Mineral Foam Binder Composition for Stable Low-Energy Insulation

Solution Overview

Problem

Existing insulation materials for buildings, such as polystyrene, polyurethane, rock wool, and autoclaved aerated concrete, suffer from environmental impact, fire resistance, moisture resistance, recyclability, and high energy consumption issues, while inorganic materials like autoclaved aerated concrete generate significant CO2 and require energy-intensive autoclaving.

Innovation Solution

A mineral foam is prepared using a mixture of natural inorganic binders, including reactive aluminosilicate, hydraulic, and aerial binders, with colloidal silica, which is stabilized and structurally incorporated to form a cellular material with thermal insulation, mechanical strength, fire resistance, and moisture breathability, and is recyclable, using a method that reduces energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If autoclaved aerated concrete is used for thermal insulation, then thermal insulation performance is improved, but environmental impact increases due to CO2 emissions and energy consumption

Engineering Contradiction:
Core Design Contradiction:
TemperatureVSObject-generated harmful factors

Solution Approach 1:

The invention changes the chemical composition parameters of the binder system by incorporating metakaolin (reactive aluminosilicate) alongside Portland cement and lime, creating a hybrid binder that reduces CO2 emissions and energy consumption while maintaining thermal insulation performance through optimized material ratios and chemical reactions

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite binder system combining Portland cement, lime, and metakaolin in specific ratios, where each component contributes different properties: Portland cement provides strength, lime contributes to workability and setting, and metakaolin reduces environmental impact while enhancing reactivity with silica fume to form strength-giving C-A-S-H phases

Inventive Principle:
Principle #40Composite materials

2Object-generated harmful factors

If pre-formed foam cellular concrete is used, then environmental impact is reduced, but mechanical resistance decreases and shrinkage increases

Engineering Contradiction:
Core Design Contradiction:
Object-generated harmful factorsVSStrength

Solution Approach 1:

The invention changes the chemical composition by incorporating reactive aluminosilicate (metakaolin) that reacts with silica fume to form C-A-S-H phases, fundamentally altering the binding mechanism to provide both early and long-term strength while controlling shrinkage through balanced hydration reactions of multiple binders

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The invention performs preliminary chemical preparation by pre-mixing the multi-component binder system (Portland cement, lime, metakaolin, silica fume) before foam addition, ensuring that all reactive components are properly distributed and positioned to react with the introduced water, thereby optimizing strength development from the outset

Inventive Principle:
Principle #10Preliminary action

3Temperature

If rock wool or glass wool is used for insulation, then thermal insulation is achieved, but moisture resistance and stability deteriorate

Engineering Contradiction:
Core Design Contradiction:
TemperatureVSReliability

Solution Approach 1:

The invention uses a porous cellular structure formed by foam stabilization, where the cell walls and struts create a network that provides thermal insulation through air trapping while the hydrophilic nature of the inorganic binder system (Portland cement, lime, metakaolin) allows moisture to pass through, preventing water accumulation and maintaining stability

Inventive Principle:
Principle #31Porous materials

4Temperature

If polystyrene is used for insulation, then thermal insulation performance is improved, but fire resistance and environmental sustainability worsen

Engineering Contradiction:
Core Design Contradiction:
TemperatureVSObject-affected harmful factors

Solution Approach 1:

The invention replaces long-lived petroleum-based polystyrene with an inorganic binder system (Portland cement, lime, metakaolin, silica fume) that is inherently fire-resistant and environmentally sustainable, accepting that the material has a finite service life but gains benefits of non-flammability and reduced environmental impact throughout its lifecycle

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention uses a composite inorganic binder system where Portland cement, lime, metakaolin, and silica fume work together to create a material that is inherently fire-resistant due to its mineral composition, eliminating the fire safety issues associated with organic insulators like polystyrene while maintaining thermal insulation performance

Inventive Principle:
Principle #40Composite materials

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 mineral foam achieves low environmental impact, high mechanical performance, thermal and acoustic insulation, fire resistance, and recyclability, with a stable wet state suitable for pouring and hardening without collapsing, and reduced energy consumption.

Implementation Method 1

the mineral foam also contains colloidal silica, which, in addition to having a stabilising effect on the wet mineral foam, is structurally incorporated into the hardened cellular material

Methodology Applied
Scientific EffectColloidal stabilization: Colloid

Implementation Method 2

The expansion that forms the cellular structure, on the other hand, is obtained by a chemical reaction between aluminium powder and lime

Methodology Applied
Scientific EffectChemical expansion reaction: Chemical Bonding

Implementation Method 3

When the foam has cured, it forms a cellular material that possesses adequate thermal and/or acoustic insulation properties

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 4

a mixture of inorganic binders comprising: at least one reactive aluminosilicate binder, at least one hydraulic binder and at least one aerial binder

Methodology Applied
Scientific EffectHydraulic hydration: Mineral Hydration

Data Source

PatentEP4092006B1Method for preparing a mineral foam, mineral foam and use thereof
Publication Date: 2026.04.29

AI summary

The present invention relates to a method for preparing a mineral foam comprising the following sequential steps: a. preparing a slurry comprising: - a mixture of inorganic binders comprising: at least one reactive aluminosilicate binder, at least one hydraulic binder and at least one aerial binder; - Portland cement; - colloidal silica; - water; - optionally, at least one additive; b. adjusting the pH of the slurry to a value within the range of 9 to 12.5; c. combining the slurry with a pre-formed foam to obtain the mineral foam. The present invention also relates to mineral foam obtained by the aforementioned method and its use as a thermally insulating material, sound-absorbing material or building material.