Aerated Composite Materials via Gas-Assisted Hydrothermal Sintering
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Solution Overview
Problem
Conventional aerated concretes have high energy consumption, carbon footprint, and production costs due to the need for specialized equipment and high temperatures, making them inefficient and expensive to produce.
Innovation Solution
Development of novel aerated composite materials using low-cost, widely available raw materials and a gas-assisted hydrothermal liquid phase sintering process, which reduces equipment needs and energy consumption while sequestering CO2, resulting in a more environmentally friendly production method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional aerated concrete is produced using autoclaving at high temperatures and pressures, then the material achieves stable Tobermorite formation and good strength, but energy consumption increases and carbon footprint increases
Solution Approach 1:
The patent changes the curing parameters from high temperature and pressure autoclaving to lower temperature (20-100°C) and atmospheric pressure conditions, using chemical reactions (hydration and carbonation) instead of thermal-pressurized autoclaving to achieve similar strength results
Solution Approach 2:
The patent replaces the mechanical autoclaving system with a chemical reaction-based curing system, where calcium silicate reacts with water and carbon dioxide to form binding elements, eliminating the need for high-pressure autoclaves
2Stability of the object's composition
If conventional aerated concrete is produced using autoclaving at high temperatures and pressures, then the material achieves stable Tobermorite formation, but production cost increases
Solution Approach 1:
The patent uses readily available, low-cost raw materials such as calcium silicate, cement, and carbon dioxide instead of expensive specialized materials, reducing production costs while achieving stable binding element formation through chemical reactions
Solution Approach 2:
The patent replaces expensive autoclaving equipment with simple curing chambers that maintain atmospheric pressure and controlled temperature, significantly reducing equipment investment and operational costs
3Reliability
If conventional aerated concrete is produced using autoclaving, then the material achieves good thermal insulation and fire resistance, but equipment complexity increases
Solution Approach 1:
The patent replaces complex autoclaving equipment with simple curing chambers that use atmospheric pressure and controlled temperature conditions, achieving fire resistance and thermal insulation through chemical binding element formation rather than high-pressure mechanical processes
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 new process enables the production of aerated composite materials with excellent physical and performance characteristics, such as thermal insulation and fire resistance, at a lower cost and with a reduced carbon footprint, suitable for large-scale production without the need for autoclaves.
Implementation Method 1
allowing the aerating agent to generate a gaseous product thereby causing volume expansion of the wet mixture
Implementation Method 2
The bonding elements react at controlled temperatures and pressures either using the process of hydration in which the reaction occurs between water and water vapor
Implementation Method 3
using water vapor and CO2... CO2, which is consumed in the production as a reactive species and ends up sequestered in the final product
Implementation Method 4
gas-assisted hydrothermal liquid phase sintering process
Implementation Method 5
The bonding elements react at controlled temperatures and pressures
Data Source
AI summary
The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.