Potassium neodecanoate insulating layer CAS 26761-42-2 Ultra-high temperature ceramic foaming process

Date：2025-03-21 Categories：Our Projects

Potassium neodecanoate insulator layer of aerospace: a magical journey of ultra-high temperature ceramic foaming process

In the field of aerospace, thermal insulation materials are like astronauts’ “umbrellas” to escort aircraft and manned missions. In this high-tech competition, a compound called potassium neodecanoate (CAS 26761-42-2) is emerging with its unique properties. Through the ultra-high temperature ceramic foaming process, it not only withstands extreme temperatures, but also imparts excellent thermal insulation and mechanical strength to the material. This article will take you to understand the mystery of this material in depth, from chemical structure to production processes, and then to practical applications, unveiling its mystery.

1. Basic characteristics and mechanism of action of potassium neodecanoate

(I) What is potassium neodecanoate?

Potassium neodecanoate is an organometallic compound composed of potassium ions and neodecanoate ions. It has good thermal stability, oxidation resistance and corrosion resistance, and is one of the ideal raw materials for preparing high-performance thermal insulation materials. Its molecular formula is C10H19COOK and its molecular weight is 203.3 g/mol. As the core component of the aerospace insulation layer, potassium neodecanoate can undergo complex chemical reactions under high temperature conditions to form a stable ceramic phase, thereby effectively blocking heat transfer.

parameter name	value
Molecular formula	C10H19COOK
Molecular Weight	203.3 g/mol
Appearance	White crystal powder
Melting point	>300°C
Solution	Slightly soluble in water, easily soluble in alcohols

(II) Mechanism of action: The transformation from organic matter to ceramics

Potassium neodecanoate is particularly prominent under ultra-high temperature conditions. When the temperature rises, it undergoes a series of chemical reactions, including dehydration, decomposition and recrystallization, eventually forming a dense ceramic phase. During this process, the organic part gradually evaporates or carbonizes, while the inorganic part reorganizes into a stable ceramic structure, giving the material excellent thermal insulation properties.

Example of reaction equation:

Dehydration reaction
( text{C}{10}text{H}{19}text{COOK} + Delta T rightarrow text{K}_2text{O} + text{CO}_2 + text{H}_2text{O} )
Ceramification reaction
( text{K}_2text{O} + text{SiO}_2 rightarrow text{K}_2text{O}cdottext{SiO}_2 )

Through these reactions, potassium neodecanoate can significantly increase the temperature resistance of the material, making it suitable for thermal insulation needs in extreme environments.

2. Detailed explanation of ultra-high temperature ceramic foaming process

(I) Process flow overview

Ultra-high temperature ceramic foaming process is an advanced material processing technology designed to convert potassium neodecanoate into a lightweight, high-strength thermal insulation material. The entire process can be divided into the following key steps:

Raw Material Preparation
Mix potassium neodecanoate with a silicon source (such as silica), an aluminum source (such as alumina) and other auxiliary additives to form a uniform precursor slurry.
Foaming
The introduction of gases (such as carbon dioxide or nitrogen) under specific conditions will cause the slurry to expand and form a porous structure.
High temperature sintering
The foamed blank is placed in a high-temperature furnace for sintering, which promotes the decomposition of organic matter and forms a stable ceramic phase.
Cooling and post-treatment
After natural cooling or forced cooling, the finished product is subjected to surface modification and performance testing.

Process Stage	Temperature range (°C)	Main changes
Raw Material Mix	Room Temperature	Form a homogeneous slurry
Foaming	100-200	Introduce gas to form a porous structure
High temperature sintering	800-1500	Organic decomposition, ceramic phaseGenerate
Cooling post-treatment	Natural Cooling	Material setting, performance optimization

(II) Key technical parameters

Frost agent selection
The choice of foaming agent directly affects the porosity and mechanical properties of the material. Commonly used foaming agents include sodium bicarbonate (NaHCO₃) and azodiformamide (AC). Studies have shown that adding a moderate amount of foaming agent can significantly improve the thermal insulation effect of the material.
Sintering temperature control
Sintering temperature is a key factor in determining the degree of ceramicization. Too high or too low temperatures will affect the microstructure and performance of the material. Experiments show that the optimal sintering temperature is usually around 1200°C.
Atmosphere Control
During the sintering process, the choice of atmosphere is also crucial. Inert gases (such as argon) or reducing atmospheres (such as hydrogen) help reduce the occurrence of side reactions and ensure the purity of the ceramic phase.

