Thermal Insulation Wall Body Groove Segmentation
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Solution Overview
Problem
The existing methods for manufacturing thermal insulation wall bodies in vertical heat treatment devices are time-consuming, require significant effort, and necessitate special equipment, with low material utilization efficiency and high costs, especially when forming a holding unit deep enough to accommodate heater elements.
Innovation Solution
A method involving the processing of plate-shaped thermal insulation members with groove portions formed at a predetermined pitch and angle, allowing for the bonding of sectional members to create a cylindrical thermal insulation wall body with a spiral holding unit, enhancing material efficiency and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plurality of ring-shaped thermal insulation blocks are stacked in the axial direction, then the thermal insulation wall body can be formed, but a long period of time and tremendous efforts are needed to manufacture it
Solution Approach 1:
The thermal insulation wall body is divided into multiple sectional members, each containing groove portions that form the holding unit. These sectional members are processed independently and then bonded together, replacing the time-consuming stacking of ring-shaped blocks while maintaining the structural integrity and functionality of the holding unit.
Solution Approach 2:
The groove portions are formed on the plate-shaped thermal insulation members before bonding. This preliminary formation of the holding unit structure allows for efficient assembly, as the groove portions are already in place to receive the heater element when the sectional members are bonded together, eliminating the need for time-consuming post-assembly modifications.
2Ease of manufacture
If ring-shaped thermal insulation blocks are stacked, then the thermal insulation wall body can be manufactured, but special equipment is required and it is difficult to form the holding unit having a depth sufficient to hold the heater element
Solution Approach 1:
The holding unit is formed by groove portions created on individual plate-shaped sectional members rather than requiring complex forming operations on ring-shaped blocks. This segmentation allows for precise formation of deep groove portions using standard processing methods, eliminating the need for special equipment while achieving the required holding unit depth.
Solution Approach 2:
Instead of forming the holding unit by stacking pre-formed ring-shaped blocks with integrated holding structures, the invention inverts the approach by creating the holding unit through groove portions formed on flat plate-shaped members. This inversion simplifies the manufacturing process and enables precise control over the holding unit depth without requiring special equipment.
3Productivity
If the conventional methods are used, then the thermal insulation wall body can be manufactured, but material utilization efficiency is low and production costs are high
Solution Approach 1:
The thermal insulation wall body is constructed from multiple plate-shaped sectional members that can be efficiently cut and bonded. This segmentation approach improves material utilization efficiency compared to forming ring-shaped blocks, as plate-shaped members allow for more flexible material layout and reduced waste during cutting and assembly operations.
Solution Approach 2:
The invention changes the geometric parameters from ring-shaped blocks to plate-shaped members with groove portions. This parameter change enables more efficient material utilization by allowing optimized cutting patterns and reducing material waste, thereby lowering production costs while maintaining the structural requirements of the thermal insulation wall body.
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 approach enables cost-effective and efficient manufacturing of thermal insulation wall bodies with improved material utilization, facilitating the production of larger units and reducing the need for specialized equipment, while maintaining effective thermal insulation.
Implementation Method 1
a plurality of groove portions are formed at a predetermined pitch, the plurality of groove portions extending from a first surface to a second surface opposite to the first surface
Implementation Method 2
manufacturing the cylindrical thermal insulation wall body by bonding a plurality of sectional thermal insulation members
Data Source
AI summary
A method of manufacturing a cylindrical thermal insulation wall body having a holding unit of a heater element formed in an inner peripheral surface includes processing a plate-shaped thermal insulation member such that a plurality of groove portions are formed at a predetermined pitch, processing the thermal insulation member such that an angle between either of the first surface and the second surface, and a third surface on which the groove portions are formed, is 90+180/n degrees, and manufacturing the cylindrical thermal insulation wall body by bonding a plurality of sectional thermal insulation members, wherein the plurality of sectional thermal insulation members are bonded such that the groove portions of the adjacent sectional thermal insulation members are aligned with each other and to form the holding unit in the inner peripheral surface of the cylindrical thermal insulation wall body.