Colloidal Inorganic Oxide Impregnated Insulation Plate
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Solution Overview
Problem
Molten metal handling equipment faces challenges in maintaining high thermal insulation and mechanical integrity while preventing premature heat loss, which limits the efficiency and capacity of equipment like ladles and torpedo cars.
Innovation Solution
A thermal insulation article comprising a colloidal inorganic oxide-impregnated, high-temperature-resistant inorganic-fiber blanket or board with a density greater than 500 kg/m3 and compression resistance of at least 50 kgf/cm2, capable of maintaining mechanical integrity up to 1000°C and offering low thermal conductivity, is developed. This article is used as a backup thermal insulation plate, made by impregnating ceramic fiber blankets or boards with colloidal inorganic oxides like silica, alumina, or zirconia, and pressing them to achieve desired thickness and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the backup insulation layer is made thinner to increase metals capacity, then the capacity of molten metal handling apparatus increases, but the thermal insulation performance deteriorates
Solution Approach 1:
The patent changes the physical and chemical parameters of the insulation material by impregnating ceramic fiber blankets with colloidal inorganic oxides (such as colloidal silica, alumina, or zirconia). This impregnation process increases the density of the insulation material from typical low-density ceramic fiber values to greater than 500 kg/m3, while simultaneously improving mechanical strength to at least 50 kgf/cm2 compression resistance. These parameter changes enable the material to provide adequate thermal insulation in thinner sections, thus increasing metals capacity without sacrificing insulation performance.
Solution Approach 2:
The patent creates a composite material structure by combining ceramic fibers with colloidal inorganic oxides. The ceramic fiber blanket serves as the base matrix, while the colloidal inorganic oxide penetrates and bonds within the fiber structure, forming a composite that exhibits both excellent thermal insulation properties and enhanced mechanical strength. This composite approach allows the material to maintain low thermal conductivity even at reduced thickness, resolving the contradiction between capacity increase and heat loss prevention.
2Volume of moving object
If the backup insulation layer is made thinner to increase metals capacity, then the capacity of molten metal handling apparatus increases, but the mechanical strength deteriorates
Solution Approach 1:
The patent fundamentally changes the mechanical parameters of the insulation material through colloidal inorganic oxide impregnation. The colloidal particles fill the void spaces between ceramic fibers and form a rigid gel structure upon drying, increasing the material's density to greater than 500 kgf/cm3 and compression resistance to at least 50 kgf/cm2. These parameter changes enable thinner insulation sections to maintain adequate mechanical strength, thus allowing increased metals capacity without compromising structural integrity.
Solution Approach 2:
The patent develops a composite material system where colloidal inorganic oxides are integrated into the ceramic fiber matrix. The colloidal particles act as binding agents that strengthen the fiber network, creating a composite structure with enhanced mechanical properties. This composite approach allows the insulation layer to be made thinner while maintaining the necessary mechanical strength to support increased metals capacity.
3Loss of energy
If high density insulation material is used to improve insulation performance, then thermal insulation improves, but the weight of the equipment increases
Solution Approach 1:
The patent optimizes the density parameter of the insulation material to greater than 500 kg/m3 through colloidal inorganic oxide impregnation, achieving a balance between thermal insulation performance and weight. This controlled density increase provides improved insulation without the excessive weight that would result from using much denser materials, as the colloidal particles efficiently fill void spaces and improve insulation properties at relatively moderate density levels.
Solution Approach 2:
The patent utilizes the porous structure of ceramic fiber blankets as the base material, which inherently provides good thermal insulation due to trapped air pockets. The colloidal inorganic oxide impregnation fills only the larger void spaces, maintaining the beneficial porous structure for insulation while adding minimal weight. This approach achieves improved insulation performance without proportionally increasing equipment weight.
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 solution provides high-temperature insulation with low thermal conductivity, maintaining mechanical integrity and allowing for a thinner insulation layer, thereby increasing the capacity of molten metal handling equipment and reducing thermal losses, as demonstrated by its ability to withstand temperatures up to 1300°C with minimal shrinkage and high compression resistance.
Implementation Method 1
impregnating an insulating ceramic fiber blanket or board with at least one colloidal inorganic oxide
Implementation Method 2
the colloidal inorganic oxide is a composition of the colloidal inorganic oxide in combination with a gelling agent
Implementation Method 3
provides high-temperature insulation with low thermal conductivity, maintaining mechanical integrity
Implementation Method 4
high-temperature-resistant inorganic-fiber blanket or board
Data Source
AI summary
A backup thermal insulation plate includes a colloidal inorganic oxide-impregnated, pressed and dried high-temperature-resistant inorganic-fiber blanket or board, the plate having a use temperature up to at least about 1000° C. and maintaining mechanical integrity after exposure to the use temperature, the plate having a density greater than or equal to about 500 kg/m3, and a compression resistance of at least about 50 kgf/cm2.