CA1209861A - Apparatus and method for securing modular insulation blocks - Google Patents
Apparatus and method for securing modular insulation blocksInfo
- Publication number
- CA1209861A CA1209861A CA000442909A CA442909A CA1209861A CA 1209861 A CA1209861 A CA 1209861A CA 000442909 A CA000442909 A CA 000442909A CA 442909 A CA442909 A CA 442909A CA 1209861 A CA1209861 A CA 1209861A
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- Canada
- Prior art keywords
- block
- wall
- base member
- stud
- metallic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- Furnace Housings, Linings, Walls, And Ceilings (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Apparatus and methods for retaining modular insulation blocks in place upon the metallic walls of furnaces, kilns and the like. A block retainer, having a base member with an aperture therein, a support member extending from the base member away from the metallic wall to be insulated and opposed block support bars extending from the support member substantially parallel to the metallic wall of the structure, is secured in place by welding a breakoff stud through the aperture to the wall. A first insulation block with one of its faces against the metallic wall is impaled upon one of the opposed support bars. One of the opposed support bars of a second retaining block is forced into the opposed side wall of the insulation block and secured in place by a further stud welded through the aperture. The process is repeated to construct a modular insulation block insulating wall.
Apparatus and methods for retaining modular insulation blocks in place upon the metallic walls of furnaces, kilns and the like. A block retainer, having a base member with an aperture therein, a support member extending from the base member away from the metallic wall to be insulated and opposed block support bars extending from the support member substantially parallel to the metallic wall of the structure, is secured in place by welding a breakoff stud through the aperture to the wall. A first insulation block with one of its faces against the metallic wall is impaled upon one of the opposed support bars. One of the opposed support bars of a second retaining block is forced into the opposed side wall of the insulation block and secured in place by a further stud welded through the aperture. The process is repeated to construct a modular insulation block insulating wall.
Description
~9~
The present invention applies to the art of securing insulation to the metallic walls of furnaces, kilns, soaking pits and the like and, more particularly, to securing modular block insulation to the inner walls of such structures.
Several years ago, the predominant method of insulating such heating apparatus as furnaces, incinerators and other devlces pf that nature was to use the heretofore conventional and well-known firebrick. The process of bricking the heated areas was expensive from a labor standpoint and extremely time consuming. Additionally, repair and replacement of the brick lining in such structures was both expensivc and time conswning.
More recent developments in the art of insulating furnaces and such structures is the utilization of insulating blankets formed o ceramic materials or ceramic glass such as alumina. These blanket.s come in varying thicknesses from 1 to 3 inches and are formed into rolls of varying widths.
During the insulating process, the blankets are applied to the walls of the structure in layers of anywhere from 1 to 3 layers and often in a crisscross pattern. The blankets may be secured to the walls of the furnace or o-ther structure in a number of different ways.
In nearly all heating clevices such as furnaces and the like, the wall upon whicll the blankets are supported is a metallic wall known as the cold wall. One manner of securing the blankets to the cold wall is the utilization of a threaded fastener which employs a drill point and self tapping combination on the end of the fastener. The fastener is drilled and threaded into the wall and projects outward from the wall. A number of these fasteners are spaced along the wall and blankets impaled upon the fasteners. Thereafter, a washer and nut are applied to the threaded ~2~
fastener to pull the blanket down into secured position.
Another device which is used for smaller blankets is a pin which has a large washer secured on the end o:E the pin. The pin is pushed through the blanket and against the metallic cold wall and stud welded in place to secure the blanket.
A third device in prevalent use is a stud and washer combination wherein the stud includes a plurality of tapered notches. The studs are welded to the cold wall in a given array Or fashion and the blanket impaled upon the studs. Thereafter, the washers, which have a complementary aperture therein, are placed over the stud to compress the blanket and rotated 90 and released whereupon the blanket brings the ~asher into locking engagement with the stud.
These blanket insulating systems have certain drawbacks. One of them is tha~ the fastening means for securing the blankets in place constitute what is called an exposed system, i.e. the outermost ends of the retaining means are e~posed to the heat. This often results in burning off of the retaining means and conse~lent loosening of the blanket. Another drawback of the blanket system is that the blankets generally are not made in thlcknesses in ~xcess of 3 inches. ~ccordingly, if an insulation depth of several inches is required, i.e. as high as 12 inches, then many blankets must be crisscrossed o~er one another to acquire the required depth. This is costly and time cons~ing.
A more recent development in the industry is the utilization of what are known as modular insulation blocks. These blocks generally come in configurations of l foot square and can range in depths from 4 to 12 inches.
One ad~-antage of the modular insula~ion blocks is that the required depth can be ohtained in a single installation. Additionally, the blocks may be of
The present invention applies to the art of securing insulation to the metallic walls of furnaces, kilns, soaking pits and the like and, more particularly, to securing modular block insulation to the inner walls of such structures.
