Ceramic Tile Binder Using Sugar-Based Polymer
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Solution Overview
Problem
The existing processes for making ceramic tiles face challenges in achieving the right balance of mechanical strength and preventing defects like black coring, especially when using organic additives.
Innovation Solution
A process that involves adding a polymer composition to ceramic raw materials, where the polymer is obtained by polymerization in the presence of a sugar or degraded polysaccharide, acting as both a binder and plasticizer, and is added in specific percentages to enhance the strength and reduce defects in ceramic tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If organic additives (binders and plasticizers) are added to ceramic raw materials to increase mechanical strength and reduce defects, then the strength of green and dried tile bodies is improved, but black coring defects are generated
Solution Approach 1:
The patent changes the chemical composition parameters of the additive by using polymers synthesized from renewable raw materials (sugars, starches, celluloses) instead of conventional fossil-based organic additives. This parameter change maintains the binding and plasticizing functions while eliminating the black coring defect associated with traditional organic additives.
Solution Approach 2:
The patent employs composite polymer materials derived from natural renewable resources (sugars, starches, celluloses) combined with ceramic raw materials. These composite materials provide both the mechanical strength enhancement and defect prevention simultaneously, resolving the contradiction between strength improvement and black coring prevention.
2Strength
If large amounts of organic additives are used to cement powdery raw materials and increase mechanical resistance, then the strength of green and dried tiles is improved, but black coring problems are typically associated with their use
Solution Approach 1:
The patent modifies the chemical origin and composition parameters of the organic additive by transitioning from fossil-based polymers to renewable-based polymers (from sugars, starches, celluloses). This parameter change preserves the necessary mechanical resistance enhancement while eliminating the black coring problem inherent in conventional organic additives.
Solution Approach 2:
The patent utilizes renewable raw materials (sugars, starches, celluloses) that are biodegradable and environmentally friendly, replacing persistent fossil-based additives. These renewable-based polymers provide the necessary binding and plasticizing functions without the harmful black coring effects, and their renewable nature allows for sustainable, repeatable use.
3Ease of operation
If conventional organic additives are used to increase the capacity of slips to change permanently in size and shape during forming, then the plasticity of slips is improved, but black coring defects are generated
Solution Approach 1:
The patent changes the chemical composition parameters of the plasticizer by using polymers synthesized from renewable raw materials (sugars, starches, celluloses) instead of conventional organic plasticizers. This parameter change maintains the necessary plasticity for slip forming while eliminating the black coring defect associated with traditional organic plasticizers.
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 polymer composition effectively increases the strength of green and dried tile bodies, prevents black coring, and has a predictable behavior without significantly affecting the viscosity of ceramic raw material mixtures, thus simplifying the manufacturing process.
Implementation Method 1
Binders are added for the specific purpose of cementing together the powdery raw materials and increasing the mechanical resistance of the dried and/or green tiles
Implementation Method 2
Plasticizers are added for the specific purpose of increasing the capacity of the slips to change permanently in size and shape during the forming of the tiles
Implementation Method 3
since it has a little effect on the viscosity of ceramic raw material mixtures or of the ceramic slips
Data Source
AI summary
A process for making tiles comprising: i) mixing the ceramic raw materials; ii) dry-grinding the ceramic raw materials or wet-grinding the ceramic raw materials and spray drying the ceramic slip obtained from the wet-grinding; iii) forming green tiles by pressing the powdery grinded ceramic raw materials obtained from step ii); said process being characterized by the addition to the ceramic raw materials, before step iii), of from 0.01 to 5.0% by weight, based on the weight of the ceramic raw materials (dry matter), of a composition comprising a polymer obtained by polymerization in the presence of a sugar or a degraded polysaccharide.