Modular Refractory Launder Heating Component

Solution Overview

Problem

Existing launder systems for conveying molten metal from a furnace to a mold lack efficient and modular heating solutions that maintain the metal in a liquid state throughout the flow path, leading to potential solidification and flow issues.

Innovation Solution

A modular apparatus comprising a refractory trough section with a fluid flow channel and a cavity to house a refractory heating component with an electrical heating element, ensuring optimal heat transfer and easy installation within a launder shell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional heating solutions are used in launder systems, then the metal can be maintained in liquid state, but the system lacks modularity and efficiency

Engineering Contradiction:

ImprovemodularityVSAvoidheating effectiveness

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The heating system is divided into modular heating components that can be independently installed and removed from the launder channel. Each heating component is a self-contained unit with refractory material and electrical heating elements, allowing for flexible configuration and maintenance without shutting down the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating component uses composite construction combining refractory material (for heat resistance and insulation) with electrical heating elements (for efficient heat generation). This composite structure enables the heating component to withstand high temperatures while maintaining effective heating capability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If heaters are installed to maintain metal in liquid state, then solidification is prevented, but the installation and maintenance complexity increases

Engineering Contradiction:

Improvemetal flow continuityVSAvoidheating system installation

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating system is divided into modular heating components that can be independently installed and removed from the launder channel. Each heating component is a self-contained unit with refractory material and electrical heating elements, allowing for flexible configuration and maintenance without shutting down the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating components are designed to be movable and adjustable within the launder channel. The components can be easily installed and removed, allowing for dynamic maintenance and replacement without permanent installation, thereby reducing overall system complexity.

Inventive Principle:

Principle #15Dynamics

3Use of energy by stationary object

If heating components are integrated into the trough, then heat transfer is optimized, but the manufacturing and installation difficulty increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidtrough manufacturing

Core Design Contradiction:

Use of energy by stationary objectVSEase of manufacture

Solution Approach 1:

The heating system is divided into modular heating components that can be independently installed and removed from the launder channel. Each heating component is a self-contained unit with refractory material and electrical heating elements, allowing for flexible configuration and maintenance without shutting down the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The refractory material serves as an intermediary between the electrical heating elements and the molten metal. It efficiently transfers heat from the electrical elements to the metal while protecting the heating components from direct contact with the molten metal, simplifying the overall design and manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 apparatus effectively maintains molten metal in a liquid state by providing consistent heating along the flow path, preventing solidification and ensuring smooth metal flow from the furnace to the mold.

Implementation Method 1

The heating component is formed of refractory material, and has a compartment configured to contain an electrical heating element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The apparatus effectively maintains molten metal in a liquid state by providing consistent heating along the flow path

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10408540B2Launder assembly

Publication Date: 2019.09.10 FIVES NORTH AMERICAN COMBUSTION INC

AI summary

An apparatus for use with a launder shell includes a heating component formed of refractory material. The heating component has a compartment configured to contain an electrical heating element. The apparatus further includes an elongated trough section configured for placement in an installed position inside the shell. The trough section has a fluid flow channel and a cavity beneath the channel. The cavity is configured to receive and support the heating component for movement into and out of the installed position together with the trough section.