Needle-Like Refractory Material for Thermal Shock and Insulation
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Solution Overview
Problem
Existing refractory materials lack high strength, thermal shock resistance, and thermal insulation properties, making them unsuitable for complex refractory products and industrial applications requiring good handling and processing.
Innovation Solution
A refractory material with a needle-like structure, comprising specific phases of Al4O4C, Al28C6O21, SiAl6O2N6, and optionally AlN, produced by thermal treatment at 1300°C to 1750°C, using a batch containing magnesium aluminate spinel, alumina, corundum, carbon, and a phenolic resin binder, enhancing mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional refractory materials are used, then basic high-temperature resistance is achieved, but high strength, thermal shock resistance, and thermal insulation properties are lacking
Solution Approach 1:
The patent employs a multi-phase composite material system comprising Al4O4C (first phase), Al28C6O21 (second phase), and SiAl6O2N6 (third phase). This composite structure combines the advantages of different phases: Al4O4C provides high strength and chemical stability, Al28C6O21 contributes to thermal shock resistance through its unique crystal structure, and SiAl6O2N6 enhances thermal insulation properties. The synergistic interaction of these phases resolves the contradiction between strength and thermal shock resistance.
Solution Approach 2:
The patent creates local quality differences through the needle-like structure formed by the first phase (Al4O4C) that grows preferentially in certain directions. This anisotropic structure provides enhanced strength in specific orientations while maintaining overall thermal shock resistance. The needle-like morphology creates a interlocking network that locally reinforces the material without compromising its ability to withstand thermal cycling.
2Temperature
If conventional refractory materials are used, then basic structural stability is achieved, but thermal insulation properties (low thermal conductivity) are insufficient
Solution Approach 1:
The composite material system balances thermal insulation and strength through phase distribution. The third phase (SiAl6O2N6) has inherently low thermal conductivity and forms a matrix that provides insulation, while the first phase (Al4O4C) forms discrete needle-like structures that provide strength without significantly increasing thermal conductivity. This composite architecture achieves both requirements simultaneously.
3Adaptability or versatility
If complex refractory products are produced, then functional requirements are met, but handling and processing of green bodies becomes difficult due to low strength
Solution Approach 1:
The patent applies preliminary action through the phenolic resin binder that is mixed into the batch before forming. This binder pre-strengthens the green body during the forming and drying stages, enabling complex shapes to be manufactured without compromising handling capability. The binder acts as a temporary reinforcement that can be removed or carbonized during subsequent processing.
Solution Approach 2:
The patent utilizes parameter changes through the phenolic resin binder system, which undergoes transformation from a plastic state during forming to a carbonized state during heating. This parameter change allows the green body to achieve sufficient strength for handling complex shapes, then transitions to the final refractory product with the desired porosity and thermal properties after binder removal and sintering.
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 refractory material exhibits high hot strength, thermal shock resistance, low thermal conductivity, and improved handling, enabling the production of complex refractory products with reduced thermal conductivity and clogging, suitable for high-temperature industrial applications.
Implementation Method 1
A refractory material which has been thermally treated at a temperature of at least 1300°C, preferably from 1300° to 1750°C
Implementation Method 2
the refractory material has a needle-like structure and comprises a combination of a first phase, a second phase and a third phase
Implementation Method 3
a batch containing magnesium aluminate spinel, alumina, corundum, carbon, and a phenolic resin binder
Implementation Method 4
high strength and high thermal shock resistance
Implementation Method 5
low thermal conductivity
Data Source
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AI summary
The invention relates to a refractory material which is thermally treated at a temperature of at least 1300°C, preferably from 1300°C to 1750°C, such that it has a needle-like structure and comprises a combination of a first phase, a second phase and a third phase, wherein: the first phase comprises 2-10 wt% C, <5 wt% N, 30-40 wt% O, 50-70 wt% Al and <5 wt% Si, based on the total proportion of the first phase, the second phase comprises 1-7 wt% C, 3-8 wt% N, 25-35 wt% O, 55-65 wt% Al and <5 wt% Si, based on the total proportion of the second phase, and the third phase <7 wt% C, 14-28 wt% N, 10-15 wt% O, 52-63 wt% Al and <20 wt% Si, based on the total proportion of the third phase, comprises a batch for producing a refractory material, a green body produced from a batch, a method for producing a refractory material and the use of such.