Snap-Lock Mounting Hardware for Refractory Module Installation
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Solution Overview
Problem
Existing methods for mounting refractory modules in high-temperature furnaces are either unreliable, time-consuming, or require costly and complex procedures, such as heat treating, and can lead to premature failure due to inadequate welding.
Innovation Solution
A mounting hardware system featuring a flexible tab bracket and annular groove stud assembly that allows for quick and secure attachment of refractory modules to the furnace wall, enabling snap-locking without the need for guide rods or heat treating, ensuring reliable and efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spikes are used to mount refractory modules on furnace wall, then the mounting method is simple, but the service life of the refractory module is unreliable
Solution Approach 1:
The mounting system is divided into separate components: a mounting bracket with flexible tabs that can be embedded in the module, and a stud with annular groove mounted on the furnace wall. This segmentation allows the bracket to be pre-installed in the module during manufacturing, ensuring proper positioning and reliable attachment while maintaining simple installation procedures.
Solution Approach 2:
The flexible tabs in the mounting bracket provide dynamic flexibility during installation. The tabs can bend and deform to accommodate the forcing action of installing the module onto the stud, then spring back to lock the module securely in place. This dynamic behavior enables simple installation while ensuring reliable long-term attachment.
2Reliability
If threaded studs are used to bolt refractory modules to furnace wall, then secure attachment is achieved, but replacement requires removal of all modules which is time-consuming and expensive
Solution Approach 1:
The system separates the mounting function into a permanent stud on the furnace wall and a removable mounting bracket with flexible tabs embedded in the module. This allows the bracket to be easily removed and replaced without affecting the stud or requiring removal of other modules, significantly reducing replacement time while maintaining secure attachment.
Solution Approach 2:
The mounting bracket is designed as a disposable or easily replaceable component. When a module needs replacement, the bracket can be quickly removed from the old module and transferred to the new module, recovering the mounting hardware investment and reducing overall replacement time and cost.
3Productivity
If quick-weld method is used to attach anchor system, then installation speed is fast, but weld quality is unreliable requiring bend tests and potentially discarding entire modules
Solution Approach 1:
The welding process is replaced with a mechanical attachment system using a stud and mounting bracket with flexible tabs. The module is forced onto the stud, causing the tabs to flex and then snap into place, creating a secure mechanical lock without requiring any welding. This eliminates weld quality issues while maintaining fast installation speed.
Solution Approach 2:
The mounting bracket is designed as a simple mechanical component that can be easily manufactured and replaced if needed, eliminating the need for complex welding procedures and quality testing. If a module fails, the bracket can be quickly removed and transferred to a replacement module without wasting the mounting hardware.
4Productivity
If mounting bracket with flexible tabs and annular groove stud is used, then quick and secure attachment is achieved, but the bracket must be embedded within the module adding manufacturing complexity
Solution Approach 1:
The mounting bracket is pre-embedded in the refractory module during manufacturing, before the module is installed in the furnace. This preliminary action ensures the bracket is properly positioned and integrated with the module structure, allowing for quick installation on-site without requiring complex embedding procedures during furnace shutdown.
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 solution provides a quick, reliable, and cost-effective method for mounting refractory modules, enhancing their service life by ensuring secure attachment to the furnace wall without the risks associated with heat treating or faulty welding.
Implementation Method 1
The free ends of the tabs are arranged about a central point and are flexible relative to the fixed ends. As the bracket moves along the stud from the free end towards the fixed end, the tabs flex and snap and lock into the annular groove when the bracket reaches the annular groove.
Data Source
AI summary
Mounting hardware for mounting an insulation module on a furnace wall. The hardware comprises a mounting bracket embedded within the module. The bracket has a plurality of flexible tabs, each tab having a fixed end and a free end. The free ends of the tabs are arranged about a central point and are movable (flexible) relative to the fixed ends. A mounting stud is provided having a fixed end attachable to an inner surface of a furnace wall and a free end. The stud extends from the inner surface, and the stud has an annular groove adjacent the fixed end. The stud is dimensioned to extend through the mounting bracket between the free ends of the tabs and to cause the tabs to flex as the bracket moves along the stud from the free end towards the fixed end, wherein the tabs snap and lock into the annular groove when the bracket reaches the annular groove.