Closed Cell Expanded Perlite Thermal Insulator Rigidity
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Solution Overview
Problem
Existing thermal insulators, particularly those using expanded perlite, face issues with particle crushing and cell structure destruction during compression molding, leading to increased thermal conductivity and reduced rigidity due to open cell structures and inappropriate particle size distributions, which complicates manufacturing and increases costs.
Innovation Solution
A thermal insulator is developed using closed cell expanded perlite with a controlled particle size distribution and a reduced amount of silicate-based binder, featuring a hollow closed cell structure without an acicular surface, which minimizes gaps between particles and enhances rigidity, achieved through a manufacturing process involving drying, expansion, and body compact filling with vibration or shock during compression molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If open cell expanded perlite with acicular structure is used, then thermal conductivity is reduced, but particle crushing and cell structure destruction occur during compression molding leading to increased thermal conductivity and reduced rigidity
Solution Approach 1:
The invention changes the structural parameters of expanded perlite from open cell with acicular structure to closed cell structure. This parameter change prevents particle crushing and cell structure destruction during compression molding, maintaining both low thermal conductivity and high rigidity in the final product
Solution Approach 2:
The invention creates a composite structure by combining closed cell expanded perlite particles with controlled particle size distribution. The hierarchical structure with different particle sizes fills gaps effectively, preventing particle crushing while maintaining thermal insulation performance and structural rigidity
2Productivity
If compression molding is applied to expand perlite, then thermal insulator density is reduced and manufacturing efficiency is improved, but particle crushing and cell structure destruction occur leading to increased thermal conductivity
Solution Approach 1:
The invention performs preliminary action by pre-drying expanded perlite to control crystal water content before compression molding. This preliminary treatment prevents particle crushing and cell structure destruction during compression, maintaining low thermal conductivity while enabling efficient manufacturing
Solution Approach 2:
The invention changes the physical state parameters of expanded perlite through controlled drying and expansion processes. By optimizing moisture content and expansion conditions, the perlite particles become more resistant to crushing during compression molding, maintaining thermal insulation performance while improving manufacturing efficiency
3Strength
If silicate-based binder is used in expanded perlite thermal insulator, then particle bonding is improved, but material costs increase and thermal conductivity increases due to binder absorption
Solution Approach 1:
The invention utilizes the porous closed cell structure of expanded perlite to minimize binder absorption. The closed cell structure prevents excessive binder penetration, reducing the amount of silicate-based binder needed while maintaining particle bonding and keeping thermal conductivity low
4Loss of energy
If gaps between particles are increased in expanded perlite, then thermal insulation is improved, but particle crushing occurs during compression molding reducing rigidity
Solution Approach 1:
The invention applies local quality by creating different particle size grades of closed cell expanded perlite. Smaller particles fill gaps between larger particles, providing local structural support that prevents particle crushing during compression while maintaining overall porosity for thermal insulation
Solution Approach 2:
The invention creates a composite particle structure with hierarchical size distribution. The combination of different sized closed cell particles provides both thermal insulation through maintained gaps and structural rigidity through interlocking and gap-filling effects
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
This solution results in a thermal insulator with improved constructability, reduced material and energy costs, and lower thermal conductivity, while maintaining high rigidity and hardness, by maximizing the use of closed cell structures and optimizing particle size distribution, thus enhancing its performance in industrial applications.
Implementation Method 1
A thermal insulator is developed using closed cell expanded perlite with a controlled particle size distribution and a reduced amount of silicate-based binder, featuring a hollow closed cell structure without an acicular surface, which minimizes gaps between particles and enhances rigidity
Implementation Method 2
lower thermal conductivity, while maintaining high rigidity and hardness
Implementation Method 3
body compact filling with vibration or shock during compression molding
Implementation Method 4
compression molding
Data Source
Figure 1(A)~1(G)
Figure 2(A)~2(E)
AI summary
The present invention relates to a thermal insulator using closed cell expanded perlite. The thermal insulator using closed cell expanded perlite of the present invention includes: expanded perlite 10 to 84 wt%ç, including dried and expanded perlite ore particles, having a surface with a closed cell shape, as an active ingredient; a liquid binder 15 to 85 wt%; and a reinforcing fiber 0.25 to 5 wt%. Accordingly, the present invention provides a thermal insulator, which enhances the rigidity of expanded perlite, minimizes porosity and gaps between the expanded perlite particles, by reducing compression ratio during compression molding, which results in lower density, improves constructability by lowering thermal conductivity, reduces material and energy costs and can reduce the area required for equipment installation by reducing the thickness of the thermal insulator.