AU2009222608A8 - Locking Element for Anchors - Google Patents

Abstract

Abstract An anchor to in use be used to support a refractory lining material from the wall of a furnace wherein the anch r comprises a refractory anchor supported from the wall by support element (11) and includes a locking element (13) which supports 5 the refractory anchor from the support element, said support element having two opposed ends (23, 25) and -wo opposed sides (21) extending from the other end, one end (23) of the support intended in use to be fixed to the wall, whereby the other end (25) is spaced outwardly from the wall, the support element having an aperture (15) intermediate of the ends and transverse to the sides, the refractory 10 anchor comprising a pair of divergent arms interconnected at a junction, wherein in use the refractory anchor is to be supported from the support element with the junction received in the ape ure and the arms extending outwardly from the wall, the locking element configured to in use be able to be supported from the support element to lie between the arms and to engage with the arms to fix the arms 15 relative to the support ele ent, the locking element comprising a plate like member having a pair of opposed end portions (29) which are divergent from each other to define a space there between, wherein in use the other end of the support element is receivable within the space and the sides are engaged by the opposed end portions, the sides having a set of spaced abutments (28) thereon, 20 the spacing between the ouler ends of the end portions enabling the end portions to be engagable with the abutments to retain the locking element on the support element, wherein the locking element is capable of being affected by the heat generated by the furnace during use to reduce the relative support provided between the refractory anch r and the support element by the locking element. A 25 locking element is also claimed. 21 -19- 2 29 11b 11a

