Socket Installation Structure for Refractory Articles
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Solution Overview
Problem
Existing socket installation structures in refractory articles, such as refractory nozzles, fail to prevent gas leakage due to deformation of flanges or raised portions during welding and uneven temperature distribution, leading to gaps and voids in the sealing material, which compromise the sealability and productivity in molten metal agitation.
Innovation Solution
A socket installation structure with a first flange positioned closer to the inward end of the socket, where a low thermally-conductive material layer is used between the flange and the article body to minimize heat transfer and deformation, ensuring a strong seal by locating the sealing section away from the outer periphery, thus reducing the need for extensive welding and minimizing thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a socket is welded to a metal plate, then the socket is securely fixed, but the socket deforms during welding and creates gaps with sealing material, causing gas leakage
Solution Approach 1:
A low thermally-conductive material layer is introduced as an intermediary between the socket and the metal plate. This intermediary layer prevents direct thermal conduction during welding, avoiding socket deformation while maintaining secure fixation. The material layer acts as a thermal barrier that decouples the welding heat from the socket body.
Solution Approach 2:
The connection structure is segmented into distinct functional layers: the socket, the low thermally-conductive material layer, and the metal plate. This segmentation allows each component to perform its specific function independently - the material layer specifically handles thermal isolation while the mechanical connection is maintained through the layered structure.
2Area of stationary object
If a flange is provided on the socket, then the contact area with sealing material is increased, but the flange deforms due to welding heat and expansion, causing gas leakage
Solution Approach 1:
The low thermally-conductive material layer serves as a mediator between the flange and the metal plate, preventing welding heat from reaching the flange. This protects the flange's dimensional stability while allowing it to maintain its enlarged contact area function for sealing.
Solution Approach 2:
The thermal insulation property is applied locally at the connection interface where the flange meets the metal plate. The low thermally-conductive material layer is positioned specifically at this critical interface to protect the flange from heat while allowing the rest of the socket to function normally.
3Strength
If welding is performed to secure the socket, then the fixation is strong, but residual moisture and crystallization water in sealing material vaporize and cause foaming, leading to gas leakage
Solution Approach 1:
The low thermally-conductive material layer acts as a thermal barrier that prevents welding heat from reaching the sealing material. This intermediary layer allows welding to proceed for secure fixation while protecting the sealing material from thermal degradation and foaming.
Solution Approach 2:
The low thermally-conductive material layer is pre-installed between the socket and metal plate before welding. This beforehand cushioning protects the sealing material from future welding heat exposure, preventing moisture vaporization and foaming that would compromise sealing reliability.
4Ease of manufacture
If the socket is installed close to the outer periphery of the article body, then the installation is simple, but the socket is exposed to uneven temperature distribution and deforms, causing gas leakage
Solution Approach 1:
The low thermally-conductive material layer is positioned at the connection interface between the socket and metal plate, serving as a thermal mediator. This allows the socket to be installed in simple positions while the material layer protects it from uneven temperature distribution and thermal deformation.
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 configuration enhances sealability by reducing non-uniform deformation and heat-induced alterations in the sealing material, effectively preventing gas leakage and improving the installation efficiency by allowing for fewer welding points, thereby maintaining a strong seal even under varying temperature conditions.
Implementation Method 1
a low thermally-conductive material layer is used between the flange and the article body to minimize heat transfer and deformation
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
Disclosed is a socket installation structure of a refractory article, designed to prevent gas leakage therein. A first flange 3 is provided between an outward end and an inward end of a socket 20, and a face of the first flange 3 on the side of an inward end thereof is bonded to an article body 30 of the refractory article through a sealing material 2. Further, a face of the first flange 3 on the side of an outward end thereof faces a metal plate 6 disposed around the outward end or a second flange provided on the side of the outward end, through a low thermally-conductive material layer 4 made of a low thermally-conductive material having a thermal conductivity at room temperature of 40 (W/(m · K)) or less.