3D-Printed Insulating Sleeve Liner for Thermal Shock Protection
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Solution Overview
Problem
Fluid flow devices in severe industrial applications face premature failure due to thermal shock from sudden changes in temperature and pressure, with existing solutions like pre-heating systems and thermal barrier coatings being unreliable, costly, and prone to erosion and cracking.
Innovation Solution
An additively manufactured thermal insulating sleeve liner with an internal infill structural pattern creating voids for enhanced thermal insulation, made from materials like Inconel 718 or ceramic composites, which can be 3D printed and post-processed for improved mechanical properties, and designed for easy replacement to minimize thermal stress and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barrier coatings are applied to protect fluid flow devices from thermal shock, then thermal protection is improved, but the coatings are susceptible to erosion, corrosion, and cracking requiring frequent replacement
Solution Approach 1:
The invention divides the protective system into two separate components: a removable thermal insulating sleeve and the fluid flow device itself. The sleeve can be independently replaced when worn or damaged, while the expensive flow device remains intact. This segmentation allows the protective element to be easily replaced without replacing the entire assembly, resolving the contradiction between providing thermal protection and maintaining long service life.
Solution Approach 2:
The thermal insulating sleeve is designed as a lower-cost, replaceable component that can be frequently replaced without significant expense. By making the protective element disposable or easily replaceable, the system maintains reliable thermal protection while avoiding the need to replace the entire expensive flow device, thus resolving the contradiction between protection reliability and component durability.
2Reliability
If pre-heating systems are used to mitigate thermal shock, then thermal stress protection is improved, but the systems are unreliable and require regular maintenance
Solution Approach 1:
The invention extracts the thermal protection function from complex active systems (pre-heating systems) and implements it through a simple passive thermal insulating sleeve. This passive design requires no power, control systems, or maintenance, yet provides reliable thermal stress protection by physically isolating the flow device from rapid temperature changes, thus resolving the contradiction between protection reliability and ease of manufacture.
3Temperature
If low thermal conductivity materials are used for thermal protection, then thermal insulation is improved, but cracking is still observed on flow device bodies indicating susceptibility to extreme cyclic temperatures
Solution Approach 1:
The invention applies thermal insulation locally at the critical interface where the fluid contacts the flow device by inserting a thermal insulating sleeve into the flow path. This localized insulation directly protects the flow device body from thermal shock at the most vulnerable point, resolving the contradiction between achieving thermal insulation and resisting thermal shock by concentrating protection where it is most needed.
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 significantly extends the life cycle of fluid flow devices by reducing thermal stress and wear, offering robust and cost-effective thermal protection with minimal material waste and quick manufacturing lead times, while allowing for easy replacement and re-use of the sleeve material.
Implementation Method 1
an internal infill structural pattern (e.g., lattice, honeycomb, or other porous structures) creating internal voids which increase thermal insulation properties
Implementation Method 2
Fluid flow devices subjected to thermal shocks in severe industrial applications can benefit from thermal protection to reduce thermal stresses, mitigate the effects of thermal shock experienced and prevent premature thermal fatigue
Data Source
AI summary
A monolithic metal thermal insulating sleeve liner for fluid flow devices such as valves and piping used in severe industrial applications is additively manufactured (e.g., by 3D printing) to fit the bore of a protected fluid flow device. Tessellated support structures obliquely extending between inside surfaces of inner and outer shells provide increased resistance to thermal conduction while also providing increased strength against compression forces. Example support structures include an array of four obliquely oriented elongated members mutually intersecting mid-way between the inside surfaces of inner and outer cylindrical shells. If internal interstices are sealed they can be vacuumed or pressurized to enhance thermal insulating properties. A pressure equalizing aperture can be provided on or through the sleeve if needed in some applications.