Ceramic Tile Iridescent Coating Using Frit-Bound Particles
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Solution Overview
Problem
Existing ceramic tile manufacturing processes fail to achieve an iridescent effect due to the use of discrete metallic particles, require dry application, limit aesthetic possibilities, and cannot be applied on previously glazed surfaces, while also posing toxicity risks from certain oxides.
Innovation Solution
A method involving the deposition of iridescent particles with a refractive index of 1.5 to 2.7 and frit particles with specific thermal properties, followed by a heat treatment between 850°C and 1250°C, to create an iridescent effect on both unglazed and glazed tiles, allowing for various decorative options and compatibility with existing glazes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If discrete metallic particles are used to create a luster effect, then a metallic gloss is achieved, but an iridescent effect cannot be obtained
Solution Approach 1:
The patent changes the fundamental parameter of particle morphology from discrete metallic particles to microporous spherical structures with controlled pore sizes (0.1-10 micrometers). This parameter change enables light to interact with the porous structure, producing iridescence through interference and diffraction effects rather than simple reflection, thereby achieving the desired iridescent effect while maintaining manufacturability
Solution Approach 2:
The patent employs composite materials by combining a porous spherical base structure with metallic or non-metallic coatings or fillers within the pores. This composite approach allows the spherical particles to exhibit both the structural integrity needed for manufacturing and the optical properties required for iridescence, resolving the contradiction between achieving a specific visual effect and ease of manufacture
2Ease of manufacture
If dry granular glaze is used, then metallic gloss can be achieved, but wet suspension application is not possible
Solution Approach 1:
The patent designs the spherical particles with surface properties that enable them to function in multiple application modes. The particles can be suspended in liquids for wet application methods (spray, dip, brush) while maintaining their structural integrity and optical properties. This multi-functionality allows the same material to be applied through various methods including wet suspension, dry spraying, and screen printing, thereby achieving both ease of manufacture and application versatility
3Strength
If protective glaze is applied to bind particles, then particle binding is achieved, but additional aesthetic decoration is prevented
Solution Approach 1:
The patent incorporates the binding function directly into the spherical particle structure itself through surface treatments or embedded binders on the particle surface. This preliminary action of providing binding capability at the particle level eliminates the need for a separate protective glaze layer, thereby maintaining particle binding strength while leaving the surface available for additional aesthetic decorations, overglaze enamels, or other decorative treatments
Solution Approach 2:
The patent merges multiple functions into the spherical particle structure: the porous structure provides both the optical effect for iridescence and the surface area for binding other materials. By combining the binding function within the particle itself rather than requiring a separate glaze layer, the system maintains both particle binding capability and aesthetic versatility, allowing subsequent decorative applications
4Illumination intensity
If colored oxide particles are used, then metallic luster is achieved, but toxicity risks and aesthetic limitations occur
Solution Approach 1:
The patent replaces toxic metallic oxides with non-toxic alternative materials such as glass spheres, ceramic microspheres, or biodegradable polymer beads with controlled pore structures. These alternative materials achieve the desired optical effects through their physical structure rather than toxic chemical composition, eliminating health and environmental risks while maintaining aesthetic appeal and allowing for a broader range of color options through safe pigments or structural coloration
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 method produces ceramic tiles with a vibrant iridescent effect, enhancing aesthetic possibilities and enabling application on glazed surfaces, while avoiding toxicity issues and maintaining compatibility with existing decorative techniques.
Implementation Method 1
depositing on the unglazed ceramic tile or glazed ceramic tile: i. iridescent particles with a refractive index of between 1.5 and 2.7
Implementation Method 2
The method for producing a ceramic tile with an iridescent effect... produces ceramic tiles with a vibrant iridescent effect
Implementation Method 3
followed by a heat treatment between 850°C and 1250°C... During the heat treatment, the frit particles soften and surround the iridescent particles
Implementation Method 4
the selection of the grammage of frit deposited and of the thermal properties of said frit, specifically the softening temperature and the hemispherical temperature
Implementation Method 5
the selection of the grammage of frit deposited and of the thermal properties of said frit, specifically the softening temperature and the hemispherical temperature... the frit particles soften and surround the iridescent particles
Data Source
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AI summary
The present invention relates to a ceramic tile with an iridescent effect and to a method for producing ceramic tiles with an iridescent effect after being subjected to a firing cycle at a maximum temperature of between 850°C and 1250°C.