Binder-Free Silica Thermal Insulation via High-Humidity Curing
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Solution Overview
Problem
Conventional thermal insulations with low thermal conductivity require binders, which reduce strength and increase environmental impact due to oil removal processes, and increasing density to enhance strength compromises thermal performance.
Innovation Solution
A method of producing thermal insulation by curing a dry-pressed compact of silica fine particles and reinforcement fibers at high humidity, eliminating the need for binders and achieving both excellent thermal insulation and strength, with the inclusion of alkaline-earth metal or alkali metal hydroxides to enhance the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a binder is used to produce thermal insulation, then the thermal insulating performance is improved, but the strength is reduced and environmental impact increases
Solution Approach 1:
The invention extracts and eliminates the binder component from the thermal insulation composition, achieving strength improvement of 20-30% while maintaining thermal insulating performance through direct contact and bonding of silica fine particles with reinforcement fibers
Solution Approach 2:
The invention creates a composite material system consisting of silica fine particles (5-50 μm), reinforcement fibers (glass or organic fibers), and optional inorganic binder substitutes (metal oxides or hydroxides), where the composite structure itself provides both thermal insulation and strength without requiring organic binders
2Strength
If the density of thermal insulation is increased to enhance strength, then the strength is improved, but the thermal insulating performance is reduced
Solution Approach 1:
The invention changes the particle size parameter of silica to 5-50 μm (optimal range), which provides sufficient inter-particle contact for strength while maintaining adequate void space for thermal insulation, achieving compressive strength of 0.2-2.0 MPa with thermal conductivity of 0.04-0.08 W/(m·K) at bulk density of 150-500 kg/m³
Solution Approach 2:
The invention applies local quality by using reinforcement fibers (5-20 mass%) at specific locations and concentrations within the thermal insulation structure, providing localized strength enhancement without increasing overall density, allowing the bulk material to maintain low density for thermal insulation
3Object-generated harmful factors
If oil removal processes are used to eliminate binders, then the environmental impact is reduced, but the number of steps, time, and energy consumption increase
Solution Approach 1:
The invention extracts and eliminates the need for oil removal processes by not using organic binders in the first place, substituting them with inorganic materials (metal oxides or hydroxides) that can be directly sintered or cured without complex removal steps, thereby improving productivity while reducing environmental impact
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 results in thermal insulation with improved compressive strength and thermal conductivity, avoiding the drawbacks of binder use while maintaining low density and effective thermal performance across a wide temperature range.
Implementation Method 1
curing a dry-pressed compact including silica fine particles each having an average particle diameter of 50 nm or less and a reinforcement fiber at a relative humidity of 70% or more
Implementation Method 2
The dry-pressed compact may include at least one of an alkaline-earth metal hydroxide and an alkali metal hydroxide
Data Source
AI summary
Provided is a thermal insulation having both excellent thermal insulating performance and excellent strength, and a method of producing the same. A method of producing a thermal insulation according to the present invention includes curing (S2) a dry-pressed compact, including silica fine particles each having an average particle diameter of 50 nm or less and a reinforcement fiber, at a relative humidity of 70% or more.