then the mechanical stability is improved, but the thermal conductivity increases
Solution Approach 1:
The continuous sheet metal is segmented into two separate semi-cylindrical strips, reducing the overall metal surface area and thus thermal conductivity. The anchors are also segmented and strategically positioned only at critical locations rather than distributed across the entire surface.
Solution Approach 2:
Sheet metal strips are applied only at specific locations (edges and critical support points) rather than covering the entire surface. This localized application maintains mechanical stability at critical points while minimizing overall thermal conductivity.
2Strength
If a large-area sheet metal jacket is used to ensure mechanical stability, then the mechanical stability is improved, but the thermal conductivity increases
Solution Approach 1:
The continuous sheet metal jacket is divided into two separate semi-cylindrical strips, which reduces the total metal surface area in contact with the insulation, thereby lowering thermal conductivity while maintaining structural integrity.
Solution Approach 2:
Metal strips are positioned only at critical locations such as edges and support points rather than covering the entire surface, providing mechanical stability where needed while minimizing thermal bridges.
3Stability of the object's composition
If the ceramic fibre mat is placed before casting to ensure proper positioning, then the positioning is improved, but the fibre mat is compressed and thermal conductivity increases
Solution Approach 1:
The ceramic fibre mat is pre-formed and positioned in a mold cavity before the insulation material is applied. This preliminary positioning ensures correct placement without requiring the mat to be compressed during the casting process.
Solution Approach 2:
Instead of placing the fibre mat and then casting over it (which causes compression), the mat is first positioned in a mold, and then the insulation material is applied around it, reversing the traditional sequence to avoid compression.
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
This design significantly reduces thermal conductivity and enhances mechanical stability by minimizing anchor contact area and preventing fibre mat deformation, thereby improving insulation performance and durability.
Implementation Method 1
The ceramic fibre mat 3 serves to reduce the thermal conductivity of the insulating concrete shell 5
Implementation Method 2
the two sheet metal strips, which are bent into a semicircle, are connected to each other by wires
Implementation Method 3
The casing of the insulating concrete shell 5 is then made of cast or tamped refractory concrete 4
Data Source
AI summary
An insulating concrete shell made of refractory cast concrete or refractory tamped concrete for insulating uprights or supporting tubes in a walking beam furnace or pusher-type furnace. The insulating concrete shell is shell-shaped and has a sheet metal strip on the inner side at each end, with which the insulating concrete shell can be fastened to an upright or to a supporting tube. The two sheet metal strips are connected to each other by wires, whereby the two wires are completely embedded in the cast or tamped concrete. A method for manufacturing an insulating concrete shell is also disclosed.