Description

P/001011 2815/91 Regulation 3.2 AUSTRALIA Datents Act 1990 ORIGINAL COMPLY ETE SPECIFICATION STANDARD PATENT Name of Applicant: Pressform Engineering Pty Ltd Actual Inventor Johr Worner Address for service is: WRAYS GrOL nd Floor, 56 Ord Street West Perth WA 6005 Attorney code: WR Invention Title: "Locking Element for Anchors" The following statement is a full description of this invention, including the best method of performing it known to me: 1 -2 "Locking Element for Anchors" Field of the Invention The present invention relates to a device and a method for locking anchors used to support castable or monolithic refractory cement in a furnace shell. 5 Background Art The interior of furnaces are often lined with castable or monolithic refractory cement. A typical furnace is constructed by first erecting a furnace shell and then applying a layer of refr ctory cement over the surface of the shell to provide insulation. It is necessary tc support the refractory cement during the application 10 of the cement and this requires the use of anchors which extend from the shell into the refractory. It is also necessary to continue that support throughout the life of the furnace. Because furnaces are raised to a very high temperature during operation and then cooled again to normal temperatures, the cement undergoes significant expansion and contraction. This causes cracking and the 15 cement would break away from the furnace shell if it is not adequately supported from the shell during use. It is the function of the anchors to provide that support but in doing so it is necess ry that the differential expansion and contraction of the anchoring does not read ily induce such cracking. One form of anchor for use in such situations is disclosed in GB2289105 20 however it is believed that this arrangement presents problems because of its complexity and results in the creation of voids within the refractory which is not desirable The applicant has previously developed an anchor which comprises a substantially V shaped anchor supported by a lug secured to the refractory shell. 25 The lug comprised a simple metal plate usually welded to the furnace shell and upstanding from the shell tr nsversely to the surface. The lug is provided with a slotted aperture which is configured to receive the anchor during installation -3 where the longitudinal axis of the slotted aperture runs generally parallel to the shell surface in the vicinity cf the lug. The anchor can be formed from stainless steel or nickel alloy rod anc comprises two opposed arms converging towards each other in a general 'V configuration which intersect at an apex configured as 5 a 'U' shaped formation rather a simple apex. The arms of the rod are formed with a slight wave formation along their length to provide better adherence to the refractory cement. In additi n the thickness of the anchor in the region of the apex is greater in the plane accommodating the arms and its thickness at that portion is greater than the thickness of the arms, while the thickness of the 10 anchor in the region of th apex is approximately equal to or less than the thickness of the arms. The width of the slotted aperture is such that the arms of the anchor are snugly received by the aperture and the thinner portion of the apex is received by the ap rture when the arms are parallel to the wall. The anchor is mounted to the luc by passing one arm through the aperture of the lug 15 with the both of the arms held to be approximately parallel to the wall until the apex is centred in the apert re. The anchor is then caused to rotate about the lug until the anchor extends substantially transversely from the wall and the lug. Because of the increased thickness of the apex the rotation of the anchor causes the frictional engagement o- the apex of the anchor within the slotted aperture 20 which results in some defor ation of the apex and/or the aperture. Due to the curvature and deformation >f the rod and/or lug at the base of the U shaped apex, the apex is jammed in the aperture of the lug to secure the anchor in position. In general, this er gagement has been satisfactory to hold anchors in place until the refractory ce ent is cast. This arrangement can be successful 25 while the furnace is in use because of its ability to allow movement of the anchor relative to the lug, in a direction substantially parallel to the plane of the shell in the vicinity of the lug to cope with expansion and contraction of the cement and the shell. This has been fou id to be particularly useful for rotatable furnaces, but is also useful in conventiona stationary furnaces. 30 A problem experienced with the above style of anchor occurs in maintaining the anchor in position prior to the cement being cast. The anchor requires only a relatively small lateral force to knock it over and once it is dislodged a little it will -4 tend to fall against the shell wall. Because the original locking of the anchor in place depends on an interfe ence fit between the surfaces of the U shaped apex and the slotted aperture, vhen the anchor is first rotated into its transverse position, some compression of the steel occurs at the contact point. This can 5 tend to deform the metal of the lug a little such that any subsequent attempt to rotate an anchor upright is not quite as effective as the initial action. It then becomes easier to knock :he anchor out of its transverse position and the knocking down of the ancho- can happen even during the casting process of the cement. Where cement is cast with the anchor dislodged (particularly against 10 the furnace shell) from its transverse position, the anchor no longer performs its function and therefore the cement in that area is not properly supported. This can lead to premature failure of the cement requiring an expensive maintenance repair and furnace downtime. It