Segmented Refractory Anchor for Thermal Stress Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Refractory anchors in high-temperature furnaces face significant stress variations due to heating and cooling cycles, leading to reduced lifespan and increased manufacturing costs, which oppose the need for long-lasting insulation and cost-effective solutions.
Innovation Solution
A refractory anchor with a truncated cone shape divided into three or more parts, featuring radial dividing planes and a shoulder transition, along with a method for manufacturing using a mould and applying mortar between parts, to distribute stress and enhance mechanical stability and insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece refractory anchor is used, then the structure is simple and manufacturing is easy, but stress concentrations occur during heating and cooling cycles reducing lifespan
Solution Approach 1:
The refractory anchor is divided into three or more separate segments that are assembled together using mortar. These segments fit into corresponding recesses in the refractory tile, allowing stress to be distributed across multiple pieces rather than concentrated in a single structure. The segmentation enables each piece to move slightly independently during thermal cycling, reducing overall stress on the anchor system.
2Loss of energy
If refractory tiles with excellent insulation properties are used, then heating costs are reduced, but manufacturing costs increase
Solution Approach 1:
The refractory tile assembly uses a composite structure combining different materials: the refractory tile itself, mortar material filling gaps, and refractory anchor segments. This composite approach allows optimization of each component for its specific function while achieving overall cost-effectiveness. The mortar and anchor segments use materials that balance insulation performance with manufacturing cost.
3Ease of manufacture
If the refractory anchor is made as a single piece, then manufacturing cost is low, but it cannot withstand stress variations over prolonged periods
Solution Approach 1:
The anchor is constructed from multiple segments rather than a single piece, with each segment fitting into recesses in the refractory tile. This segmentation allows the anchor system to accommodate thermal expansion and contraction stresses better, as the individual segments can adjust independently. The mortar bonding material accommodates minor movements while maintaining structural integrity over the 15-20 year service life.
4Reliability
If a divided refractory anchor design is used, then stress concentrations are reduced and lifespan is extended, but device complexity increases
Solution Approach 1:
The anchor is divided into three or more segments with radial dividing planes, creating a structured but not overly complex design. Each segment has a defined geometry that fits into corresponding recesses in the refractory tile, providing a systematic assembly process. The segmentation pattern is regular and predictable, making installation straightforward despite the multi-component nature.
Solution Approach 2:
Mortar material is used as an intermediary bonding agent between the anchor segments and the refractory tile recesses. This mortar layer accommodates dimensional variations and provides a forgiving interface that simplifies assembly while maintaining structural integrity. The intermediary material absorbs stress concentrations that would otherwise require complex joint designs.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
The invention relates to a refractory anchor for a refractory tile for a furnace and to a method to manufacture such a refractory anchor, wherein the refractory anchor has an overall truncated cone shape, wherein the refractory anchor is divided in at least two parts with one or more dividing planes between the parts which run from bottom plane to top plane of the truncated cone shaped refractory anchor.