Non-wetted Solid Pore Coating for Molten Salt Infiltration
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Solution Overview
Problem
Molten salts, such as MgCl2—KCl—NaCl, infiltrate and penetrate porous ceramic materials at high temperatures, degrading their mechanical and thermal properties and leading to undesired loss, with existing solutions requiring regular inspections and repairs to maintain non-wetted coatings or using expensive dense materials.
Innovation Solution
Introducing a non-wetted solid within the pores of porous solid materials, which provides resistance to molten salt infiltration and penetration while maintaining erosion resistance and minimizing thermal insulation degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If porous solid materials are used for thermal insulation, then thermal insulation performance is improved, but resistance to molten salt infiltration and penetration deteriorates
Solution Approach 1:
The patent applies local quality by treating only the pore spaces within the porous solid material with a non-wetted solid coating, rather than changing the entire material structure. This localized treatment provides molten salt resistance at the pore level while preserving the bulk material's thermal insulation properties and porosity structure.
Solution Approach 2:
The patent creates a composite material system by combining porous solid material (for thermal insulation) with non-wetted solid (for molten salt resistance). The non-wetted solid penetrates and coats the pore surfaces, forming a composite structure that exhibits both thermal insulation and molten salt resistance properties simultaneously.
2Reliability
If dense solid materials are used to prevent infiltration, then resistance to molten salt penetration is improved, but thermal insulation performance deteriorates
Solution Approach 1:
Instead of making the entire material dense, the patent applies local quality by treating only the pore spaces with non-wetted solid. This provides molten salt resistance at the critical pore interfaces while maintaining the overall porous structure and thermal insulation performance of the bulk material.
Solution Approach 2:
The patent forms a composite where porous solid material provides thermal insulation and non-wetted solid provides molten salt resistance. This composite approach achieves both protection functions without requiring complete densification of the base material.
3Reliability
If non-wetted coatings are applied to porous materials, then resistance to molten salt infiltration is improved, but maintenance requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-penetrating the non-wetted solid into the pore spaces during manufacturing or initial treatment. This creates a built-in, permanent molten salt barrier that does not require subsequent maintenance or reapplication, unlike surface coatings that may degrade over time.
Solution Approach 2:
The non-wetted solid penetrates and coats the pore structures to create a self-sustaining molten salt barrier. Once established, this internal coating structure provides ongoing protection without requiring external maintenance, inspection, or repair interventions.
4Ease of manufacture
If porous materials are used for containment, then cost-effectiveness is improved, but erosion resistance deteriorates
Solution Approach 1:
The patent applies local quality by concentrating the erosion-resistant non-wetted solid specifically at the pore surfaces and interfaces where molten salt contact occurs. This localized reinforcement provides erosion protection at critical locations while maintaining the cost-effective porous structure of the bulk containment material.
Solution Approach 2:
The patent creates a composite containment structure where porous solid material provides cost-effective containment and non-wetted solid provides erosion resistance. The non-wetted solid penetrates the pore structure to form a protective composite that enhances erosion resistance without requiring complete replacement with expensive dense 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 method effectively inhibits molten salt infiltration and penetration, allowing for prolonged, cost-effective use in high-temperature systems without significant degradation of thermal insulation or increased maintenance costs.
Implementation Method 1
Introducing a non-wetted solid within the pores of porous solid materials, which provides resistance to molten salt infiltration and penetration
Data Source
AI summary
Methods, materials systems, and devices for inhibiting the infiltration and penetration of molten salts into solid materials, including porous materials at temperatures above the solidus temperature of the molten salt. The methods, materials systems, and devices utilize a non-wetted solid that is introduced into pores having entrances at an exterior surface of a porous solid material adapted to contact the molten salt.