Porous Ceramic Insulating Material via Low-Temperature Sintering
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Solution Overview
Problem
Existing insulating materials face challenges such as high production costs due to high-temperature processes, toxicity, and limited commercial value due to fire vulnerability, while inorganic materials require separate damp-proof layers and generate toxic gases when exposed to water.
Innovation Solution
A ceramic composition comprising 44-60 wt % glass powder, 8-15 wt % fly ash, and 23-29 wt % water glass, processed at 800˜900° C. to create a porous ceramic insulating material with closed pores, low thermal conductivity, and excellent flame retardance, reducing production costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic insulating materials are used, then flame retardant properties are improved, but production costs increase due to high-temperature processes
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature processes (1000°C or higher) to a lower temperature range (800-900°C), achieving both flame retardant properties and reduced production costs through this parameter modification
Solution Approach 2:
The patent uses a composite material system comprising glass powder (44-60 wt%), fly ash (8-15 wt%), surface treatment agent (4-8 wt%), and water glass (23-29 wt%), which enables the material to achieve flame retardancy at lower temperatures, resolving the contradiction between reliability and manufacturing ease
2Reliability
If glass wool is used, then noncombustible and sound absorbing properties are improved, but water absorption increases requiring separate damp-proof layers
Solution Approach 1:
The patent employs porous ceramic materials with controlled pore structures that provide sound absorption and noncombustible properties while maintaining water repellency, eliminating the need for separate damp-proof layers and reducing structural complexity
Solution Approach 2:
The patent uses fly ash as a key component, which is a waste product from coal combustion, making the material environmentally friendly and cost-effective while achieving the desired functional properties without requiring additional protective layers
3Use of energy by moving object
If organic insulating materials are used, then insulation properties are improved, but fire vulnerability increases
Solution Approach 1:
The patent creates a composite material system combining glass powder, fly ash, surface treatment agent, and water glass that achieves both excellent insulation properties and fire resistance, eliminating the trade-off between these two properties that plagues organic insulating materials
Solution Approach 2:
The patent converts the harmful effect of fire vulnerability in organic materials into a benefit by using inorganic materials (glass powder, fly ash, water glass) that are inherently fire-resistant while maintaining or improving insulation properties, turning the weakness of organic materials into a strength
4Reliability
If conventional ceramic insulating materials are used, then flame retardant properties are improved, but production costs increase due to high-temperature processes
Solution Approach 1:
The patent modifies the temperature parameter from conventional high-temperature ceramic processing (1000°C or higher) to a lower range (800-900°C), achieving flame retardancy while reducing energy consumption and production costs
Solution Approach 2:
The patent incorporates fly ash, a cheap and abundant waste material, as a key component, replacing expensive traditional ceramic raw materials and significantly reducing production costs while maintaining flame retardant properties
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 resulting material is lightweight, environmentally friendly, non-toxic, and cost-effective, with improved insulation and flame retardant properties, suitable for large-scale continuous manufacturing.
Implementation Method 1
a foaming method which uses fly ash, clay and the like as main materials and calcium carbonate (CaCO3) and carbon as foaming agents
Implementation Method 2
calcining and foaming the powdered material in a heat-treatment furnace at 800 ̃900° C. for 20 minutes to 3 hours
Implementation Method 3
calcining and foaming the powdered material in a heat-treatment furnace at 800 ̃900° C.
Implementation Method 4
porous ceramic insulating material with closed pores, low thermal conductivity
Data Source
AI summary
The present invention relates to a ceramic composition and a porous ceramic insulating material comprising the same, which is widely used as a core material in sandwich panels or fire doors. The ceramic composition comprises 44-60 wt % of glass powder, 8-15 wt % of fly ash, 4-8 wt % of surface treatment agent, and 23-29 wt % of water glass. The porous ceramic insulating material manufactured from the composition is lightweight and is an environmentally friendly material which generates no toxic gas when it catches fire. The ceramic insulating material can be produced at a low temperature of 800˜900° C., and thus has low production cost. In addition, it can be continuously manufactured in a sheet form.