Ceramic Coloring Process Using Silica Additives and Iron Solutions
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Solution Overview
Problem
Current methods for coloring ceramic materials using aqueous chromophore ion solutions cannot achieve brownish-red to pinkish-orange tones on both the surface and interior, lacking the aesthetic depth and penetration of traditional solid pigments while introducing fusibility issues with melt-lowering additives.
Innovation Solution
Incorporating 1-15% by weight of precipitated silica or silica gel with an active surface area of at least 100 m2/g into the ceramic mix, combined with aqueous or organic iron-based colorant solutions, to interact and produce the desired color variations, achieving ΔE>6 for brownish-red tones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional solid ceramic pigments are used to obtain brownish-red tones, then the coloration can be achieved throughout the material thickness, but the aesthetic effects (smoky tones, chiaroscuro effects, depth effects) are limited and machining after firing is not enabled
Solution Approach 1:
The patent changes the physical state of the colorant from solid pigment particles to aqueous solution containing chromophore ions. This parameter change enables the colorant to penetrate deeply into the ceramic material during firing, creating smoky tones and chiaroscuro effects while allowing machining after firing without compromising the decoration appearance.
Solution Approach 2:
The patent uses an aqueous solution as an intermediary carrier to deliver chromophore ions into the ceramic material. This intermediary enables deep penetration and interaction with the ceramic matrix, producing the desired aesthetic effects and allowing subsequent machining operations.
2Adaptability or versatility
If aqueous colorant solutions are used to obtain deep penetration and aesthetic effects, then smoky tones and chiaroscuro effects are achieved, but the available chromatic range is limited and new colors cannot be obtained
Solution Approach 1:
The patent establishes a universal approach by demonstrating that aqueous solutions of various chromophore ions (Fe, Co, Cr, Ni, Mn, Cu, Zn, Ti, V, Nb, Ta, Mo, W, Au, Ag, Pd, Pt, Hg, Pb, Bi, Sr, Ba, Ca, Al, Si) can be used to color ceramic materials. This multi-functional system enables access to a wide chromatic range while maintaining deep penetration and aesthetic effects characteristic of aqueous solution application.
Solution Approach 2:
The patent changes the concentration and type of chromophore ions in the aqueous solution to achieve different color tones and chromatic ranges. By adjusting these parameters, the system maintains uniform coloration and deep penetration while expanding the available color palette.
3Ease of manufacture
If melt-lowering additives are added to the ceramic mix to facilitate coloration, then the coloring process is improved, but excessive fusibility is introduced causing deformation during firing
Solution Approach 1:
The patent extracts the coloring function from the bulk ceramic mix by applying aqueous colorant solutions to the surface before firing. This separates the coloring operation from the mixing process, eliminating the need to add melt-lowering additives to the ceramic mix while maintaining good coloration results without excessive fusibility.
Solution Approach 2:
The patent performs the coloring action preliminarily by applying aqueous colorant solutions to the ceramic green body before firing. This preliminary action allows the colorant to be deposited and activated during firing without requiring melt-lowering additives to be mixed into the ceramic composition, thus avoiding fusibility issues.
4Manufacturing precision
If solid ceramic pigments are applied superficially by silk-screen printing, then surface decorations are obtained, but the aesthetic effects (smoky effect, chiaroscuro effects, depth penetration) are not achieved
Solution Approach 1:
The patent changes the state of the colorant from solid pigment to aqueous solution, enabling deep penetration into the ceramic material during firing. This parameter change allows the colorant to reach the interior of the material, creating smoky tones and chiaroscuro effects that are not possible with surface-level solid pigment application.
Solution Approach 2:
The patent uses aqueous solution as an intermediary that facilitates deep penetration of chromophore ions into the ceramic matrix during firing. This intermediary enables the colorant to reach deep into the material, producing the desired aesthetic effects while maintaining surface decoration quality.
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
This process allows for uniform brownish-red to pinkish-orange coloration on both the surface and interior of ceramic materials, maintaining the aesthetic benefits of aqueous solutions while avoiding excessive fusibility, enabling machining and preserving the appearance of the decoration.
Implementation Method 1
Because of their diffusive properties, the colorant solutions penetrate into the interior of the ceramic material from the surface to which they are applied, to develop 'in situ' coloration during firing of the material.
Implementation Method 2
adding to the ceramic mix from 1% to 15% by weight... of precipitated silica and/or silica gel... applying to the surface of the additive-containing ceramic mix solutions comprising iron... the variation in the resultant colour being equal to ΔE>6
Data Source
AI summary
The invention relates to a new process for coloring ceramic materials by using aqueous solutions of chromophore ions. In particular, certain types of silica are added to the ceramic mixes which are to be colored, after which aqueous or organic solutions comprising inorganic salts of Fe (II) and/or Fe (III), or organic derivatives of Fe (II) and/or Fe (III) are applied to the surface of the said additive-containing ceramic mixes.