Several years ago, the predominant method of insulating such heating apparatus as furnaces, incinerators and other devlces pf that nature was to use the heretofore conventional and well-known firebrick. The process of bricking the heated areas was expensive from a labor standpoint and extremely time consuming. Additionally, repair and replacement of the brick lining in such structures was both expensivc and time conswning.
More recent developments in the art of insulating furnaces and such structures is the utilization of insulating blankets formed o ceramic materials or ceramic glass such as alumina. These blanket.s come in varying thicknesses from 1 to 3 inches and are formed into rolls of varying widths.
During the insulating process, the blankets are applied to the walls of the structure in layers of anywhere from 1 to 3 layers and often in a crisscross pattern. The blankets may be secured to the walls of the furnace or o-ther structure in a number of different ways.
In nearly all heating clevices such as furnaces and the like, the wall upon whicll the blankets are supported is a metallic wall known as the cold wall. One manner of securing the blankets to the cold wall is the utilization of a threaded fastener which employs a drill point and self tapping combination on the end of the fastener. The fastener is drilled and threaded into the wall and projects outward from the wall. A number of these fasteners are spaced along the wall and blankets impaled upon the fasteners. Thereafter, a washer and nut are applied to the threaded ~2~
fastener to pull the blanket down into secured position.
Another device which is used for smaller blankets is a pin which has a large washer secured on the end o:E the pin. The pin is pushed through the blanket and against the metallic cold wall and stud welded in place to secure the blanket.
A third device in prevalent use is a stud and washer combination wherein the stud includes a plurality of tapered notches. The studs are welded to the cold wall in a given array Or fashion and the blanket impaled upon the studs. Thereafter, the washers, which have a complementary aperture therein, are placed over the stud to compress the blanket and rotated 90 and released whereupon the blanket brings the ~asher into locking engagement with the stud.
These blanket insulating systems have certain drawbacks. One of them is tha~ the fastening means for securing the blankets in place constitute what is called an exposed system, i.e. the outermost ends of the retaining means are e~posed to the heat. This often results in burning off of the retaining means and conse~lent loosening of the blanket. Another drawback of the blanket system is that the blankets generally are not made in thlcknesses in ~xcess of 3 inches. ~ccordingly, if an insulation depth of several inches is required, i.e. as high as 12 inches, then many blankets must be crisscrossed o~er one another to acquire the required depth. This is costly and time cons~ing.
A more recent development in the industry is the utilization of what are known as modular insulation blocks. These blocks generally come in configurations of l foot square and can range in depths from 4 to 12 inches.
One ad~-antage of the modular insula~ion blocks is that the required depth can be ohtained in a single installation. Additionally, the blocks may be of
- 2 -varying density, i.e., higher density and greater insulating qualities -toward the hot face then back toward the cold face.
The modular insulation blocks are secured to the wall of the furnace Or the like in a number of ways. One type of retaining device is a wire re-tainer that is shaped in an H configuration which has 4 projecting prongs interconnected to a central portion. The central portion has an offset portion which is welded to the cold wall of the furnace. A given modular insulation block is impaled upon a pair of the prongs~ Thereafter, a next H
configured device is shoved into the opposite wall of the block and welded in place followed by another block being placed upon the opposing projecting pair of prongs. The process is repeated until a plurality of blocks form the modular insulation block wall.
Another method of securing the modular insulation ~locks is to utili~e a metallic expanded metal backing on the blocks. The blocks are positioned in place against the wall of the t`urnace with the expanded metal against the furnace wall. Thereafter, a collar stud is pushed through the block into contact with the expanded metal and furnace wall and stud welded to secure the modular block in place. ~dditionally, self tapping threaded melllbers ll~ay be employed wh:ich are pushed through the block and ?O drilled and threaded into the ~all of the furnace. Thereafter, a washer and nut are placed on the threaded member and tightened against the expanded metal to hold tl~e blocks in place.
The advantages of the modular blocks over the insulation blankets are the ease of assembly and the ability to obtain the required insulation thickness quickly. Additionally, the fastening systems used for the modular blocks are not exposed to the hot face and the likelihood of burnoff of the retaining de~ice is substantially less.
~9~
The advantages of the modular in~ula~ion blocks over the insulation blankets are the ease of assembly and the ability to obtain the required insulation thickness quickly. Additionally, the fastening systems used for the modular insulation blocks are not exposed to the hot face and the likelihood of burnoff of the retaining device is substantially less~
The utilization of H anchors, collar studs and self tapping threaded members is more costly and time consuming in assembly and otherwise generally cumbersome.
