Interlocking Refractory Bricks for Faster, Stable Furnace Installation

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Solution Overview

Problem

The assembly and installation of checker bricks in regenerative glass melting furnaces are labor-intensive, require skilled personnel, and result in unstable constructions prone to deformation and failure due to unidirectional load and vertical movement, leading to inefficiencies and potential collapse.

Innovation Solution

The use of refractory bricks with angled or curved geometry and interlocking protrusions and notches that form vertically oriented passageways, allowing for horizontal locking and secure stacking, enabling safer, faster installation and reducing localized stresses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional checker bricks with simple perpendicular geometry are used, then the construction process is simple, but the bricks are subject to easy displacement and shifting within individual layers, leading to instability

Engineering Contradiction:

Improvesimplicity of brick geometryVSAvoidstability of brick arrangement

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies asymmetry by designing bricks with non-perpendicular geometry where adjacent bricks are angled relative to each other (e.g., 30-60 degree angles from vertical). This asymmetric arrangement prevents bricks from shifting horizontally or vertically, as the angled surfaces interlock to resist movement in multiple directions, thereby solving the stability problem while maintaining manufacturing simplicity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent employs curvature by specifying that brick surfaces can be convex or concave (curved) rather than flat. These curved surfaces are designed to mate with complementary curved surfaces of adjacent bricks, creating an interlocking effect that prevents displacement and enhances the stability of the brick arrangement

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Stability of the object's composition

If interlocks between individual layers are added to increase stability, then vertical movement and slippage are reduced, but the construction requires many crane movements and significantly slows down the installation process

Engineering Contradiction:

Improvestability of checker settingVSAvoidinstallation speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-assembling complete layers of interlocking bricks on the ground outside the regenerator chamber before lifting them into position. This allows the complex interlocking arrangement to be constructed in advance with proper alignment, eliminating the need for time-consuming crane movements and adjustments during installation, thereby maintaining both stability and productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the construction into discrete, complete layers that can be independently assembled and then stacked. Each layer is a self-contained unit with all interlocks already formed, allowing for efficient handling as a single module during installation while maintaining the stability benefits of interlocking design

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If heavy construction load is unidirectionally projected from top to bottom, then the structure is simple to construct, but flaws in the assembly cannot be properly absorbed, generating local stress that may lead to shift and collapse

Engineering Contradiction:

Improvesimplicity of constructionVSAvoidresistance to deformation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The asymmetric, angled brick arrangement redistributes the construction load by directing forces along the angled surfaces of adjacent bricks rather than purely vertically. This creates a more uniform stress distribution throughout the structure, preventing localized stress concentration at flaw points and enhancing reliability while maintaining construction simplicity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The curved (convex/concave) brick surfaces facilitate more uniform load distribution by allowing gradual force transfer between adjacent bricks rather than concentrated point contacts. This curvature-based design helps absorb and redistribute stresses throughout the structure, preventing local stress buildup that could lead to deformation or collapse

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS20250243101A1Interlocking refractory bricks and refractory layer structures formed therewith

Publication Date: 2025.07.31 HARBISONWALKER INTERNATIONAL HOLDINGS INC

AI summary

A refractory layer structure includes a plurality of refractory layers stacked on each other. Each of the refractory layers includes refractory bricks. Each of the refractory bricks is formed as a cuboid having a pair of oppositely positioned first diverging sides and a pair of oppositely positioned second diverging sides. The first diverging sides diverge away from each other from a top to a bottom of the refractory bricks. The second diverging sides diverge away from each other from the bottom to the top of the refractory bricks. The first diverging sides and the second diverging sides are connected to each other. Each of the first diverging sides have a first diverging side protrusion projecting from a top surface thereof. Each of the second diverging sides have a second diverging side protrusion projecting from a top surface thereof.