Holed Ingot Design for Coating Line Productivity
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Solution Overview
Problem
The formation of dross and ingot pileup at the bottom of the molten metal bath in coating lines reduces productivity and coating quality due to slow ingot melting rates and inefficient bath management.
Innovation Solution
A metallic ingot with a volume between 0.15 m3 and 0.80 m3 and a surface area to volume ratio between 10 m−1 and 18 m−1, featuring at least one hole extending from one longitudinal face to another, which increases the ingot melting rate by fragmenting it during supply and reducing pile formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ingot volume is increased to reduce the frequency of ingot addition, then the productivity of the coating line is improved, but the ingot melting time increases and ingots may pile at the tank bottom
Solution Approach 1:
The ingot is segmented by introducing at least one hole through its body, dividing the solid structure into multiple sections. This segmentation increases the surface area exposed to the molten metal bath, accelerating heat transfer and melting rate, thereby allowing larger ingots to melt within acceptable timeframes without piling at the tank bottom.
Solution Approach 2:
The ingot incorporates a hole creating a porous or cavity structure that enhances thermal interaction with the molten metal bath. This internal void space allows more efficient heat penetration and distribution throughout the ingot volume, significantly improving the melting rate while maintaining structural integrity during the feeding process.
2Object-affected harmful factors
If the ingot melting rate is increased by reducing ingot volume, then the bath management is improved and dross formation is reduced, but the frequency of ingot addition increases
Solution Approach 1:
By segmenting the ingot through hole introduction, the effective melting surface area is increased without proportionally increasing the total volume. This allows the ingot to melt at a faster rate comparable to smaller ingots, preventing dross formation and improving bath management, while the overall larger volume maintains productivity by reducing addition frequency.
Solution Approach 2:
The invention changes the geometric parameters of the ingot by introducing holes, which fundamentally alters the surface area to volume ratio. This parameter modification enables the ingot to achieve high melting rates typically associated with smaller volumes, while maintaining the larger volume benefits for reduced addition frequency and sustained productivity.
3Speed
If the ingot surface area to volume ratio is increased to accelerate melting, then the melting rate is improved, but the ingot structural integrity may be compromised
Solution Approach 1:
The hole introduction segments the ingot structure in a controlled manner that increases surface area for heat transfer while maintaining overall structural integrity. The hole configuration is designed to optimize thermal exposure without creating weak points that would compromise the ingot's ability to withstand handling and positioning forces during the feeding process.
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 ingot design enhances melting speed, reduces dross formation, and increases coating line productivity while maintaining mechanical properties, ensuring efficient bath management and improved coating quality.
Implementation Method 1
The hole increases the surface area to volume ratio between 10 m−1 and 18 m−1, which enhances the melting rate by improving thermal contact with the molten metal bath
Implementation Method 2
the ingot is introduced little by little into the bath until the ingot portion where the ingot is held melts. Thirdly, the ingot at the tank bottom melts
Data Source
AI summary
An ingot, having a volume between 0.15 m3 and 0.80 m3 and a surface area to volume ratio between 10 m−1 and 18 m−1, made of at least one metal, having longitudinal faces extending between two end faces and including at least one hole extending from one of the longitudinal faces, the maximum distance between any point of the hole periphery, to its closest longitudinal face, noted MaxL, the at least one hole being configured such that said maximum distance MaxL is smaller than the minimal distance, noted MinE, between any point of the hole periphery and its closest end face.