Refractory Mortar Cured Material Crack Suppression
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Solution Overview
Problem
Existing refractory mortar cured materials for ceramic refractory materials suffer from insufficient thermal impact resistance and crack suppression, particularly during the initial forming and heating processes, due to moisture absorption and uneven shrinkage, leading to reduced coating performance and mechanical strength.
Innovation Solution
A refractory mortar cured material with ceramic particles of average size 10 to 50 μm and a controlled particle size distribution, combined with an inorganic binder and ceramic fibers, is developed to suppress crack propagation and enhance thermal resistance, with a bulk density of 0.9 to 1.5 g/cm3 and average pore size of 5 to 25 μm, ensuring uniform pore size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If refractory mortar is applied on porous ceramic refractory material, then corrosion resistance and mechanical strength are enhanced, but moisture is absorbed in the base material causing local shrinkage difference and fine cracks
Solution Approach 1:
The patent changes the particle size parameters of ceramic particles to a specific range (10 to 50 μm average) with controlled distribution (difference of 90% and 10% particle sizes is 10 to 60 μm). This parameter optimization reduces moisture absorption and shrinkage difference, preventing crack formation while maintaining mechanical strength and corrosion resistance.
Solution Approach 2:
The patent uses composite ceramic particles with controlled size distribution rather than single-size particles. This composite approach creates a more uniform mortar structure that reduces local shrinkage differences and improves both strength and crack resistance simultaneously.
2Reliability
If refractory mortar is applied on ceramic refractory material, then corrosion resistance is improved, but viscosity of the mortar is raised and coating performance is lowered
Solution Approach 1:
The patent optimizes particle size parameters (average 10 to 50 μm, with controlled distribution) to achieve a balance between corrosion resistance and coating performance. The controlled particle size distribution ensures proper flow characteristics for easy application while maintaining the protective function against corrosion.
3Reliability
If ceramic material is exposed to thermal stress during drying or heating process, then cracks are caused, but propagation of cracks may be blocked by pores existing in the texture
Solution Approach 1:
The patent controls pore size parameters (average pore size 5 to 25 μm, width of pore size distribution 20 to 80 μm) to create an optimal pore structure. This controlled porosity effectively blocks crack propagation during thermal stress while maintaining thermal impact resistance.
Solution Approach 2:
The patent utilizes a controlled porous structure in the refractory mortar cured material. The specific pore size distribution (average 5 to 25 μm) creates barriers that block crack propagation during thermal stress, improving thermal impact resistance while maintaining structural integrity.
Data Source
AI summary
A refractory mortar cured material is formed in the surface or joint portions of a ceramic refractory material, such as fire bricks used in the lining of melting furnace or firing furnace used at high temperature, and includes ceramic particles with an inorganic binder having silanol group that are kneaded together with water. The kneaded mortar is applied on the surface of a ceramic base material. The average particle size of ceramic particles in the refractory mortar is 10 to 50 μm, and the difference between the 90% particle size and the 10% particle size is 10 μm or more to 60 μm or less. The average pore size of the refractory mortar cured material is 5 to 25 μm, and the width of pore size distribution is 20 to 80 μm, so that the cracks are suppressed. In addition, the bulk density is 0.9 to 1.5 g/cm3.