SU~RY O~ THE INVENTION
The invention provides in insulation systems for insulating metallic alled structures such as furnaces~ kilns and the like ~herein modular insulation blocks having top and bottom faces and side ~Yalls are secured in side by side relationship with one face against the metallic wall of the structure by a block retaining system, the improvements in the block retaining system comprising:
a block retainer including a base member adapted to ~ngage the metallic wall of the structure;
support means extending from the base member away from the metallic lYall of the structure a predetermined distance;
2~ at least one pair of opposed block support bars extending from the support means substantially parallel to the metallic wall of the structure; and securing means for securing the block retainer by its base member to the metallic ~all of the structure whereby the modular blocks may be impaled upon the block supporting bars and retained in place. The block retainer is preferably formed from a single piece of material in either wire or sheet metal, and the block support bars are preferably of a length approximately one half the width of the modular block.
The invention also provides the method of securing a plurality of rectangular insulation blocks having top, bottom and side walls to the metallic wall of structures such as kilns, furnaces and the like comprising the steps of:
securing to the metallic wall of the structure a first block retainer having a base member in contact with the wall, a support extending from the base member away from the wall and opposed block support bars extending from the support substantially parallel to the wall;
impaling a first insulation block by one of its side walls upon one of the opposed block support bars;
impaling one o~ the opposed block support bars of a second block retainer into another side wall of the insulation block and securing the block retainer to the metallic wall of the structure;
impaling a second insulation block by its side wall upon the rer~;ning opposed block support bar of the second block retainer; and repeating the foregoing steps with additional block retainers and insulation blocks.
The base member of the block retainer preferably includes an aperture and a breakof~' stud having an area of reduced cross section is stud welded through the aper~ure against the metallic wall by the stud end welding technique. The resultant weld fuses the stud and base member of the block retainer to the wall to secure the block retainer in place. Thereafter, the unwelded end of the breakoff stud is broken away to provide clearance for the side wall of the modular insulation block.
Ne~t, a modular insulation block is placed with its face against the metallic wall and its side wall impaled upon one of the opposed block support _ 5 _ bars. Thereafter, the support bar of a second block retainer opposite the base member of the block retainer is pushed into the opposing side wall of the insulation block and secured in place to the metallic wall by welding of a stud through the aperture in the base member. The process is then repeated until a composite modular insulation block wall is built.
In a first embodiment, the block retainer may be ormed of flat stock or sheet metal. In that em~odiment, the opposed support bars may be twisted such that they are inclined to the surface of the metallic wall to provide a greater bearing area to the insulation blocks. In a second embodiment, the block retainer may be formed of round wire material.
The invention will further be described, by way of e~ample only, with reference to the accompanying drawings, wherein:-Figure 1 is a top view of a first embodiment of block retainer according to the present invention;
Figure 2 is a perspective view of a second embodiment of the block retainer of the present invention;
Figure 3 is a perspective view of the block retainer of the ~irst embodimerlt prior to being welded in place upon a metallic wall;
Figure ~ is a perspective view o~ the block retainer of the first embodiment secured in place upon a metallic wall;
Figure 5 is a block retainer of the first embodiment and modular insulat1on block prior to positioning upon the block retainer; and Figure 6 is a perspective view partially cut away of a plurality of modular insulation blocks and block retainers in assembled relationship.
The first embodiment of block retainer according to the prese~t invention is sho~n in Figure 1 of the drawings. The block retainer 10 is formed of a unitary piece of sheet me~al or flat stock. The block retainer ~2~
10 includes a base member 11 which is adapted to be positioned against and secured to the metallic wall of the structure to be insulated and as to be described more fully hereinafter.
The block retainer 10 includes a support member 12 extending from the base member 11 at approximately a 90 angle. The height of the support 12 is approximately one half of the *hickness of the insulating block to be installed on the metallic wall.
The block retainer 10 includes a pair of opposed block supports 13 extending from the outer end of the support 12 at an angle to be approximately parallel to the wall of the structure to be insulated. The opposed block supports 13 are generally tapered down to a point to aid in insertion into the side wal}s of the block members to be described hereinafter.
Additionally, the opposed block supports 13 are twisted or inclined relative to the surface of the metallic wall of the structure to be insulated such that they present a greater bearing surface to the side walls of the insulation block as will be described hereinater.
The base member 11 is oEfset to one side of the center line of tlle block retainer 10. As will be described more fully hereinaEter, this offset permits the block support 13 opposite the base member 11 to be fully ~o inserted into the side wall of an insulation block while the base member 11 is fully exposed in order that it may be secured to the side wall of the structure to be insulated without interference with the insulation block.
The base member 11 also includes an aperture 14 in the base member 11.
The aperture 1~ is positioned, as best seen in Figure 3, in the upper portion of the base member 11 above the opposed block s~pport 13 o~erlying the base member 11 such that there is no interference between the opposed member 13 overlying the base mem~er 11 and the aperture 14 in order that a stud may be we]ded 1~0~
through the aperture as will be described in more detail hereinaf~er.
