Ceramic Fiber Refractory Container with Metal Support Structures
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Solution Overview
Problem
Refractory containers made of ceramic composite materials lack the mechanical load capacity to handle multiple smaller workpieces simultaneously without compromising their structural integrity or causing contamination.
Innovation Solution
A refractory container with a mat of long fibers embedded in a ceramic shell, featuring support structures with at least 50% more flexural strength than retaining structures, allowing for the safe handling of multiple smaller workpieces and preventing contamination through a barrier between carbon-loaded charging racks and the workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory containers are made of ceramic composite materials to withstand high temperatures, then thermal resistance is improved, but mechanical load capacity deteriorates
Solution Approach 1:
The patent uses a composite structure combining ceramic fibers (for thermal resistance) with metal components (for mechanical strength). The container consists of a ceramic fiber mat forming the main body to withstand high temperatures, while metal support structures are integrated to provide the necessary mechanical load capacity for handling multiple workpieces.
2Object-generated harmful factors
If ceramic materials are used to prevent contamination of workpieces, then chemical inertness is improved, but mechanical flexibility deteriorates
Solution Approach 1:
The invention combines chemically inert ceramic fiber material with mechanically flexible metal components. The ceramic fiber mat provides contamination resistance and thermal stability, while the metal support structures provide the flexibility and strength needed for mechanical handling and load-bearing applications.
3Productivity
If containers are designed to accommodate multiple smaller workpieces, then productivity is improved, but structural integrity deteriorates
Solution Approach 1:
The container is segmented into distinct functional zones: a ceramic fiber mat body that provides thermal resistance and chemical inertness, and integrated metal support structures that provide mechanical strength. This segmentation allows each material to perform its optimal function while working together to accommodate multiple workpieces without compromising structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The container achieves improved mechanical properties, enhanced load capacity, and prevents carburization of metallic workpieces, ensuring effective heat treatment without structural failure or contamination.
Implementation Method 1
They are generally based on continuous ceramic fibers that are infiltrated with a slurry and subsequently fired at temperatures below the melting point of the material of the slurry, thus forming a ceramic material. This process is called sintering.
Data Source
AI summary
The invention relates to a refractory container 1 for use in a furnace for heat treatment of workpieces, comprising a mat 5 of long fibers that are embedded in a ceramic shell, with the mat 5 being shaped into a container that forms a receiving space for workpieces, and to a green body of such a container 1. Furthermore, advantageous uses of the container 1 as well as a method for manufacturing a green body or container 1 according to the invention are specified.