Self-Casting Refractory Block for Molten Glass Feeder Channel
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Solution Overview
Problem
The existing methods for manufacturing infrastructure blocks for molten glass feed channels are time-consuming and prone to defects, which can lead to scrap in glass articles and have limitations due to the constraints of blocks in contact with molten glass, particularly regarding corrosion mechanisms and the difficulty in achieving high-quality sintering and minimizing joints.
Innovation Solution
A method involving self-casting and sintering in situ, where the block is arranged with the U-shaped opening upwards, allowing for the production of large blocks with reduced joints and improved sintering quality, using a self-casting unshaped product activated and degassed under partial vacuum, and sintered in a controlled oven environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pressing or casting methods are used to manufacture infrastructure blocks, then the blocks can be produced with standard procedures, but the manufacturing process is time-consuming and lengthy
Solution Approach 1:
The method performs preliminary actions by pre-mixing the refractory materials and binders in precise proportions before casting. The mixture is prepared with all necessary components (refractory particles, binder, water, additives) already combined, eliminating the need for multiple separate manufacturing steps and significantly reducing production time.
Solution Approach 2:
The casting mixture is designed to be self-leveling and self-compacting, eliminating the need for external vibration or tamping during the casting process. The mixture flows and settles automatically under its own weight, reducing manual intervention and accelerating the manufacturing cycle.
2Ease of repair
If blocks are assembled edge to edge without bonding cement, then the blocks remain simple and easy to replace, but the joints are susceptible to degradation by molten glass and can open under temperature effects
Solution Approach 1:
The method merges the block body and joint material into a single integrated casting process. The bonding cement is mixed into the casting mixture itself, so that when blocks are cast adjacent to each other, the joint material is already present and bonds the blocks together as they cure, creating a monolithic structure that resists thermal degradation while maintaining replaceability.
Solution Approach 2:
The joint region uses a composite material composition combining refractory particles and bonding cement in specific proportions. This composite provides both the thermal resistance required for furnace environments and the bonding strength needed to prevent joint degradation and opening under thermal stress.
3Volume of moving object
If the block is cast with the U-shaped opening facing upwards for self-casting, then large blocks can be produced with reduced joints, but bubbles rise towards the contact surface causing defects
Solution Approach 1:
The method applies local quality by using different particle size distributions in different regions of the mixture. The surface layer contains finer particles and higher binder concentration that rise during casting, forming a dense, bubble-free cap on the contact surface. The bulk material maintains the original mixture composition for structural integrity, while the surface layer specifically addresses bubble elimination.
Solution Approach 2:
The method changes the physical parameters of the casting mixture by adjusting water content, binder concentration, and particle size distribution. These parameter changes create a mixture that is sufficiently fluid to allow bubbles to rise and escape during casting, yet viscous enough to trap bubbles away from the contact surface as the mixture sets.
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
This method enables the rapid manufacturing of high-quality infrastructure blocks with improved corrosion resistance and reduced joint degradation, resulting in increased lifespan and efficiency of the glassmaking process.
Implementation Method 1
preparation of a self-casting unshaped product, activated and degassed under partial vacuum
Implementation Method 2
sintered in a controlled oven environment
Data Source
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AI summary
Feeder channel for molten glass comprising an infrastructure comprising a block self-cast and sintered in situ. Furthermore, a method for manufacturing a block of such an infrastructure and a supply channel for a glassmaking furnace are claimed.