A second embodiment of the block support of the presen~ invention is shown in Figure 2 of the drawings. The second embodiment of block retainer 15 is formed of a unitary piece of round stock or wire.
The block retainer 15 is formed into an arcuate base member 16 in the form of an aperture. Two legs or prongs 17 extending from the arcuate base member 16 form an upstanding support extending away from the arcuate base member 16 which is adapted to be secured to the metallic wall of the structure to be insulated.
Extending from each leg or prong 17 is an opposed block support 18.
The opposed block supports 18 extend in opposite directions from each other and extend generally parallel to the wall of the structure ~o be insulated when the arcuate base member 16 is in place against the wall of the structure.
As in the case of the embodiment of Figure 1, the length of the legs or prongs 17 is approximately one half of the thickness of the insulation block to be insulated. The le~gth of the opposed block supports 13 and 18 in the embodiments of Figures 1 and 2 is approximately one half of tl~c width ancl/or cleptll of the ins~lation block to be installed.
The opposed block supports 18 are preferably sheared at an angle to provide a sharp point to aid in insertion of the opposed block support into the s:ide walls of the insulation blocks as to be described hereinafter.
The block retainer embodiments sho~n in both Fig~res 1 and 2 are utilized generally in the same manner. Therefore, the description of the manner of use of the block retainers of the embodiments of both Figures 1 and 2 will be described in respect to the embodiment of Figure 1 only.
_ ~ _ 8~1 Referring now to Figure 3, the initial procedure in starting insulation of a metallic wall 20 of a structure to be insulated is to place the block retainer 10 by means of its base member 11 against the metallic wall 20.
A metallic stud 21 is provided. The metallic stud 21 includes a first welding end 22. An area of reduced cross section 23 formed in the stud to provide what is known as a breakaway stud. The unwelded end 24 of the stud back of the area of reduced cross section 23 provides the necessary material for the stud to be received by a chuck 25 of a stud welding gun 26.
During assembly, the stud 21 is inserted in~o the chuck 25 of the stud welding gun 26 and an arc shield 19 positioned in place. The welding end 22 of the stud is placed into the aperture 14 of the base member 11. The aperture 14 o~ the base member 11 is slightly larger than the welding end 22 of the stud 210 The stud is then welded by the drawn arc process. During the welding process, an arc is drawn between the stud and the metallic wall 20 with resultant melting of the end of the stud 22 and the metallic wall 20 of the s~ructure being lnsulated~ Additionally, the arc will cause melting of a portion of the base member 11 around the circumference of the aperture 1~.
After a predetermined time of arcing between the stud and the metallic wall 20, the stud is plunged into the molten pool of me-tal formed upon the metallic wall 20 and the base member 11 around the aperture 1~ and allowed to solidify. Upon solidification, the welding end 22 of the stud is fused with the base member 11 around the circumference of the aperture 1~
and with the wall 22 of the structure being insulated to securely fasten the block retainer 10 in place.
Following welding of the stud 21 in place, and as shown in Figure ~, _ 9 _ the unwelded end 2~ of the s~ud is broken away from the weld end 22 by means of flexing of the unwelded end 24 such ~hat the stud will break at the area of reduced cross section 23. This reduces the height of the overall resultant welding structure as shown in ~igure 4 in order that the height of the stud remaining does not provide any interference to the side wall of an insulation block to be impaled upon the opposed block support 13 overlying the welded stud as to be described hereinafter.
One type of modular insulation block which may be utilized with the block retainer of the present invention is *hat shown in Figures 5 and 6 of the drawings. T~e modular insulation block 26 is preferably a square block formed of multiple layers of insulating material. The block 76 includes a front face 27, a rear face 2~ and four equal side walls 29.
During installation, the back wall 28 of the insulation block 26 is placed against the metallic wall 2U. The insulation block is then moved along horizontally upon the metallic wall 20 and impaled upon the opposed block support 13 opposite the base member 11. The position of the insulation block 26 just prior to being impaled upon the opposed block support 13 is sho-~n in Flgure 5 of the drawings.
Following positioning of the first insulation block 26 upon the block retainer 10, and as seen in Figure 6, a second insulation block 30 is im~aled by its side wall upon the opposed block support 13 overlying the base member 11. Ther~after, a second bloc~ retainer 31 is positioned with its opposed block support 33 opposite the base member 11 piercing or impaling the side wall 32 of the insulation block 30. Lateral pressure is applied to the block retainer 31 to firmly push the block retainer 31 into the side wall 32 of the insulation block 30 such that the support member 3~ of the retaining block 31 engages the side wall 32 of the retaining block 30 and firmly urges the block into compressed fit with the first block retainer support member 12.
Once the second block retainer 31 is in placa, a stud 21 is welded through the aperture in the block retainer to secure the block retainer 31 in place as in the case of the first block retainer 10.
