Cellular Glass Foaming for Low Density and Higher Strength
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Solution Overview
Problem
Existing cellular glass production technologies struggle to produce products with densities below 90 kg/m3 while maintaining acceptable mechanical properties, leading to a compromise between thermal insulation and mechanical strength.
Innovation Solution
A process where the foaming gas is present at a higher supersaturated level, exceeding the theoretical minimum requirement, resulting in smaller cell diameters and improved mechanical properties at lower densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the density of cellular glass is reduced to improve thermal insulation, then thermal insulation properties improve, but mechanical properties deteriorate
Solution Approach 1:
The patent changes the parameter of cell size distribution by controlling the foaming process to achieve a specific size distribution. By optimizing the foaming conditions and glass composition, the patent creates a cellular structure with controlled cell size distribution that maintains mechanical strength while achieving low density for improved thermal insulation.
Solution Approach 2:
The patent uses composite materials by combining glass with specific foaming agents and additives. This composite approach allows the creation of a cellular glass structure with optimized properties, where the combination of materials enables simultaneous achievement of low density and adequate mechanical strength.
2Use of energy by moving object
If the density of cellular glass is reduced by extending residence time or increasing temperature in the foaming step, then thermal insulation improves, but mechanical properties deteriorate
Solution Approach 1:
The patent applies partial action by using a controlled amount of foaming agent that is sufficient to achieve the desired density but not excessive. This partial action approach prevents over-foaming that would lead to large cells and poor mechanical properties, while still achieving adequate thermal insulation performance.
Solution Approach 2:
The patent optimizes the foaming parameters including temperature profile, residence time, and atmosphere composition to achieve the desired cell structure. By precisely controlling these parameters, the patent prevents excessive cell growth that would compromise mechanical strength while maintaining low enough density for good thermal insulation.
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 process allows for the production of cellular glass products with densities as low as 90 kg/m3, offering superior thermal insulation and mechanical properties compared to conventional methods.
Implementation Method 1
The foaming agents are normally carbon black and/or alkali carbonates. Carbon black may combine with free oxygen to form CO and/or CO2 gas to foam the glass.
Implementation Method 2
1) melting of glass raw material at high temperature to form a base glass
Implementation Method 3
allowing the melt to cool so as to produce the amorphous product
Data Source
Figure 1
AI summary
Disclosed is a cellular glass product having a density D at ambient temperature of at most 200 kg/m3 and a process for the production of a cellular glass product having a density D at ambient temperature of at most 200 kg/m3. The process comprises the steps of: a) contacting glass powder with foaming agent to form a dry mixture, b) thermally treating the mixture in a foaming furnace, thereby forming cellular glass, and c) annealing the cellular glass of step b) in an annealing lehr, wherein the concentration of at least one of the reagents in the dry mixture of step a) that are necessary for enabling the foaming reaction is at least 150% of the concentration corresponding to the theoretical minimum requirement for obtaining the density D.