Lightweight Ceramic Production Using Burnout Polymer Pore Formers
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Solution Overview
Problem
Conventional methods for producing refractory ceramic materials with reduced specific weight and improved insulation properties are limited by the presence of open pores, which compromise corrosion resistance and mechanical strength, and often result in the formation of harmful black cores during the burning process.
Innovation Solution
A method involving the use of spherical, thermoplastic polymer particles with a ceiling temperature below 250°C, specifically polymethacrylates, to create predominantly closed and isolated pores in ceramic materials, allowing for the production of lightweight, high-strength, and thermally insulating ceramics without the risk of black core formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional porous additives (diatomaceous earth, perlite, hollow ceramic spheres) are used to create pores in ceramics, then porosity is achieved for thermal insulation, but the materials remain relatively heavy and the pores are not closed and coherent
Solution Approach 1:
The patent uses polymer particles with controlled porosity and structure that burn out to leave behind closed spherical pores. These pores are inherently closed and isolated, providing thermal insulation while allowing significant weight reduction compared to conventional porous additives.
Solution Approach 2:
The patent changes the physical and chemical parameters of the pore-forming additive by using polymer particles with specific ceiling temperatures (below 250°C) and controlled pore structures. This allows complete burnout without residue, creating closed pores that provide both insulation and weight reduction.
2Temperature
If burnable additives (coal, coke, sawdust, nut shells) are used to create pores in ceramics, then porosity is achieved for thermal insulation, but harmful black cores form in the burned-out ceramic
Solution Approach 1:
The patent uses polymer particles that are designed to burn out completely and disappear during the firing process. These disposable pore formers leave no harmful residues or black cores, unlike conventional burnable additives that carbonize and form harmful residues.
Solution Approach 2:
The patent converts the potential harm of incomplete combustion (black core formation) into a benefit by selecting polymers with ceiling temperatures below 250°C that undergo complete depolymerization and oxidation, transforming the burning process into a clean decomposition that creates closed pores without harmful residues.
3Temperature
If open pore systems are used in ceramic materials, then thermal conductivity is reduced for insulation, but corrosion resistance and mechanical strength deteriorate
Solution Approach 1:
The patent uses spherical polymer particles that burn out to form spherical closed pores. This spheroidality creates isolated pore chambers that maintain thermal insulation properties while preventing the interconnected pathways that would compromise corrosion resistance and mechanical strength.
Solution Approach 2:
The patent segments the pore structure into isolated, closed spherical pores rather than continuous open pore systems. This segmentation creates discrete insulation chambers that maintain thermal performance while blocking the pathways for corrosive substances and stress propagation.
4Temperature
If high porosity is achieved in ceramic materials, then thermal insulation properties are improved, but mechanical strength and corrosion resistance deteriorate
Solution Approach 1:
The patent creates a porous structure with closed spherical pores that provides high thermal insulation through the air gap effect while maintaining mechanical strength because the closed pores do not create the same stress concentration and corrosion pathways as open pore systems.
Solution Approach 2:
The patent creates a composite structure combining ceramic matrix material with polymer pore formers that burn out to leave closed pores. This composite approach allows high porosity for insulation while the ceramic matrix maintains structural integrity and mechanical strength.
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 achieves ceramics with enhanced corrosion resistance, mechanical strength, and thermal insulation properties while eliminating the risk of black core formation, enabling the production of lightweight, high-performance refractory materials suitable for high-temperature applications.
Implementation Method 1
The pores with a specifically adjustable pore diameter are created by using polymer particles, in particular polymethacrylates, in particular polymers or copolymers produced by suspension polymerization, as burnout pore formers.
Implementation Method 2
The combustion residues of some of these substances, such as ash or slag, are very reactive and can affect the operational properties of the FF ceramics
Implementation Method 3
The specific, closed pore system also contributes to reducing the thermal conductivity of the ceramic materials
Data Source
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AI summary
The present invention relates to a novel method for producing ceramic materials, in particular fireproof materials with reduced specific weight. In particular, the invention relates to a method for producing light, fireproof materials with non-coherent pores based on shaped and non-shaped materials. These materials can be used as a working lining in high-temperature applications. The method is based on the generation of spherical, closed and insulated pores in the material structure. The pores are generated with a pore diameter adjustable in a targeted manner using polymer particles, in particular polymethacrylates, in particular polymers and/or copolymers produced by means of suspension polymerisation as a combustible shaping means. The polymers and/or copolymers are spherical with a defined diameter. The introduction of insulated spherical pores enables ceramic materials to be produced with a partially significantly reduced specific weight and improved resistance to corrosion and better mechanical stability when compared to the prior art. The specific closed pore system simultaneously contributes to the reduction of the thermal conductivity of the ceramic materials. In addition, the novel method provides the benefit that there is no danger of harmful black cores forming even when producing thick-walled ceramic products.