Insulating ceramic fiber batting module, anchoring system, ladle cover assembly and method of assembly

• US 5,234,660 A
• Filed: 06/25/1992
• Issued: 08/10/1993
• Est. Priority Date: 10/10/1990
• Status: Expired due to Fees

• Current Assignee: Simko & Sons Industrial Refractories Incorporated
• Original Assignee: Simko & Sons Industrial Refractories Incorporated
• Inventors: Simko, Joseph S. Jr.
• Primary Examiner(s): KASTLER, SCOTT R
• Application Number:
  US07/904,750
• Time in Patent Office: 411 Days
• Field of Search: 266/280, 266/286, 266/275, 266/283, 52/506, 52/509, 52/512, 52/504
• US Class Current: 266/286
• CPC Class Codes: B22D 41/00 Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like B22D39/00, B22D43/00 take precedence
• CPC Class Codes: F27D 1/0016 Interleaved multiple folded blankets
• CPC Class Codes: F27D 1/144 Supports for ceramic fibre materials
• CPC Class Codes: F27D 1/1808 Removable covers

Abstract

A lightweight ladle cover employing ceramic fiber mats in modules. The modules are formed by having the generally rectilinear mat folded into five adjacent sections, the first of which depends vertically toward the "hot" side of the cover but is sandwiched between the second, third and fourth sections which form a vertical, horizontal ("hot" side) and vertical U-shape configuration about the first section. The last section is folded to extend horizontally to overlay part of the next module. The modules are anchored to an expanded metal wall at the "cold" side of the cover by an anchoring system which employs flat bars with spaced apart threaded studs welded to one flat side of the bar. In assembly, the studs are pierced through the mat at the junction of the first and second sections and then passed through openings in the expanded metal wall and secured by a washer and nut arrangement. The modules are then held by two bar-stud assemblies. The modules can be assembled by the process of laying down successive mats, securing them with anchoring assemblies, folding them in place and then repeating the process.

Claims

1. The process of making a heat insulating assembly for an insulating structure of the type that has a wall adjacent to the insulation assembly that is to be provided, employing a plurality of mats of spun ceramic fiber material, each of which mats has a predetermined length, width and thickness and is capable of being folded between a plurality of adjacent sections, including a first end section and a last end section;

and a plurality of anchor units made of elongated bars having elongated studs secured in a spaced array along the bars, the studs having one longitudinal end secured to the bar and the other end adapted to receive fastener means, all of the studs secured to a bar being aligned with one another and projecting in the same direction on the same side of the bar; and

fastener means for securing to the studs when projected into the wall and for preventing inadvertent removal of the studs from the wall;

comprising the steps of;

(a) placing a mat against the end section of a mat, which end section is against the wall, said placed mat being positioned so that the junction between its first end section and second section are against the cold side of said end section of the mat section against the wall;

(b) placing the anchoring unit along the junction of the placed mat and pushing the studs thereof through both said placed mat and the mat section against the wall to pierce both to pass into the wall;

(c) securing the studs of the anchoring unit passed into the wall with the fastener means so as to sandwich both mats between the wall and the bar of the anchoring unit;

(d) folding the first section of said newly placed mat to extend away from the wall in an approximately vertical arrangement while folding the next adjacent sections of the mat into a generally U-shape about the end section and placing the end section of the mat horizontally against the wall to form a section for receiving another mat; and

(e) repeating steps (a) through (d) until the assembly is substantially formed.

2. An insulation module in insulating structures having a cold side and a hot side, the module being fastened to form at least in part the hot side of the insulating structure, said insulating module comprising:

a mat of fibrous resilient ceramic fiber insulating material formed in folded condition in said module with successive contiguous mat sections as follows;

a first section arranged to extend at an approximately right angle to said sides of the structure followed by a generally 180°

fold to a second contiguous section which lies parallel and adjacent the first section, the fold between said sections serving to receive a longitudinal bar extending along said fold, a further third section folded across the end of said first section and forming part of the hot side of the structure, a fourth section folded parallel to and adjacent said first section, said second, third and fourth sections forming a general U-shaped cross section with said first section sandwiched between said second and fourth sections and in the opening of said U-shape, a fifth section contiguous to said fourth section and folded to be at approximately a right angle to said first, second and fourth sections and to extend parallel to the sides of the structure and extend for a distance from the fourth section, which distance is approximately equal to the thickness of said folded together first, second and fourth sections so said fifth section is able to provide a layer of mat for overlaying a portion of an adjacent similarly constructed module; and

anchoring means including a bar placed at said 180°

fold between said first and second mat sections and including means passing through said mat for being secured to the cold side of the insulated structure.

3. The module of claim 2 wherein said bar of said anchoring means is generally flat with a length many times its width and a thickness less than its width and has a flat surface facing the cold side, and said anchoring means further includes

a plurality of studs having two longitudinal ends, said studs each having one end secured to said cold side facing flat surface of said bar at spaced intervals along the length of said bar, which studs pierce and pass through the mat and into the cold side;

said module including fastener means for captivating the studs of said anchoring means and securing it and the pierced mat to the cold side.

4. The module of claim 3 wherein said studs are threaded and said fastener means includes nut means threadably receivable on said threaded studs.

5. In an insulating structure having a cold side and a hot side, the improvement comprising successive adjacent insulation modules being fastened to form at least in part the hot side of the insulating structure, said insulating modules including a first insulating module which comprises:

a mat of fibrous resilient ceramic fiber insulating material formed in folded condition with successive contiguous mat sections, one of which sections forms a part of said hot side and another of which sections extends parallel to the cold side of the structure for a distance which is at least approximately equal to the thickness of said one section forming part of the hot side, so as to form an overlaying section to part of a second mat;

a second module comprising a second mat of fibrous resilient ceramic fiber insulating material formed in folded condition and substantially underlying said another section of said first mat of said first module, said second mat with successive contiguous second mat sections, one of which second mat sections forms another part of said hot side adjacent to said hot side part formed by said first mat of said first module and substantially under said another section of said first mat of said first module and said second mat, including another section of said second mat which extends parallel to the cold side of the structure for a distance, which distance is at least approximately equal to the thickness of said second one mat section, and said second another section of said second mat, forming another overlaying section and

anchoring means for said second module including means passing through said first and said second mats for being secured to the cold side of the insulated structure.