Conductive Template for Resistance Heating in Metallurgical Casting
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Solution Overview
Problem
Existing methods for heating in metallurgical processes, such as steel production and casting molds, require additional equipment like hot air burners or infrared radiation, which is inefficient and costly.
Innovation Solution
A template with a frame-shaped or box-shaped configuration made from current-conducting materials for resistance heating, where the wall and base are designed with strip-shaped subregions and corner elements to maximize heating efficiency, eliminating the need for external heating equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional heating methods (hot air burners or infrared radiation) are used, then heating can be achieved, but additional equipment is required and energy efficiency is reduced
Solution Approach 1:
The heating function is merged with the template structure itself. The template wall is made of conductive material with electrical connection points, allowing current to flow directly through the template to generate heat via Joule heating. This eliminates the need for separate heating equipment and achieves direct energy conversion with high efficiency.
Solution Approach 2:
The template serves itself by generating the required heat through its own structure. The conductive material in the template wall acts as a resistance heater, converting electrical energy directly into thermal energy without requiring external heating devices. The template structure itself becomes the heating element.
2Productivity
If the template wall is made entirely of conductive material for heating, then heating efficiency increases, but the wall structure must accommodate electrical connections and insulation
Solution Approach 1:
The template wall is divided into multiple strip-shaped sections that are electrically insulated from each other. This segmentation allows current to flow through multiple parallel paths, increasing heating efficiency while the insulation between strips prevents electrical short circuits. The segmented design also facilitates easier manufacturing and assembly.
3Quantity of substance
If strip-shaped sections are used to reduce current draw, then energy requirements decrease, but the number of sections and insulation requirements increase
Solution Approach 1:
The wall is divided into multiple strip-shaped sections with heights between 15-50 cm (preferably around 30 cm). This segmentation reduces the cross-sectional area of each conductor, thereby reducing the current draw for each section. While the number of sections increases, the standardized dimensions and modular design simplify manufacturing and assembly.
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
This solution achieves high efficiency, with power requirements lower than traditional methods, allowing for significantly higher temperatures and more economical energy use, enabling the use of new binder systems in trickling compound technology.
Implementation Method 1
making at least the wall and, if present, the base of the template from a conductive material that heats up when current flows
Data Source
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AI summary
The invention relates to a template having a frame-shaped or box-shaped configuration, preferably tapering slightly towards the bottom, with a circumferential wall and, in the case of a box-shaped configuration, also a base, for producing casting molds or a wear layer in metallurgical vessels by drying a heat-setting, free-flowing compound filled into the space between the wall of the container on the one hand and the wall and, optionally, the base of the template on the other. To provide a means of avoiding heating by hot air, a burner, or infrared radiation, at least the wall and, if present, also the base of the template are to be formed from an electrically conductive material that is resistance-heated when an electric current flows.The base should have two electrical connection points at the two points furthest apart to form a heating conductor, and in the case of a box-shaped design, the wall and the base should be insulated from each other.