has been attempted to prevent the anchor from being dislodged from a 15 transverse position by tack welding the anchor to the lug. The intention being that the weld will be sufficie t to hold the anchor during casting of the refractory cement but that the weld will break when the furnace is in use enabling the refractory cement to move relative to the lug. However this method has created further problems. Firstly it is difficult to control the amount of tack welding 20 required. If too much welc is applied, the tack will not break in use thereby preventing the anchor from moving relative to the lug. This is likely to lead to failure of the anchor and/or the refractory cement in its vicinity. If too little weld is applied, the weld will still break prematurely and the original problem will not be overcome. In addition, the welding action may affect the strength of the anchor. 25 Furthermore this practice is very time consuming and therefore an expensive process to apply. The inventor of the present invention had previously invented a locking means which was intended to at least in part to overcome the above difficulties and that invention is the subject of A stralian patents 2005100846 and 2006225331. The 30 specifications of each Aus ralian patents 2005100846 and 2006225331 are expressly incorporated here n in their entirety by reference, which means that it -5 should be read and considered by the reader as part of this text. That the document, reference, patent application or patent cited in this text is not repeated in this text is merely for reasons of conciseness. Reference to cited material or information contained in the text should not be 5 understood as a concession that the material or information was part of the common general knowledge or was known in Australia or any other country. Disclosure of the Inventio Throughout the specification, unless the context requires otherwise, the word "comprise" or variations suci as "comprises" or "comprising", will be understood 10 to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. According to one aspect the invention resides in a locking element intended in use to support a refractory I ning material from the wall of a furnace wherein the anchor comprises a refractory anchor supported from the wall by support 15 element and includes a locking element which supports the refractory anchor from the support element, said support element having two opposed ends and two opposed sides extending from the other end, one end of the support intended in use to be fixEd to the wall, whereby the other end is spaced outwardly from the wall, the support element having an aperture intermediate of 20 the ends and transverse to the sides, the refractory anchor comprising a pair of divergent arms interconnected at a junction, wherein in use the refractory anchor is to be supported from the support element with the junction received in the aperture and the arms extending outwardly from the wall, the locking element configured to in use be ab e to be supported from the support element to lie 25 between the arms and to engage with the arms to fix the arms relative to the support element, the locking element comprising a plate like member having a pair of opposed end portions which are divergent from each other to define a space there between, wherein in use the other end of the support element is receivable within the space and the sides are engaged by the opposed end 30 portions, the sides having a set of spaced abutments thereon, the spacing -6 between the outer ends of the end portions enabling the end portions to be engagable with the abutm nts to retain the locking element on the support element, wherein the locking element is capable of being affected by the heat generated by the furnace during use to reduce the relative support provided 5 between the refractory anch r and the support element by the locking element. According to another aspect the invention resides in an anchor to in use be used to support a refractory lini g material from the wall of a furnace wherein the anchor comprises a refractory anchor supported from the wall by support element and includes a locking element which supports the refractory anchor 10 from the support element, said support element having two opposed ends and two opposed sides extending from the other end, one end of the support intended in use to be fixE d to the wall, whereby the other end is spaced outwardly from the wall, the support element having an aperture intermediate of the ends and transverse to the sides, the refractory anchor comprising a pair of 15 divergent arms interconnect d at a junction, wherein in use the refractory anchor is to be supported from the support element with the junction received in the aperture and the arms extending outwardly from the wall, the locking element configured to in use be ab e to be supported from the support element to lie between the arms and to engage with the arms to fix the arms relative to the 20 support element, the locking element comprising a plate like member having a pair of opposed end portions which are divergent from each other to define a space there between, whersin in use the other end of the support element is receivable within the space and the sides are engaged by the opposed end portions, the sides having a set of spaced abutments thereon, the spacing 25 between the outer ends of the end portions enabling the end portions to be engagable with the abutments to retain the locking element on the support element, wherein the locking element is capable of being affected by the heat generated by the furnace during use to reduce the relative support provided between the refractory anch r and the support element by the locking element. 30 According to a preferred fe ture of the invention the support element comprises a lug fixed to the wall of the urnace.

