Buffered Sol-Gel Binder for Controlled Solidification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing binders for bulk materials and geological formations are hindered by the presence of finely divided components, which cause premature initiation of the solidification reaction due to catalytic effects, leading to reduced 'open' time and impaired consolidation.
Innovation Solution
A binder system comprising a hydrolysate or heterocondensate of hydrolyzable silicon compounds and metal or boron compounds, buffered with an organic acid and its conjugate to stabilize pH, preventing the influence of fine particles and ensuring controlled solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If peroxide initiators are used for free radical polymerization, then the consolidation reaction can be initiated at a specified temperature, but finely divided components cause premature initiation due to catalytic effects, reducing the open time
Solution Approach 1:
The patent introduces a buffer system as an intermediary substance that mediates between the peroxide initiator and the finely divided components. The buffer prevents catalytic effects from the fine particles by maintaining a stable pH environment, thereby preventing premature initiation while still allowing controlled polymerization at the desired temperature. This intermediary buffer solution resolves the conflict between reliable controlled solidification and maintaining adequate open time.
Solution Approach 2:
The patent changes the pH parameter of the binder system by adding a buffer solution. This parameter change stabilizes the chemical environment, preventing pH-dependent catalytic effects from fine particles that would otherwise accelerate peroxide decomposition. By controlling the pH parameter, the system maintains consistent open time and prevents premature solidification while preserving the temperature-controlled initiation mechanism.
2Manufacturing precision
If the binder infiltrates into bulk material, then consolidation can occur, but premature solidification blocks feed lines and surface, preventing complete infiltration
Solution Approach 1:
The patent applies preliminary action by adding a buffer solution to the binder before infiltration. This preliminary step ensures that the binder maintains its liquid state and flow properties throughout the infiltration process. The buffer pre-prevents premature solidification, allowing the binder to fully infiltrate the bulk material through feed lines and pores without blocking, thereby ensuring complete infiltration and reliable consolidation.
3Reliability
If sol-gel systems are used, then consolidation can occur, but they show strong dependence on external parameters like pH and water content, reducing stability
Solution Approach 1:
The patent applies parameter changes by introducing a buffer system that stabilizes the pH parameter of the sol-gel binder. This buffer prevents pH fluctuations that would otherwise cause variability in the consolidation effect. By maintaining a constant pH environment, the buffer eliminates the strong dependence on external parameters, thereby improving both the reliability of consolidation and the stability of the binder composition during storage and application.
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 binder system maintains a consistent 'open' time regardless of fine particles, allowing complete infiltration and significantly enhancing the mechanical strength of bound materials by inhibiting catalytic effects, thus ensuring reliable consolidation without premature curing.
Implementation Method 1
a buffer to adjust the pH of the binder to a value of from 2 to 7
Implementation Method 2
a hydrolysate and/or a heterocondensate of at least one hydrolyzable silicon compound
Implementation Method 3
thermally initiatable peroxides are suitable as free radical formers. The initiation temperature is the temperature at which the decomposition rate of the peroxides is sufficient for starting a polymerization chain reaction
Implementation Method 4
free radical polymerization mechanisms which have a known initial period are suitable for this purpose
Data Source
AI summary
A binder is described which comprises A) a hydrolysate or heterocondensate of at least one hydrolysable silicon compound and at least one metal, phosphorus or boron compound, the metal being selected from Al, Ge, Sn, Pb, Ti, Mg, Li, V, Nb, Ta, Zr and Hf, B) an organic polymerizable or polycondensable monomer or oligomer and C) a buffer, so that the pH of the buffered binder is in the range from 2 to 7, and optionally a complexing agent, if appropriate, the at least one hydrolysable silicon compound comprising one or more hydrolysable silicon compounds having at least one nonhydrolysable group or oligomers thereof. The binder is suitable for consolidating bulk or loose substrates.