Thermally insulative compositions for a ceramic coating

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Solution Overview

Problem

Conventional thermal insulation materials lack effectiveness in extreme temperatures and often contain organic components that can contaminate or burn off, leading to inefficiencies and safety issues in applications like furnaces and solar panels.

Innovation Solution

A non-sacrificial, fully inorganic ceramic coating with a composition of insulative particles, amorphous silica, inorganic fibers, and an insulating compound, providing high emissivity, low thermal conductivity, and mechanical resistance, which can be applied thinly and efficiently to various surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal insulation materials are used, then thermal insulation is provided, but organic components burn off and cause contamination at extreme temperatures

Engineering Contradiction:

Improvethermal insulation effectivenessVSAvoidcontamination from burning organic components

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using fully inorganic materials (amorphous silica, electrofused silica, inorganic fibers, metal oxides) instead of organic-based insulation materials. This parameter change eliminates the burning off and contamination issue while maintaining thermal insulation effectiveness at extreme temperatures up to 1800°C.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite ceramic coating material combining multiple inorganic components (amorphous silica 20-40%, electrofused silica 10-30%, inorganic fibers 5-20%, metal oxides 10-30%) to achieve both thermal insulation properties and high-temperature stability without organic contamination.

Inventive Principle:

Principle #40Composite materials

2Temperature

If conventional refractory materials are used, then high temperature resistance is achieved, but the materials are thick and heavy

Engineering Contradiction:

Improvehigh temperature resistanceVSAvoidweight and thickness of insulation layer

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent utilizes porous ceramic structures with controlled porosity (30-70%) to provide thermal insulation through air pockets while maintaining a thin coating profile. The porous network of inorganic fibers and particles creates effective thermal barriers without requiring thick layers, reducing both weight and thickness compared to conventional refractories.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent changes the density and thickness parameters by formulating a lightweight ceramic coating with optimized particle size distributions and porosity levels, achieving equivalent thermal insulation performance at 1/10th the thickness and significantly reduced weight compared to traditional refractory materials.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If polymer-based coatings are used, then application is simplified, but the coatings are sacrificial and burn off at extreme temperatures

Engineering Contradiction:

Improvecoating application simplicityVSAvoidcoating durability under thermal cycling

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent changes the material phase from organic polymer to inorganic ceramic, enabling the coating to withstand extreme temperatures and thermal cycling without degrading. The inorganic composition (metal oxides, silica) provides non-sacrificial durability while maintaining ease of application through slurry or spray formulations that cure to form protective ceramic layers.

Inventive Principle:

Principle #35Parameter changes

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 ceramic coating effectively reduces thermal absorption, enhances heat retention, and protects surfaces from damage, maintaining performance across a wide temperature range while being lighter and more durable than traditional refractory materials.

Implementation Method 1

The ceramic coating demonstrates advantageous thermal insulation properties (e.g., low thermal conductivity) over a wide range of temperatures

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The ceramic coating also demonstrates high emissivity, low thermal conductivity, and high resistance mechanical properties

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20240246866A1Thermally insulative compositions for a ceramic coating

Publication Date: 2024.07.25 NANOTECH INC

AI summary

A new and innovative hard ceramic coating having refractory properties is provided. The ceramic coating may be used as a replacement for refractory materials. As opposed to polymer-based coatings that are sacrificial when exposed to extreme temperatures, the ceramic coating is a non-sacrificial, fully inorganic (e.g., free of organic components) coating that resists many thermal cycles. The ceramic coating is also thinner and lighter than conventional refractory materials the ceramic coating can replace. The ceramic coating demonstrates advantageous thermal insulation properties (e.g., low thermal conductivity) over a wide range of temperatures and when applied with minimal thickness. The ceramic coating also demonstrates high emissivity, low thermal conductivity, and high resistance mechanical properties, which are all desirable properties for use as a thermally insulating replacement coating for refractory materials.