Foldable Noble Metal Bushing for Mineral Fiber Spinnerets
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Solution Overview
Problem
The existing spinneret assembly for producing mineral fibers faces issues with reduced lifespan due to bending stresses and uneven heat distribution, leading to mechanical stress on weld seams, especially when using oxide-dispersed noble metals where fusion welding causes oxide particles to coagulate, weakening the welds.
Innovation Solution
A bushing is designed from a one-piece blank of foldable precious metal, avoiding weld seams by relocating them to less stressed areas, and using different thicknesses and beads for reinforcement, with the option of attaching cover plates and power supply lines, fabricated from materials like PtAu5, PtIr1, and oxide dispersion-reinforced metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bottom plate is welded directly to the opposite side and end walls to form a rectangular body, then the structural integrity is improved, but the weld seams are subjected to significant bending stresses and mechanical stress from prolonged contact with heavy molten material, leading to deflection and shortened service life
Solution Approach 1:
The bushing is divided into a base plate and a separate rectangular body portion. The base plate with nozzles is separated from the side and end walls, eliminating the welded connections between these components. This segmentation removes the weld seams from the high-stress areas where they would otherwise be subjected to bending stresses and mechanical stress from molten material contact.
Solution Approach 2:
The weld seams are extracted or removed from the critical stress-bearing areas of the bushing structure. By eliminating the welded joints between the base plate and side/end walls, the design removes the weak points that would otherwise be subjected to significant mechanical stress and bending moments during operation with heavy molten material.
2Temperature
If oxide-dispersed noble metals are used to manufacture the nozzle assemblies, then the material properties and heat resistance are improved, but fusion welding causes the finely divided oxide particles to coagulate, making the welds structurally weaker than the surrounding material
Solution Approach 1:
The welding process is extracted or eliminated from the manufacturing of oxide-dispersed noble metal components. By avoiding fusion welding of these specialized materials, the design prevents coagulation of the finely divided oxide particles that would otherwise occur during welding, thereby maintaining both the heat resistance and structural strength of the material.
Solution Approach 2:
The bushing is segmented into parts that can be manufactured separately using appropriate joining methods. The base plate and rectangular body are designed as separate components that avoid requiring fusion welding of oxide-dispersed noble metals, thus preserving the material's heat-resistant properties without compromising structural integrity.
3Duration of action of stationary object
If the bushing is manufactured as a one-piece blank with folded construction, then welding seams are avoided in critical areas and service life is extended, but the manufacturing complexity and precision requirements increase
Solution Approach 1:
The bushing components are prepared in advance as pre-formed base plate and rectangular body portions with precise geometries. The base plate is prepared with nozzle openings and the rectangular body is formed with appropriate dimensions and corner parts, allowing for assembly without complex welding operations. This preliminary preparation of components simplifies the final assembly process.
Solution Approach 2:
The traditional welding-based joining method is replaced with a mechanical assembly approach. The base plate and rectangular body are designed to fit together without requiring fusion welding, thereby avoiding the complexities and quality issues associated with welding oxide-dispersed noble metals while extending service life by eliminating weld seam failures.
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
The foldable bushing made of one-piece blank has a base plate (101) provided with side walls (102) and end walls (103). The flanges (104) are welded on side walls and end walls that are connected with each other via base plate or corner. One-piece blank is made of noble metals having different thickness. The reinforcing beads (106) are provided in side walls respectively. An independent claim is included for method for manufacturing foldable bushing made of one-piece blank.