Microporous Composite Insulation With Hydrogel Binder Stability
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Solution Overview
Problem
Existing microporous insulation materials suffer from low mechanical strength, high thermal conductivity, and high cost due to the use of acid-stabilized colloidal silica and large amounts of inorganic fiber, which are not beneficial for thermal conductivity.
Innovation Solution
A method involving the use of pyrogenic and precipitated silica, optionally with alumina, and a hydrophobic microporous powder, is combined with a hydrogel formed by crosslinking a hydrophilic polymer and waterglass to create a processable insulation material with improved mechanical strength and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acid-stabilized colloidal silica and large amounts of inorganic fiber are used, then mechanical strength is improved, but thermal conductivity increases and cost increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing acid-stabilized colloidal silica with base-stabilized colloidal silica and adjusting the inorganic fiber content to a specific range (15-30 wt%). It also modifies the binder system by using base-stabilized colloidal silica combined with specific polymers (polyethylene oxide, cellulose ethers, or vinyl amide/acrylic acid copolymers), thereby achieving both mechanical strength and thermal insulation performance without the drawbacks of the prior art.
Solution Approach 2:
The patent creates a composite insulation material system combining base-stabilized colloidal silica with specific polymers and controlled amounts of inorganic fibers. This composite approach allows the material to achieve both mechanical integrity and thermal insulation properties, resolving the contradiction between strength and thermal conductivity by synergistically combining multiple materials with complementary properties.
2Stability of the object's composition
If acid-stabilized colloidal silica is used, then binding properties are improved, but cost increases and thermal conductivity worsens
Solution Approach 1:
The patent fundamentally changes the binder system from acid-stabilized colloidal silica to base-stabilized colloidal silica combined with specific polymers. This parameter change in the chemical composition maintains binding properties while improving thermal insulation and reducing cost, as base-stabilized colloidal silica is more cost-effective and provides better thermal performance.
3Strength
If inorganic fiber content is increased to 18wt%, then mechanical strength is improved, but thermal conductivity increases
Solution Approach 1:
The patent optimizes the inorganic fiber content parameter to a specific range (15-30 wt%, preferably 18 wt%) and combines it with base-stabilized colloidal silica and specific polymer binders. This parameter optimization ensures that the fiber content is sufficient for mechanical strength but not excessive, thereby maintaining thermal insulation performance while achieving adequate mechanical properties.
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 insulation material achieves a density of 300-500 g/dm³, providing adequate thermal conductivity and mechanical stability up to 400°C, with reduced shrinkage and cost, and can be easily applied to surfaces without additional fasteners.
Implementation Method 1
a gelled material in which a microporous powder is loaded
Implementation Method 2
microporous powder comprises fiber, an opacifier and pyrogenic silica, wherein said pyrogenic silica is hydrophobic
Implementation Method 3
The gel comprises a hydrogel obtained by crosslinking a hydrophilic polymer
Data Source
AI summary
The processable microporous insulation material is prepared by providing a hydrogel or a precursor thereof; generating an aqueous siliceous composition based on waterglass; mixing the aqueous siliceous composition with the hydrogel or the precursor thereof to obtain a gel; loading a microporous powder into the gel, said microporous powder comprising opacifier and particulate silica material from the group of pyrogenic silica and precipitated silica, said particulate silica material optionally further comprising alumina, said weight% based on total dry weight of the microporous powder, wherein said microporous powder and/or at least part of said particulate silica material is hydrophobic. The processable microporous insulation material can be processed to provide insulation to an object.