Compacted Ceramic Tile Composition for Faster Cutting
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Solution Overview
Problem
Large format ceramic tiles or slabs with high mechanical resistance, low porosity, and whitish or cream color are difficult to cut efficiently without damaging cutting tools.
Innovation Solution
A ceramic material with a specific chemical composition comprising SiO2, Al2O3, CaO, MgO, ZrO2, and Fe2O3, along with a glassy phase, anorthite, albite, mullite, and quartz, which allows for efficient cutting and reduced density without compromising mechanical resistance or porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic material is made with high mechanical resistance, low porosity, and whitish color, then the tile achieves outstanding performance properties, but it becomes difficult to cut efficiently without damaging cutting tools
Solution Approach 1:
The patent modifies the chemical composition parameters of the ceramic material by introducing specific oxide ratios (SiO2: 59.0-70.0 wt%, Al2O3: 19.0-25.0 wt%, CaO: 1.7-5.8 wt%, MgO: 1.2-5.6 wt%, ZrO2: 0.0-1.9 wt%, Fe2O3: 0.0-1.0 wt%) and controlling phase composition (glassy phase: 45-75 wt%, anorthite: 5-20 wt%, albite: 5-17 wt%, mullite: 0-10 wt%, quartz: 1-9 wt%). These parameter changes create a balanced composition that maintains high mechanical strength and low porosity while improving cutability and reducing tool wear.
Solution Approach 2:
The patent creates a composite ceramic material system combining multiple crystalline phases (anorthite, albite, mullite, quartz) with a glassy matrix phase. This composite structure provides both the mechanical strength and low porosity required for high-performance tiles while the specific combination of phases improves cutting characteristics and reduces tool damage compared to conventional single-phase or different-phase compositions.
2Ease of operation
If ceramic material density is reduced for easier cutting, then cutability improves, but mechanical resistance and low porosity properties may be compromised
Solution Approach 1:
The patent precisely controls the density-related parameters through chemical composition adjustments. The oxide ratios and phase compositions are optimized to achieve the right balance where the material is dense enough for high mechanical strength and low porosity, yet not so dense as to be uncuttable. The specific phase distribution and crystal structure parameters are controlled to facilitate cutting while maintaining structural integrity.
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 material can be cut faster and with less tool damage, providing more tiles per cutting cycle while maintaining low water absorption and high mechanical resistance.
Implementation Method 1
a fired ceramic material... highly compacted ceramic material
Implementation Method 2
45-75 wt% of glassy phase... highly compacted vitrified porcelain ceramic layer
Data Source
AI summary
The invention relates to tiles or slabs comprising a fired ceramic material which has a chemical composition with a particular combination of oxides; to a method for the manufacture of said tiles or slabs; and to the use thereof for construction or decoration applications. The fired ceramic material may have a whitish/cream color with a ClELAB L* coordinate in the range 75-85.