Flowable Refractory Composition Using Polyether Plasticizer

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Solution Overview

Problem

Existing refractory materials containing calcium aluminate cement require excessive mixing water, leading to reduced strength and durability due to excess water content, and current setting retarders like boric acid are hazardous and not suitable for use.

Innovation Solution

A composition comprising calcium aluminate cement, a filler, a plasticizer with polyether side chains, and an acid-based retarder, which minimizes mixing water usage while maintaining high strength and flowability, and is free from boric acid derivatives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If boric acid or boric acid derivatives are used as setting retarders, then good flow behavior and processability are achieved, but health hazards and environmental toxicity increase

Engineering Contradiction:

Improveflow behaviorVSAvoidhealth hazard

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent removes boric acid and its derivatives from the refractory composition entirely, extracting the harmful substance while maintaining the desired flow behavior through alternative plasticizing agents and mixtures that do not contain boron compounds

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs conventional, well-known plasticizing agents (such as naphthalene sulfonate, melamine sulfonate, or lignosulfonate) that are safer and more environmentally friendly than boric acid, using substances that are less hazardous and can be readily replaced without long-term environmental persistence

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If mixing water amount is reduced to improve strength, then strength and durability increase, but processability and flow behavior deteriorate

Engineering Contradiction:

ImprovestrengthVSAvoidprocessability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent modifies the chemical composition parameters by introducing specific plasticizing agents and mixtures that alter the rheological properties of the refractory material, enabling maintainable flow behavior at reduced water contents through chemical modification rather than physical adjustment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs plasticizing agents as intermediary substances that mediate between the cementitious binder and water, allowing reduced water content while maintaining processability through the intermediate action of these chemical additives that improve water efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If mixing water amount is increased to improve processability, then flow behavior improves, but strength and durability decrease due to excess water content

Engineering Contradiction:

Improveflow behaviorVSAvoidstrength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent changes the chemical parameters by incorporating specific plasticizing agents that modify the water-binder interaction, allowing achievement of desired flow behavior at lower water-to-binder ratios through chemical enhancement of water efficiency

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If boric acid-free setting retarders are used to eliminate health hazards, then safety improves, but mixing water requirement increases

Engineering Contradiction:

Improvehealth hazardVSAvoidmixing water

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent modifies the chemical composition by using alternative plasticizing agents in combination with boric acid-free retarders, changing the chemical parameters to achieve both safety and water efficiency simultaneously through synergistic interactions between the additive components

Inventive Principle:

Principle #35Parameter changes

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 composition achieves good flow behavior and high strength with minimal mixing water, comparable to boric acid-containing systems, while being safer and more environmentally friendly.

Implementation Method 1

at least one plasticizer which comprises at least one copolymer comprising a main chain and polyether side chains

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

at least one retarder comprising at least one acid

Methodology Applied

Scientific EffectHydration inhibition:

Data Source

PatentUS11542200B2Composition for flowable fire-resistant materials

Publication Date: 2023.01.03 BASF SE

AI summary

A composition may be suitable for flowable refractory materials and include calcium aluminate cement, a filler, a plasticizer in the form of a copolymer comprising polyether side chains, and a retarder having at least one acid. An article may include such a composition.