Granular Silica Insulation With Low Density and High Strength
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Solution Overview
Problem
Existing silicon dioxide-based thermal insulation materials have high density and suboptimal mechanical stability, limiting their effectiveness and increasing costs.
Innovation Solution
A granular material comprising hydrophobized silicon dioxide and an IR opacifier, with a tamped density of up to 250 g/l and compressive strength of 150 to 300 kPa or greater, achieved through a process involving mixing, densification, thermal treatment, and hydrophobization, which enhances mechanical stability and reduces density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional densification methods are used to produce granular thermal insulation material, then the material achieves adequate thermal insulation, but the density becomes too high and mechanical stability is insufficient
Solution Approach 1:
The invention changes the particle size distribution parameter by combining coarse granules (0.5-2.0 mm) with fine powder (<0.063 mm) in a specific ratio (3:1 to 1:3). This parameter optimization allows achieving adequate thermal insulation with lower density (100-250 g/l) while improving mechanical stability through the synergistic effect of different particle sizes that interlock and distribute stress more effectively
Solution Approach 2:
The invention creates a composite granular material by combining silicon dioxide-based granules with at least one IR opacifier (such as silicon carbide, titanium dioxide, or zirconium dioxide) in a weight ratio of 95:5 to 50:50. This composite structure provides both thermal insulation properties and enhanced mechanical stability while maintaining low density, as the opacifiers fill voids and strengthen the granule matrix without significantly increasing overall density
2Strength
If hydrophobized fumed silicon dioxide is used with high tamped density, then thermal insulation is achieved, but mechanical stability and abrasion resistance are compromised
Solution Approach 1:
The invention optimizes the tamped density parameter to a specific range of 100-250 g/l, which is lower than conventional materials (250-570 g/l). This parameter change is achieved by using a broad particle size distribution (0.063 mm to 2.0 mm) that creates a more open, less compacted structure. The coarse granules provide structural framework for compressive strength while the fine powder fills critical voids, achieving high compressive strength (100-300 kPa at 50% compression) without requiring high density
Solution Approach 2:
The invention applies local quality by using fine powder (<0.063 mm) specifically to fill voids and reinforce critical regions within the granular structure, while coarse granules (0.5-2.0 mm) provide the overall structural framework. This spatial differentiation of particle functions allows the material to achieve high mechanical stability and compressive strength with lower overall density, as the fine powder locally strengthens without requiring uniform high density throughout the entire material
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 resulting material offers excellent thermal insulation with improved mechanical stability and low density, reducing abrasion and dust formation, and is economically viable for various insulation applications.
Implementation Method 1
a granular material comprising hydrophobized silicon dioxide and at least one IR opacifier
Implementation Method 2
at least one IR opacifier selected from the group consisting of silicon carbide, titanium dioxide, zirconium dioxide, ilmenites, iron titanates, iron oxides, zirconium silicates, manganese oxides, graphites, carbon blacks and mixtures thereof
Data Source
AI summary
The present invention relates to a granular thermal insulation material comprising hydrophobized silicon dioxide and at least one IR opacifier, having a tamped density of up to 250 g/l and a compressive strength according to DIN EN 826:2013 at 50% compression of 150 to 300 kPa or greater than 300 kPa, to processes for production thereof and to the use thereof for thermal insulation.