Liquid Cooled Glass Metal Electrode with Integrated Cooling Passage
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Solution Overview
Problem
Current glass melt electrodes with two-piece assemblies face challenges in achieving a watertight joint, limiting the extension of the cooling passage into the electrode head and compromising durability due to high temperatures.
Innovation Solution
A one-piece liquid-cooled electrode design with a teardrop-shaped electrode head and a cooling passage extending from the shaft into the head, featuring a double 'U' shaped closed end and constructed from refractory metals like molybdenum, enhances cooling efficiency and durability by reducing thermal gradients and mechanical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a two-piece assembly with water-tight joint is used between head and shaft, then cooling passage can be extended into the head, but the joint durability is compromised due to high temperatures
Solution Approach 1:
The electrode head and shaft are merged into a single integrated component made of refractory metal, eliminating the water-tight joint between them. The cooling passage is formed as a continuous channel through both the head and shaft, allowing coolant to flow through the entire length without compromising durability at joints.
2Temperature
If cooling passage is extended into the electrode head, then cooling efficiency is improved, but mechanical failure risk increases due to thermal gradients
Solution Approach 1:
The electrode head is designed with a teardrop shape featuring a negatively curved middle portion that changes the thermal gradient parameters. This geometric configuration reduces localized thermal stresses and improves heat distribution, allowing the cooling passage to extend into the head without causing mechanical failure.
3Temperature
If refractory metal is used for electrode construction, then heat resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The electrode is constructed as a single-piece refractory metal component with the cooling passage formed by drilling or machining operations. This segmentation approach allows the complex teardrop-shaped head and integrated cooling channels to be manufactured in one piece from refractory metal, avoiding the need for assembling multiple materials.
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 design significantly extends the lifespan of the electrode by improving heat dissipation, reducing localized thermal gradients, and eliminating mechanical failure points, resulting in electrodes lasting weeks compared to minutes in similar conditions.
Implementation Method 1
A cooling passage extends from an open end disposed at the attachment end of the shaft to a closed end, which is disposed within the electrode head
Implementation Method 2
The electrode head is formed to have approximately a teardrop shape... the middle portion of the radial profile may exhibit a single maximum
Implementation Method 3
the shaft and electrode head may be constructed from a refractory metal, such as molybdenum or a molybdenum alloy
Implementation Method 4
eliminating mechanical failure points, resulting in electrodes lasting weeks compared to minutes in similar conditions
Implementation Method 5
the middle portion of the radial profile may exhibit a single maximum. Alternatively, or in addition, the middle portion of the radial profile may be negatively curved
Data Source
AI summary
In various embodiments, an electrode has a shaft extending from an electrode head and a cooling passage extending from an open end disposed at an attachment end of the shaft to a closed end disposed within the electrode head.