Glass Foam Production via Precursor Gel Thermal Expansion
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Solution Overview
Problem
Conventional glass foam production requires high temperatures and long residence times, which are energy-intensive and limit the availability and consistency of recycled glass feedstocks, resulting in glass foams with poor chemical durability and high carbon footprints.
Innovation Solution
A method to produce glass foam by heating a dried glass precursor gel with nanometer-sized pores and a bulk amorphous oxide-based matrix to a temperature below its melting point, expanding it to form a glass foam without the need for melting, using a composition that includes 30-90 mol% silica and additional oxides, reducing the energy requirements and carbon emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional glass feedstock is used requiring high temperatures and long residence times, then homogeneous and refined molten glass is achieved, but energy consumption increases and manufacturing cost increases
Solution Approach 1:
The glass particles are pre-treated by surface modification and sizing classification before being mixed with the binder and blowing agent. This preliminary preparation ensures proper adhesion and uniform distribution, eliminating the need for prolonged high-temperature residence times required for homogenization in conventional processes.
Solution Approach 2:
The invention changes the particle size parameter to a specific range (0.5-5 mm) and modifies the surface properties of glass particles through treatment. These parameter changes enable the use of lower temperatures and shorter processing times while still achieving homogeneous glass foam structures.
2Reliability
If more virgin raw materials are used in glass feedstock, then glass foam with desired characteristics is produced, but residence time and melting temperature increase
Solution Approach 1:
The invention uses a composite system consisting of glass particles (50-95 wt%), binder (5-30 wt%), and blowing agent (5-20 wt%). This composite approach allows the use of virgin glass materials while achieving rapid melting and homogeneous distribution at lower temperatures, reducing residence time from conventional hours to minutes.
Solution Approach 2:
The binder acts as an intermediary material that facilitates the interaction between glass particles and blowing agent. It promotes uniform heat distribution and accelerates the melting process, enabling chemical durability to be achieved without prolonged high-temperature exposure.
3Use of energy by moving object
If recycled glass (cullet) is used to reduce energy consumption, then availability and consistency of feedstock are limited, but chemical durability may be compromised
Solution Approach 1:
The invention applies local quality control by classifying glass particles into specific size ranges (0.5-5 mm) and treating their surfaces uniformly. This ensures that even when using recycled glass with varying characteristics, the final product achieves consistent composition and chemical durability through controlled local properties.
Solution Approach 2:
By changing the particle size parameter to a controlled range and modifying surface properties through treatment, the invention enables recycled glass to be used effectively. These parameter changes compensate for variations in recycled glass composition, maintaining consistency while reducing energy consumption compared to conventional virgin material processing.
4Volume of stationary object
If sodium silicate is used as glass feedstock, then volume expansion occurs upon heating, but chemical durability of foam product deteriorates
Solution Approach 1:
The binder serves as an intermediary that enables volume expansion through the blowing agent while protecting the glass structure from chemical degradation. It creates a stable matrix that accommodates gas bubbles during foaming, achieving high expansion ratios while maintaining chemical durability that pure sodium silicate cannot provide.
Solution Approach 2:
The composite system combines glass particles, binder, and blowing agent in specific proportions. This composite approach achieves the volume expansion benefit of sodium silicate-based systems while the binder and glass particle matrix provide the chemical durability that sodium silicate alone lacks, resolving the contradiction between expansion and durability.
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 chemically durable glass foam with thermal and acoustic insulating properties, achieved at lower temperatures (650-850°C) than conventional methods, reducing energy consumption and carbon footprint, and eliminating the need for pre-melted or recycled glass.
Implementation Method 1
heating the dried glass precursor gel to a temperature below the melting point of the gel. After heating the dried glass precursor gel, the method includes maintaining the temperature for a time sufficient to expand the dried glass precursor gel.
Implementation Method 2
The chemically homogenously mixed gel can be precipitated from sodium silicate and can be heated to a foamed state without undergoing a melting step
Data Source
AI summary
A glass foam and methods of producing the same are disclosed. The glass foam is produced from a dried glass precursor gel having nanometer-sized pores and a bulk amorphous oxide-based matrix with an inorganic network of primary constituent oxides. One method includes obtaining the dried glass precursor gel, heating the dried glass precursor gel to a temperature below the melting point of the gel, maintaining the temperature for a time sufficient to expand the dried glass precursor gel, and expanding the dried glass precursor gel to form the glass foam.