-7 According to a preferred fea ure of the invention the support element the portion proximate the one end is ol substantially circular cross-section and the portion proximate the other end being of a substantially rectangular cross sectional configuration. 5 According to a preferred feature of the invention at least one side of the locking element is provided with a recess, the width of the locking element and the configuration of the recess enabling one arm of the refractory anchor to be received in the recess when the junction is received in the aperture and the refractory anchor is positioned to extend transversely from the wall the is the 10 arms when the locking element is supported from the support element. According to a preferred fea ure of the invention the locking element comprises a central portion between the end portions and the recess is located in the central portion.. According to a preferred feature of the invention a recess is provided on opposed 15 sides of the locking member wherein in use both arms are engaged by the recesses. According to a preferred feature of the invention the locking element is formed with an opening which is located intermediate of the width of the locking element and intermediate of the length of the locking element, the opening being 20 configured to enable at least a portion of the of other end of the support element to be received in, the opening. According to a preferred feature of the invention the opening defines a web portions at the outer ends of the end portions, said web portions being engagable with the abutme ts. 25 According to a preferred fe ture of the invention the abutments are formed as ratchet like teeth elements which enable the web portions to move over the surface of the second faces towards the one end of the support element but resist movement away from he one end According to a preferred fea ure of the invention the locking element is formed of a material which will melt and/or vaporise under the influence of the heat generated by the furnace. A locking element as claimed at claim 5 wherein the locking element is formed of 5 a plastics material. According to a preferred feature of the invention the locking element is has an inherent resilience and/or te nper which is reduced by the heat generated by the furnace. According to a preferred fea ure of the invention is formed from mild steel which 10 becomes deformable during use of the furnace to permit movement of the anchor relative to the support element during use of the furnace. According to a preferred feature of the invention the locking element is formed from a spring steel which will lose its temper during use of the furnace due to the heat to permit movement of the anchor relative to the lug during use of the 15 furnace. According to a preferred feature of the invention the end face of the one end of the support element is formed with a recess which accommodates a quantity of a suitable flux to facilitate the welding of the support element to the wall. The invention will be more fully understood in light of the following description of 20 several specific embodiments. Brief Description of the Drawings The description is made with reference to the accompanying drawings, of which: Figure 1 is a side elevation >f a support element and locking element according to the first embodiment; and -9 Figure 2 is a plan view of tha support element and locking element according to the second embodiment; Detailed Description of Pre ferred Embodiment The embodiments of the in ention are each directed to a locking element for a 5 refractory anchor which are adapted to prevent rotation of the refractory anchor relative to a support and vhich engagingly supports the anchor prior to and during casting of refractory cement but wherein the locking element will lose its ability to restrain the anchor when the furnace is in use and once the heat of the furnace is applied to the locking element. 10 The first embodiment as shown in Figures 1 and 2 comprises a locking element in the form of a locking clip -3. The locking clip is adapted to be positioned over a support element 11 which is to be mounted at one end to the wall of a furnace shell (not shown) to hold a refractory anchor (not shown) in place in a transverse position relative to the support element 11. The lug 11 comprises an elongate 15 member which is formed of mild steel having one end portion 11a of a substantially cylindrical cross sectional configuration and the other end portion 11b which is of a generally rectangular cross sectional configuration. The other end portion is formed with al aperture 15 which extends between the major first faces 19 of the other end p rtion and which is to receive the refractory anchor 20 (not shown). The aperture 15 is of a generally slotted configuration where the elongate axis of the aperture is substantially parallel to the end faces 23 and 25 of the support element. E ch of the minor second faces 21 of the other end portion are formed to be ge erally convergent in the direction of the one end 23. In addition each of the second faces 21 are formed with a set of spaced 25 abutments 28 which are spaced longitudinally along the respective face and which take the form of ratc et-like teeth from a position spaced from the from the other end face 25. The locking clip 13 accordir g to the to embodiment comprises a metal bracket formed from mild steel sheet, and having a central portion 27 of a generally 30 rectangular configuration a d a pair of opposed end portions 29 which are - 10 angularly offset from the central portion and which define a space between themselves and the central portion. The sides of the central portion are each provided with a recess 31 which are configured to conform to the refractory anchor which is formed of a -cd-like material. The recesses 31 in the locking clip 5 13 will in use receive and support the arms of the anchor. The locking clip is formed with a central elongate opening 33 which extends for the full length of the central portion and a portion of the end portions to define a web element 35 at the ends of the locking clip. The spacing between the web elements 35 is a little less than the spacing between the second faces of the support element. 10 In use, once the refractorY anchor has been positioned within the support element such that the juncti n between the arms is received in the aperture and the arms extend substantial y perpendicularly from the wall, a force is applied to the locking clip to cause re ilient deformation such that the web elements 35 of the locking clip are caused o be moved way from each other and in order that 15 the locking clip can be placed onto the support element 11. in so doing the arms of the refractory anchor are engaged by the recesses of the locking clip 13. Once the web elements 35 are engaged with the opposed second faces of the other end of the support ele ent the locking clip can be moved along the support element towards the one end 21 to become engaged with the abutments. 20 Because of the ratchet-like configuration of the abutments the web elements 35 will be able to move over t e second faces towards the one end of the support element to positively engage and hold the refractory anchor in place of the support element but will resi st movement the opposite direction. In addition the one end 23 is formed with a central recess which can be tapered 25 and is variable in depth. The recess is intended to accommodate a suitable flux to facilitate the welding of the one end of the support element to the wall of the furnace and in enabling an dequate weld to be made when welding the support element to the shell of the furnace. The depth and degree of taper of the recess will vary upon the amount >f flux which is to be accommodated in the recess 30 which in turn is dependant at least in part upon the diameter of the one end of - 11 the support element and the nature of the material of which the support element and furnace wall are made. Once the refractory cement has been applied and cured, the use of the furnace will result in the wall and the refractory cement being heated. The resultant slow 5 heating and cooling of the Icoking clip 31 will cause it to lose its temper and thus the capacity to prevent movement of the anchor relative to the support element which will result from the repetitive heating and cooling of the furnace walls. This loss of temper is sufficient to accommodate for the relative movement that will occur between the support element, the locking clip, the refractory anchor and 10 the surrounding refractory cement that will arise from the heating and cooling of the walls of the furnace anc the resultant differential contraction and expansion between each of the elemen s. According to a further emb diment the locking clips of the first embodiment are formed of a resilient plasticE material which will lose their resilience and/or melt 15 when heated by the furnace. The present invention is rot to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly witt in the scope of the invention as described herein.

