Non-Settling Refractory Mortar Thixotropy
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Solution Overview
Problem
Existing refractory mortars suffer from settling issues, reduced coating performance over time, and dimensional changes leading to cracks and gaps when stored or exposed to high temperatures, requiring immediate use and on-site kneading.
Innovation Solution
A non-settling refractory mortar composed of ceramic powder, clay minerals, and a colloidal oxide solution with controlled Ca content and particle size distribution, providing thixotropic properties to maintain fluidity and reduce dimensional changes, eliminating the need for immediate use and on-site kneading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If refractory mortar is stored after kneading with solvent, then it can be preserved for future use, but ceramic particles settle and viscosity increases gradually, reducing coating performance
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the mortar system. Specifically, it uses a colloidal oxide solution with controlled Ca content (0.01 to 0.5% as converted to oxide) and specific ratios of ceramic powder to colloidal oxide solution. These parameter changes create a stable suspension system that prevents particle settling and maintains coating performance throughout the storage period.
Solution Approach 2:
The patent creates a composite material system by combining ceramic powder with colloidal oxide solution containing clay minerals. This composite structure provides thixotropic properties where the mortar maintains stability during storage but regains fluidity when agitated, effectively resolving the contradiction between long-term storage and coating performance.
2Manufacturing precision
If refractory mortar is kneaded immediately before use, then coating performance is maintained, but on-site kneading work is required and it cannot be stored for long time
Solution Approach 1:
The patent applies preliminary action by pre-mixing the ceramic powder with the colloidal oxide solution containing clay minerals at the factory before use. The mortar is prepared in advance with optimized composition and thixotropic properties, eliminating the need for on-site kneading work while maintaining coating performance even after long-term storage.
Solution Approach 2:
The thixotropic properties of the composite material system enable self-service functionality. The mortar automatically maintains its stability during storage and self-regulates its fluidity when applied, requiring no additional kneading or processing at the application site.
3Strength
If refractory mortar is applied and then dried or fired, then coating is formed, but shrinkage occurs causing fine cracks and gaps on surface
Solution Approach 1:
The patent controls the chemical composition parameters, specifically the Ca content (0.01 to 0.5% as converted to oxide) and the ratio of ceramic powder to colloidal oxide solution (100:0.5 to 1.5 for clay minerals). These parameter changes ensure controlled shrinkage during drying and firing that prevents crack and gap formation while maintaining coating integrity.
Solution Approach 2:
The patent applies local quality by incorporating particles of specific size ranges (0.1 to 5 μm) at controlled content (1 to 20%) within the ceramic powder composition. This localized control of particle distribution and size ensures uniform shrinkage behavior throughout the coating, preventing differential stress that would cause cracking.
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 mortar maintains coating performance over long periods, reduces dimensional changes, and prevents cracks and gaps, ensuring stable application even after storage and high-temperature exposure.
Implementation Method 1
the Ca content in total solid content is 0.01 to 0.5% (mass %) as converted to oxide so that thixotropic properties may be provided
Data Source
AI summary
A non-settling refractory mortar is provided, which includes 100 mass % of a ceramic powder such as cordierite, mullite, alumina, or silicon carbide, 0.5 to 1.5 mass % of a clay mineral, and a colloidal oxide solution, in which the Ca content in the total solid component is defined at 0.01 to 0.5 mass % as converted to oxide so as to be provided with a thixotropic property. As a result, the coating performance is not lowered if stored for a long period after kneading, the dimension change rate after coating is small, and cracks or gaps are not formed on the coat surface. The median diameter of ceramic powder is preferred to be 10 to 50 μm, and in order to reduce the dimension change rate after coating, the content of particles of 0.1 to 5 μm in ceramic powder is desired to be 1 to 20%.