3D-Printed Sleeve Liner Structure for Valve Thermal Shock
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Solution Overview
Problem
Fluid flow devices in severe industrial applications are prone to thermal shock damage due to sudden changes in temperature and pressure, leading to premature failure, as existing solutions like pre-heating systems and thermal barrier coatings are unreliable, costly, and prone to erosion and cracking.
Innovation Solution
An additively manufactured thermal insulating sleeve liner with an internal infill structural pattern, made from materials like Inconel 718 or ceramic composites, that reduces heat transfer while maintaining structural integrity, featuring a ceramic coating for enhanced wear resistance and insulation, and a design that allows for easy replacement to mitigate thermal shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pre-heating systems are used to mitigate thermal shock, then thermal stress protection is improved, but system reliability deteriorates due to malfunction and maintenance requirements
Solution Approach 1:
The patent extracts the thermal protection function from complex pre-heating systems and external TBC coatings, implementing it directly within the sleeve liner structure through internal geometry and material selection. This eliminates the need for separate pre-heating systems while maintaining thermal shock protection.
Solution Approach 2:
The sleeve liner acts as an intermediary thermal barrier between the hot process fluid and the valve body. It absorbs and mitigates thermal shock internally, protecting the valve body without requiring external pre-heating systems or coatings.
2Temperature
If thermal barrier coatings are applied to protect against thermal shock, then thermal protection is improved, but device complexity and cost increase due to laborious preparation processes
Solution Approach 1:
The patent merges the thermal barrier function with the structural sleeve liner component. The thermal protection is integrated into the sleeve's wall structure through material selection and internal geometry rather than being applied as a separate coating layer, eliminating complex preparation processes.
Solution Approach 2:
The patent changes the material parameters of the sleeve liner itself, using materials with inherently low thermal conductivity and high thermal shock resistance. This eliminates the need for external thermal barrier coatings while maintaining protective functionality.
3Temperature
If thermal barrier coatings are used for thermal protection, then thermal shock resistance is improved, but ease of manufacture deteriorates due to frequent replacement requirements
Solution Approach 1:
The patent employs a sacrificial sleeve liner that can be easily removed and replaced. Rather than attempting to repair damaged thermal barrier coatings, the entire sleeve is designed as a replaceable component that protects the valve body during its service life, then is discarded and replaced when worn.
Solution Approach 2:
The patent segments the valve assembly into a permanent valve body and a replaceable sleeve liner. This allows the thermal protection function to be isolated in a separate component that can be independently replaced without affecting the valve body or other components.
4Temperature
If low thermal conductivity materials are used for sleeve construction, then thermal insulation is improved, but strength deteriorates due to susceptibility to extreme cyclic temperatures
Solution Approach 1:
The patent uses composite construction combining materials with complementary properties. The sleeve liner incorporates materials that provide both low thermal conductivity for insulation and high strength for withstanding cyclic temperatures and pressures. This may include metal matrix composites or layered structures.
Solution Approach 2:
The patent applies different material properties to different regions of the sleeve liner. The internal surface facing the hot fluid may use materials optimized for thermal shock resistance, while the outer surface and structural framework use materials optimized for mechanical strength and pressure containment.
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 solution significantly extends the design life of fluid flow devices by reducing thermal stress and wear, achieving up to 40,000 cycles compared to 1,800 cycles without thermal protection, while being cost-effective and easier to maintain.
Implementation Method 1
thermal insulating sleeve liner constructed of a suitable material for the serviced application... with an internal infill structural pattern creating internal voids which increase thermal insulation properties
Data Source
AI summary
A monolithic metal thermal insulating sleeve liner for fluid flow devices such as valves and piping used in severe industrial applications is additively manufactured (e.g., by 3D printing) to fit the bore of a protected fluid flow device. Tessellated support structures obliquely extending between inside surfaces of inner and outer shells provide increased resistance to thermal conduction while also providing increased strength against compression forces. Example support structures include an array of four obliquely oriented elongated members mutually intersecting mid-way between the inside surfaces of inner and outer cylindrical shells. A ceramic coating may be applied an inner surface of the sleeve or to the inner surface of the to improve thermal insulation.