Aerated Silicate Insulation Composition for Fire-Resistant Low Heat Flow
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Solution Overview
Problem
Commercially-available thermally insulating materials, such as organic foamed materials, are highly flammable and inorganic fibrous materials are susceptible to humidity and have higher densities and thermal conductivities, necessitating the development of lightweight, thermally insulating products with improved fire resistance and lower thermal conductivity.
Innovation Solution
A method involving the formation of a mixture comprising solvent and gel network former, optionally with a foaming agent, dispersing a thermally insulating filler, and drying to create a thermally insulating product with a dispersed filler in an aerated matrix, using expanded silicate materials with specific density and thermal conductivity ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If organic foamed materials are used for thermal insulation, then lightweight and low thermal conductivity are achieved, but fire resistance deteriorates (high flammability)
Solution Approach 1:
The invention uses composite materials combining inorganic fibrous materials with expanded silicate beads. The expanded silicate beads serve as fire-resistant filler within the organic foam matrix, creating a composite that maintains the lightweight and low thermal conductivity properties of the foam while adding fire resistance through the inorganic silicate component.
Solution Approach 2:
The invention applies local quality by distributing expanded silicate beads throughout the organic foam matrix. These fire-resistant particles are locally dispersed to provide fire protection at specific points within the material, allowing the bulk material to maintain its lightweight foam structure while having localized fire resistance enhancement.
2Object-affected harmful factors
If inorganic fibrous materials are used for thermal insulation, then fire resistance is improved, but density and thermal conductivity increase
Solution Approach 1:
The invention utilizes porous expanded silicate beads with high porosity (low bulk density) as the inorganic component. These porous structures provide fire resistance while maintaining low density and low thermal conductivity, avoiding the problem of heavy, high-conductivity inorganic fibrous materials.
Solution Approach 2:
The invention creates a composite material system where expanded silicate beads are incorporated into an organic foam matrix. This composite approach allows the inorganic component to provide fire resistance while the overall structure maintains low thermal conductivity through the foam's air-filled cells and the silicate beads' porous structure.
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 method produces lightweight, thermally insulating products with enhanced fire resistance and reduced thermal conductivity, addressing the limitations of existing materials by providing a safer and more efficient insulation solution.
Implementation Method 1
forming a mixture comprising solvent and gel network former
Implementation Method 2
drying the mixture to form the thermally insulating product
Implementation Method 3
optionally foaming agent
Implementation Method 4
thermally insulating filler dispersed in an aerated matrix
Implementation Method 5
porous granular material such as an expanded silicate material
Data Source
AI summary
A method of manufacturing a thermally insulating product comprises: (a) forming a mixture comprising solvent and gel network former and optionally foaming agent; (b) dispersing a thermally insulating filler in the mixture; and (c) drying the mixture to form the thermally insulating product.