Refractory Anchor Eye-Mount Snap-Fit for Thermal Cycling
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Solution Overview
Problem
Existing anchoring devices for refractory linings in high-temperature and abrasive environments, such as those used in thermal-process vessels, face limitations in securing the refractory material effectively and preventing cracking due to thermal cycling.
Innovation Solution
An anchoring assembly comprising a V-anchor and an eye-mount with a snap-fit connection, which includes a saddle channel and through-hole configuration, allowing for a tight or floating snap-fit connection to securely hold the V-anchor in place, enabling slight movement to accommodate thermal expansion and contraction, thereby reducing cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tight snap-fit connection is used to securely hold the V-anchor in place, then the refractory material is firmly anchored, but thermal expansion and contraction causes cracking
Solution Approach 1:
The connection between the eye-mount and V-anchor transitions from a static tight snap-fit during installation to a dynamic floating connection during operation. The spacer is removed after refractory application, allowing the V-anchor to move slightly with thermal expansion and contraction, converting the rigid connection into a flexible one that accommodates thermal cycling.
Solution Approach 2:
A removable spacer is installed during the anchoring process to establish the initial tight snap-fit connection needed for secure mounting. The spacer is then removed after the refractory material is applied, leaving a floating connection that allows thermal movement. This preliminary action of installing and then removing the spacer enables both secure initial attachment and subsequent thermal flexibility.
2Reliability
If a loose connection is used to accommodate thermal movement, then cracking is reduced, but the refractory material is not securely anchored
Solution Approach 1:
The connection transitions from a dynamic floating state during thermal operation to a static tight snap-fit during installation and removal. The spacer provides the necessary constraint during installation to ensure secure anchoring, then its removal creates the dynamic floating connection that accommodates thermal movement, achieving both secure attachment and thermal flexibility at different stages.
Solution Approach 2:
The removable spacer is installed beforehand to provide the tight connection needed for secure anchoring during installation. After the refractory material is applied and cured, the spacer is removed to create the floating connection that prevents cracking during thermal cycling. This preliminary installation of the spacer ensures both secure initial attachment and subsequent thermal flexibility.
3Ease of manufacture
If traditional anchoring devices are used, then installation is simple, but they cannot effectively prevent cracking under thermal cycling
Solution Approach 1:
The anchoring system is segmented into distinct components: the eye-mount, the V-anchor, and the removable spacer. This segmentation allows the spacer to be installed temporarily to provide tight anchoring during installation, then removed to create a floating connection that prevents cracking during thermal cycling, combining installation simplicity with cracking resistance.
Solution Approach 2:
The removable spacer acts as an intermediary element between the eye-mount and V-anchor. During installation, it mediates to provide a tight snap-fit connection for secure anchoring. After refractory application, it is removed, allowing the V-anchor to float and accommodate thermal movement, thus preventing cracking while maintaining installation simplicity.
Data Source
AI summary
An eye mount for a refractory anchor includes a mounting base and an attachment head extending from the mounting base. The attachment head includes a through-hole and a saddle channel. The saddle channel includes two side portions formed integrally with the attachment head, and a curved portion between the two side portions. The curved portion is formed integrally with the attachment head.