Highly Reactive Geopolymer Foam Formulation for Rapid Ambient Cure
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Solution Overview
Problem
Existing geopolymer materials require long curing times at ambient temperatures, which limits their use in on-site applications and manufacturing processes, and they have high densities that add significant weight, necessitating the development of rapid-curing, low-density geopolymer formulations that can be produced without specialized equipment.
Innovation Solution
A method involving an alkaline aqueous slurry composed of inorganic aluminate and/or silicate precursors, saccharides, water-soluble peroxy compounds, and inorganic bases, which reacts exothermically to produce a foamed geopolymer rapidly at ambient temperatures, and can be formulated as a two-component system for ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If geopolymer materials are used to replace flammable organic materials, then non-combustible construction materials are provided, but long curing times at ambient temperatures limit their use in on-site applications
Solution Approach 1:
The patent changes the chemical parameters of the geopolymer formulation by incorporating saccharides and water-soluble peroxides into the alkaline aqueous slurry. This modification enables the system to undergo rapid exothermic reaction at ambient temperatures, reducing curing time from days to minutes while maintaining the non-combustible property of the geopolymer product.
Solution Approach 2:
The patent utilizes the phase transition and exothermic reaction of water-soluble peroxides decomposing in the alkaline environment to generate heat and gas bubbles. This phase change-driven reaction accelerates the geopolymerization process and creates foam structure, enabling rapid curing without requiring external heating equipment.
2Loss of time
If heating is applied to accelerate curing, then curing time is reduced, but costs increase due to added energy requirements and specialized heating equipment
Solution Approach 1:
The patent employs self-service by using the chemical reaction itself to generate the heat required for curing. The water-soluble peroxides decompose exothermically in the alkaline slurry, producing heat that accelerates the geopolymerization process. This eliminates the need for external heating equipment and reduces energy costs while achieving rapid curing.
Solution Approach 2:
The patent replaces the mechanical/thermal system (external heating equipment) with a chemical system (exothermic decomposition of peroxides). This substitution allows the curing process to be driven by chemical energy rather than thermal energy input, eliminating the need for specialized heating devices and reducing operational complexity.
3Weight of moving object
If chemical blowing agents are incorporated to reduce density, then lower density geopolymer is produced, but cure times extend to three days requiring high humidity and drying step
Solution Approach 1:
The patent changes the chemical composition parameters by using saccharides combined with water-soluble peroxides instead of traditional chemical blowing agents. This formulation produces gas bubbles through rapid exothermic decomposition, creating foam structure with low density (as low as 47 kg/m3) while simultaneously accelerating curing to minutes rather than extending it to days.
Solution Approach 2:
The patent utilizes the rapid phase transition and gas generation from peroxide decomposition to create foam bubbles during the curing process. This phase change-driven foaming mechanism produces low-density structure instantly, eliminating the need for prolonged drying steps and high humidity conditions required by conventional blowing agents.
4Weight of moving object
If air or inert gas is bubbled into water-surfactant mixture to produce foam, then low density geopolymer is achieved, but specialized equipment is required for handling and incorporating gas
Solution Approach 1:
The patent employs self-service by generating the gas bubbles needed for foaming through the chemical decomposition of water-soluble peroxides in the alkaline slurry. This eliminates the need for external gas supply systems and specialized equipment for introducing gas into the mixture. The system creates its own foaming agent through the chemical reaction, simplifying the overall process and equipment requirements.
Solution Approach 2:
The patent replaces the mechanical system of gas bubbling equipment with a chemical system of peroxide decomposition. Instead of requiring external mechanical or pneumatic equipment to introduce gas into the mixture, the chemical reaction itself generates the gas bubbles that form the foam structure, thereby eliminating specialized equipment and reducing operational complexity.
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 method enables rapid curing of geopolymer materials to a self-supporting state within minutes to hours without additional heat, producing lightweight, non-combustible geopolymer products suitable for construction and other applications, with improved handling and storage stability.
Implementation Method 1
The reaction between the saccharide and the water-soluble peroxy compound is highly exothermic. The exothermic heat of reaction in turn drives the polymerization reaction.
Implementation Method 2
Geopolymers are produced by condensation of aluminosilicate starting materials in the presence of water and a strong base.
Data Source
AI summary
A rapidly-expanding and -curing geopolymer formulation includes a liquid aqueous phase with silicate, aluminate and/or silico-aluminate precursors, an inorganic base, a monosaccharide and/or disaccharide, and a water-soluble peroxy compound. The saccharide and peroxy compound react spontaneously and rapidly in strongly alkaline conditions, producing an expanding gas and exothermic heat of reaction that drives at least an initial cure of the geopolymer formulation. The resulting foamed geopolymer formulation can be used in a variety of building and construction applications, as well as and others.