Polystyrene Foam Thermal Insulation Using Petroleum Coke Infrared Blocking
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Solution Overview
Problem
Current polystyrene foams used for thermal insulation have high thermal conductivity, requiring high amounts of flame retardant agents and posing processing challenges, with existing additives like carbon black and graphite either ineffective or hazardous.
Innovation Solution
Incorporating ground, calcined petroleum coke particles with a platelet-like shape and high aspect ratio into polystyrene foams as an infrared blocker, reducing thermal conductivity and flame retardant agent usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the raw density of polystyrene foam is reduced to decrease material and volume, then the thermal insulation value significantly worsens with thermal conductivity exceeding 45 mW/m·K
Solution Approach 1:
The patent introduces petroleum coke particles as a secondary material component to create a composite foam structure. The petroleum coke particles with platelet-like shape and high aspect ratio are distributed within the polystyrene foam matrix, forming a composite material that maintains low density while improving thermal insulation through the unique geometry and infrared-blocking properties of the petroleum coke particles.
Solution Approach 2:
The patent applies local quality enhancement by specifically introducing petroleum coke particles at strategic locations within the foam structure. The platelet-like particles with high aspect ratio create localized barriers to heat transfer, particularly blocking infrared radiation pathways, while maintaining the overall low-density foam structure. This localized intervention improves thermal insulation without requiring uniform densification throughout the entire material.
2Reliability
If carbon black particles are incorporated to improve thermal insulation and fire behavior, then the high specific surface area absorbs flame retardant agents and degrades rheological behavior during processing
Solution Approach 1:
The patent fundamentally changes the key parameters of the additive: instead of using carbon black with high specific surface area (greater than 100 m2/g), it employs petroleum coke particles with low specific surface area (5-20 m2/g) and high aspect ratio. This parameter change reduces the total surface area available to absorb flame retardant agents, thereby preserving rheological properties during processing while still achieving improved fire behavior and thermal insulation through the platelet-like geometry that blocks infrared radiation.
Solution Approach 2:
The patent inverts the conventional approach by selecting an additive with low specific surface area rather than high specific surface area. While carbon black's high surface area was thought to provide better dispersion and coverage, the patent discovers that low surface area petroleum coke particles with high aspect ratio actually perform better by reducing harmful interactions with flame retardants while maintaining effective infrared blocking through their platelet morphology.
3Reliability
If graphite particles are introduced to reduce thermal conductivity, then a limit is reached due to the good intrinsic thermal conductivity of graphite and percolation threshold deterioration
Solution Approach 1:
The patent changes the geometric parameters of the additive by using petroleum coke particles with high aspect ratio and platelet-like shape instead of conventional graphite particles. This geometric transformation allows the particles to stack and orient in ways that create more effective thermal barriers perpendicular to the heat flow direction, achieving better thermal insulation at lower dosages and avoiding the percolation threshold issue that limits graphite effectiveness.
4Reliability
If aluminum particles are used to insulate infrared rays, then there is a high risk of dust explosions during processing and necessary fire retardant values are not achieved
Solution Approach 1:
The patent replaces hazardous aluminum particles with petroleum coke particles that are inherently safer and more effective. Petroleum coke is a carbon-based material that does not pose dust explosion risks like aluminum, and it provides superior infrared blocking capabilities. This substitution eliminates the safety hazard while achieving the desired infrared insulation function, making the material both safer and more effective.
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
Significantly improves thermal insulation and reduces the need for expensive flame retardants, achieving lower thermal conductivity and enhanced processing ease in both EPS and XPS foams.
Implementation Method 1
Incorporating ground, calcined petroleum coke particles with a platelet-like shape and high aspect ratio into polystyrene foams as an infrared blocker
Implementation Method 2
petroleum coke particles...exhibits improved thermal insulation
Data Source
AI summary
The invention relates to a body, particularly a molded body made of polystyrene, particularly polystyrene particle foam or polystyrene hard foam, wherein the polystyrene, particularly the polystyrene particle foam or the polystyrene hard foam, comprises petroleum coke, particularly petroleum coke particles.