Fireproof Material Production Using Sodium Silicate and Propellant Microcapsules
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Solution Overview
Problem
Current fire protection materials face challenges in achieving low density, uniform structure, and water resistance while being energy-efficient and cost-effective, with suboptimal swelling behavior and high energy-intensive production processes.
Innovation Solution
A process involving a composition of water glass and propellant-gas microcapsules, where the polymer shell is broken up using propylene carbonate or temperature, resulting in a solid fire protection material with improved thermal insulation and water resistance, utilizing a mixture of sodium and potassium silicate glasses with specific viscosities and water content to enhance swelling and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If traditional fire protection materials are used to achieve low density, then transport and attachment are simplified, but the structure becomes less durable and water resistance decreases
Solution Approach 1:
The patent uses a composite composition containing water glass, silicate glasses, and propellant-gas microcapsules. The water glass provides low density and thermal insulation, while the silicate glasses and microcapsules contribute to structural durability and water resistance. This composite approach allows achieving low density without sacrificing structural integrity.
Solution Approach 2:
The patent specifies precise parameter ranges for the composition, including water glass content (50-90 wt%), silicate glass composition ratios, and microcapsule size (1-50 μm). By optimizing these parameters, the material achieves the desired balance between low density and structural durability.
2Loss of energy
If the production process is made energy-efficient and cost-effective, then production costs decrease, but manufacturing precision and quality control become more difficult
Solution Approach 1:
The microcapsules containing propellant gas automatically expand and release gas when mixed with water glass, creating foam structure without requiring external energy input or complex equipment. This self-service mechanism simplifies the production process, reduces energy consumption, and maintains consistent quality.
Solution Approach 2:
The patent utilizes phase transition of water glass from liquid to foam state through gas release from microcapsules. This phase transition occurs spontaneously when the composition is activated, enabling energy-efficient production while maintaining uniform foam structure and consistent product quality.
3Stability of the object's composition
If swelling behavior is enhanced to achieve uniform structure, then thermal insulation improves, but the production process becomes more complex and energy-intensive
Solution Approach 1:
The patent optimizes composition parameters including water glass viscosity (100-10,000 cP), silicate glass ratios, and microcapsule size distribution to achieve uniform swelling behavior. These parameter optimizations enable controlled foam formation without complex processing equipment or procedures.
Solution Approach 2:
The propellant-gas microcapsules act as intermediaries that facilitate uniform swelling. When the microcapsules rupture and release gas, they create uniform bubbles throughout the water glass matrix, achieving homogeneous foam structure without requiring complex mixing equipment or high energy input.
4Reliability
If water resistance is enhanced to improve durability, then the material performance improves, but the production cost and energy consumption increase
Solution Approach 1:
The patent incorporates silicate glasses and water glass in specific ratios to create a composite material that inherently provides water resistance. The silicate components form a water-resistant matrix that protects the foam structure without requiring additional energy-intensive treatments or coatings.
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 produces fire protection materials with low density, good uniform structure, and enhanced water resistance, achieving effective thermal insulation and structural stability while reducing energy consumption and production costs.
Implementation Method 1
swelling the microcapsules and/or breaking up the polymer material of the shell of the microcapsules by the addition of propylene carbonate; or by the following process steps (1') and (2'): (1') providing a composition comprising at least one potassium hydroxide glass and propellant-provided microcapsules having a propellant-provided core and a polymer material as a shell; (2') swelling the microcapsules and/or breaking up the polymer material of the shell of the microcapsules by the action of temperature from 60 to below 90° C.
Implementation Method 2
Fire protection materials in the sense of the invention refers in this respect to materials which are (to a large extent) non-combustible, have a temperature-insulating or heat-insulating effect and thus provide heat or flame protection
Implementation Method 3
Fire protection materials in the sense of the invention refers in this respect to materials which are (to a large extent) non-combustible, have a temperature-insulating or heat-insulating effect and thus provide heat or flame protection, and may even contribute to the prevention of fires, for example by releasing water.
Data Source
AI summary
The present invention concerns a process for the production of a solid fire protection material. The composition for producing the fire protection material contains at least one water glass and microcapsules provided with propellant gas. The fire protection material is formed by expanding the microcapsules or by breaking the polymer material of the shell of the microcapsules by the influence of temperature or by adding an agent which breaks the shell of the microcapsules.