Claims (31)

1. A locking element intended in use to be used in an anchor which is used to support a refractory I ning material from the wall of a furnace wherein the 5 anchor comprises a refractory anchor supported from the wall by support element and includes a locking element which supports the refractory anchor from the S pport element, said support element having two opposed ends and tvo opposed sides extending from the other end, one end of the support intended in use to be fixed to the wall, whereby the other 10 end is spaced outwardly from the wall, the support element having an aperture intermediate of the ends and transverse to the sides, the refractory anchor comprising a pair of divergent arms interconnected at a junction, wherein in use the refractory anchor is to be supported from the support element with the junction received in the aperture and the arms 15 extending outwardly f om the wall, the locking element configured to in use be able to be supported from the support element to lie between the arms and to engage with the arms to fix the arms relative to the support element, the locking element comprising a plate like member having a pair of opposed end portions which are divergent from each other to define a 20 space there between wherein in use the other end of the support element is receivable within the space and the sides are engaged by the opposed end portions, the si es having a set of spaced abutments thereon, the spacing between tE! outer ends of the end portions enabling the end portions to be engag ble with the abutments to retain the locking element 25 on the support element, wherein the locking element is capable of being affected by the heat generated by the furnace during use to reduce the relative support prov ded between the refractory anchor and the support element by the locking element.

2. A locking element as claimed at claim I wherein the support element 30 comprises a lug fixed to the wall of the furnace. - 14

3. A locking element as claimed at claim I or 2 wherein the support element wherein the portion proximate the one end is of substantially circular cross section and the portion proximate the other end being of a substantially rectangular cross sectional configuration. 5

4. A locking element as claimed at claim 1 or 2 wherein at least one side of the locking element s provided with a recess, the width of the locking element and the configuration of the recess enabling one arm of the refractory anchor to be received in the recess when the junction is received in the aperture and the refractory anchor is positioned to extend 10 transversely from the wall the is the arms when the locking element is supported from the su port element.

5. A locking element as claimed at claim 4 wherein the locking element element comprises a central portion between the end portions and the recess is located in th central portion. 15

6. A locking element as claimed at claim 4 or 5 wherein a recess is provided on opposed sides of the locking member wherein in use both arms are engaged by the reces es.

7. A locking element as claimed at any one of the preceding claims wherein the locking element is formed with an opening which is located 20 intermediate of the w dth of the locking element and intermediate of the length of the locking element, the opening being configured to enable at least a portion of the of other end of the support element to be received in, the opening.

8. A locking element as claimed at claim 7 wherein the opening defines a web 25 portions at the outer ends of the end portions, said web portions being engagable with the abutments.

9. A locking element as -laimed at any one of the preceding claims wherein the abutments are fored as ratchet like teeth elements which enable the -15 web portions to move over the surface of the second faces towards the one end of the support element but resist movement away from the one end

10.A locking element as claimed at any one of the preceding claims wherein the locking element i< formed of a material which will melt and/or vaporise 5 under the influence of the heat generated by the furnace.

11.A locking element as claimed at claim 10 wherein the locking element is formed of a plastics material.

12.A locking element as claimed at any one of claims 1 to 9 wherein the locking element is has an inherent resilience and/or temper which is 10 reduced by the heat generated by the furnace.

13.A locking element as claimed at claim 12 wherein the locking element is formed from mild steel which becomes deformable during use of the furnace to permit movement of the anchor relative to the support element during use of the furn ace. 15

14.A locking element as claimed at claim 12 wherein the locking element is formed from a spring steel which will lose its temper during use of the furnace due to the heat to permit movement of the anchor relative to the lug during use of the furnace.