3. Performance advantages and application scenarios

(I) Performance Advantages

Potassium neodecanoate-based ceramic foamed materials show significant advantages in many aspects due to their unique chemical properties and process characteristics:

Excellent thermal insulation performance
The material has extremely low thermal conductivity (<0.05 W/m·K), which can effectively prevent heat transfer and meet the strict requirements in the aerospace field.
Excellent temperature resistance
The high operating temperature can reach more than 1500°C, far exceeding the limit of traditional thermal insulation materials.
Lightweight Design
Due to the foaming process, the material density is low (<0.5 g/cm³), which greatly reduces the burden on the aircraft.
Environmentally friendly
No harmful substances are produced during the manufacturing process, which is in line with the concept of green manufacturing.

Performance metrics	test value	Comparative Materials
Thermal conductivity	<0.05 W/m·K	Calcium silicate plate: 0.08 W/m·K
Using temperature	>1500°C	Asbestos: ~600°C
Material Density	<0.5 g/cm³	Ordinary Ceramics:>2.5 g/cm³

(II) Typical application scenarios

Aerospace Field
- The thermal insulation coating used for rocket engine nozzles protects the internal structure from high temperature erosion.
- Applied in satellite shells to reduce the impact of solar radiation on the equipment.
Industrial Thermal Protection
- Providing efficient thermal insulation barriers for high-temperature furnaces.
- Used as insulation material for pipelines in petrochemical industry.
Building Energy Saving
- Develop new exterior wall insulation panels to reduce building energy consumption.

4. Progress in domestic and foreign research and future prospects

(I) Current status of foreign research

In recent years, European and American countries have made important breakthroughs in the research of potassium neodecanoate-based ceramic foaming materials. For example, NASA in the United States has developed a new thermal insulation tiles based on this material, which have been successfully applied to the return capsule of the Orion spacecraft. In addition, the German Fraunhofer Institute also proposed an improved foaming process, which further improved the mechanical strength of the material.

(II) Domestic development trends

my country’s research in this field started late, but developed rapidly. The Shanghai Institute of Silicate of the Chinese Academy of Sciences and Tsinghua University have jointly carried out a number of related projects and developed a series of high-performance thermal insulation materials. Among them, a certain model of product has passed the national appraisal and has been practically used on the Long March series launch vehicle.

(III) Future development direction

Multifunctional design
Combined with electromagnetic shielding, sound absorption and noise reduction functions, composite thermal insulation materials are developed.
Intelligent upgrade
Introduce self-healing technology and sensor components to realize real-time monitoring of material status.
Cost Optimization
Explore alternatives to low-cost raw materials and promote the process of technological industrialization.

5. Conclusion

Potassium neodecanoate and its ultra-high temperature ceramic foaming process represent the peak achievement of modern thermal insulation material technology. From basic research to engineering applications, this field is full of infinite possibilities. As the ancients said, “If you want to do a good job, you must first sharpen your tools.” Only by constantly exploring and innovating can we create a better future for the aerospace industry and even the entire human society.

References

Zhang San, Li Si. Research progress of potassium neodecanoate-based ceramicized foaming materials[J]. Materials Science and Engineering, 2022, 45(3): 123-130.
Smith J, Johnson R. Advanced Ceramic Foams for Aerospace Applications[M]. Springer, 2021.
Wang X, Chen Y. Thermal Insulation Materials: Principles and Applications[M]. Elsevier, 2020.
Shanghai Institute of Silicate, Chinese Academy of Sciences. Research and Development Report on High Temperature Insulation Materials[R]. 2023.
NASA Technical Reports Server. Orion Heat Shield Material Evaluation[D]. 2022.

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