The process is repeated for insulation block after insulation block to -Eorm both horizontal and vertical rows until the entire area desired to be insulated has been covered with insulation block.
In a given embodiment and by way of example only, the insulation blocks are of 1 foot square configuration and may range in thickness from 4 to 12 inches. The blocks are formed of fibrous alumina glass. In the embodiment shown, the blocks are formed of layers of the insulating material although blocks formed of multiple and continuous folds may also be utilized.
Additionally, the blocks are shown in alternate patterns wherein the folds or layers are at 90 one to another. However, this is not necessary to the invention.
The material of which the block retainer is formed is preferably of a stainless steel material. The length of the support bars and the height of the support member will depend upon the configuration of the block utilized.
The breakaway stud utilizad in a given embodiment and by way of example only is a 1 inch long stud o ~/16 inch diameter. The length of the weldable end of the stud is approximately 3/16 inch and the diamater of the area of reduced cross section approximately 1/8 inch. The stud is formed of mild steel material. The aperture in the block retainer is approximately
The modular insulation blocks are secured to the wall of the furnace Or the like in a number of ways. One type of retaining device is a wire re-tainer that is shaped in an H configuration which has 4 projecting prongs interconnected to a central portion. The central portion has an offset portion which is welded to the cold wall of the furnace. A given modular insulation block is impaled upon a pair of the prongs~ Thereafter, a next H
configured device is shoved into the opposite wall of the block and welded in place followed by another block being placed upon the opposing projecting pair of prongs. The process is repeated until a plurality of blocks form the modular insulation block wall.
Another method of securing the modular insulation ~locks is to utili~e a metallic expanded metal backing on the blocks. The blocks are positioned in place against the wall of the t`urnace with the expanded metal against the furnace wall. Thereafter, a collar stud is pushed through the block into contact with the expanded metal and furnace wall and stud welded to secure the modular block in place. ~dditionally, self tapping threaded melllbers ll~ay be employed wh:ich are pushed through the block and ?O drilled and threaded into the ~all of the furnace. Thereafter, a washer and nut are placed on the threaded member and tightened against the expanded metal to hold tl~e blocks in place.
The advantages of the modular blocks over the insulation blankets are the ease of assembly and the ability to obtain the required insulation thickness quickly. Additionally, the fastening systems used for the modular blocks are not exposed to the hot face and the likelihood of burnoff of the retaining de~ice is substantially less.
~9~
The advantages of the modular in~ula~ion blocks over the insulation blankets are the ease of assembly and the ability to obtain the required insulation thickness quickly. Additionally, the fastening systems used for the modular insulation blocks are not exposed to the hot face and the likelihood of burnoff of the retaining device is substantially less~
The utilization of H anchors, collar studs and self tapping threaded members is more costly and time consuming in assembly and otherwise generally cumbersome.
SU~RY O~ THE INVENTION
The invention provides in insulation systems for insulating metallic alled structures such as furnaces~ kilns and the like ~herein modular insulation blocks having top and bottom faces and side ~Yalls are secured in side by side relationship with one face against the metallic wall of the structure by a block retaining system, the improvements in the block retaining system comprising:
a block retainer including a base member adapted to ~ngage the metallic wall of the structure;
support means extending from the base member away from the metallic lYall of the structure a predetermined distance;
2~ at least one pair of opposed block support bars extending from the support means substantially parallel to the metallic wall of the structure; and securing means for securing the block retainer by its base member to the metallic ~all of the structure whereby the modular blocks may be impaled upon the block supporting bars and retained in place. The block retainer is preferably formed from a single piece of material in either wire or sheet metal, and the block support bars are preferably of a length approximately one half the width of the modular block.
The invention also provides the method of securing a plurality of rectangular insulation blocks having top, bottom and side walls to the metallic wall of structures such as kilns, furnaces and the like comprising the steps of:
securing to the metallic wall of the structure a first block retainer having a base member in contact with the wall, a support extending from the base member away from the wall and opposed block support bars extending from the support substantially parallel to the wall;
impaling a first insulation block by one of its side walls upon one of the opposed block support bars;
impaling one o~ the opposed block support bars of a second block retainer into another side wall of the insulation block and securing the block retainer to the metallic wall of the structure;
impaling a second insulation block by its side wall upon the rer~;ning opposed block support bar of the second block retainer; and repeating the foregoing steps with additional block retainers and insulation blocks.
The base member of the block retainer preferably includes an aperture and a breakof~' stud having an area of reduced cross section is stud welded through the aper~ure against the metallic wall by the stud end welding technique. The resultant weld fuses the stud and base member of the block retainer to the wall to secure the block retainer in place. Thereafter, the unwelded end of the breakoff stud is broken away to provide clearance for the side wall of the modular insulation block.
