Multi-layered Wear Lining with Nanoporous Silica Insulation
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Solution Overview
Problem
High-temperature technical installations face challenges in maintaining wear protection and thermal insulation while preventing heat transfer to the installation walls, which increases manufacturing costs and complicates material transport due to inadequate sliding properties of existing wear protective linings.
Innovation Solution
A multi-layered wear protective lining comprising a ceramic outer layer with polished plate-shaped elements, an adhesive layer, a pressure-relieving mineral layer, a nanoporous insulation layer based on pyrogenic silicic acid, and a mineral inner layer, designed to create a thermal conductivity gradient and provide mechanical stability, with fastening means for secure adhesion and reduced heat bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wear protective lining is used at high temperatures, then wear protection is provided, but heat transfer to the installation walls increases manufacturing costs
Solution Approach 1:
The patent applies composite materials by combining multiple layers with different properties: a ceramic outer layer for wear protection, intermediate layers for mechanical stability, and a nanoporous insulation layer for thermal isolation. This composite structure provides both wear protection and heat insulation simultaneously, resolving the contradiction between durability and energy loss.
Solution Approach 2:
The patent implements local quality by giving each layer specific localized functions: the outer ceramic layer provides wear resistance where material contact occurs, while the inner nanoporous layer provides thermal insulation where heat transfer is problematic. Each layer is optimized for its specific location and function within the overall lining system.
2Loss of energy
If the wear protective lining holds heat, then manufacturing costs are reduced, but the sliding property on the surface deteriorates
Solution Approach 1:
The patent applies local quality by providing the polished surface only on the outer wear protective layer where sliding contact occurs, while the inner layers maintain their insulating and structural properties. This localized polishing ensures good sliding properties at the material interface without compromising the thermal insulation function of the inner layers.
3Loss of energy
If a multi-layered structure is used, then thermal insulation is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the wear protective lining into multiple functional layers, each with a specific thickness and material composition optimized for its role. This segmented approach allows independent optimization of wear protection, mechanical stability, and thermal insulation functions.
Solution Approach 2:
The patent uses composite materials to justify the multi-layered structure by combining materials with complementary properties. The ceramic outer layer, intermediate mineral layers, and nanoporous insulation layer form a composite system where each material contributes its unique properties, making the overall structure more effective than a single-material solution.
4Ease of manufacture
If plate-shaped elements are used, then the lining can be composed of individual parts, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by using plate-shaped elements that can be manufactured separately and assembled into the final lining structure. This modular approach allows for easier manufacturing, transport, and installation of the wear protective lining while maintaining structural integrity through proper connection design.
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 achieves a smooth, durable, and thermally efficient wear protective lining that maintains heat within the installation, ensuring effective material transport and reducing manufacturing costs through a carefully tuned thermal gradient and stable adhesion.
Implementation Method 1
a fourth layer of a nanoporous insulation material based on pyrogenic silicic acid
Implementation Method 2
a fourth layer of a nanoporous insulation material based on pyrogenic silicic acid
Implementation Method 3
a first outer layer of ceramic material having a polished surface pointing away from the base
Implementation Method 4
configured to be seamlessly connected to one another. Mechanically particularly stable layers are also very advantageously provided which enable a pressure relief of the neighbouring inner layers
Data Source
Figure 1
AI summary
High-temperature wear protective lining for use on metal bases (1) comprising a first outer layer (2) of ceramic material having a polished surface (3) pointing away from the base, wherein the first layer (2) consists of a plurality of by means of an adhesive agent (6) interconnected plate-shaped elements (4), further comprising a second layer (5) adjoining the first layer (2) in the direction of the base, further comprising a third layer (7) of a mineral body adjoining the second layer (5) in the direction of the base, which is fabricated to relieve pressure of the following fourth layer (9), further comprising a fourth layer (9) of a nanoporous insulation material based on pyrogenic silica, further comprising a fifth inner layer (10) of a mineral body, where the middle layers (5, 7, 9) are each directly adjacent to the respectively adjacent layers and where the fifth layer (10) is in contact with the base.