Glass Flake Composition for Heat Resistance
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Solution Overview
Problem
Glass flakes used in resin moldings, coating materials, and cosmetics face challenges due to insufficient heat resistance, chemical durability, and formability issues, particularly with the presence of volatile components like diboron trioxide, fluorine, zinc oxide, barium oxide, strontium oxide, and zirconium oxide, which affect melting and furnace longevity.
Innovation Solution
A glass composition with controlled ranges of SiO2, Al2O3, and (SiO2—Al2O3) is developed, excluding B2O3, F, ZnO, BaO, SrO, and ZrO2, to enhance heat resistance, chemical durability, and formability, allowing for the production of glass flakes with improved acid resistance and ease of formation at lower working temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soda-lime glass composition is used to reduce production cost, then manufacturing cost is reduced, but heat resistance is insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the glass by strictly limiting alkali metal oxide content to 5 mass% or lower and excluding volatile components, thereby improving heat resistance while maintaining production feasibility through controlled raw material selection
Solution Approach 2:
The patent replaces expensive heat-resistant glass compositions (C glass, E glass) that contain volatile components requiring frequent furnace maintenance with a cheaper, stable composition that eliminates B2O3 and F, reducing both material cost and operational maintenance costs
2Ease of manufacture
If diboron trioxide and fluorine are added to adjust devitrification temperature and viscosity, then formability is improved, but volatility increases causing dispersion during melting and furnace erosion
Solution Approach 1:
The patent extracts and eliminates the volatile components B2O3 and F from the glass composition, removing the source of harm (volatility and furnace erosion) while maintaining formability through alternative composition design with controlled alkali metal oxides and other stable components
Solution Approach 2:
The patent converts the potential harm of volatile components by replacing them with non-volatile alternatives that provide similar functional benefits (viscosity control, devitrification temperature adjustment) without the harmful side effects of dispersion and furnace erosion
3Ease of manufacture
If alkali metal oxide content is increased to improve meltability, then melting process is improved, but heat resistance decreases
Solution Approach 1:
The patent optimizes the alkali metal oxide content parameter to 5 mass% or lower, finding the optimal balance point that provides sufficient meltability for production while maintaining the heat resistance required for high-temperature applications and coating processes
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 resulting glass flakes exhibit excellent heat resistance, chemical durability, and acid resistance, making them suitable for high-temperature applications and use in resin compositions, coating materials, and cosmetics, while avoiding the volatility and cost issues associated with the excluded components.
Implementation Method 1
the devitrification temperature is the temperature at which crystals are formed in the molten glass base material and start to grow
Implementation Method 2
they exhibit interference colors due to interference of reflected light when the surfaces thereof are coated with metal oxides
Data Source
AI summary
A glass flake of the present invention has a composition that includes, in terms of mass %, 59≦SiO2<65, 8≦Al2O3≦15, 47<(SiO2—Al2O3)≦57, 1≦MgO≦5, 20≦CaO≦30, 0<(Li2O+Na2O+K2O)<2, and 0≦TiO2≦5 and that is substantially free from B2O3, F, ZnO, BaO, SrO, and ZrO2.