Crystallized Glass Manufacturing via Single-Step Heat Treatment
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Solution Overview
Problem
The existing methods for producing crystallized glass require a two-step heat treatment process for nucleation and crystal growth, which is complex and time-consuming, necessitating a simplification of the crystallization process.
Innovation Solution
A production method that involves melting glass raw materials, molding them into a predetermined shape, annealing to incorporate crystal nuclei or separated phases, and then undergoing heat treatment for crystal growth, thereby simplifying the process and reducing the number of steps and time required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-step heat treatment process (nucleation followed by crystal growth) is used to produce crystallized glass, then the crystal structure and strength are improved, but the process complexity and processing time increase
Solution Approach 1:
The patent combines the nucleation and crystal growth steps into a single heat treatment process. By adding specific nucleating agents (such as TiO2, ZrO2, or P2O5) to the glass composition, the nucleation occurs simultaneously with crystal growth during one heating cycle, eliminating the need for separate nucleation and growth furnaces and reducing process complexity while maintaining glass strength
Solution Approach 2:
The patent modifies the chemical composition parameters of the glass by incorporating specific nucleating agents (TiO2: 0.1-5 wt%, ZrO2: 0.1-5 wt%, P2O5: 0.1-5 wt%). These compositional changes enable the glass to undergo both nucleation and crystal growth at comparable heating rates (10-100°C/min) in a single heat treatment step, resolving the contradiction between strength and process complexity
2Strength
If a two-step heat treatment process (nucleation followed by crystal growth) is used to produce crystallized glass, then the crystal structure and strength are improved, but the processing time increases
Solution Approach 1:
The patent merges nucleation and crystal growth into one continuous heat treatment process. The glass is heated at a controlled rate (10-100°C/min) to a target temperature (500-900°C), held for a combined time (1-24 hours) that accomplishes both nucleation and crystal growth simultaneously, thereby halving the total processing time compared to sequential two-step methods while preserving glass strength
Solution Approach 2:
The patent incorporates nucleating agents into the glass composition beforehand, preparing the glass matrix in advance to facilitate rapid nucleation during the single heat treatment. This preliminary incorporation of nucleating sites allows the nucleation process to occur concurrently with crystal growth, reducing the overall time required to achieve the desired crystal structure and strength
3Stability of the object's composition
If traditional molding and separate annealing processes are used, then the glass structure is stabilized, but the process complexity increases
Solution Approach 1:
The patent combines the molding and annealing operations into a single integrated process step. The glass is molded into its final shape and then annealed in the same equipment without requiring separate annealing furnaces, thereby achieving structural stabilization while reducing equipment complexity and process steps
Solution Approach 2:
The molding equipment is designed to perform multiple functions: shaping the glass and simultaneously annealing it through controlled heating and cooling. This multi-functional approach eliminates the need for dedicated annealing equipment, reducing overall equipment complexity while maintaining glass structure stability
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
This method allows for the production of crystallized glass with a reduced process complexity, shorter processing time, and simplified equipment, while maintaining the strength and properties of crystallized glass.
Implementation Method 1
obtaining a molten glass by melting a glass raw material
Implementation Method 2
obtaining a raw glass sheet including at least one of a crystal nucleus and a separated phase by annealing the glass molded body
Implementation Method 3
obtaining the crystallized glass by causing the crystal growth through heat treatment of the raw glass sheet
Data Source
AI summary
The present invention relates to a method for producing crystallized glass, including: (a1) melting a glass raw material to obtain molten glass; (a2) molding the molten glass into a predetermined shape by a molding unit to obtain a glass molded body; (a3) slowly cooling the glass molded body to obtain a raw glass plate containing at least one of a crystal nucleus and a separated phase; and (a4) heat-treating the raw glass plate containing the at least one of the crystal nucleus and the separated phase to cause crystal growth so as to obtain the crystallized glass.