Ceramic Tile Production via Controlled Particle Size Distribution
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Solution Overview
Problem
The use of recycled aluminium silicate material in ceramic production, particularly for ceramic porcelain floor tiles, leads to inconsistent shrinkage, internal stresses, and poor water absorption properties, resulting in defects such as fractures and black coring.
Innovation Solution
A process that controls the particle size distribution of the particulate mixture, specifically targeting a d50 particle size of 10 μm to 30 μm, d70 particle size of less than 40 μm, and d98 particle size of less than 60 μm, to ensure consistent properties and prevent black coring, while maintaining low water absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled aluminium silicate material is used in higher levels, then environmental benefits are achieved, but shrinkage consistency and internal stress control deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution parameters (d10, d50, d90, d98) of the particulate mixture. By adjusting these particle size parameters to specific ranges, the invention resolves the contradiction between using recycled materials and maintaining shrinkage consistency, enabling high levels of recycled aluminium silicate material to be used while achieving uniform shrinkage and minimal internal stresses.
2Volume of moving object
If particle size is increased, then shrinkage is reduced, but water absorption properties deteriorate
Solution Approach 1:
The patent resolves this contradiction through parameter changes by optimizing the particle size distribution to specific ranges (d10: 3-15 μm, d50: 10-30 μm, d90: 20-40 μm, d98: 30-60 μm). This controlled parameter range ensures both minimal shrinkage and excellent water absorption properties by achieving proper vitrification, demonstrating that specific parameter values can simultaneously satisfy opposing requirements.
Solution Approach 2:
The invention applies composite materials by creating a multi-component particulate mixture with controlled particle size distribution that includes recycled aluminium silicate material, clay, and other ceramic materials. This composite approach enables the material to exhibit both low shrinkage and low water absorption properties that cannot be achieved with single materials alone.
3Reliability
If particle size is decreased, then water absorption properties improve, but black coring defects increase
Solution Approach 1:
The patent resolves this contradiction by changing the particle size distribution parameters to specific ranges that balance water absorption and defect prevention. The controlled d10 (3-15 μm), d50 (10-30 μm), d90 (20-40 μm), and d98 (30-60 μm) parameters ensure fine particles are present for good water absorption while preventing the excessive fineness that causes black coring, achieving optimal balance through parameter optimization.
4Object-affected harmful factors
If recycled aluminium silicate material is used, then environmental benefits are achieved, but ceramic article quality deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling multiple parameters of the particulate mixture including particle size distribution (d10, d50, d90, d98), recycled material content (30-80 wt%), and water content (5-15%). By optimizing these parameters simultaneously, the invention enables high levels of recycled aluminium silicate material (30-80 wt%) to be used while producing high-quality ceramic articles without defects, resolving the contradiction between environmental benefits and product quality.
Solution Approach 2:
The invention uses composite materials by formulating a complex particulate mixture comprising recycled aluminium silicate material (30-80 wt%), clay (10-40 wt%), and other ceramic materials in specific proportions. This composite formulation, combined with controlled particle size distribution, enables the use of high levels of recycled material while maintaining excellent ceramic article quality including uniform shrinkage, no black coring, and low water absorption.
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 controlled particle size distribution results in ceramic articles with minimal shrinkage, no black coring, and excellent water absorption properties, producing high-quality ceramic porcelain floor tiles with improved strength and impermeability.
Implementation Method 1
subjecting the green article to a heat treatment step in a kiln to form a hot fused article
Implementation Method 2
poor water absorption properties due to lack of vitrification
Data Source
AI summary
A process for the production of a ceramic article includes the steps of: (a) preparing a particulate mixture; (b) contacting the particulate mixture to water to form a humidified mixture; (c) pressing the humidified mixture to form a green article; (d) optionally, subjecting the green article to an initial drying step; (e) optionally, glazing the green article to form a glazed green article; (f) subjecting the green article to a heat treatment step to form a hot fused article; and (g) cooling the hot fused article to form a glazed ceramic article. The particulate mixture includes from 30 wt % to 80 wt % recycled aluminium silicate material. The particulate mixture has: (i) a d50 particle size from 10 μm to 30 μm; (ii) a d70 particle size of less than 40 μm; and (iii) a d98 particle size of less than 60 μm. Steps (c) and (f), and optionally steps (d) and (e) are continuous process steps.