Cement-Based Thermal Insulating Material for High Temperature
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Solution Overview
Problem
Existing thermal insulating materials lack the necessary combination of low density, high thermal insulation, and durability across a wide temperature range, particularly above 900 degrees Celsius.
Innovation Solution
A method for manufacturing a lightweight thermal insulating material by mixing cement with water and a rheology modifying agent, followed by foaming with an aluminum powder or surfactant, and then curing to achieve a material with specific density, thermal conductivity, and strength characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the density of thermal insulating material is reduced to improve insulation performance, then thermal conductivity decreases, but mechanical strength deteriorates
Solution Approach 1:
The patent uses composite materials by combining cementitious binders with lightweight aggregates (expanded perlite, vermiculite, or foam beads) to create a material that achieves both low density and adequate mechanical strength. The composite structure allows the lightweight aggregates to provide insulation while the cement matrix provides structural integrity, resolving the contradiction between low density and mechanical strength
Solution Approach 2:
The patent employs porous materials by incorporating air-entraining agents and foam generators that create controlled void spaces within the cement matrix. This porous structure reduces density and thermal conductivity while the interconnected pore structure and cement binding maintain sufficient mechanical strength, simultaneously addressing both requirements
2Ease of manufacture
If ordinary Portland cement is used to ensure material availability and ease of manufacture, then manufacturing cost decreases, but maximum use temperature is limited to approximately 900 degrees Celsius
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the cementitious binder. It specifies using calcium aluminate cement (CAC), Sorel cement, CSA cement, phosphate cement, or geo-polymer cement instead of ordinary Portland cement. These alternative binders have fundamentally different chemical properties that enable them to withstand temperatures up to 1800 degrees Celsius while maintaining workability and setting characteristics suitable for manufacturing
3Quantity of substance
If foam generators or air-entraining agents are added to reduce material density, then density decreases to 0.05-1.0 g/cm³, but manufacturing process complexity increases
Solution Approach 1:
The patent applies self-service by using foam generators or air-entraining agents that automatically generate the required foam structure during the mixing and setting process. These agents self-regulate the foam formation based on the mixing conditions, eliminating the need for complex external foam generation equipment or precise manual control, thus achieving low density while keeping the manufacturing process relatively simple
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 resulting insulating material exhibits a density range of 0.05 to 1.0 g/cm³, thermal conductivity of 0.02 to 1.0 W/(mK), and compressive and flexural strengths up to 3000 PSI, while maintaining effectiveness up to 1800 degrees Celsius.
Implementation Method 1
foaming the cement-water mixture using a foaming agent comprising an aluminum powder in an amount of 0.5 to 3.0% by weight of the cement
Implementation Method 2
The insulating material has a thermal conductivity in the range of about 0.02 to 1.0 W/(m·K)
Data Source
AI summary
A lightweight thermal insulating cement-based material is formed from a mixture that includes cement, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature of about 900 degrees Celsius or more.