Refractory Kiln Furniture with Interconnected Post Support Structure
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Solution Overview
Problem
Existing kiln furniture lacks sufficient structural rigidity and open volume carrying capacity, leading to potential loss of ceramic bodies during high-temperature processing and multiple heating cycles.
Innovation Solution
A refractory article comprising a support structure with a first plurality of posts and a second plurality of posts, interconnected by first and second members, which provide structural stability and high open volume carrying capacity while maintaining mechanical integrity at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional kiln furniture is used, then manufacturing simplicity is maintained, but structural rigidity and open volume carrying capacity are insufficient
Solution Approach 1:
The kiln furniture is divided into multiple discrete posts (first plurality and second plurality) rather than using a monolithic structure. These posts are arranged in arrays and interconnected, allowing the structure to achieve high rigidity through distributed load-bearing elements while maintaining manufacturing simplicity for each individual component.
Solution Approach 2:
The kiln furniture employs composite construction by interconnecting multiple posts with horizontal members to create a framework that combines the strength of individual refractory posts with the structural stability of the interconnected lattice, achieving superior overall rigidity without requiring complex single-piece manufacturing.
2Quantity of substance
If kiln furniture structure is increased to improve carrying capacity, then open volume carrying capacity improves, but structural rigidity may be compromised
Solution Approach 1:
The patent utilizes three-dimensional spatial arrangement by positioning posts at specific heights (between 0.3H and 0.7H of total height H) and arranging them in multiple parallel arrays. This vertical and horizontal distribution creates open volumes for carrying ceramic bodies while the interconnected framework maintains structural rigidity through geometric stability.
Solution Approach 2:
By segmenting the support structure into multiple discrete posts rather than using solid bulk material, the design achieves high open volume carrying capacity (allowing ceramic bodies to be positioned and supported in multiple locations) while each individual post maintains sufficient rigidity and the interconnected system provides overall structural stability.
3Duration of action of stationary object
If kiln furniture is designed for multiple processing cycles, then durability is improved, but mechanical stability at elevated temperatures becomes more challenging
Solution Approach 1:
The kiln furniture is designed with inherent thermal expansion considerations by using refractory materials and structures that can accommodate temperature fluctuations. The interconnected post framework allows for controlled movement and stress distribution during heating and cooling cycles, preventing catastrophic failure and enabling multiple processing cycles.
Solution Approach 2:
The use of refractory ceramic posts interconnected in a framework creates a composite structure that combines high-temperature stability of refractory materials with the mechanical stability of the geometric framework, allowing the kiln furniture to maintain integrity through repeated heating and cooling cycles.
Data Source
AI summary
A refractory article having a support structure including a first plurality of posts coupled by a first member; and a second plurality of posts substantially parallel with the first plurality of posts, the second plurality of posts coupled by a second member, wherein the support structure has a height, H, and wherein the first and second members are positioned between 0.3H and 0.7H. In another aspect, the support structure has a height to width ratio of at least 1.5, a stiffness factor of no greater than 100 mm, and a solid to open volume ratio of no greater than 5%. In another aspect, the support structure has a weight of no greater than 1200 kg, a stiffness factor of no greater than 100 mm, and a solid to open volume ratio of no greater than 5%.