Ne~t, a modular insulation block is placed with its face against the metallic wall and its side wall impaled upon one of the opposed block support _ 5 _ bars. Thereafter, the support bar of a second block retainer opposite the base member of the block retainer is pushed into the opposing side wall of the insulation block and secured in place to the metallic wall by welding of a stud through the aperture in the base member. The process is then repeated until a composite modular insulation block wall is built.
In a first embodiment, the block retainer may be ormed of flat stock or sheet metal. In that em~odiment, the opposed support bars may be twisted such that they are inclined to the surface of the metallic wall to provide a greater bearing area to the insulation blocks. In a second embodiment, the block retainer may be formed of round wire material.
The invention will further be described, by way of e~ample only, with reference to the accompanying drawings, wherein:-Figure 1 is a top view of a first embodiment of block retainer according to the present invention;
Figure 2 is a perspective view of a second embodiment of the block retainer of the present invention;
Figure 3 is a perspective view of the block retainer of the ~irst embodimerlt prior to being welded in place upon a metallic wall;
Figure ~ is a perspective view o~ the block retainer of the first embodiment secured in place upon a metallic wall;
Figure 5 is a block retainer of the first embodiment and modular insulat1on block prior to positioning upon the block retainer; and Figure 6 is a perspective view partially cut away of a plurality of modular insulation blocks and block retainers in assembled relationship.
The first embodiment of block retainer according to the prese~t invention is sho~n in Figure 1 of the drawings. The block retainer 10 is formed of a unitary piece of sheet me~al or flat stock. The block retainer ~2~
10 includes a base member 11 which is adapted to be positioned against and secured to the metallic wall of the structure to be insulated and as to be described more fully hereinafter.
The block retainer 10 includes a support member 12 extending from the base member 11 at approximately a 90 angle. The height of the support 12 is approximately one half of the *hickness of the insulating block to be installed on the metallic wall.
The block retainer 10 includes a pair of opposed block supports 13 extending from the outer end of the support 12 at an angle to be approximately parallel to the wall of the structure to be insulated. The opposed block supports 13 are generally tapered down to a point to aid in insertion into the side wal}s of the block members to be described hereinafter.
Additionally, the opposed block supports 13 are twisted or inclined relative to the surface of the metallic wall of the structure to be insulated such that they present a greater bearing surface to the side walls of the insulation block as will be described hereinater.
The base member 11 is oEfset to one side of the center line of tlle block retainer 10. As will be described more fully hereinaEter, this offset permits the block support 13 opposite the base member 11 to be fully ~o inserted into the side wall of an insulation block while the base member 11 is fully exposed in order that it may be secured to the side wall of the structure to be insulated without interference with the insulation block.
The base member 11 also includes an aperture 14 in the base member 11.
The aperture 1~ is positioned, as best seen in Figure 3, in the upper portion of the base member 11 above the opposed block s~pport 13 o~erlying the base member 11 such that there is no interference between the opposed member 13 overlying the base mem~er 11 and the aperture 14 in order that a stud may be we]ded 1~0~
through the aperture as will be described in more detail hereinaf~er.
A second embodiment of the block support of the presen~ invention is shown in Figure 2 of the drawings. The second embodiment of block retainer 15 is formed of a unitary piece of round stock or wire.
The block retainer 15 is formed into an arcuate base member 16 in the form of an aperture. Two legs or prongs 17 extending from the arcuate base member 16 form an upstanding support extending away from the arcuate base member 16 which is adapted to be secured to the metallic wall of the structure to be insulated.
Extending from each leg or prong 17 is an opposed block support 18.
The opposed block supports 18 extend in opposite directions from each other and extend generally parallel to the wall of the structure ~o be insulated when the arcuate base member 16 is in place against the wall of the structure.
As in the case of the embodiment of Figure 1, the length of the legs or prongs 17 is approximately one half of the thickness of the insulation block to be insulated. The le~gth of the opposed block supports 13 and 18 in the embodiments of Figures 1 and 2 is approximately one half of tl~c width ancl/or cleptll of the ins~lation block to be installed.
The opposed block supports 18 are preferably sheared at an angle to provide a sharp point to aid in insertion of the opposed block support into the s:ide walls of the insulation blocks as to be described hereinafter.
The block retainer embodiments sho~n in both Fig~res 1 and 2 are utilized generally in the same manner. Therefore, the description of the manner of use of the block retainers of the embodiments of both Figures 1 and 2 will be described in respect to the embodiment of Figure 1 only.
_ ~ _ 8~1 Referring now to Figure 3, the initial procedure in starting insulation of a metallic wall 20 of a structure to be insulated is to place the block retainer 10 by means of its base member 11 against the metallic wall 20.
A metallic stud 21 is provided. The metallic stud 21 includes a first welding end 22. An area of reduced cross section 23 formed in the stud to provide what is known as a breakaway stud. The unwelded end 24 of the stud back of the area of reduced cross section 23 provides the necessary material for the stud to be received by a chuck 25 of a stud welding gun 26.
