Monolithic Refractory Anchor Single Weld Attachment
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Solution Overview
Problem
Existing refractory anchors for process equipment are labor-intensive to manufacture and require multiple components and welds, making uniform application of refractory material difficult due to complex construction and additional appendages that complicate the attachment process.
Innovation Solution
A monolithic refractory anchor with a solid, cast structure made from stainless steel, featuring a bridge with V-shaped end portions and angled tabs, requiring only a single weld for attachment to a metal substrate, allowing for uniform coverage and easy application of refractory material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-piece constructed anchor with multiple weldable appendages is used, then the anchor can be fabricated to engage the metal substrate, but the manufacturing process becomes labor-intensive requiring jigs and fixtures, and uniform application of refractory material becomes difficult
Solution Approach 1:
The patent combines multiple separate anchor components into a single monolithic structure. Instead of using two-piece construction with separate feet and body that require assembly, the invention integrates everything into one cast piece, eliminating the need for jigs and fixtures during manufacturing and simplifying the production process while maintaining attachment strength
Solution Approach 2:
The monolithic anchor design performs multiple functions in a single structure: it provides substrate engagement through the bridge portion, creates refractory receptacles through the V-shaped end portions, and eliminates the need for separate fabrication components. This multi-functional design simplifies manufacturing while maintaining all necessary attachment and refractory-holding capabilities
2Reliability
If multiple weldable feet and appendages are used to attach the anchor to the metal substrate, then secure engagement is achieved, but the number of welds increases making the attachment process more complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the unnecessary weldable feet and appendages from the anchor design. By removing these extra components that added complexity to the attachment process, the invention achieves reliable substrate engagement through a simplified single-weld connection using only the bridge portion, reducing both the number of welds and overall attachment complexity
Solution Approach 2:
Instead of adding multiple appendages to increase engagement, the invention inverts the approach by using a single integrated bridge portion that provides sufficient engagement reliability. This simplifies the attachment process from multiple complex welds to a single weld while maintaining reliable substrate engagement
3Strength
If a fabricated anchor with multiple components is used, then the anchor can be designed to engage the substrate, but uniform coverage of refractory material is compromised due to complex construction
Solution Approach 1:
The patent merges the anchor body and refractory receptacles into a single monolithic structure where the V-shaped end portions naturally form uniform receptacles. This integrated design ensures consistent geometry throughout, allowing uniform refractory material application while maintaining strong substrate engagement through the bridge portion
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
The monolithic anchor simplifies the attachment process, reduces labor requirements, and enables uniform refractory coverage by minimizing the number of welds and allowing for easier application of refractory material, while providing strong resistance to thermal and pressure forces.
Implementation Method 1
requiring only a single weld to attach the refractory anchor to the metal substrate
Data Source
AI summary
A monolithic refractory anchor which has a bridge portion and first and second V-shaped end portions attached to opposite ends of the bridge portion. The anchor has a pedestal located generally centrally of the anchor which extends below the bottom surfaces of the wing portions of the V-shaped sections, the pedestal forming a single welding attachment point for attachment, preferably by stud welding, to a metal substrate.