Method and apparatus for insulating a furnace having a corrosive atmosphere

Claim 2

A high temperature insulation module for use in a chamber containing a corrosive atmosphere, comprising: a first ceramic fiber mat, the first mat having a hot face adapted for exposure to the interior of a high temperature chamber, the first mat having a thickness, the first mat having a rear face generally opposite from the hot face; a support member, the support member being disposed against the rear face of the first mat, the support member being displaced from the hot face of the first mat by at least the thickness of the first mat to protect the support member from excessive heat; a second ceramic fiber mat, the second mat having a front face disposed against the support member, the second mat having a thickness, the second mat having a cold face generally opposite from the front face, the second mat being adapted to maintain the support member in a region displaced from the cold face by at least the thickness of the second mat; and, the first mat, the support member and the second mat forming a module, the support member being positioned between the first mat and the second mat and being displaced from the cold face in a zone of the module where the temperature at the zone during operation of the chamber will generally be too high for corrosive gases and water vapor to condense.

Claim 3

The module of claim 1, wherein said first ceramic fiber mat is comprised of resilient ceramic fiber material.

Claim 4

The module of claim 1, wherein said first ceramic fiber mat is comprised of a plurality of side-by-side strips of resilient ceramic fiber insulation material.

Claim 5

The module of claim 1, wherein said first and said second mats are comprised of a single resilient fibrous block, said block being comprised of a plurality of side-by-side planes of ceramic fiber material wherein said fibers are randomly arranged within said planes.

Claim 6

The module of claim 4 wherein said block has been cut transversely prior to installation.

Claim 7

The module of claim 1, wherein said second ceramic fiber mat is comprised of resilient ceramic fiber material.

Claim 8

The module of claim 6 wherein said second mat is comprised of a blanket material with the fibers arranged in planes generally parallel to said cold face.

Claim 9

The module of claim 1, wherein said support member is rigid with respect to said first and said second mats.

Claim 10

The module of claim 8 wherein said support member is comprised of expanded metal.

Claim 11

The module of claim 8 wherein said support member is comprised of insulation material.

Claim 12

The module of claim 1, further including a fastener carried by said module.

Claim 13

The module of claim 11 wherein said fastener is actuated by insertion of a tool through said hot face.

Claim 14

The module of claim 11 wherein said fastener is attached to the wall of the high temperature chamber by welding.

Claim 15

The module of claim 11 wherein said fastener is attached to the wall of the high temperature chamber by rotating a threaded member.

Claim 16

The module of claim 1, further comprising cement intermediate said first and said second mats generally around an outer perimeter of said support member.

Claim 17

The module of claim 15 wherein cement is applied to a hot side of said support member.

Claim 18

The module of claim 15 wherein cement is applied to a cold side of said support member.

Claim 19

A high temperature insulation module for use in a chamber containing a corrosive atmosphere, said module comprising: a first ceramic fiber mat defining a hot face of the module; a second ceramic fiber mat defining a cold face of the module; said first and said second mats being comprised of a single resilient fibrous block, said block being comprised of a plurality of side-by-side planes of ceramic fiber material wherein said fibers are randomly arranged within said planes, said block having been cut transversely prior to installation; and, a support member positioned intermediate said first and said second mats, said support member being cooperable with a fastener positionable below the hot face intermediate said hot face and said cold face to affix the module to a wall of a high temperature chamber and maintain said support member at a location whereat during operation of the chamber the temperature exceeds that at which corrosive gases can condense.

Claim 20

A high temperature insulation module for use in a chamber containing a corrosive atmosphere, said module comprising: a first ceramic fiber mat defining a hot face of the module; a second ceramic fiber mat defining a cold face of the module; said first and said second mats being comprised of a single resilient fibrous block, said block being comprised of a plurality of side-by-side planes of ceramic fiber material wherein said fibers are randomly arranged within said planes, said block having been cut transversely prior to installation; and, a support member positioned intermediate said first and said second mats, said support member being cooperable with a fastener positionable below the hot face intermediate said hot face and said cold face to affix the module to a wall of a high temperature chamber and maintain said support member at a location whereat during operation of the chamber the temperature exceeds that at which corrosive gases can condense.

Claim 21

A high temperature insulation module for use in a chamber containing a corrosive atmosphere, comprising: a first ceramic fiber mat, the first mat having a hot face adapted for exposure to the interior of a high temperature chamber, the first mat having a thickness, the first mat having a rear face generally opposite from the hot face; a planar support member, the support member being disposed against the rear face of the first mat, the support member being displaced from the hot face of the first mat by at least the thickness of the first mat to protect the support member from excessive heat; a second ceramic fiber mat, the second mat having a front face disposed against the support member, the second mat having a thickness, the second mat having a cold face generally opposite from the front face, the second mat being adapted to maintain the support member in a plane displaced from the cold face by a distance generally equal to the thickness of the second mat; and, the first mat, the support member and the second mat forming a module, the support member being positioned between the first mat and the second mat and being displaced from the cold face in a plane of the module where the temperature at the plane during operation of the chamber will exceed the condensation temperature for corrosive vapors.

Claim 22

A high temperature insulation module for use in a chamber containing a corrosive atmosphere, comprising: a first ceramic fiber mat, the first mat having a hot face adapted for exposure to the interior of a high temperature chamber, the first mat having a thickness, the first mat having a rear face generally opposite from the hot face; a planar support member, the support member being disposed against the rear face of the first mat, the support member being displaced from the hot face of the first mat by at least the thickness of the first mat to protect the support member from excessive heat; a second ceramic fiber mat, the second mat having a front face disposed against the support member, the second mat having a thickness, the second mat having a cold face generally opposite from the front face, the second mat being adapted to maintain the support member in a plane displaced from the cold face by a distance generally equal to the thickness of the second mat; and, the first mat, the support member and the second mat forming a module, the support member being positioned between the first mat and the second mat and being displaced from the cold face in a plane of the module where the temperature at the plane during operation of the chamber will exceed the condensation temperature for corrosive vapors.