Glass-Ceramic Slab Devitrification for Hardness and Translucency
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Solution Overview
Problem
Existing methods for manufacturing ceramic slabs, such as Lapitec technology, limit the range of aesthetic effects and color intensity, particularly failing to achieve a deep translucid white color and high hardness, resulting in slabs with low resistance to scratching and alkaline attack.
Innovation Solution
A method using a preponderant amount of high-melting glass frit with specific composition, sintered at high temperature and controlled cooling, to produce glass-ceramic slabs with a white or translucid color and enhanced hardness, exceeding 5 Mohs, through partial or total devitrification and crystallization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ceramic granulated materials and ceramic mineral powders are used in the base mix, then the slab articles can be manufactured with established technology, but the aesthetic effects on visible surfaces are limited and cannot achieve deep translucid white color
Solution Approach 1:
The patent changes the chemical composition parameters of the base mix by incorporating glass frit containing specific oxides (SiO2, Al2O3, B2O3, Na2O, K2O, CaO, MgO) in controlled proportions. This compositional parameter change enables the material to achieve deep translucid white color and aesthetic effects while maintaining manufacturability through established ceramic processing techniques.
Solution Approach 2:
The patent creates a composite material system by combining glass frit with ceramic mineral powders (feldspars, clays, kaolins) and granulated ceramic materials. This composite approach integrates the aesthetic properties of glass (translucency, color depth) with the structural properties of ceramics, resolving the contradiction between manufacturability and aesthetic quality.
2Illumination intensity
If glass frit is used in the base mix to improve aesthetic effects, then deep translucid white color can be achieved, but the hardness and resistance to scratching decrease
Solution Approach 1:
The patent carefully controls the chemical composition parameters of the glass frit, specifically limiting certain oxides and optimizing others to balance aesthetic properties with mechanical strength. The controlled crystallization process parameters (temperature, time, cooling rate) are also adjusted to achieve the desired hardness while maintaining translucency.
Solution Approach 2:
The patent utilizes controlled phase transitions during firing, specifically the controlled crystallization of glass frit into glass-ceramic material. This phase transition from amorphous glass to crystalline glass-ceramic structure enhances hardness and mechanical strength while preserving the aesthetic translucid white color achieved through the glass frit composition.
3Strength
If high-melting glass frit is sintered at high temperature with controlled cooling, then hardness exceeding 5 Mohs is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent performs preliminary actions by pre-mixing the glass frit with ceramic minerals and granulated materials in specific proportions before firing. This preliminary preparation ensures uniform distribution of components, which simplifies the subsequent high-temperature sintering process and reduces the complexity of process control during firing.
Solution Approach 2:
The glass frit composition is designed to undergo controlled crystallization automatically during the firing process at high temperature. The material self-organizes and transforms into the desired glass-ceramic structure with hardness exceeding 5 Mohs through its own thermal history, reducing the need for complex external control mechanisms during the sintering process.
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 method achieves a glass-ceramic material with improved hardness and aesthetic appearance, maintaining the physical and mechanical characteristics of ceramics while retaining some glass properties, resulting in slabs with deep translucid white color and increased resistance to scratches and alkaline attack.
Implementation Method 1
the glass frit, together with the controlled cooling referred to above, results in its partial or total devitrification, so that the frit assumes a crystalline structure
Implementation Method 2
The mix is then cooled, while ensuring that cooling is slowed down so that it remains at a temperature not higher than 1160° C. and not less than 1000° C. for a predetermined time period equal to at least one minute
Data Source
AI summary
Method for manufacturing slab articles from a mix, comprising the steps of a) preparing a mix comprising a preponderant amount of a glass frit and a binder, b) distributing the mix in a support, c) compacting the mix, d) drying the mix, e) sintering the mix and f) cooling the article. The glass frit comprises a weight amount of silica (SiO2) comprised between 62% and 68%, a weight amount of alumina (Al2O3) comprised between 3% and 5%, a weight amount of potassium oxide (K2O) comprised between 3% and 5%, a weight amount of calcium oxide (CaO) comprised between 18% and 26% and a weight amount of magnesium oxide (MgO) comprised between 1% and 4% The cooling step is performed in a controlled manner by modulating the cooling speed in a temperature range not greater than 1.160° C. and not less than 1.000° C. in order to perform the at least partial devitrification and crystallization of the glass frit. The invention also relates to a glass frit and an article in slab form.