Refractory Metal Ceramic Composite Thermal Shielding
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Solution Overview
Problem
Conventional thermal shielding systems for high-temperature furnaces face limitations in shielding action and energy efficiency, with radiant plate systems experiencing structural issues and ceramic bricks having suboptimal thermal conductivity, leading to increased maintenance and replacement costs.
Innovation Solution
A thermal shielding system comprising refractory metal sheets with ceramic material in a particulate or fibrous structure based on zirconium oxide, which reduces thermal conductivity and heat capacity, allowing for modular design and easy maintenance, and when combined with radiant plates, provides superior shielding action and energy efficiency at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of radiant plates is increased to improve shielding action, then the shielding action is improved, but the device complexity and age-related issues increase
Solution Approach 1:
The patent uses composite materials consisting of a refractory metal matrix (tungsten or molybdenum) combined with ceramic fillers (alumina, zirconia, or boron nitride) to create shielding elements that achieve superior shielding action compared to conventional radiant plates. This composite structure provides both thermal shielding and structural stability without requiring multiple separate components.
Solution Approach 2:
The patent changes the material parameters by using refractory metals with high melting points and low thermal conductivity, combined with ceramic fillers that have low thermal conductivity. This parameter optimization enables the shielding elements to maintain effective shielding performance at high temperatures while reducing the need for multiple plates.
2Weight of stationary object
If radiant plates are made thinner to reduce weight and complexity, then the plate thickness is reduced, but the structural stability and service life decrease
Solution Approach 1:
The refractory metal-ceramic composite structure provides enhanced structural stability compared to conventional thin radiant plates. The ceramic fillers reinforce the metal matrix, enabling thinner shielding elements to maintain both lightweight characteristics and long service life at high temperatures.
Solution Approach 2:
The patent optimizes the thickness parameter by using materials with superior strength-to-weight ratios and thermal stability. The refractory metal-ceramic composites allow for reduced thickness while maintaining structural integrity and extended service life through improved material properties.
3Reliability
If ceramic bricks are used to reduce thermal conductivity, then the thermal shielding is improved, but the manufacturing complexity and installation difficulty increase
Solution Approach 1:
The patent changes the form factor from traditional brick-shaped ceramic insulation to modular shielding elements with standardized dimensions and attachment mechanisms. This parameter change simplifies manufacturing and installation while maintaining the low thermal conductivity properties of ceramic materials.
Solution Approach 2:
The shielding system is divided into modular segments that can be independently manufactured and assembled. Each shielding element is a self-contained unit with standardized interfaces, making the system easier to manufacture and install compared to traditional brick-by-brick construction.
4Reliability
If conventional ceramic bricks are used for thermal shielding, then the thermal insulation is provided, but the replacement effort and costs increase
Solution Approach 1:
The shielding system consists of modular, interchangeable segments that can be independently replaced. Each shielding element is designed as a complete functional unit with standardized attachment and removal mechanisms, enabling quick replacement without requiring replacement of the entire shielding system or disassembly of adjacent components.
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 system achieves enhanced thermal shielding, improved energy efficiency, and extended service life by minimizing temperature gradients and reducing energy consumption, particularly effective at temperatures above 1500°C, while allowing for easy replacement and maintenance of components.
Implementation Method 1
heat conduction between the individual particles or fibers is made possible only via the relatively small contact points between the individual particles or fibers
Implementation Method 2
radiation effects arise between the individual particles and fibers
Data Source
AI summary
A thermal shielding system for thermally shielding a batch space of high-temperature furnaces includes at least one shielding element. The shielding element has an encasing wall formed of refractory metal sheet(s) and a ceramic material accommodated in the wall. The ceramic material is present in a particulate and/or fibrous structure and it is based on zirconium oxide (ZrO2)