Composite Particle Insulation via Matrix Encapsulation

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Solution Overview

Problem

Current insulation materials in the construction industry, such as polystyrene, phenolic foams, and polyurethane, face issues with high flammability, toxic gas emissions, and environmental concerns, while inorganic materials like expanded and foamed glasses have limitations in thermal conductivity and mechanical stability.

Innovation Solution

A process for producing composite particles with a matrix encapsulation method, using sheet silicates, lightweight fillers, and nonrefractory solids to create insulating materials with low thermal conductivity, high thermal stability, and low bulk density, which are nonflammable and have low emissions, suitable for various construction applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If organic insulation materials (polystyrene, phenolic foams, polyurethane) are used, then thermal conductivity is improved (lower values), but flammability increases and toxic emissions occur

Engineering Contradiction:

Improvethermal conductivityVSAvoidflammability and toxic emissions

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The invention uses composite particles consisting of a core material (expanded glass, perlite, or pumice) coated with a binder system containing silicate and organic thickening agents. This composite structure combines the low thermal conductivity of expanded materials with the fire-resistant properties of silicates, achieving both thermal insulation performance and fire safety without toxic emissions.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If inorganic insulation materials (expanded and foamed glasses) are used, then flammability is improved (noncombustible), but thermal conductivity worsens (higher values)

Engineering Contradiction:

ImproveflammabilityVSAvoidthermal conductivity

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The invention applies different materials to different parts of the insulation system: the core uses expanded glass/perlite/pumice for low thermal conductivity, while the coating layer uses silicate-based binder for fire resistance. This local differentiation allows each component to optimize its specific function without compromising the other.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If flame retardants are added to polystyrene, then flammability is improved, but harmful emissions increase (brominated compounds release toxic gases)

Engineering Contradiction:

ImproveflammabilityVSAvoidtoxic gas emissions

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

Instead of using harmful brominated flame retardants, the invention converts naturally fire-resistant inorganic materials (silicates, expanded glass) into the insulation system. These materials inherently resist combustion without releasing toxic gases, transforming the problem of fire safety into a benefit of using inorganic core materials.

Inventive Principle:

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

4Loss of energy

If insulation material density is reduced, then thermal insulation is improved, but mechanical strength decreases

Engineering Contradiction:

Improvethermal insulationVSAvoidmechanical strength

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The composite particle structure combines lightweight expanded core material (for thermal insulation) with a binder coating (for mechanical strength). The binder system containing silicate and organic thickening agents provides structural integrity to the lightweight particles, enabling them to maintain both low density and adequate mechanical strength for construction applications.

Inventive Principle:

Principle #40Composite materials

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 results in insulating materials with improved thermal insulation, mechanical strength, and reduced environmental impact, offering flexibility in composition and size, and enhanced safety features like nonflammability and low emissions.

Implementation Method 1

solidifying the solidifiable liquid, such that the droplets harden to give hardened droplets

Methodology Applied

Scientific EffectSolidification: Freezing

Implementation Method 2

treating (preferably heat-treating) the hardened droplets so as to result in said composite particles, the treating comprising a sintering of the hardened droplets

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11603334B2Process for producing composite particles and insulation material for the production of insulating products for the building materials industry, and corresponding uses

Publication Date: 2023.03.14 HUTTENES-ALBERTUS CHEMISCHE WERKE GMBH

AI summary

What are described are a process for producing an insulating product for the construction materials industry or an insulating material as intermediate for production of such a product, and a corresponding insulating material/insulating product. Also described are the use of a matrix encapsulation method for production of composite particles in the production of an insulating product for the construction materials industry or of an insulating material as intermediate for production of such a product, and the corresponding use of the composite particles producible by means of a matrix encapsulation method.