Hydrolysis-Stable Silane-Metal Consolidant for Porous Materials
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Solution Overview
Problem
Existing consolidants face challenges in maintaining hydrolysis and hydrothermal stability under aggressive conditions, often resulting in reduced bond strength and porosity loss, especially when exposed to high pressures, temperatures, and corrosive media.
Innovation Solution
A consolidant comprising a hydrolyzate or precondensate of organosilane, hydrolyzable silane, and metal compounds, specifically using a molar ratio of silicon to metal compounds ranging from 10,000:1 to 10:1, which includes metals like Ti, Al, and Zr, and is prepared via the sol-gel process with a sub-stoichiometric amount of water, allowing for curing under elevated pressure and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic polymer binders are used, then ease of manufacture is improved, but hydrolysis stability and bond strength deteriorate under aggressive conditions
Solution Approach 1:
The patent uses composite materials by combining organic polymer binders with inorganic binder components (silanes and metal compounds). This hybrid approach allows the consolidant to benefit from both organic and inorganic properties, achieving hydrolysis stability under aggressive conditions while maintaining ease of manufacture through the polymer matrix.
2Quantity of substance
If purely inorganic binders are used via sol-gel process, then porosity retention is improved, but mechanical strength and resistance to mechanical stresses deteriorate
Solution Approach 1:
The patent creates a composite binder system where inorganic components (silanes and metal compounds) provide porosity retention through sol-gel processes, while organic polymer components contribute mechanical strength and flexibility. This composite approach resolves the contradiction between porosity retention and mechanical strength.
3Strength
If consolidants are cured under elevated pressure, then bond strength is improved, but many consolidants cannot withstand such conditions
Solution Approach 1:
The hybrid consolidant system combines organic and inorganic components that together can withstand elevated pressure curing conditions. The inorganic metal compounds and silanes provide structural stability under pressure, while the organic polymer matrix maintains flexibility and bond strength, enabling successful curing under elevated pressure that neither component could achieve alone.
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 solution achieves hydrolysis and hydrothermal stability, maintaining porosity and bond strength, enabling long-term use under corrosive conditions and allowing for consolidation under elevated pressure and temperature.
Implementation Method 1
comprising a hydrolyzate or precondensate of (a) at least one organosilane... (b) at least one hydrolyzable silane
Implementation Method 2
comprising a hydrolyzate or precondensate... the bond in which an appropriate porosity is maintained
Implementation Method 3
The use of purely inorganic binders which are obtainable, for example, via the sol-gel process
Data Source
AI summary
Described is a consolidant comprising a hydrolyzate or precondensate of at least one organosilane and at least one metal compound, where the molar ratio of silicon compounds to metal compounds is in the range of from 10 000:1 to 10:1.The consolidant can be used for the hydrolysis-stable consolidation of porous or particulate materials to form moldings. The consolidant can be used for the hydrolysis-stable coating of substrates.