Modular Refractory Sidewall for Faster Combustion Chamber Repair

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Solution Overview

Problem

The construction and maintenance of refractory brick sidewalls in combustion chambers for syrup production evaporators are laborious and require frequent replacement due to suboptimal mechanical qualities, leading to inefficiencies in productivity and increased maintenance costs.

Innovation Solution

A modular refractory chamber wall comprising removably mountable refractory panels, secured by resilient members, which can be easily assembled and repaired without mortar, using silica-alumina composite materials with improved thermal insulation and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If refractory bricks are cemented together with mortar to construct sidewalls, then thermal insulation is provided, but construction becomes laborious and time-consuming

Engineering Contradiction:

Improvethermal insulationVSAvoidconstruction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The refractory wall is divided into modular panels that can be independently manufactured and installed. Each panel is a self-contained unit with integrated mounting features, eliminating the need for time-consuming mortar application and brick-by-brick construction. The panels are designed to interlock and secure to the combustion chamber frame efficiently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical system of mortar cementing bricks together is replaced with a mechanical mounting system using resilient members and mounting features integrated into the panel design. This substitution eliminates the laborious process of mixing and applying mortar while providing equivalent or superior structural integrity and thermal insulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If refractory bricks are used for combustion chamber walls, then thermal insulation is achieved, but mechanical strength is suboptimal leading to frequent replacement

Engineering Contradiction:

Improvethermal insulationVSAvoidresistance to log impacts

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The refractory panels are constructed from composite materials that combine materials with complementary properties. The composite structure provides both thermal insulation properties and enhanced mechanical strength to withstand log impacts and combustion conditions. The composite material integrates the thermal performance of refractory materials with the structural strength needed for impact resistance.

Inventive Principle:

Principle #40Composite materials

3Reliability

If damaged refractory bricks are replaced by dismantling and removing bricks, then replacement is achieved, but productivity is lost and maintenance costs increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmaintenance efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The wall structure is segmented into removable panels that can be independently accessed and replaced. When damage occurs, only the affected panel needs to be removed and replaced, rather than dismantling the entire wall structure. This modular approach minimizes maintenance time and productivity loss while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The refractory wall transitions from a static, permanent structure to a dynamic, maintainable system. The panels are designed to be removable and replaceable, allowing for easy maintenance and repair operations. This dynamic design enables quick replacement of damaged panels without disrupting the entire combustion chamber structure.

Inventive Principle:

Principle #15Dynamics

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

Facilitates rapid installation and repair of combustion chambers, reducing downtime and maintenance costs while maintaining thermal efficiency.

Implementation Method 1

when the combustion chamber is assembled, the resilient member is compressible to release the at least one refractory panel from the combustion chamber frame

Methodology Applied

Scientific EffectCompressibility: Compression

Implementation Method 2

a modular refractory chamber wall extending along a longitudinal side of the firebox, the modular refractory chamber wall comprising at least one refractory panel removably mountable to the combustion chamber frame to provide a thermal insulation to the combustion chamber

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250354225A1Combustion chamber comprising a modular refractory sidewall and refractory panel for the same

Publication Date: 2025.11.20 LES EQUIP LAPIERRE INC

AI summary

A combustion chamber for an evaporator configured for the production of a syrup, the combustion chamber comprising a combustion chamber frame defining a firebox configured to receive a fuel for combustion, and a modular refractory chamber wall extending along a longitudinal side of the firebox, the modular refractory chamber wall comprising at least one refractory panel removably mountable to the combustion chamber frame to provide a thermal insulation to the combustion chamber.