15.A locking element s bstantially as herein described with reference to the 20 accompanying drawir gs.

16.An anchor to in use e used to support a refractory lining material from the wall of a furnace herein the anchor comprises a refractory anchor supported from the w all by support element and includes a locking element which supports the refractory anchor from the support element, said 25 support element having two opposed ends and two opposed sides extending from the ot er end, one end of the support intended in use to be fixed to the wall, whe -eby the other end is spaced outwardly from the wall, - 16 the support element having an aperture intermediate of the ends and transverse to the sides, the refractory anchor comprising a pair of divergent arms interconnected at a junction, wherein in use the refractory anchor is to be supported from tl e support element with the junction received in the 5 aperture and the anns extending outwardly from the wall, the locking element configured to in use be able to be supported from the support element to lie betwe n the arms and to engage with the arms to fix the arms relative to the support element, the locking element comprising a plate like member -aving a pair of opposed end portions which are 10 divergent from each other to define a space there between, wherein in use the other end of the support element is receivable within the space and the sides are engaged by the opposed end portions, the sides having a set of spaced abutments thereon, the spacing between the outer ends of the end portions enabling the end portions to be engagable with the abutments to 15 retain the locking element on the support element, wherein the locking element is capable oi being affected by the heat generated by the furnace during use to reduce the relative support provided between the refractory anchor and the suppc rt element by the locking element.

17. An anchor as claimed at claim 16 wherein the support element comprises 20 a lug intended in use o be fixed to the wall of the furnace.

18.A locking element as claimed at claim 16 or 17 wherein the support element wherein the portion proximate the one end is of substantially circular cross-sectior and the portion proximate the other end of a substantially rectangular cross sectional configuration. 25

19.An anchor as claimed at any one of claims 16 to 18 wherein at least one side of the locking element is provided with a recess, the width of the locking element and tie configuration of the recess enabling one arm of the refractory anchor to be received in the recess when the junction is received in the aperture and the refractory anchor is positioned to extend 30 transversely from the wall the is the arms and when the locking element is supported from the s pport element. -17

20.An anchor as claimed at claim 19 wherein the locking element comprises a central portion between the end portions and the recess is located in the central portion.

21.An anchor as claime at claim 19 or 20 wherein a recess is provided on 5 opposed sides of t e locking member wherein in use both arms are engaged by the recesses.

22.An anchor as claimed at any one of claims 16 to 21 wherein the locking element is formed with an opening which is located intermediate of the width of the locking element and intermediate of the length of the locking 10 element, the opening being configured to enable at least a portion of the other end of the supp rt element to be received in the opening.

23.An anchor as claim d at claim 22 wherein the opening defines a web portions at the outer ends of the end portions, said web portions being engagable with the abutments. 15

24.An anchor as claime at any one of claims 16 to 23 wherein the abutments are formed as ratchet-like teeth elements which enable the web portions to move over the surfa e of the second faces towards the one end of the support element but to resist movement of the web portions away from the one end 20

25.An anchor as claime at any one of claims 16 to 24 wherein the locking element is formed of a material which will melt and/or vaporise under the influence of the heat generated by the furnace.

26. An anchor as claimed at claim 25 wherein the locking element is formed of a plastics material. 25

27.An anchor as claimed at any one of claims 16 to 24 wherein the locking element is has an inherent resilience and/or temper which is reduced by the heat generated by the furnace. -18

28.An anchor as claimed at claim 27 wherein the locking element is formed from mild steel which becomes deformable during use of the furnace to permit movement of the anchor relative to the support element during use of the furnace. 5

29.An anchor as claime at claim 27 wherein the locking element is formed from a spring steel w ich will lose its temper during use of the furnace due to the heat to permit movement of the anchor relative to the lug during use of the furnace.

30.An anchor as claimed at any one of claims 16 to 29 wherein the end face of 10 the one end of the support element is formed with a recess which accommodates a quantity of a suitable flux to facilitate the welding of the support element to th B wall.

31.An anchor substanally as herein described with reference to the accompanying drawir gs. 15