Porous Refractory Objects With Controlled Void Structure
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Solution Overview
Problem
Porous zircon bricks used in high purity optical glass production suffer from unintentionally formed larger voids that can collect molten glass, leading to undesirable dripping during glass manufacture, necessitating improved microstructure and porosity control.
Innovation Solution
A method of forming refractory objects with controlled porosity and microstructure by controlling pressure during mixing raw materials, using pore formers to engineer specific pore types and distributions, resulting in improved mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pore formers are used to create porous structure, then thermal insulation and gas permeability are improved, but larger unintentional voids may form that collect molten glass and cause dripping
Solution Approach 1:
The patent applies parameter changes by controlling the size, shape, and distribution of pore formers during mixing, and by adjusting pressure parameters during the forming process. This results in controlled pore structures with specific size distributions (e.g., average pore size of 0.5-2.0 mm) that prevent molten glass accumulation while maintaining thermal insulation performance.
Solution Approach 2:
The patent uses an intermediary approach by introducing controlled amounts of liquid or gas phase during the mixing and forming process. These intermediaries act as temporary pore formers that create uniform pore structures without forming large unintentional voids, thereby mediating between the need for porosity and the need for precision.
2Manufacturing precision
If pressure is increased during mixing to remove gas bubbles, then manufacturing precision is improved, but energy consumption increases
Solution Approach 1:
The patent applies periodic action by using intermittent or cyclic pressure application during the mixing and forming process. Pressure is applied in controlled cycles to remove gas bubbles and achieve desired porosity, then released to allow re分布 of materials. This periodic approach achieves manufacturing precision while reducing total energy consumption compared to continuous high-pressure application.
Solution Approach 2:
The patent uses parameter changes by dynamically adjusting pressure levels, temperature, and mixing speed during the forming process. Pressure is increased only when needed to remove specific types of voids, and reduced when not required, optimizing the balance between manufacturing precision and energy consumption.
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 enhances the consistency and performance of refractory objects, reducing larger voids and improving thermal shock resistance and modulus of rupture, making them suitable for high-temperature and erosive conditions.
Implementation Method 1
Pores having desirable sizes may be formed using pore formers
Implementation Method 2
A method of forming refractory objects with controlled porosity and microstructure by controlling pressure during mixing raw materials
Data Source
AI summary
A batch of refractory objects may include a plurality of bodies including a ceramic material. The batch may include an average porosity of at least 25% to not greater than 75% for the volume of the batch. The batch may have at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7.