Foamed Glass-Ceramic Blocks Uniform Porosity
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Solution Overview
Problem
Existing methods for producing foamed ceramic blocks face issues such as cavity formation, loss of linear motion, low hydraulic press capacity, high energy consumption, inhomogeneous pore formation, and difficulty in achieving crystallized structures with open porosity, which hinder the production of high-quality, heat-insulating glass-ceramic materials.
Innovation Solution
A method involving the preparation of a finely ground glass-ceramic phase with silicon carbide content, followed by drying, pressing, and foaming, where the tiles are coated with a double-layered engobe and rapidly cooled to create uniformly closed finely porous structures, allowing for the production of large-size blocks with improved physical and chemical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tiles are stacked to increase height of foamed bar, then productivity is improved, but manufacturing precision deteriorates due to formation of large cavities in foamed block
Solution Approach 1:
The method divides the foaming process into two distinct stages: first forming a continuous bar from stacked tiles, then separating it into individual blocks. This segmentation allows the bar to maintain structural integrity during foaming while preventing cavity formation that would occur with stacked tiles, thus resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The method applies preliminary action by coating the stacked tiles with engobe before foaming. This coating layer prevents direct contact between tiles during expansion, eliminating cavity formation while allowing the bar to maintain continuous structure for high productivity. The engobe coating is applied in advance to prepare the tile surfaces for unified foaming.
2Use of energy by moving object
If conventional firing methods are used, then energy consumption is reduced, but manufacturing precision deteriorates due to inhomogeneous pore formation
Solution Approach 1:
The method changes the thermal parameters by implementing a specific heating program with distinct stages: initial heating to 400-600°C for moisture removal, then continued heating to foaming temperature (900-1100°C) at controlled rates. This parameter control ensures homogeneous pore formation throughout the bar while maintaining energy efficiency, resolving the contradiction between energy consumption and manufacturing precision.
3Productivity
If rapid cooling is applied, then productivity is improved, but reliability deteriorates due to potential shape instability
Solution Approach 1:
The method applies local quality by implementing differential cooling: rapid cooling is applied to the surface and exterior regions of the bar to lock in the porous structure and prevent further expansion, while the core cools more slowly to maintain structural integrity. This localized approach to cooling rates ensures both productivity through overall rapid cooling and reliability through shape stability.
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 method enables the production of glass-ceramic foamed blocks with thickness up to 200 mm and uniformly closed finely porous structures, enhancing their physical and chemical properties, including sound-proofing and impregnation capabilities.
Implementation Method 1
foaming with silicon carbide oxidation
Implementation Method 2
uniformly closed finely porous structure
Implementation Method 3
lower and two side surfaces of which parallel to the roller conveyor motion are covered with double-layered engobe
Implementation Method 4
rapidly cooled
Data Source
AI summary
This invention belongs to the field of porous silicate foamed materials production, namely, production of foamed glass-ceramic blocks which may be used in building, radio engineering, metallurgy, shipbuilding, chemical, medical industries and agriculture. The technical result is manufacturing of foamed ceramic materials with thickness up to 200 mm with uniformly closed finely porous structure over the whole material volume and high physicochemical properties. The method of large-size glass-ceramic foamed blocks fabrication includes preparation of finely ground glass-ceramic phase with particle size of 1 to 50 µm containing production waste with silicon carbide content of at least 10 weight %. Then a finely ground batch is prepared with particle size of 1 to 50 µm for foamed blocks fabrication containing finely ground glass-ceramic phase in quantity of 5 to 95 weight % and binding component as a remainder, subsequent drying and pressing thereof to obtain blanks with thickness of 15 to 60 mm in the form of large-size tiles, and drying of large-size tiles to residual moisture content of 0.5 %. Then large-size tiles are fed to kiln by roller conveyor without moulds and trays application. Roller conveyor speed in the end of large-scale tiles sintering zone of kiln is lower by 5 to 25% than before this zone, which ensures formation of uniform sintered bar with subsequent foaming thereof. Prior to feeding of dried large-size tiles to kiln their lower surface and two side surfaces parallel to roller conveyor movement are covered with double-layered engobe, and after foaming in the end of kiln the bar is cooled rapidly to the temperature providing bar shape stability, and a notch is applied on its surface perpendicularly to roller conveyor movement movement. After bar removal from kiln it is separated into blocks along notched lines, then blocks are fed to annealing furnace and then to mechanical treatment.