Immersion Probe Porous Ceramic Filter Groove Design
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Solution Overview
Problem
Existing immersion probes for analyzing gases in molten metals face issues with mechanical stress and corrosion, leading to cracks and breaks in the porous ceramic filter, causing erratic readings and increased operational risks, with high error rates and frequent probe failures.
Innovation Solution
The immersion probe design includes a porous ceramic filter with a groove and a concentric gas sampler, where the ceramic filter's body is increased at the association area, providing a double sealing mechanism with adhesive material applied within the groove, enhancing mechanical support and reducing the risk of molten metal penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive material is used to associate the porous ceramic filter with the gas sampling tube, then mechanical support and sealing are provided, but cracks and breaks occur in the porous ceramic filter under thermal shock and mechanical stress
Solution Approach 1:
The gas sampling tube is divided into inner and outer portions, with the porous ceramic filter associated to both portions through grooves. This segmentation distributes mechanical stress across multiple attachment points rather than concentrating it at a single adhesive bond, preventing crack propagation and improving overall reliability under thermal shock conditions.
2Productivity
If the porous ceramic filter is used for gas extraction, then gas sampling is enabled, but the filter breaks under aggressive environmental conditions causing erratic readings
Solution Approach 1:
The porous ceramic filter is nested within the gas sampling tube structure, with grooves formed in the filter body that receive adhesive material and secure the filter to both inner and outer portions of the tube. This nested configuration provides multi-point mechanical support and sealing, protecting the filter from breakage while maintaining gas extraction functionality and measurement accuracy.
3Reliability
If adhesive material is applied to seal the association between porous ceramic filter and gas sampling tube, then sealing is achieved, but molten metal penetration occurs causing probe failure
Solution Approach 1:
The sealing system is segmented into multiple attachment points through grooves in the porous ceramic filter that connect to both inner and outer portions of the gas sampling tube. This multi-point sealing distribution prevents molten metal from concentrating at a single weak point, maintaining sealing effectiveness while preventing penetration even under aggressive environmental conditions.
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 design significantly reduces detection errors, increases probe reliability, and minimizes the need for frequent replacements, while reducing the amount of adhesive material required, thus improving operational safety and efficiency.
Implementation Method 1
a porous ceramic filter (1) at its gas-collecting end
Implementation Method 2
adhesive material, usually cement or ceramic adhesive, which provides mechanical support for the porous ceramic filter in the gas sampling tube
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention refers to an immersion probe for analysis of gases in molten metal, comprising a gas sampler (2), a gas injection tube (4) and a porous ceramic filter (1). The porous ceramic filter (1) has a groove (7) that associates it to the gas sampler (2), this groove (7) comprising an outer portion (9) and an inner portion (8) with respect to the gas sampler (2), said inner portion (8) of the porous ceramic filter (1) having an increase in body for better association of the porous ceramic filter (1) to the gas sampler (2). An adhesive material (3) provides mechanical support of the porous ceramic filter (1), the adhesive material (3) being located in both the inner portion (8) and the outer portion (9) of the gas sampler (2).