Refractory insulating module

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 having a slot extending therein from a slot joint edge; and a second section having a tab extending from a tab joint edge thereof;

wherein the slot has an inner contour which substantially corresponds in shape to an outer contour of the tab; the tab interlocking engaged in the slot such that the joint edges of the first and second sections are held in juxtaposition along a section juncture;

the first and second sections each comprise a fibrous refractory insulation material; and

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.

2. The module of claim 1 wherein each tab has an enlarging profile outer contour.

3. The module of claim 1 wherein each first section comprises a first fibrous refractory material; and each second section comprises a second fibrous refractory material which is different from the first fibrous refractory material.

4. The module of claim 3 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.

5. The module of claim 3 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.

6. 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.

7. 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.

8. The module of claim 7 wherein the first section of each insulating module layer includes a hot face fibrous refractory material comprising mullite fibers; and the second section of each insulating module layer comprises a cold face fibrous refractory material comprising alumina-silica-zirconia fibers.

9. The module of claim 1 wherein each tab has an extension length, which is less than an offset distance between the section juncture in its layer and the section juncture in any adjacent layer.

10. The module of claim 9 wherein each first section has a tab clearance of at least about two inches.

11. The module of claim 1 wherein the plurality of insulating module layers are compressingly engaged by application of a compressive force in a direction substantially perpendicular to the major surfaces of the insulating module layers such that the module has a compression factor of at least about 1.05.

12. 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.

13. The module of claim 12 wherein the at least one anchor rod is disposed in a transverse orientation through each second section of the at least a majority of insulating module layers.

14. 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.

15. The module of claim 1 wherein in each second section, the tab has an enlarging profile outer contour and is centrally positioned on the tab joint edge;

and 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; and

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. The module of claim 15 wherein each first section has a density of about 5-9 pcf and comprises a hot face fibrous refractory material comprising mullite fibers; and each second section has a density of about 4-10 pcf and comprises a cold face fibrous refractory material comprising alumina-silica-zirconia fibers.

17. The module of claim 16 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.

18. The module of claim 1 wherein each first section has a density of about5-9 pcf;

and each second section has a density of about 4-10 pcf.

19. The module of claim 1 wherein the insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1.

20. An insulating module comprising a plurality of insulating module layers arranged with major surfaces in a side-by-side orientation,

each layer comprising a first section having at least one slot extending therein from a slot joint edge; and a second section having 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 a fibrous refractory insulation material; and

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.

21. The module of claim 20 wherein in each second section, each tab has an enlarging profile outer contour.

22. The module of claim 20 wherein all of the first sections are exposed to a hot face of the module and each first section comprises mullite fibers; and all of the second sections have an edge which is exposed to a cold face of the module and each second section comprises alumina-silica-zirconia fibers.

23. The module of claim 20 wherein each tab an extension length, which is less than an offset distance between the section juncture in its layer and the section juncture in any adjacent layer.

24. The module of claim 20 wherein each first section has a density of about 5-9 pcf;

and each second section has a density of about 4-10 pcf.

25. The module of claim 20 wherein the insulating module layers are compressingly engaged such that the module has a compression factor of at least about 1.1.

26. 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 fibrous refractory section having at least one slot extending therein from each of its two slot joint edges; and two second fibrous refractory 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 and each slot has an inner contour which substantially corresponds in shape to an outer contour of its paired tab; whereby the joint edge of each second fibrous refractory section is held in juxtaposition with one of the slot joint edges of the U-shaped fibrous refractory section along a section juncture; and

each section juncture is positioned such that the section junctures in any two adjacent insulating module elements are offset with respect to each other.

27. The module of claim 26 wherein each U-shaped fibrous refractory section is folded such that the two slot joint edges are offset by an offset distance which is greater than the tab extension lengths of the at least one paired tab extending from the second fibrous refractory sections.