Feldspar Granules for Silica-Free Artificial Stone
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Solution Overview
Problem
The use of quartz and cristobalite in artificial agglomerate stone manufacturing poses a significant occupational health risk due to respirable crystalline silica dust, and existing alternatives like feldspar suffer from variability in color, transparency, and high quartz content, limiting their ability to replace quartz without compromising performance and color richness.
Innovation Solution
Specific types of feldspar granules with defined chemical compositions, characterized by specific metal oxide ranges, are used as fillers in artificial agglomerate stone articles, reducing crystalline silica emissions and maintaining the performance and color properties of quartz-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quartz and cristobalite are used as fillers in artificial agglomerate stone, then the material achieves high hardness, wear resistance, and aesthetic quality, but respirable crystalline silica dust is generated posing occupational health risks
Solution Approach 1:
The invention changes the chemical composition parameter of the filler material by specifying precise oxide ranges (SiO2: 60.0-69.5 wt.%, Al2O3: 17.0-20.0 wt.%, Na2O: 10.0-11.9 wt.%, K2O: 12.0-16.9 wt.%, Fe2O3 + TiO2: 0.0-0.5 wt.%) to create feldspar granules that maintain the desired mechanical properties while reducing crystalline silica content
Solution Approach 2:
The invention extracts and removes the harmful crystalline silica component from the filler material by replacing quartz and cristobalite with feldspar granules that have a different mineralogical composition, thereby eliminating the source of respirable crystalline silica dust while retaining beneficial properties
2Object-affected harmful factors
If natural feldspar is used as an alternative filler, then crystalline silica content is reduced, but variability in color, transparency, and composition limits performance and appearance quality
Solution Approach 1:
The invention transforms natural feldspar with variable properties into a standardized material by defining precise chemical composition parameters (oxide ranges) that ensure consistent colorimetry, transparency, and physical properties across different batches, enabling reliable manufacturing
Solution Approach 2:
The invention applies specific compositional requirements to different oxide components (higher SiO2 range, controlled Al2O3, specific Na2O and K2O ranges, and limited Fe2O3 + TiO2) to optimize local properties such as color, transparency, and chemical resistance while maintaining overall performance
3Object-affected harmful factors
If feldspar with variable composition is used, then quartz content may be reduced, but the ability to maintain color richness and visual appearance is compromised
Solution Approach 1:
The invention optimizes the SiO2 content range (60.0-69.5 wt.%) and controls Fe2O3 + TiO2 (0.0-0.5 wt.%) to achieve the right balance between reducing crystalline silica and maintaining color richness, transparency, and visual appearance comparable to quartz-based materials
Data Source
AI summary
The invention relates to the use of feldspar granules with a particular combination of oxide constituents in the manufacture of artificial agglomerate stone materials and to the agglomerate stone materials resulting thereof.