During assembly, the stud 21 is inserted in~o the chuck 25 of the stud welding gun 26 and an arc shield 19 positioned in place. The welding end 22 of the stud is placed into the aperture 14 of the base member 11. The aperture 14 o~ the base member 11 is slightly larger than the welding end 22 of the stud 210 The stud is then welded by the drawn arc process. During the welding process, an arc is drawn between the stud and the metallic wall 20 with resultant melting of the end of the stud 22 and the metallic wall 20 of the s~ructure being lnsulated~ Additionally, the arc will cause melting of a portion of the base member 11 around the circumference of the aperture 1~.
After a predetermined time of arcing between the stud and the metallic wall 20, the stud is plunged into the molten pool of me-tal formed upon the metallic wall 20 and the base member 11 around the aperture 1~ and allowed to solidify. Upon solidification, the welding end 22 of the stud is fused with the base member 11 around the circumference of the aperture 1~
and with the wall 22 of the structure being insulated to securely fasten the block retainer 10 in place.
Following welding of the stud 21 in place, and as shown in Figure ~, _ 9 _ the unwelded end 2~ of the s~ud is broken away from the weld end 22 by means of flexing of the unwelded end 24 such ~hat the stud will break at the area of reduced cross section 23. This reduces the height of the overall resultant welding structure as shown in ~igure 4 in order that the height of the stud remaining does not provide any interference to the side wall of an insulation block to be impaled upon the opposed block support 13 overlying the welded stud as to be described hereinafter.
One type of modular insulation block which may be utilized with the block retainer of the present invention is *hat shown in Figures 5 and 6 of the drawings. T~e modular insulation block 26 is preferably a square block formed of multiple layers of insulating material. The block 76 includes a front face 27, a rear face 2~ and four equal side walls 29.
During installation, the back wall 28 of the insulation block 26 is placed against the metallic wall 2U. The insulation block is then moved along horizontally upon the metallic wall 20 and impaled upon the opposed block support 13 opposite the base member 11. The position of the insulation block 26 just prior to being impaled upon the opposed block support 13 is sho-~n in Flgure 5 of the drawings.
Following positioning of the first insulation block 26 upon the block retainer 10, and as seen in Figure 6, a second insulation block 30 is im~aled by its side wall upon the opposed block support 13 overlying the base member 11. Ther~after, a second bloc~ retainer 31 is positioned with its opposed block support 33 opposite the base member 11 piercing or impaling the side wall 32 of the insulation block 30. Lateral pressure is applied to the block retainer 31 to firmly push the block retainer 31 into the side wall 32 of the insulation block 30 such that the support member 3~ of the retaining block 31 engages the side wall 32 of the retaining block 30 and firmly urges the block into compressed fit with the first block retainer support member 12.
Once the second block retainer 31 is in placa, a stud 21 is welded through the aperture in the block retainer to secure the block retainer 31 in place as in the case of the first block retainer 10.
The process is repeated for insulation block after insulation block to -Eorm both horizontal and vertical rows until the entire area desired to be insulated has been covered with insulation block.
In a given embodiment and by way of example only, the insulation blocks are of 1 foot square configuration and may range in thickness from 4 to 12 inches. The blocks are formed of fibrous alumina glass. In the embodiment shown, the blocks are formed of layers of the insulating material although blocks formed of multiple and continuous folds may also be utilized.
Additionally, the blocks are shown in alternate patterns wherein the folds or layers are at 90 one to another. However, this is not necessary to the invention.
The material of which the block retainer is formed is preferably of a stainless steel material. The length of the support bars and the height of the support member will depend upon the configuration of the block utilized.
The breakaway stud utilizad in a given embodiment and by way of example only is a 1 inch long stud o ~/16 inch diameter. The length of the weldable end of the stud is approximately 3/16 inch and the diamater of the area of reduced cross section approximately 1/8 inch. The stud is formed of mild steel material. The aperture in the block retainer is approximately
3/8 inch.
As may be seen from the foregoing9 the block retainer and method of securing insulation blocks to the metallic wall of structures to be insulated ~2~
provides a cheap, quick and effective way of securing the block retainer to the metallic walls of struc~ures to be insulated and also of assembling the modular blocks to the metallic wall of the structure.
The apparatus and methods of securing insulation blocks to the metallic walls of structures to be insulated of the present invention has been described in respect to the particular embodiment thereof set forth in the specification and as shown in the d~awings. ~o limitation as to the scope of the invention is intended by the description thereof in respect to the particular embodiments set forth in the specification and the drawings but the scope of the invention is to be interpreted in view of the appended claims.
As may be seen from the foregoing9 the block retainer and method of securing insulation blocks to the metallic wall of structures to be insulated ~2~
provides a cheap, quick and effective way of securing the block retainer to the metallic walls of struc~ures to be insulated and also of assembling the modular blocks to the metallic wall of the structure.
