Monolithic Coke Oven Corbels to Reduce Gas Leakage
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Solution Overview
Problem
Current corbel designs for coke ovens are susceptible to gas leakage due to thermal expansion, require multiple blocks or modules that create seams, and are difficult to replace, leading to increased installation time and downtime.
Innovation Solution
A monolithic corbel design with integral gunblock sections and through-bores that eliminate the need for additional blocks, providing seamless construction and improved air and gas flow, and allowing for efficient replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple blocks or modules are used to construct corbels, then ease of manufacture and adaptability are improved, but gas leakage increases due to thermal expansion gaps and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate corbel blocks into a single monolithic unit that integrates the gunblock section, base, and support structures. This eliminates the joints between multiple blocks, preventing gas leakage while maintaining structural adaptability through the integrated design.
Solution Approach 2:
The monolithic corbel is designed with integrated segments for different functional zones (gunblock section, base, support structures) that are formed as one piece. This segmentation within unity allows the structure to adapt to different configurations while eliminating leakage paths between separate components.
2Ease of manufacture
If multiple blocks or modules are used to construct corbels, then ease of manufacture is improved, but construction time and installation complexity increase
Solution Approach 1:
By combining multiple corbel components into a single monolithic unit, the patent reduces the number of assembly steps and installation operations. The integrated design eliminates the time required to install multiple separate blocks and their associated joints, while manufacturing is optimized through integrated mold design.
3Ease of repair
If traditional multi-block corbel designs are used, then ease of repair is improved through modular replacement, but reliability decreases due to numerous potential failure points
Solution Approach 1:
The monolithic corbel design consolidates all functional components into a single replaceable unit. This maintains ease of repair through complete unit replacement while eliminating the numerous failure points associated with multiple blocks, joints, and mortar connections.
4Adaptability or versatility
If multiple blocks or modules are used to construct corbels, then adaptability to different configurations is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functional sections into a single monolithic corbel design, reducing device complexity by eliminating the need for multiple separate components and their associated joints, mortar work, and alignment procedures while maintaining adaptability through integrated design variations.
Data Source
AI summary
Monolithic corbels for coke ovens that incorporate multiple tiers that traditionally are formed by a plurality of stacked bricks or block. The monolithic corbels may have integral gunblock sections for use in gunfire coke ovens or the corbels may be designed without integral gunblock sections. The corbels may have one or more air flues (diagonal channels) disposed therein.