Expanded Granular Materials via Synthetic Silicate Precursors

Solution Overview

Problem

Natural perlite's variable chemical composition and impurities lead to inconsistent physical properties in expanded granular materials, making it difficult to achieve controllable and reliable thermal insulation and construction applications.

Innovation Solution

A method involving the formation of a mixture of a silicate material, an alkali compound, and water, followed by curing and heating to produce an expanded granular material with controlled physical properties, such as low bulk density and thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If natural perlite is used as the raw material, then the expanded granular material has low bulk density and low thermal conductivity, but the physical properties are inconsistent due to variable chemical composition and impurities

Engineering Contradiction:

Improveconsistency of physical propertiesVSAvoidcontrol of chemical composition

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the chemical composition parameters by using synthetic materials (silica sand, alumina, alkali compounds) with precisely controllable compositions instead of natural perlite with variable composition. This allows consistent control of expansion characteristics, bulk density, and thermal conductivity in the expanded granular material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials consisting of silica sand, alumina, and alkali compounds in specific ratios to create a synthetic precursor that expands consistently. This composite approach replaces the variable natural perlite with a designed material system that provides reliable and controllable physical properties.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If natural perlite is expanded by heating to remove bound water, then the expansion degree depends on hydroxyl content, but the hydroxyl content is highly variable in natural perlite

Engineering Contradiction:

Improvecontrol of expansion degreeVSAvoidhydroxyl content consistency

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The invention changes the chemical composition parameters by using synthetic materials (silica sand, alumina, alkali compounds) with precisely controllable compositions instead of natural perlite with variable composition. This allows consistent control of expansion characteristics, bulk density, and thermal conductivity in the expanded granular material.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If natural perlite contains mineral impurities such as quartz and feldspar, then the raw material is readily available, but the expansion consistency and physical property control are compromised

Engineering Contradiction:

Improveavailability of raw materialVSAvoidcontrol of physical properties

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention changes the chemical composition parameters by using synthetic materials (silica sand, alumina, alkali compounds) with precisely controllable compositions instead of natural perlite with variable composition. This allows consistent control of expansion characteristics, bulk density, and thermal conductivity in the expanded granular material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials consisting of silica sand, alumina, and alkali compounds in specific ratios to create a synthetic precursor that expands consistently. This composite approach replaces the variable natural perlite with a designed material system that provides reliable and controllable physical properties.

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 method produces expanded granular materials with consistent low bulk density, high compaction resistance, and low thermal conductivity, suitable for thermally insulating products, construction materials, and horticultural substrates, while minimizing impurities and maximizing floatability.

Implementation Method 1

curing the mixture to form a solid precursor

Methodology Applied

Scientific EffectCuring: Chemical Bonding

Implementation Method 2

heating the expandable granular material to form an expanded granular material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

low thermal conductivities

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20220017415A1Expanded and expandable granular materials

Publication Date: 2022.01.20 IMERTECH SAS

AI summary

A method of manufacturing an expanded granular material comprises: forming a mixture comprising a silicate material, an alkali compound and water; curing the mixture to form a solid precursor; crushing and/or milling the solid precursor to form an expandable granular material; and heating the granular material to form an expanded granular material.