Refractory insulating module

Abstract

Refractory modules and other insulating modules, which include a plurality of insulating module layers arranged with their major surfaces in a side-by-side orientation, are provided. Each insulating module layer includes a first section having a slot extending into a joint edge and a second section having a tab extending from a joint edge. The first and second sections each comprise a refractory insulation material, which typically includes fibrous refractory blanket material. The tab has an outer contour and the slot has an inner contour which substantially corresponds in shape such that when the tab is inserted in interlocking engagement into the slot, the joint edges of the first and second sections are held in juxtaposition along a section juncture.

What is claimed is: 
     
         1 . An insulating module comprising a plurality of insulating module layers arranged with their major surfaces in a side-by-side orientation,
 each layer comprising a first section comprising at least one slot extending therein from a slot joint edge; and a second section comprising at least one tab extending from a tab joint edge thereof;   wherein each tab is interlocking engaged with a paired slot on the first section and each slot has an inner contour which substantially corresponds in shape to an outer contour of its paired tab; whereby the joint edges of the first and second sections are held in juxtaposition along a section juncture; and   the first and second sections each comprise fibrous refractory blanket.   
     
     
         2 . The module of  claim 1  wherein each first section has a density of about 5-9 pcf; and each second section has a density of about 4-10 pcf. 
     
     
         3 . The module of  claim 1  wherein each second section includes a tab centrally positioned on the tab joint edge. 
     
     
         4 . The module of  claim 3  wherein each centrally positioned tab has an enlarging trapezoid outer contour and has a tab extension length of at least about one inch and a tab base which is about 20-40% of a width of the second section;
 each first section has a tab clearance of at least about 2 inches; and 
 the insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1. 
 
     
     
         5 . The module of  claim 1  wherein the plurality of insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1. 
     
     
         6 . The module of  claim 1  wherein each tab has an enlarging profile outer contour. 
     
     
         7 . The module of  claim 1  wherein each tab has an outer contour in which at least one edge of the contour extends in an outward direction from a line perpendicular to a tab base of the tab. 
     
     
         8 . The module of  claim 1  wherein the section juncture in each insulating module layer is positioned such that the section junctures in any two adjacent layers are offset with respect to each other. 
     
     
         9 . The module of  claim 8  wherein each tab has an extension length, which is less than an offset distance between a tab base of the tab, and the section juncture in any adjacent insulating module layer. 
     
     
         10 . The module of  claim 1  wherein each first section comprises mullite fibers; and each second section comprises alumina-silica-zirconia fibers. 
     
     
         11 . The module of  claim 1  further comprising a fastening device for attaching the insulating module to an inner surface of a furnace; wherein the fastening device comprises a support member and at least one anchor rod disposed in a transverse orientation through at least a majority of the insulating module layers. 
     
     
         12 . The module of  claim 1  wherein the first fibrous refractory material has a temperature rating which is at least about 100° F. higher than a temperature rating of the second fibrous refractory material. 
     
     
         13 . The module of  claim 12  wherein the first fibrous refractory material has a temperature rating of about 3,000° F.; and the second fibrous refractory material has a temperature rating of no more than about 2,600° F. 
     
     
         14 . The module of  claim 1  wherein each of the first and second sections comprise fibrous refractory materials comprising soluble fibers, fiber glass, mineral fibers, alumina fibers, zirconia fibers, alumina-zirconia fibers, alumina-silica-zirconia fibers, alumina-silica fibers, and/or chromia-alumina-silica fibers. 
     
     
         15 . The module of  claim 1  wherein all of the first sections have an edge which is exposed to a hot face of the module; and all of the second sections have an edge which is exposed to a cold face of the module. 
     
     
         16 . An insulating module comprising a plurality of insulating module elements arranged with major surfaces in a side-by-side orientation;
 each element comprising a U-shaped section comprising fibrous refractory blanket and having at least one slot extending therein from each of its two slot joint edges; and second and third fibrous refractory blanket sections each having at least one tab extending from a tab joint edge thereof;   wherein each tab is interlocking engaged with a paired slot on the corresponding slot joint edge of the U-shaped section and each slot has an inner contour which substantially corresponds in shape to an outer contour of its paired tab; whereby each tab joint edge of the second and third sections is held in juxtaposition with one of the slot joint edges of the U-shaped section along a section juncture.   
     
     
         17 . The module of  claim 16  wherein each U-shaped fibrous refractory section has a density of about 5-9 pcf; and each second fibrous refractory section has a density of about 4-10 pcf. 
     
     
         18 . The module of  claim 16  wherein the plurality of insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1. 
     
     
         19 . The module of  claim 16  wherein each of the U-shaped fibrous refractory section comprises mullite fibers and the second fibrous refractory sections comprise alumina-silica-zirconia fibers. 
     
     
         20 . An insulating module comprising a plurality of insulating module layers arranged with their major surfaces in a side-by-side orientation,
 each layer comprising a first section, which comprises a slot extending therein from a slot joint edge; and a second section comprising a tab extending from a tab joint edge thereof; the first and second sections each comprising fibrous refractory blanket;   wherein the slot has an inner contour which substantially corresponds in shape to an outer contour of the tab; the tab is interlocking engaged in the slot such that the joint edges of the first and second sections are held in juxtaposition along a section juncture;   each first section has a density of about 5-9 pcf; and each second section has a density of about 4-10 pcf; and   the plurality of insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1.