The apparatus and methods of securing insulation blocks to the metallic walls of structures to be insulated of the present invention has been described in respect to the particular embodiment thereof set forth in the specification and as shown in the d~awings. ~o limitation as to the scope of the invention is intended by the description thereof in respect to the particular embodiments set forth in the specification and the drawings but the scope of the invention is to be interpreted in view of the appended claims.
Claims (12)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. In insulation systems for insulating metallic walled structures such as furnaces, kilns and the like wherein modular insulation blocks having top and bottom faces and side walls are secured in side by side relationship with one face against the metallic wall of the structure by a block retaining system, the improvements in the block retaining system comprising:
a block retainer including a base member adapted to engage the metallic wall of the structure;
support means extending from the base member away from the metallic wall of the structure a predetermined distance;
at least one pair of opposed block support bars extending from the support means substantially parallel to the metallic wall of the structure; and securing means for securing the block retainer by its base member to the metallic wall of the structure whereby the modular blocks may be impaled upon the block supporting bars and retained in place.
a block retainer including a base member adapted to engage the metallic wall of the structure;
support means extending from the base member away from the metallic wall of the structure a predetermined distance;
at least one pair of opposed block support bars extending from the support means substantially parallel to the metallic wall of the structure; and securing means for securing the block retainer by its base member to the metallic wall of the structure whereby the modular blocks may be impaled upon the block supporting bars and retained in place.
2. The improvements of Claim 1 wherein the base member includes an aperture therethrough and the securing means includes a metallic stud, stud welded through the aperture to the metallic wall to fusion bond the stud, metallic wall and base member together.
3. The improvements of Claim 2 wherein the stud includes a portion of reduced cross section permitting the stud to be broken off following welding to reduce the length of the stud and restriction to impalement of the modular block upon the block support bars.
4. The improvements of either Claims 1 or 2 wherein the block retainer is formed of a unitary material.
5. The improvements of Claims 1 or 2 wherein the block retainer formed of round stock unitary material.
. The improvements of Claim 1 wherein the block retainer is formed of a unitary material of flat stock.
7. The improvements of Claim 6 wherein the block support bars are inclined relative to the metallic wall to provide increased bearing area to the modular blocks impaled thereupon.
8. The improvements of Claim 1 wherein the block retainer is formed of a unitary flat stock material and wherein the securing means includes a coined weld base area and tip upon the base member of the block retainer permitting capacitor discharge welding of the base member to the metallic wall of the structure.
9. The improvements of Claim 8 wherein the block support bars are inclined relative to the metallic wall to provide increased bearing area to the metallic blocks impaled thereupon.
10. The] method of securing a plurality of rectangular insulation blocks having top bottom and side walls to the metallic wall of structures such as kilns furnaces and the like comprising the steps of:
securing to the metallic wall of the structure a first block retainer having a base member in contact with the wall a support extending from the base member away from the wall and opposed block support bars extending from the support substantially parallel to the wall;
impaling a first insulation block by one of its side walls upon one of the opposed block support bars;
impaling one of the opposed block support bars of a second block retainer into another side wall of the insulation block and securing the block retainer to the metallic wall of the structure;
impaling a second insulation block by its side wall upon the remaining opposed block support bar of the second block retainer; and repeating the foregoing steps with additional block retainers and insulation blocks.
securing to the metallic wall of the structure a first block retainer having a base member in contact with the wall a support extending from the base member away from the wall and opposed block support bars extending from the support substantially parallel to the wall;
impaling a first insulation block by one of its side walls upon one of the opposed block support bars;
impaling one of the opposed block support bars of a second block retainer into another side wall of the insulation block and securing the block retainer to the metallic wall of the structure;
impaling a second insulation block by its side wall upon the remaining opposed block support bar of the second block retainer; and repeating the foregoing steps with additional block retainers and insulation blocks.
11. The method of Claim 10 wherein the base member of the block retainer is secured to the metallic wall of the structure by the step of welding a stud through an aperture in the base member to the metallic wall to fuse the base member, stud and wall together.
12. The method of Claim 11 further including the steps of welding a stud having an area of reduced cross section through the aperture to the wall and breaking off the unwelded end of the stud following welding to remove restriction to the insulation block.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000442909A CA1209861A (en) | 1983-12-08 | 1983-12-08 | Apparatus and method for securing modular insulation blocks |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000442909A CA1209861A (en) | 1983-12-08 | 1983-12-08 | Apparatus and method for securing modular insulation blocks |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1209861A true CA1209861A (en) | 1986-08-19 |
Family
ID=4126703
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000442909A Expired CA1209861A (en) | 1983-12-08 | 1983-12-08 | Apparatus and method for securing modular insulation blocks |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1209861A (en) |
-
1983
- 1983-12-08 CA CA000442909A patent/CA1209861A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |