Non-Destructive Ceramic Quality Estimation via Colorimetry
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Solution Overview
Problem
Conventional quality control methods for ceramic products require destructive testing to measure porosity, pore diameter, and thermal expansion coefficient, leading to increased costs and delayed delivery, as well as sample wastage.
Innovation Solution
A method that estimates these characteristics non-destructively by measuring the color of the ceramic fired body using correlations established between color parameters in CIE 1931 XYZ and CIE 1976 (L*, a*, b*) color spaces, allowing for the prediction of porosity, pore diameter, and thermal expansion coefficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing is performed to measure porosity, pore diameter, and thermal expansion coefficient, then measurement precision is improved, but productivity deteriorates and loss of substance increases
Solution Approach 1:
The patent replaces destructive mechanical/chemical testing methods with non-destructive optical measurement (colorimetry). By measuring the color of the ceramic green body and using pre-established correlation data, the system estimates porosity, pore diameter, and thermal expansion coefficient without physically damaging or consuming the sample, thus maintaining measurement precision while dramatically improving productivity and eliminating sample wastage
Solution Approach 2:
The patent creates a correlation model (a type of data copy) between color measurements and actual material characteristics. Instead of directly measuring difficult-to-obtain properties through destructive means, the system uses easily obtainable color data combined with pre-determined correlation coefficients to infer the target characteristics, enabling non-destructive quality assessment
2Measurement precision
If destructive testing is performed to measure porosity, pore diameter, and thermal expansion coefficient, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent replaces time-consuming destructive testing procedures with rapid optical color measurement. The colorimetric method provides immediate data that can be processed through the correlation model to estimate material characteristics, reducing inspection time from potentially hours or days of destructive testing to seconds of non-destructive measurement while maintaining acceptable measurement precision
Solution Approach 2:
The patent performs preliminary work by establishing correlation data between color measurements and material characteristics before actual production inspection. This pre-determined correlation model allows for rapid estimation during quality control without repeating the complex destructive testing procedures, significantly reducing loss of time during production while maintaining measurement precision through the validated correlation
3Productivity
If sampling inspection is performed instead of inspecting all products, then productivity is improved, but reliability deteriorates
Solution Approach 1:
The patent enables every product to serve its own inspection function by using its inherent color property (which naturally varies with composition and structure) as the measurement parameter. This self-service approach eliminates the need for separate destructive sampling, allowing 100% inspection of all products without reducing productivity, thereby improving reliability through comprehensive quality assurance
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
Enables efficient and non-destructive quality inspection of ceramic products, reducing costs and sample wastage while providing accurate estimates of key characteristics in a short time.
Implementation Method 1
measuring a color of the ceramic fired body
Data Source
AI summary
A method for estimating characteristics of a ceramic fired body, the method including: preparing a ceramic fired body by firing a formed green body; measuring a color of the ceramic fired body; and with use of a correlation between the color and at least one characteristic selected from a group consisting of a porosity, a pore diameter, and a thermal expansion coefficient previously determined for a ceramic fired body having a same composition as that of the ceramic fired body, estimating the at least one characteristic of the ceramic fired body from the color of the ceramic fired body, measured in the previous step.