Ferromanganese Powder Oxidation for Metallic Pigments

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing metallic pigments, such as those using aluminum, magnesium, copper, or bronze, face challenges with oxidation sensitivity and the need for surface modifiers to achieve desired colors and stability, while being costly and inefficient, particularly in processes like PVD.

Innovation Solution

A method involving heating ferromanganese powder in the presence of oxygen to form a manganese or iron oxide layer, which acts as a colorant without additional surface modifiers, allowing for the production of colored metal-containing powders with enhanced stability and aesthetic value.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional metallic pigments (aluminum, magnesium, copper, bronze) are used, then metallic appearance is achieved, but oxidation sensitivity increases and surface modifiers are required

Engineering Contradiction:

Improveoxidation resistanceVSAvoidsurface modifier requirement

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies oxidation to the ferromanganese powder to form a colored oxide layer (manganese oxide or iron oxide) on the surface, converting the harmful oxidation effect into a beneficial coloration mechanism. This oxide layer naturally protects the underlying metal while providing the desired metallic pigment colors (gold, purple/violet, blue) without requiring additional surface modifiers

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical composition parameter by using ferromanganese powder instead of traditional metallic pigments. This compositional change enables the formation of colored oxide layers through controlled oxidation, eliminating the need for surface modifiers while maintaining metallic appearance and improving oxidation resistance

Inventive Principle:

Principle #35Parameter changes

2Reliability

If PVD process is used to produce metallic pigments, then good dispersability and high concentration suspensions are achieved, but manufacturing cost increases

Engineering Contradiction:

ImprovedispersabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the expensive PVD process with a simpler, more cost-effective oxidation method. By using controlled oxidation of ferromanganese powder in a furnace or reactor, the patent achieves the desired colored metallic pigment without requiring complex PVD equipment, thereby significantly reducing manufacturing costs while maintaining product performance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If surface modifiers are added to protect metallic powders from tarnishing, then oxidation resistance is improved, but the formulation becomes more complex and costly

Engineering Contradiction:

Improveoxidation resistanceVSAvoidformulation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent enables the ferromanganese powder to protect itself from further oxidation by forming a stable colored oxide layer on its surface during the manufacturing process. This self-protecting oxide layer eliminates the need for additional surface modifiers or protective formulations, simplifying both the pigment formulation and its application

Inventive Principle:

Principle #25Self-service

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 produces colored metal-containing powders with a range of metallic effects, including gold, purple/violet, and blue, without the need for surface modifiers, offering improved stability and cost-effectiveness compared to traditional methods, and can be used in various applications like paints and cosmetics.

Implementation Method 1

heating the bulk powder up to a temperature ranging from 100°C to 1000°C in a container, in the presence of oxygen, until an outer layer of manganese oxides and/or iron oxides is formed on the particles

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

The outer layer of the particles produces different colours (gold, purple/violet, blue) having different tonalities

Methodology Applied

Scientific EffectThin film interference: Interference

Data Source

PatentEP3973024B1Method for obtaining coloured metal-containing powder, the powder obtained thereof and its use as metallic pigment

Publication Date: 2022.10.12 FERROGLOBE INNOVATION SL

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The present invention relates to a method for producing a coloured metal-containing powder, which can be used as a metallic pigment, said method comprising: preparing a bulk metal-containing material in the form of powder (which acts as a particle substrate), which is a ferromanganese (FeMn) powder; and heating said material up to a temperature ranging from 100ºC to 1000ºC in a container, in the presence of oxygen. Preferably, the bulk powder is a refined FeMn powder. It is also an object of the invention the coloured metal-containing powder obtainable by means of the disclosed method, in the absence of surface modifiers, wherein it can have a blue, purple/violet and gold colour, or any intermediate tonality, depending on the metal oxide content. Said oxides are present forming an outer layer on the particles of the powder. The invention also refers to the use of the powder as a metallic pigment.