Additive Sleeve Liner Insulation for Severe-Service Valve Bores
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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, with existing solutions like pre-heating systems and thermal barrier coatings being unreliable and costly, and low thermal conductivity materials proving ineffective in preventing cracking.
Innovation Solution
An additively manufactured thermal insulating sleeve liner with an internal infill structural pattern creating voids for enhanced thermal insulation, made from materials like Inconel 718 or ceramic composites, which can be 3D printed and post-processed for improved mechanical properties, and designed for easy installation and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If pre-heating systems are used to mitigate thermal shock, then thermal stress protection is improved, but system reliability deteriorates due to malfunction risks and maintenance requirements
Solution Approach 1:
The patent extracts the thermal protection function from complex active pre-heating systems and implements it through a passive thermal barrier coating applied directly to the valve body. This eliminates the need for separate pre-heating equipment, control systems, and maintenance interventions, thereby improving reliability while maintaining thermal stress protection.
Solution Approach 2:
The thermal barrier coating provides self-service thermal protection by inherently resisting heat transfer during thermal shock events. The coating automatically performs the protective function without requiring external control systems, power sources, or maintenance, thus eliminating the reliability issues associated with active pre-heating systems.
2Object-affected harmful factors
If low thermal conductivity materials are used for thermal protection, then thermal insulation is improved, but effectiveness deteriorates due to cracking susceptibility under extreme cyclic temperatures
Solution Approach 1:
The patent changes the thermal conductivity parameter of the valve body surface by applying a thermal barrier coating with optimized thermal properties. This coating provides sufficient thermal insulation to reduce thermal shock effects while maintaining adequate heat transfer to prevent excessive temperature differentials that cause cracking, thus resolving the contradiction between insulation and cracking resistance.
Solution Approach 2:
The solution employs a composite structure consisting of the metal valve body combined with a thermal barrier coating layer. This composite material system combines the mechanical strength and thermal conductivity of metal with the thermal insulation properties of the coating, achieving both thermal protection and cracking resistance simultaneously.
3Object-affected harmful factors
If thermal barrier coatings are applied to provide thermal shock protection, then thermal protection effectiveness is improved, but manufacturing complexity and cost increase due to laborious preparation processes
Solution Approach 1:
The thermal barrier coating serves multiple functions simultaneously: thermal shock protection, corrosion resistance, and wear protection. This multi-functionality consolidates what would otherwise require separate protective systems, simplifying the overall manufacturing process and reducing costs while maintaining thermal protection effectiveness.
Solution Approach 2:
The coating is applied specifically to the thermal shock-prone regions of the valve body (such as the valve seat and body surfaces exposed to thermal cycling), providing localized thermal protection where needed most. This targeted approach reduces the overall complexity compared to protecting entire components and allows for more efficient manufacturing processes.
4Object-affected harmful factors
If thermal barrier coatings are used for thermal protection, then thermal shock resistance is improved, but maintenance frequency increases due to erosion and corrosion susceptibility
Solution Approach 1:
The patent uses composite material systems where the thermal barrier coating is integrated with corrosion and wear-resistant properties. This composite approach ensures that the protective coating resists thermal shock, erosion, and corrosion simultaneously, thereby extending service life and reducing maintenance frequency compared to conventional single-function coatings.
Solution Approach 2:
The coating is designed as a consumable protective layer that can be economically applied and, if necessary, reapplied. The coating provides extended service life through its multi-functional protection capabilities, but when wear or damage occurs, it can be efficiently reapplied without requiring replacement of the entire valve assembly, thus reducing overall maintenance costs and frequency.
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 reduces thermal stress and extends the design life of fluid flow devices by minimizing heat transfer and supporting internal pressures, with the ability to be easily replaced, thus providing robust and cost-effective thermal protection.
Implementation Method 1
an internal infill structural pattern creating internal voids which increase thermal insulation properties
Implementation Method 2
minimizing heat transfer (i.e., from the inside to the outside of the sleeve)
Implementation Method 3
remaining structurally adequate to serve as a thermal insulating flow device liner... to support internal/external pressures to be experienced by the sleeve
Implementation Method 4
The infill may have variable patterns that may be in the form of, but not limited to, centroidally-directed lattices, hollow honeycomb-like structures and so forth. These patterns form a porous network of supporting structure containing voids between the two shells. This network of structure entraps air (or other insulating material such as an inert nitrogen gas or an insulating vacuum)
Data Source
AI summary
A thermal insulating sleeve liner for fluid flow devices such as valves and piping used in severe industrial applications is preferably additively manufactured (e.g., by 3D printing) to fit into the bore of a protected fluid flow device. Internal interstices and/or external ribs provide added thermal insulation. An integrally formed end-lip or a separate end-cap secures and/or locates the sleeve liner within the protected fluid flow device between different diameter distal and proximal portions of the bore. If internal interstices are sealed they can be vacuumed or pressurized to enhance thermal insulating properties. Fitted dimensions are sufficiently small to prevent ingress of thermally conductive particles circulating in use within the flow path of the protected flow device. A pressure equalizing aperture can be provided on or through the sleeve if needed in some applications.