Fibrous Insulation Block with Removable Packing for Furnace Lining
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Solution Overview
Problem
The existing methods for lining furnace surfaces with fibrous heat-insulating blocks, such as the checker method, face inefficiencies in removing packing materials between blocks, leading to physical strain, material breakage, and environmental issues due to the need for manual removal and reuse challenges.
Innovation Solution
A fibrous heat-insulating block system with a packing material that includes pressed surface contact parts and heated surface protection parts, where the binding band is removable, allowing the packing material to be easily pulled out and reused, using a pulling jig to facilitate efficient collection and reduce operational time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the checker method is used for lining furnace surfaces with fibrous heat-insulating blocks, then the lining structure is stabilized and gaps between blocks are reduced, but the removal of packing materials becomes difficult and time-consuming
Solution Approach 1:
The packing material is divided into two functional segments: a pressed surface contact part that remains embedded to maintain structural stability, and a heated surface protection part that is detachable for easy removal. This segmentation allows the system to simultaneously achieve structural stability and ease of maintenance.
Solution Approach 2:
The heated surface protection part of the packing material is extracted as a separable component that can be easily removed after the lining process. This extraction principle enables the removal of unnecessary protective elements without affecting the core structural integrity provided by the pressed surface contact parts.
2Productivity
If manual removal of packing materials is performed, then the lining process can be completed, but physical strain on workers increases and material breakage occurs
Solution Approach 1:
The packing material design enables self-service removal through the detachable heated surface protection part, which can be easily separated without requiring excessive manual force or complex removal tools. The structural design itself facilitates its own removal process.
Solution Approach 2:
The packing material transitions from a static, permanently embedded component to a dynamic system where the heated surface protection part can be selectively removed. This dynamic design allows the packing material to serve different functions at different stages: structural support during lining and easy removal during maintenance.
3Loss of substance
If packing materials are reused, then material costs are reduced, but collection and reuse processes become complex and environmentally problematic
Solution Approach 1:
By segmenting the packing material into pressed surface contact parts and heated surface protection parts, the system enables selective collection and reuse of the pressed surface contact parts while the heated surface protection parts can be discarded or separately managed, simplifying the reuse process.
Solution Approach 2:
The design facilitates discarding the heated surface protection part after use while recovering and reusing the pressed surface contact parts. This selective discarding and recovering approach reduces overall material waste while maintaining a simple collection process.
4Ease of operation
If the unit block shape is maintained during lining, then handling and installation are simplified, but the binding bands and packing materials become difficult to remove
Solution Approach 1:
The packing material is segmented into pressed surface contact parts and heated surface protection parts, allowing the binding bands to be removed from the pressed surface contact parts while leaving them in place for structural support, and enabling separate removal of the heated surface protection parts.
Solution Approach 2:
The heated surface protection part is extracted as a removable component that can be separated from the unit block after lining. This extraction allows the binding bands to be easily removed from the pressed surface contact parts without compromising the structural integrity of the lining.
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 solution enhances the operational efficiency of furnace wall lining by allowing easy collection and reuse of packing materials, reducing physical strain and environmental impact, while improving the handling and durability of the lining process.
Implementation Method 1
fibrous heat-insulating materials, such as ceramic fibers, have been used for lining of furnace walls in various kiln equipment
Implementation Method 2
a restoring force in a stacking direction of the stacked layers
Data Source
AI summary
Disclosed are a fibrous insulation block which can improve work efficiency of lining construction in various types of refractory furnace in iron works, and a construction method for a heated furnace-surface lining using the same. Specifically disclosed is a fibrous insulation block which comprises: a unit block (2) formed by laminating fibrous insulation blankets under pressure; a packing material (3) which has a pressing surface abutting section (5) covering at least a part of each pressing surface (2a, 2b) which are the side surfaces of the unit block in the direction in which the blankets are laminated, and a heating surface protection section (6) connected to the pressing surface abutting section so as to cover at least a part of a heating surface (2c) of the unit block, and in which a boundary section (7) between the pressing surface abutting section and the heating surface protection section covers an angle section formed by the pressing surfaces and the heating surface of the unit block; and a binding band (4) which maintains the shape of the unit block (2) using the packing material (3). The heating surface protection section (6) of the packing material (3) can be moved by the removal of the binding band and disposed on the same plane as the pressing surface abutting section, and has handhold sections (10) provided therein.