Modular Refractory Blocks with Recesses for Kiln Space Optimization
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Solution Overview
Problem
Existing kiln support systems are inefficient in maximizing space utilization and providing customizable support for ceramic tiles of varying sizes and shapes during the firing process, as they lack flexibility and stability at high temperatures.
Innovation Solution
A modular refractory block system with transverse recesses on upper and lower surfaces, combined with connecting rods, allows for variable spacing and configuration to create customizable racks or shelves within the kiln, optimizing space use and supporting ceramic tiles effectively during firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional fixed support systems are used in kilns, then structural stability is maintained, but space utilization efficiency deteriorates
Solution Approach 1:
The support system is divided into separate modular refractory blocks that can be independently positioned and configured. Each block contains recesses for receiving rods, allowing the system to be segmented into customizable units rather than using a fixed monolithic structure.
Solution Approach 2:
The support system transitions from a fixed configuration to a dynamic, adjustable configuration. Rods can be inserted into recesses at various positions on different blocks, enabling the spacing and arrangement of support shelves to be dynamically adjusted based on the specific dimensions and requirements of the ceramic pieces being fired.
2Adaptability or versatility
If custom support structures are created for each tile size, then support precision is improved, but manufacturing complexity increases
Solution Approach 1:
The modular refractory blocks are designed with multiple recesses at different positions, allowing a single standardized block design to serve multiple functions. The same block type can be used in various configurations to support different tile sizes, shapes, and arrangements, eliminating the need to manufacture custom support structures for each application.
Solution Approach 2:
The system allows adjustment of geometric parameters (spacing, arrangement, configuration) by changing the position of rods within the standardized recesses of modular blocks, rather than changing the fundamental structure or manufacturing different support components for different tile dimensions.
3Adaptability or versatility
If modular refractory blocks with multiple recesses are used, then adaptability for different configurations is improved, but block complexity increases
Solution Approach 1:
The complexity is distributed across multiple simple modular blocks rather than concentrated in a single complex structure. Each block contains standardized recesses that are simple in design, but the combination of multiple blocks creates the overall configurational flexibility needed for different support requirements.
Data Source
AI summary
A variable modular support system for use in a kiln, as well as a method of constructing such a support system in a kiln, comprises plurality of refractory blocks each having an upper surface and a lower surface and at least one transverse recess in either the upper or lower surface, the plurality of refractory blocks comprising a first base refractory block and a second base refractory block spaced from the first refractory block by a variable and selectable distance. Connecting rods extend from the recess of the first base refractory block or a refractory block stacked thereon to the recess of the second base refractory block or a refractory block stacked thereon, the connecting rods forming a rack or shelf located between the first base refractory block and the second base refractory block.