Coal-Derived Carbon Structural Units for Strength and Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The increasing demand for renewable energy and environmental concerns related to coal combustion have led to a need for environmentally friendly and efficient methods to utilize coal-derived materials, particularly in the production of structural building materials, which should have reduced density, increased strength, and improved insulation properties.

Innovation Solution

A composition comprising pyrolysis char, coal deposits and extracts, and residual tar materials is used to create carbon-based structural units (CSUs) through a process involving pyrolysis, heat treatment, and mixing with pitch materials, followed by molding and carbonization to enhance mechanical and thermal properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional building materials are used, then structural strength is maintained, but density and thermal conductivity are high resulting in poor insulation properties

Engineering Contradiction:

Improvecompressive and flexural strengthsVSAvoiddensity

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent creates carbon-based structural units by combining pyrolysis char (1-80%), coal deposits extracts and residual tar (0.1-35%), and pitch material (0-99%) to form a composite material that achieves both high strength and low density. The composite structure allows the material to exhibit superior mechanical properties while maintaining reduced density compared to conventional building materials.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional building materials are used, then structural strength is maintained, but thermal conductivity is high resulting in poor insulation properties

Engineering Contradiction:

Improvecompressive and flexural strengthsVSAvoidthermal conductivity

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The composite composition of pyrolysis char, coal derivatives, and pitch material creates a material with reduced thermal conductivity while maintaining structural strength. The specific combination and ratios of these materials produce a composite that provides both mechanical integrity and thermal insulation properties.

Inventive Principle:

Principle #40Composite materials

3Power

If coal is used as energy source, then energy generation is achieved, but greenhouse gas emissions and air pollution increase

Engineering Contradiction:

Improveenergy generationVSAvoidgreenhouse gas emissions

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent converts coal-derived materials that would otherwise be waste products into valuable structural building materials. By utilizing pyrolysis char and coal deposits extracts and residual tar in the fabrication of carbon-based structural units, the process transforms potentially harmful byproducts of coal combustion into beneficial construction materials, reducing waste and environmental impact.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies heat treatment at specific temperatures (e.g., 400-600°C) to transform the chemical and physical properties of coal-derived materials. This thermal processing changes the material parameters to create a stable, strong, and environmentally friendly structural unit that maintains coal utilization while minimizing harmful emissions.

Inventive Principle:

Principle #35Parameter changes

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 CSUs exhibit higher compressive and flexural strengths, lower density, and reduced thermal conductivity compared to conventional materials, making them suitable for construction applications while minimizing environmental impact.

Implementation Method 1

fabricating pyrolysis char (PC) and a coal deposits, extracts, and residual tar (CDER) material from the CER

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

followed by molding and carbonization to enhance mechanical and thermal properties

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS20250206666A1Coal-derived carbon-based structural units and methods fabrication

Publication Date: 2025.06.26 UNIVERSITY OF WYOMING

AI summary

Embodiments of the present disclosure related carbon-based structural unit (CSU). The CSUs include a cured composition. The cured composition includes about 1% to about 80% pyrolysis char (PC), about 0.1% to about 35% coal deposits, extracts, and residual tar (CDER) materials, and about 0% to about 99% pitch material. The CDER material includes a tetralin insoluble (TI), a deposit (De), a distillation residue (DR), and a residue (Re). A method of making a composition includes extracting a coal extraction residue (CER) from coal; fabricating pyrolysis char (PC) and a coal deposits, extracts, and residual tar (CDER) material from the CER; sieving and milling the PC into milled PC; and mixing the pyrolysis char (PC) and the CDER material to form a composition.