Mineral Foam Mechanical Foaming Device
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Solution Overview
Problem
Existing external thermal insulation composite systems for buildings are thick due to multiple layers and lack sufficient mechanical strength between layers, while also relying on chemical foaming processes that cause environmental pollution.
Innovation Solution
A mechanical foaming device is used to create a mineral foam with a single layer that combines thermal insulation and mechanical cohesion, utilizing a kneading device with internal channels for air introduction and a lance with flat obstacles to enhance pore formation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple layers of mineral wool insulation board and mineral plaster are used for thermal insulation, then thermal insulation performance is improved, but overall thickness increases and mechanical strength between layers is insufficient
Solution Approach 1:
The patent combines thermal insulation and plastering functions into a single mineral foam layer. The mineral foam formulation integrates insulation materials with plaster components, allowing one layer to perform both thermal insulation and surface coating functions, thereby reducing the number of layers and overall thickness while maintaining insulation performance
Solution Approach 2:
The mineral foam uses composite material formulation combining sulfate-aluminate cement, sulfate components, aluminum silicates, calcium oxide-providing components, and foam components. This composite structure provides both thermal insulation properties and mechanical strength within a single layer, eliminating the need for multiple separate layers
2Shape
If chemical foaming process is used to produce mineral foam, then foam structure is formed, but environmental pollution occurs
Solution Approach 1:
The patent replaces chemical foaming processes with mechanical foaming. The mineral slurry is mechanically beaten and aerated using mixing equipment to incorporate air bubbles and form the foam structure, eliminating the need for chemical foaming agents and their associated environmental pollution while still achieving the desired porous foam structure
Solution Approach 2:
The patent converts the mechanical energy input into beneficial air incorporation and foam structure formation. The mechanical beating process that would normally just mix materials is instead used to deliberately incorporate air and create the foam structure, turning a simple mixing operation into an effective foaming mechanism without chemical additives
3Object-generated harmful factors
If mechanical foaming process is used to create pores, then environmental pollution is eliminated, but sufficient air supply for pore formation and stability is challenging
Solution Approach 1:
The mineral slurry mixture itself provides the air supply mechanism through its composition and processing. The slurry contains components that trap and stabilize air bubbles during mechanical beating, and the viscosity and surface tension properties of the slurry naturally maintain pore structure without requiring external air supply systems or additional stabilizing devices
Solution Approach 2:
The patent adjusts physical parameters of the mineral slurry including viscosity, surface tension, and composition ratios of cement, sulfate components, and aluminum silicates. These parameter changes enable the slurry to naturally stabilize air bubbles and maintain foam structure through its inherent physical properties rather than requiring complex external air supply systems
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 solution achieves a thinner, more efficient thermal insulation layer with improved mechanical strength and non-combustibility, while eliminating environmental pollution from chemical foaming processes.
Implementation Method 1
exposes the mass to the strongest possible pressure gradients, particularly with the creation of localized negative pressure zones where the mass can rupture
Implementation Method 2
In addition, (compressed) air is supplied or injected, particularly in or near the negative pressure zones
Data Source
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AI summary
The invention relates to a predominantly inorganic, in particular mineral, material for thermal insulation in construction, especially for coating load-bearing structures and/or for filling cavities or as a self-supporting component, comprising at least one binder and at least one thermally insulating additive, wherein the material has a solid consistency in the set state and a foamed structure, in particular a mechanically foamed structure, with a three-dimensional matrix and a pore volume of 60 vol.% or more, preferably 70 vol.% or more, in particular 80 vol.% or more; and to a method for producing such a material, wherein the material is mechanically foamed before setting, such that it has a solid consistency in the set state with a three-dimensional matrix, the structure of a foam and a pore volume of 60 vol.% or more, preferably 70 vol.% or more.-% or more, in particular 80 vol.% or more; and finally, a device for carrying out such a process, comprising a mortar pump and/or a mortar mixer with an automatic dispensing device, wherein in the area of the dispensing device the free cross-section of the flow path for the mortar is reduced by one, two or more planar obstacles arranged one behind the other in the direction of flow of the mortar.