Sliding Plate Bonding via Impregnation Agent
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Solution Overview
Problem
Existing sliding gate systems for metallurgical melting vessels face issues with wear resistance due to the detachment of wear-resistant inserts from the base plate, especially at high temperatures, leading to gaps and reduced strength, which increases maintenance costs and wear.
Innovation Solution
Filling the gap between the wear-resistant insert and the base body with an impregnation agent, such as coal-tar pitch, to create a non-positive direct connection, which solidifies at moderate temperatures and enhances the mechanical bonding between the two components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the annular insert is pressed together with the fire-resistant matrix material, then the manufacturing process is simple and any insert design can be used, but the insert and base plate detach after removal from the press creating gaps
Solution Approach 1:
The patent introduces a binding agent as an intermediary substance between the insert and the fire-resistant base plate. This binding agent fills the gaps created during pressing and provides strong adhesion, ensuring the insert remains securely connected to the base plate during service while maintaining the simplicity of the pressing manufacturing process
2Adaptability or versatility
If fire-resistant hydraulic mass is cast around the insert, then any insert geometry can be used, but the hydraulic bond loses strength at high temperatures below 1000°C
Solution Approach 1:
The patent changes the chemical composition parameters of the binding agent to remain effective at high temperatures. The binding agent is formulated with materials that maintain their bonding properties in the temperature range of 100-1000°C, unlike conventional hydraulic bonds that lose strength in this range. This allows the use of diverse insert geometries while ensuring strong connection strength at operating temperatures
3Temperature
If the sliding plate is used with temperature gradients, then the passage opening area reaches high temperatures, but areas heated only to the strength hole temperature exhibit high wear
Solution Approach 1:
The patent creates a composite structure where the binding agent is specifically formulated to provide enhanced wear resistance in the intermediate temperature zones (100-1000°C). This composite material system combines the heat resistance of the fire-resistant base plate with the wear-resistant properties of the specialized binding agent, protecting areas that experience temperature gradients and would otherwise be vulnerable to high wear
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 provides a stable, high-strength connection that maintains wear resistance over the entire volume of the sliding plate, reducing wear and improving the sliding plate's tightness and sliding properties, while allowing for the use of more economical materials.
Implementation Method 1
A space (3) present between insert (1) and base body (2) is filled with an impregnation agent that non-positively connects base body (2) and insert (1)
Implementation Method 2
which solidifies at moderate temperatures and enhances the mechanical bonding between the two components
Data Source
AI summary
A process for manufacturing a sliding plate for a valve closure on metallurgical melt containers may include forming the sliding plate by: integrating in a pressing procedure with a press, a pre-pressed annular insert made of a refractory ceramic material in a base body made of a refractory ceramic material; and removing the sliding plate from the press, resulting in an annular gap between a circumferential surface of the insert and a corresponding surface of the base body. The process may also include impregnating a transition area including the annular gap between the insert and the base body with an impregnation agent, and tempering the plate at temperatures between 200° C. and 700° C. to cause the impregnation agent to create a non-positive direct connection between the base body and the insert.