Insulating Brick with Expanded Polystyrene Particles
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Solution Overview
Problem
Conventional bricks with insulating fillings face challenges in achieving both high thermal insulation and fire protection, as improvements in one aspect often compromise the other properties, and they tend to break under high temperatures, risking structural integrity during fires.
Innovation Solution
A method involving a brick blank with expandable polystyrene particles that are steam-expanded to create an insulating body with a density between 10 kg/m³ and 30 kg/m³, minimizing residual propellant gas to prevent further expansion under heat, ensuring the brick's stability and maintaining insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the brick is filled with foamed plastic to improve thermal insulation, then thermal insulation properties are improved, but fire resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the insulating material by using expanded polystyrene particles with specific density (10-30 kg/m³) and controlled residual propellant gas content. This parameter optimization allows the material to achieve both high thermal insulation and improved fire resistance compared to conventional foamed plastics.
Solution Approach 2:
The patent creates a composite structure by combining expanded polystyrene particles with brick material. The insulating filling consists of discrete expanded particles rather than continuous foam, forming a composite material system that balances thermal insulation performance with fire safety requirements.
2Strength
If the insulating material is expanded to high density to improve structural strength, then strength is improved, but thermal insulation deteriorates
Solution Approach 1:
The patent identifies and optimizes the critical parameter of density to a specific range (10-30 kg/m³). This parameter window balances the competing requirements: sufficient density to prevent particle collapse and maintain structural integrity, while maintaining enough porosity to preserve thermal insulation performance.
3Object-affected harmful factors
If residual propellant gas is minimized to prevent fire expansion, then fire resistance is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent applies partial action by not completely removing all propellant gas from the expanded particles. Instead, it maintains a controlled residual amount that is sufficient to allow complete expansion during manufacturing but insufficient to cause dangerous expansion during fire conditions. This partial removal strategy balances safety requirements with manufacturing controllability.
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 enhances thermal insulation, soundproofing, and fire resistance while preventing the brick from breaking under high temperatures, allowing for more efficient use of insulating material and improved structural stability.
Implementation Method 1
the polystyrene particles are expanded by means of steam, so that they expand and bond together in the respective cavities to form an insulating body
Implementation Method 2
insulating bricks are increasingly becoming the focus of development activities. Such bricks typically achieve particularly good thermal insulation properties when filled with foamed plastics
Data Source
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AI summary
The method involves introducing expandable polymer particles comprising polystyrene into multiple through-holes (4) of a damming filling (6) of a masonry blank (2). The polymer particles are expanded by applying steam or hot air, and are connected with each other, such that an insulating element is formed in the respective through-holes. The polymer particles are expanded to a degree at which the insulating element having a density in a range between 10-30 kg per m 3> is comprised. Independent claims are included for the following: (1) an apparatus for manufacturing a masonry block; and (2) a masonry block.