Ceramic Glaze Additive with Silver Carrier for Antimicrobial Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ceramic products, particularly sanitary ware, face challenges in achieving antimicrobial protection without compromising their appearance, as traditional antimicrobial components like bismuth and zinc cause issues such as fluidity, dripping, discoloration, and surface defects due to high firing temperatures and long firing times.
Innovation Solution
A ceramic glaze additive formulation incorporating a fritted antimicrobial composition with a silver carrier in a glass matrix, combining bismuth oxide (Bi2O3) and zinc oxide (ZnO) with flux frit, which allows for a wider range of compositions and easier integration into the glaze, reducing surface defects and energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional antimicrobial components (bismuth and zinc) are used in ceramic glazes, then antimicrobial protection is achieved, but the glaze exhibits increased fluidity, dripping, and surface defects due to high firing temperatures and long firing times
Solution Approach 1:
The patent introduces a carrier material as an intermediary substance that delivers antimicrobial components to the glaze surface. The carrier material acts as a vehicle that prevents direct interaction between bismuth/zinc and the glaze matrix, thereby reducing harmful effects like fluidity and dripping while maintaining antimicrobial functionality through controlled release or surface deposition.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the antimicrobial components by changing their form (e.g., particle size, coating, or chemical compound form) and controlling their release characteristics. This allows the antimicrobial agents to remain stable at high firing temperatures and long firing times without causing excessive glaze fluidity or surface defects.
2Manufacturing precision
If high firing temperatures and long firing times are used for sanitary ware, then the glaze achieves desired aesthetic color and appearance, but energy consumption increases and surface defects occur
Solution Approach 1:
The patent performs preliminary processing of the glaze formulation by pre-mixing antimicrobial components with carrier materials and preparing the glaze in advance with optimized composition. This preliminary action allows the glaze to achieve aesthetic properties and antimicrobial functionality at lower firing temperatures and shorter times, thereby reducing energy consumption while maintaining manufacturing precision.
Solution Approach 2:
The patent creates a composite glaze material combining traditional glaze components with antimicrobial agents and carrier materials in specific ratios. This composite formulation enables the glaze to achieve desired aesthetic color and appearance at reduced firing temperatures and shorter times, reducing energy consumption while maintaining surface quality and preventing defects.
3Reliability
If bismuth and zinc are added to the glaze formulation, then antimicrobial properties are achieved, but the glaze experiences discoloration and dimensional changes
Solution Approach 1:
The patent uses carrier materials as intermediaries that isolate bismuth and zinc from direct interaction with the glaze matrix. This intermediary approach prevents unwanted chemical reactions that cause discoloration and dimensional changes, while still allowing the antimicrobial components to function effectively on the glaze surface through controlled delivery mechanisms.
Solution Approach 2:
The patent changes the physical and chemical parameters of the antimicrobial components by controlling their particle size, surface treatment, or chemical form to minimize reactions with other glaze components. This parameter optimization maintains color stability and dimensional accuracy while preserving antimicrobial functionality.
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 formulation provides effective antimicrobial properties while maintaining the desired aesthetic appearance and reducing the energy and time required for firing, overcoming the limitations of traditional antimicrobial components by enhancing glaze stability and reducing surface defects.
Implementation Method 1
fritting an antimicrobial formulation in a flux frit
Implementation Method 2
providing a silver carrier in a glass matrix
Data Source
AI summary
A method of making a ceramic glaze formulation having an antimicrobial property for use with a ceramic article. The method comprises fritting an antimicrobial formulation in a flux frit, providing least one unfritted antimicrobial component, providing a silver carrier in a glass matrix, and combining the flux frit, the at least one unfritted component, and the silver carrier in the glass matrix to form the ceramic glaze formulation. The silver carrier is combined at an addition rate based on a dry weight basis of the ceramic glaze formulation. A ceramic glaze additive formulation and ceramic glazed article are also provided.