Glass-Ceramic Composition Using Low-Temperature Sintering
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Solution Overview
Problem
Current methods for synthesizing glass-ceramic materials are costly due to the use of expensive raw materials and high temperature conditions, which are inefficient and energy-intensive.
Innovation Solution
A method involving the admixing of a crystallization promoter with glass having a median particle distribution of 50 to 70 μm, followed by sintering at lower temperatures (500 to 1500°C) to produce a glass-ceramic material comprising 50 to 70 wt% silicon dioxide, 5 to 10 wt% aluminium oxide, and 5 to 10 wt% calcium oxide, with less than 35 wt% cristobalite and more than 35 wt% pyroxene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods using pure oxides and nucleating agents are used, then the glass-ceramic material achieves dense and homogeneous structure, but the production cost increases significantly
Solution Approach 1:
The patent replaces expensive pure oxide raw materials with cheaper waste glass and industrial by-products. These lower-cost materials are processed through a simplified method using organic acid to achieve acceptable glass-ceramic structures without requiring high-purity inputs, thereby reducing production costs while maintaining structural quality.
Solution Approach 2:
The patent changes the chemical parameters by introducing organic acid (oxalic acid, citric acid, or acetic acid) as a alternative to conventional nucleating agents. This parameter change allows the use of cheaper raw materials while still achieving the desired crystallization and structural properties of the glass-ceramic material.
2Reliability
If high temperature synthesis (higher than 1000°C) is used, then complete crystallization and dense structure are achieved, but energy consumption increases
Solution Approach 1:
The patent changes the temperature parameter by using organic acid to facilitate crystallization at lower temperatures (below 1000°C). The organic acid acts as a flux and nucleating agent that lowers the activation energy required for crystallization, enabling complete crystallization and dense structure formation without the need for high-temperature processing, thereby significantly reducing energy consumption.
Solution Approach 2:
The organic acid serves as an intermediary substance that mediates the crystallization process. It facilitates the transformation from glass to glass-ceramic at lower temperatures by providing a chemical pathway that reduces the energy barrier for nucleation and crystal growth, replacing the need for high-thermal-energy input.
3Reliability
If long duration heating (24 hours or more) is used, then thorough crystallization is achieved, but production time increases
Solution Approach 1:
The patent changes the time parameter by using organic acid to accelerate the crystallization kinetics. The organic acid promotes faster nucleation and crystal growth rates, allowing thorough crystallization to be achieved in significantly reduced time (from 24+ hours to much shorter durations), thereby reducing production time while maintaining crystallization quality.
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 reduces production costs and energy consumption while maintaining mechanical properties such as high compressive strength and flexural strength, providing an alternative to traditional ceramic materials.
Implementation Method 1
heating the formed glass product to a temperature high enough to stimulate crystals to nucleate throughout the glass
Implementation Method 2
converting the amorphous glass grains into a crystalline glass-ceramic material
Implementation Method 3
sintering the admixture obtained in step (a)
Data Source
AI summary
A method of preparing a glass-ceramic material, the method comprising the steps of:(a) admixing a crystallisation promoter and a glass; wherein the glass has a median particle distribution (D50) of from 50 to 70 μm; and(b) sintering the admixture obtained in step (a).A glass-ceramic material and the use of such a glass-ceramic material are also described.