Ceramic Glass Sheet Production via Controlled Crystallization
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Solution Overview
Problem
The processing cycles for glass and ceramic glass materials are distinct, making it difficult to use standard glass manufacturing processes for ceramic glass, which would simplify production and allow for easier creation of materials in various dimensions.
Innovation Solution
A process involving the melting of a mixture of SiO2, Al2O3, and Li2O oxides, with optional additional oxides, is processed using standard glass manufacturing techniques like rolling and blowing, followed by crystallization cycles to produce ceramic glass materials with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rapid cooling operations (static or roller pressing) are applied to molten oxide mass for ceramic glass, then crystalline phases are formed with superior chemical-physical features, but the processing cycle becomes complex and cannot use standard glass manufacturing equipment
Solution Approach 1:
The patent applies parameter changes by carefully controlling the cooling rate and thermal gradients during the shaping operation. The molten mass is cooled at a controlled rate that allows crystalline nuclei to form and grow within the amorphous matrix, transforming the material properties while using standard glass manufacturing equipment. This resolves the contradiction by achieving superior chemical-physical features through parameter optimization rather than complex specialized processing cycles.
2Strength
If rapid cooling operations are used to form ceramic glass, then crystalline phases are developed with enhanced properties, but continuous processing like standard glass manufacturing cannot be implemented
Solution Approach 1:
The patent enables continuous processing by integrating the crystallization step into the continuous shaping operation. The molten oxide mass is continuously fed through the shaping device where it undergoes rapid cooling and crystallization in one continuous flow, eliminating the need for separate batch processing steps. This allows standard glass manufacturing equipment to produce ceramic glass continuously while maintaining the enhanced properties from rapid cooling.
3Ease of manufacture
If standard glass manufacturing processes are used for ceramic glass, then process simplicity and ease of manufacture are achieved, but the molten mass cannot be rapidly cooled to form crystalline phases
Solution Approach 1:
The patent makes standard glass manufacturing equipment multi-functional by adjusting operational parameters to achieve both glass forming and ceramic glass crystallization in the same equipment. The shaping device, originally designed for glass, is operated with modified cooling rates and thermal profiles to simultaneously perform shaping and crystallization functions, enabling ease of manufacture without sacrificing the enhanced properties of ceramic glass.
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 approach allows for the continuous processing of ceramic glass materials, enabling the production of large, high-quality sheets with superior mechanical and chemical properties, such as high microhardness and thermal shock resistance, using existing glass manufacturing equipment and conditions.
Implementation Method 1
the molten mass thus obtained is subjected to rapid cooling by means of shaping operations (static or roller pressing, centrifugation, injection, blowing, extrusion, hot bending) then the semi-finished product is subjected to appropriate thermal cycles in which (homogeneous or heterogeneous) crystalline nuclei are developed and subsequently grow
Implementation Method 2
glass is an amorphous material obtained by melting of crystalline compounds, normally oxides
Data Source
AI summary
A process allowing to obtain ceramic glass material in the form of sheets of large dimensions usable in constructions for panelling or for flooring is described.