Bio-Soluble Refractory Blanket With Colloidal Silica Strength
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Solution Overview
Problem
Existing refractory materials used in furnaces, such as those made from asbestos or ceramic fibers, pose health risks due to inhalation hazards, and they lack sufficient strength and wind erosion resistance.
Innovation Solution
A flexible refractory material in the form of a wet blanket comprising bio-soluble inorganic fibers impregnated with colloidal silica, which provides improved strength and resistance to wind erosion while being safe for human inhalation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional inorganic fibers (asbestos or ceramic fibers) are used as refractory material, then the material exhibits good fire resistance and structural integrity, but it causes health hazards due to inhalation and lung invasion
Solution Approach 1:
The patent changes the chemical composition parameters of the inorganic fibers by using bio-soluble fibers with specific oxide ratios (SiO2: 50-82 wt%, CaO: 10-43 wt%, MgO: 1-30 wt%) instead of traditional asbestos or ceramic fibers. This parameter change maintains fire resistance while eliminating inhalation hazards, as the bio-soluble fibers are safely metabolized by the human body.
Solution Approach 2:
The patent creates a composite refractory material by combining bio-soluble inorganic fibers with colloidal silica binder. This composite structure provides both the safety of bio-soluble fibers and the fire resistance required for refractory applications, resolving the contradiction between inhalation safety and fire resistance.
2Adaptability or versatility
If flexible refractory blankets are used to conform to curved surfaces, then the material provides good adaptability to complex shapes, but it lacks sufficient strength and wind erosion resistance
Solution Approach 1:
The patent uses a composite structure combining bio-soluble inorganic fibers with colloidal silica binder. The fiber network provides flexibility and adaptability to curved surfaces, while the colloidal silica matrix provides strength and wind erosion resistance, simultaneously achieving both requirements.
Solution Approach 2:
The patent applies different functional components to different aspects of the blanket: the bio-soluble fibers provide flexibility and conformability to curved surfaces, while the colloidal silica binder provides structural strength and erosion resistance. This local differentiation of material functions resolves the contradiction between adaptability and strength.
3Strength
If colloidal silica is used as binder for bio-soluble fibers, then the strength and stability of the refractory material is improved, but the material may solidify prematurely during storage
Solution Approach 1:
The patent uses a chelating agent (EDTA) as an intermediary substance that controls the interaction between colloidal silica and metal ions. This mediator prevents premature solidification of the colloidal silica during storage while allowing it to properly bind the fibers in the final refractory product, resolving the contradiction between strength and storage stability.
Solution Approach 2:
The patent extracts or removes the harmful solidification tendency from the colloidal silica system by adding a chelating agent that prevents unwanted chemical reactions during storage. This allows the colloidal silica to maintain its liquid state and binding capability during storage while providing strength in the final product.
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 bio-soluble inorganic fibers with colloidal silica impregnation enhance the strength and stability of the refractory material, ensuring safety and effectiveness even when stored for long periods, with improved heat resistance and flexibility.
Implementation Method 1
a wet blanket obtained by impregnating a blanket comprising bio-soluble inorganic fibers with a colloidal silica liquid
Implementation Method 2
bio-soluble inorganic fibers which do not or hardly cause disorders even if inhaled by a human body
Data Source
AI summary
A wet blanket obtained by impregnating a blanket including bio-soluble inorganic fibers with a colloidal silica liquid. A cured blanket obtained by curing the wet blanket.