Microporous Insulation Composition With Hydrogel-Bound Silica
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Solution Overview
Problem
Existing microporous insulation materials suffer from low mechanical strength and high thermal conductivity at elevated temperatures, primarily due to the use of acid-stabilized colloidal silica and large amounts of inorganic fiber, which increase cost and density.
Innovation Solution
A microporous insulation composition based on a hydrogel formed from polyalkylene oxide, with reduced inorganic fiber content and increased opacifier and hydrophobic pyrogenic silica, eliminating the need for colloidal silica gelation, resulting in improved thermal insulation and mechanical stability.
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 ratio of inorganic fiber to particulate filler. This parameter change reduces thermal conductivity while maintaining mechanical strength through optimized composition rather than relying on large amounts of fiber
Solution Approach 2:
The patent uses a composite material system combining base-stabilized colloidal silica, inorganic fiber, and particulate filler in specific proportions. This composite approach creates a synergistic effect where the colloidal silica matrix provides thermal insulation while the fiber network provides mechanical strength, avoiding the need to prioritize one over the other
2Stability of the object's composition
If acid-stabilized colloidal silica is used, then binding is improved, but thermal insulation performance deteriorates at elevated temperatures
Solution Approach 1:
The patent changes the stabilization parameter of the colloidal silica from acid-stabilized to base-stabilized. This parameter change fundamentally alters the thermal stability characteristics, allowing the binder to maintain its insulating properties at elevated temperatures up to 400°C while still providing adequate binding strength
3Strength
If inorganic fiber content is increased, then mechanical strength is improved, but density increases and thermal conductivity increases
Solution Approach 1:
The patent optimizes the particle size distribution and aspect ratio parameters of the inorganic fiber to maximize mechanical strength contribution while minimizing density. By carefully controlling fiber morphology and using base-stabilized colloidal silica as a matrix, the patent achieves high strength-to-density ratio
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 composition achieves higher densities (above 350 g/dm³) with reduced thermal conductivity, enhancing mechanical strength and thermal insulation performance at temperatures up to 400°C, suitable for applications like piping, fuel cells, and aerospace.
Implementation Method 1
A microporous insulation composition based on a hydrogel formed from polyalkylene oxide
Implementation Method 2
increased opacifier and hydrophobic pyrogenic silica, eliminating the need for colloidal silica gelation, resulting in improved thermal insulation
Implementation Method 3
the microporous powder comprises 0-10% by weight of inorganic fiber, 20-50% by weight of an opacifier
Data Source
AI summary
The processable microporous insulation material comprises a gelled material in which a microporous powder is loaded. The gelled material is a hydrogel that is based on a polyalkylene oxide, wherein alkylene is C2-C6 alkylene. The microporous powder comprises 0-10% by weight of inorganic fiber, 20-50% by weight of an opacifier and 30-70% by weight of a 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.