Metal Transfer Device High Conductivity Refractory Filler
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Solution Overview
Problem
Existing metal transfer devices, such as launders, face inefficiencies in heat transfer due to refractory materials with low thermal conductivity and risk of thermal shock, and potential damage from liquid metal leaks to heating elements.
Innovation Solution
A metal transfer device featuring a cast trough body with a filler layer of high thermal conductivity refractory material, a metallic shell, and a leakage detection system to prevent damage from leaks and enhance heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If alumina-based refractory material is used for the trough body, then thermal shock resistance is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The patent applies composite materials by combining alumina-based refractory material for the trough body (providing thermal shock resistance) with a separate silicon carbide-based filler layer (providing high thermal conductivity). This composite structure allows each material to perform its optimal function: the alumina trough body resists thermal shock while the silicon carbide filler layer efficiently transfers heat from the heater to the metal, resolving the contradiction between thermal shock resistance and heat transfer efficiency.
2Temperature
If heated launder is used, then temperature maintenance of metal is improved, but risk of cracking in refractory material increases
Solution Approach 1:
The patent applies preliminary action by preheating the launder before introducing liquid metal. The heater continuously heats the trough body and filler layer, maintaining them at an elevated temperature prior to metal introduction. This preliminary heating reduces the temperature differential between the refractory material and the incoming hot metal, minimizing thermal shock and cracking risk while maintaining temperature during transfer.
3Use of energy by moving object
If trough body material is changed for high thermal conductivity, then heat transfer efficiency is improved, but thermal shock resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction by using composite materials with distinct functional roles: the trough body is made of alumina-based refractory material optimized for thermal shock resistance, while a separate filler layer made of silicon carbide-based refractory material provides high thermal conductivity. This separation allows each material to be optimized for its specific function without compromise.
4Use of energy by moving object
If heater is placed directly adjacent to trough body, then heat transfer efficiency is improved, but damage from liquid metal leak to heater increases
Solution Approach 1:
The patent applies the intermediary principle by introducing a filler layer made of silicon carbide-based refractory material between the heater and the trough body. This filler layer serves dual purposes: it maintains high thermal conductivity for efficient heat transfer while simultaneously acting as a protective barrier that prevents liquid metal leaks from directly contacting and damaging the heater elements.
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 device achieves efficient heat transfer and prevents damage from leaks by using a high thermal conductivity filler layer and metallic shell, while the leakage detection system alerts operators to potential issues, allowing for timely maintenance.
Implementation Method 1
said filler layer comprising a cast refractory material having a thermal conductivity of at least 3W/m.K
Implementation Method 2
a heater for heating the trough body
Data Source
Figure 1
Figure 2~3
AI summary
A metal transfer device (1) includes a cast trough body (2) for receiving liquid metal, a heater (4) for heating the trough body, and a filler layer (6) between the trough body and the heater. The filler layer (6) comprises a cast refractory material having a high thermal conductivity.