Y-Shaped Refractory Anchor Layout for Single-Weld Installation
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Solution Overview
Problem
Conventional refractory anchor systems are cumbersome to fabricate and install, particularly when dealing with curved or nonuniform geometries, as they require large sheets of hexagonal metal anchors that need to be rolled and cut to size, making them difficult to work with in various applications.
Innovation Solution
A single equilateral leg fabricated steel Y-shaped anchor system is introduced, which can be easily installed to create a hexagonal pattern with only a single weld, using a folded rectangular metal plate with a thicker stem and non-welded branches that include voids and tabs for refractory material adherence, along with a ceramic ferrule for enhanced installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If large sheets of hexagonal metal anchors are used, then the anchor system provides uniform support and heat transfer, but the system becomes cumbersome to fabricate, roll, cut, and install, especially on curved or nonuniform geometries
Solution Approach 1:
The patent divides the continuous hex mesh sheet into individual discrete Y-shaped anchor units. Each anchor is a separate component that can be independently handled, positioned, and installed. This segmentation eliminates the need to roll, cut, and shape large continuous sheets, making installation much easier especially on curved or nonuniform geometries while still providing uniform distribution when arranged in hexagonal patterns
Solution Approach 2:
The Y-shaped anchor design with flexible branches allows the anchor to adapt to different installation geometries. The branches can be positioned and oriented to conform to curved or nonuniform surfaces, providing dynamic adaptability during installation that rigid hex mesh sheets cannot achieve
2Strength
If multiple welds are required for installation, then the anchor can be securely attached to the backing surface, but the risk of weld failure increases and installation time increases
Solution Approach 1:
The Y-shaped anchor is designed with a distinct stem portion that is dedicated to welding, separating the welding function from the support function. This allows for a single focused weld at the stem base that securely attaches the entire anchor to the backing surface, reducing the number of welds required compared to conventional hex anchors that may require multiple weld points
Solution Approach 2:
The design incorporates a thickened stem base area that provides a larger weld zone and better stress distribution. This pre-engineered feature cushions against weld failures by providing redundancy in the weld attachment area, reducing the overall risk of attachment failure
3Strength
If the anchor stem is made thicker for stronger welding, then the weld strength increases, but the anchor becomes more difficult to fabricate and handle
Solution Approach 1:
The anchor is designed with non-uniform thickness, featuring a locally thickened stem base area specifically where the weld is applied, while the branches and other portions remain thinner. This local quality approach provides the necessary weld strength at the attachment point without making the entire anchor component difficult to fabricate or handle
Solution Approach 2:
The anchor is fabricated as a single piece from folded metal plate with the thickened stem created by the folding process itself, rather than requiring separate assembly of thick and thin sections. This segmentation of function (thick where needed, thin where not needed) within a single fabricated component maintains ease of manufacture while achieving the required local strength
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
This solution allows for efficient and repeatable installation of refractory anchors with minimal weld failure risk, enabling uniform refractory material distribution and support across various geometries without the need for cumbersome sheet handling, thus simplifying the installation process and enhancing the durability of the refractory lining.
Implementation Method 1
The stem of the Y comprises at least one triangular section to be welded to the metal surface, preferably stud welded
Data Source
AI summary
A Y-shaped refractory anchor, a plurality of Y-shaped refractory anchors, and a method of installing a plurality of Y-shaped refractory anchors in a hexagonal pattern is disclosed. The Y-shaped refractory anchor comprises a singular rectangular folded metal plate comprising a stem that comprises at least one tapered triangular section to be welded to a backing surface and a folded stem base and a branch section comprising two branches, wherein the singular metal plate is folded together at the stem base, such that the stem of the Y-shaped anchor is twice as thick as the two individual branches.