Geopolymer Composite Slurry Processing Without Curing, Drying, or Milling
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Solution Overview
Problem
Existing processes for producing geopolymer and geopolymer composites are energy-intensive, requiring curing, drying, and milling steps, which are costly and inefficient, and lack versatility for modification.
Innovation Solution
A process involving mixing aluminate and silicate in alkaline solution to form a sol-gel, optionally adding additives, diluting with water, and forming a geopolymer composite through decantation or organic phase emulsification, eliminating the need for curing, drying, and milling, and allowing for various modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional curing, drying, and milling steps are used in geopolymer production, then the geopolymer composite can be formed with proper structure, but the process becomes energy-intensive and costly
Solution Approach 1:
The patent applies preliminary action by pre-forming the geopolymer composite in a slurry state with all necessary additives incorporated before final setting. The slurry is prepared with water, geopolymer binder, aggregates, and additives mixed together, allowing the geopolymerization reaction to proceed in situ without requiring separate curing, drying, and milling steps. This eliminates energy-intensive post-processing while ensuring proper structure formation.
2Reliability
If traditional production process is used, then geopolymer can be produced, but the process lacks versatility for modification and encapsulation of additives
Solution Approach 1:
The patent implements universality by creating a multi-functional slurry-based production process that simultaneously achieves geopolymer formation, additive encapsulation, and material modification. The slurry formulation allows incorporation of various additives (nano-particles, carbon-based materials, fibers) and modification agents (silane coupling agents, latex) in a single mixing step, making the process versatile for different applications and material compositions without requiring separate processing steps.
3Ease of manufacture
If curing, drying, and milling steps are eliminated, then energy consumption and cost are reduced, but the challenge is to achieve proper geopolymer composite formation
Solution Approach 1:
The patent applies parameter changes by optimizing the slurry composition parameters (water-to-binder ratio, additive concentrations, particle size distributions) to ensure proper geopolymer composite formation without traditional processing steps. The slurry is formulated with specific proportions of water, geopolymer binder, aggregates, and additives, along with controlled pH and temperature conditions during mixing, allowing the geopolymerization reaction to proceed correctly and form a dense, well-structured composite directly from the slurry state.
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 geopolymer composites more efficiently and cost-effectively, enabling encapsulation of additives like nano particles and carbon-based materials, and allows for various modifications, including silane coupling and latex hybridization, enhancing self-extinguishing and thermal insulation properties.
Implementation Method 1
mixing of precursor for aluminate and silicate in alkaline solution, to form a sol-gel
Implementation Method 2
The synthesis of geopolymers from aluminosilicate materials takes place by the so-called geopolymerization process, which involves polycondensation phenomena of aluminate and silicate groups, with formation of Si—O—Al type bonds
Implementation Method 3
step e) comprises e1) decantation
Implementation Method 4
e2) adding of an organic phase, emulsifying, and stripping of the organic phase
Implementation Method 5
e2) adding of an organic phase, emulsifying, and stripping of the organic phase
Data Source
AI summary
The present invention relates to a simple process for the production of geopolymer or geopolymer composite comprising additive. The process preferably comprises modification of the geopolymer or geopolymer composite. The invention further relates to a geopolymer or geopolymer composite as obtainable according to the process.