Thermally Insulating Mortar High-Speed Mixing Homogeneity
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Solution Overview
Problem
Existing methods for producing thermally insulating mortars on construction sites face challenges such as complex process control, energy intensity, and inability to achieve uniform mixing of foamed agents with cement, leading to density deviations and prolonged drying times, along with environmental concerns from protein-based foaming agents and instability of synthetic agents.
Innovation Solution
A method involving high-speed mixing of water, cement, and a liquid surfactant-foam concentrate in a mixing device with a horizontal drive shaft, creating a colloidal suspension with finely dispersed foam, resulting in a homogeneous, thermally insulating, and high-strength mortar with uniformly dispersed microscopic pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pre-foaming method is used to produce porous mortar, then thermal insulation properties are improved, but uniform mixing of foam with cement cannot be achieved and density deviations occur
Solution Approach 1:
The foam is generated and mixed with cement in a predetermined sequence within the mixing device, ensuring uniform distribution before application. The foam generator is integrated into the mixing process, allowing the foam to be incorporated systematically rather than added separately, thus achieving homogeneous density throughout the mortar mixture.
Solution Approach 2:
A foam generator device acts as an intermediary mechanism between the foam production and cement mixing processes. This device ensures that foam is generated and distributed uniformly throughout the cement matrix, preventing the density deviations that occur when foam is mixed afterward.
2Ease of manufacture
If protein-based foaming agents are used, then foam generation is achieved, but unpleasant smell and environmental pollution occur
Solution Approach 1:
The patent changes the chemical composition parameters of the foaming agent from protein-based to synthetic surfactant-based formulations. This parameter change eliminates the unpleasant odor and environmental pollution associated with animal protein decomposition while maintaining the foam generation capability necessary for porous mortar production.
Solution Approach 2:
The patent employs synthetic foaming agents that can be easily disposed of or degraded without environmental harm. These agents complete their function of foam generation and then decompose benignally, unlike protein-based agents that cause long-term environmental issues and odors.
3Manufacturing precision
If synthetic foaming agents are used, then constant quality is achieved, but stability is reduced
Solution Approach 1:
The patent uses composite foaming agent formulations that combine synthetic surfactants with stabilizing additives. This composite approach maintains the consistent quality and reliable performance of synthetic agents while enhancing foam stability through the synergistic effect of multiple chemical components working together.
4Manufacturing precision
If high-speed mixing is used to achieve uniform dispersion, then mixing homogeneity is improved, but energy consumption increases
Solution Approach 1:
The mixing device employs dynamic adjustment of mixing speed and intensity during the foam generation and incorporation process. The system starts with lower speed to generate foam, then increases speed for uniform distribution, and finally reduces speed for final mixing, achieving homogeneity while minimizing overall energy consumption compared to continuous high-speed mixing.
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 method produces a mortar with optimal thermal insulation, high strength, and low environmental impact, featuring a bulk density of 100-1000 kg/m3, low energy consumption, and recyclability, while meeting fire protection and vapor diffusion requirements, and being free from pollutants.
Implementation Method 1
a liquid surfactant-foam concentrate (liquid surfactant containing, foam generating concentrate) are introduced in a predefined mixing ratio into a mixing device
Implementation Method 2
the foam is distributed in the water-cement mixture in such a finely dispersed way, that a colloidal suspension or dispersion is formed
Implementation Method 3
A speed of 3-4 m/s is preferred. In this way, gravimetric forces act on the dispersion to be mixed. Due to the high rotational speed of preferably about 8,000 rpm, and the gravimetric friction effects thus generated on the container walls of the mixing device
Implementation Method 4
The mortar contains pores, which reduce the density of the mortar and provide the mortar with thermally insulating properties
Data Source
AI summary
A method for producing a thermally insulating mortar includes introducing water, cement and a liquid surfactant containing a foam concentrate that forms a foam in a predetermined mixing ratio into a mixing device provided with a mixing impeller, and rotating the mixing impeller at a very high speed, wherein a homogeneous mixing between the water, the cement and the formed foam occurs.