Cellular Aluminous Hydraulic Binder for Thermal Insulation
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Solution Overview
Problem
Current thermal insulation materials for buildings face challenges such as settling issues, increased thickness requirements for efficiency, recycling problems, fire resistance concerns, and variable performance, which hinder effective energy reduction and compliance with energy performance regulations.
Innovation Solution
A thermal insulating material with a cellular structure is developed using a specific aluminous hydraulic binder composition that incorporates high quantities of air in finely divided form, achieving low thermal conductivity and high mechanical strength, allowing for efficient thermal insulation and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rock wool, glass wool or vermiculite are used for thermal insulation, then thermal insulation performance is achieved, but the materials settle over time leading to loss of efficiency
Solution Approach 1:
The invention uses a composite material comprising a polymer binder and an inorganic filler (such as expanded perlite, vermiculite, or glass beads) to create a rigid foam insulation panel. This composite structure prevents settlement by binding the insulating particles in a fixed matrix, while maintaining thermal insulation performance through the air-filled cellular structure of the expanded filler particles.
Solution Approach 2:
The invention incorporates expanded perlite, vermiculite, or glass beads as filler materials that create a porous, cellular structure within the rigid foam panel. These expanded particles trap air in their cellular structures, providing thermal insulation while their rigid, expanded nature prevents them from settling over time, unlike traditional loose-fill materials.
2Reliability
If the thickness of insulation materials is increased to meet energy performance requirements, then thermal insulation performance improves, but useful space is lost
Solution Approach 1:
The invention changes the physical and chemical parameters of the insulation material by using a rigid foam matrix with high-density expanded filler particles. This creates a material with superior thermal insulation properties per unit thickness, allowing meeting of energy performance requirements (such as RT 2005) with reduced thickness, thereby preserving useful space in building applications.
3Reliability
If polymers are used for thermal insulation, then low thermal conductivity is achieved, but recycling problems and fire resistance issues arise
Solution Approach 1:
The invention creates a composite material where a polymer binder (such as polyurethane or epoxy) is combined with inorganic expanded filler particles (perlite, vermiculite, or glass beads). This composite structure maintains the low thermal conductivity benefit of polymer foams while the high proportion of inorganic filler (90-99% by volume) improves fire resistance and recyclability, as the inorganic particles are non-combustible and can be separated and reused.
Solution Approach 2:
The invention applies different materials with different properties to different functional requirements: the polymer binder provides structural integrity and low thermal conductivity, while the inorganic expanded filler particles provide fire resistance, dimensional stability, and recyclability. This local assignment of materials to functions allows the composite to overcome the limitations of pure polymer insulation.
4Reliability
If natural plant or animal origin materials are used, then thermal insulation is achieved, but performance varies between batches and settlement occurs
Solution Approach 1:
The invention transforms natural insulation materials (such as cellulose, hemp, or wood fibers) into expanded, rigid particles through chemical or physical treatment. This parameter change in the material structure improves consistency between batches by creating a standardized particle morphology and size distribution, while the expansion process creates air-filled cellular structures that enhance thermal insulation. The rigidified structure also prevents settlement.
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 material achieves thermal conductivity coefficients as low as 0.04 W/m°C with high compressive strength, enabling effective thermal insulation while maintaining mechanical integrity and ease of implementation, addressing the limitations of existing materials.
Implementation Method 1
comprising a cement matrix obtained by hydration of a hydraulic binder characterized, before contact with water, in that it comprises at least one phase chosen from C3A, CA, C12A7, C11A7CaF2, C4A3$ (y'ee lemite), C2A(1-x)Fx
Implementation Method 2
The material achieves thermal conductivity coefficients as low as 0.04 W/m°C with high compressive strength, enabling effective thermal insulation
Implementation Method 3
comprising a cement matrix obtained by hydration of a hydraulic binder
Implementation Method 4
obtained by hydration of a hydraulic binder characterized, before contact with water
Data Source
Figure 1
Figure 2a~3b
Figure 4
AI summary
The invention relates to a cellular thermal insulation material comprising, by weight relative to the total weight of the material: - 4 to 96% of a hydraulic binder characterized before contact with water, in that it comprises at least one phase selected from C3A, CA, C12A7, C11A7CaF2, C4A3$ (yée lemite), C2A(1-x)Fx (with x belonging to ]0, 1]), hydraulic amorphous phases having a C/A molar ratio between 0.3 and 15 and such that the cumulative Al2O3 content of these phases is between 3 and 70% by weight of the total hydraulic binder, - 4 to 96% of at least one filler, said material having a volume porosity between 70% and 95%. The invention also relates to the use of a mineral foam for manufacturing said thermal insulation material as well as the manufacturing processes for said mineral foam.