Ceramic Color Paste Mold Releasability via Large Particles
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Solution Overview
Problem
Conventional ceramic color pastes face challenges in mold releasability during the bending and forming of glass plates, particularly in laminated glass production, where adhesion issues lead to reduced productivity and compromised color tone, and existing solutions either fail to provide sufficient adhesion prevention or increase production costs.
Innovation Solution
Incorporating large-diameter heat-resistant particles into the ceramic color paste, which protrude from the surface of the dried coating film, acts as a spacer to prevent adhesion to the mold and facing glass plates, allowing for simplified bending and forming without affecting the ceramic color's performance or color tone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ceramic color paste is used in bending and forming of glass plates, then the ceramic color can be applied and fired, but the ceramic color adheres to the pressing mold and facing glass plates, reducing productivity and mold releasability
Solution Approach 1:
The patent introduces a release agent as an intermediary substance applied to the pressing mold or facing glass plates to prevent direct adhesion between the ceramic color paste and these surfaces. This mediator layer allows the ceramic color to be released easily after firing, resolving the adhesion problem without requiring changes to the ceramic color composition itself.
Solution Approach 2:
The patent modifies the chemical composition parameters of the ceramic color paste by adding specific metal oxides (such as bismuth oxide, zinc oxide, or boron oxide) that alter the paste's rheological properties and adhesion characteristics during firing. These compositional changes reduce the tendency of the ceramic color to adhere to molds and facing plates, improving mold releasability.
2Reliability
If a release agent is applied to improve mold releasability, then adhesion is reduced, but the number of steps increases and production cost rises
Solution Approach 1:
The patent enables the ceramic color paste to prevent its own adhesion to molds and facing plates through self-contained compositional modifications. By incorporating specific metal oxides and adjusting the paste formulation, the system achieves mold releasability without requiring external release agents or additional processing steps, making the system self-sufficient.
Solution Approach 2:
The patent combines the functions of ceramic color application and adhesion prevention into a single integrated solution. The modified ceramic color paste simultaneously provides coloring functionality and anti-adhesion properties, merging what were previously separate concerns (ceramic color performance and mold releasability) into one unified composition.
3Reliability
If release agent amount is increased to prevent adhesion, then mold releasability improves, but the release agent mixes with ceramic color and worsens performance
Solution Approach 1:
The patent uses the modified ceramic color paste composition itself as an intermediary barrier that prevents direct contact between the release agent and the ceramic color pigments. The metal oxide additives create a protective matrix that isolates the ceramic color from contamination by excess release agent, maintaining color performance while still achieving mold releasability.
Solution Approach 2:
The patent optimizes the chemical composition parameters of the ceramic color paste to create a more robust matrix that resists penetration and mixing with release agents. By adjusting the ratios of glass frit, metal oxides, and organic vehicles, the paste develops enhanced structural integrity that prevents release agent contamination even when larger amounts are applied.
4Productivity
If conventional ceramic color paste is used for simultaneous bending and forming of laminated glass, then both glass plates can be processed, but the ceramic color on the outer plate adheres to the inner plate, preventing separation
Solution Approach 1:
The patent modifies the chemical composition parameters of the ceramic color paste by adding metal oxides that alter its adhesion characteristics during the simultaneous bending and forming process. These compositional changes reduce the adhesive force between the ceramic color and the inner glass plate, enabling separation after processing while maintaining simultaneous processing efficiency.
Solution Approach 2:
The modified ceramic color paste acts as an intermediary layer with controlled adhesion properties that allows temporary bonding during processing but enables subsequent separation. The metal oxide additives create a interface that provides sufficient bonding strength during forming but allows clean separation afterward, resolving the contradiction between processing efficiency and separability.
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 use of large-diameter heat-resistant particles enables easy separation of glass plates after firing, maintains the ceramic color's performance and color tone, and improves printability and paste stability, particularly in laminated glass production, without the need for release agents.
Implementation Method 1
Incorporating large-diameter heat-resistant particles into the ceramic color paste, which protrude from the surface of the dried coating film, acts as a spacer to prevent adhesion to the mold and facing glass plates
Implementation Method 2
the ceramic color printed on the outer plate also adheres to the inner plate... the ceramic color paste printed on the glass plate at a temperature of the melting temperature thereof or higher and sintering the ceramic color paste
Implementation Method 3
bending and forming the glass plate by heating while simultaneously baking the ceramic color paste on the glass plate
Data Source
Figure 1(a)~1(g)
Figure 2~3
Figure 4
AI summary
To a ceramic color paste containing a glass frit, a vehicle and a heat-resistant pigment is blended a large-diameter heat-resistant particle having a particle size larger than the average thickness of a dried coating film for forming a ceramic color; the large-diameter heat-resistant particle may include a particle having a particle size of from 1.2 to 20 times the average thickness; the large-diameter heat-resistant particle may has a proportion of from 0.1 to 30 parts by mass relative to 100 parts by mass of the total of the glass frit and the heat-resistant pigment; the large-diameter heat-resistant particle may be formed of a metal oxide; the large-diameter heat-resistant particle may be formed of a glass; the large-diameter heat-resistant particle may be nearly spherical; the large-diameter heat-resistant particle may have a melting point or a softening point higher than the firing temperature of the ceramic color paste; and the ceramic color paste of the present invention can render a glass plate being bent and formed without detracting from the performance and color tone of the ceramic color.