Glazed Ceramic Antimicrobial Coating to Avoid Glaze Defects
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Solution Overview
Problem
Existing methods of adding antimicrobial minerals to ceramic glazes result in defects, alter texture and color, and are costly, with most minerals being ineffective on the surface due to depth loss during firing.
Innovation Solution
Applying an antimicrobial composition comprising additives like Bi2O3, ZnO, Ag2CO3, Zn, Bi, or Ag on the outermost surface of glazed ceramics, which diffuses into the glaze during firing, maintaining high concentration at the surface for efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial minerals are added to the ceramic glaze prior to firing, then antimicrobial effect is achieved, but defects are caused and texture, color, and slip resistance are altered
Solution Approach 1:
The patent divides the antimicrobial treatment into two separate stages: first applying a base glaze layer, then applying a separate antimicrobial mineral layer on top. This segmentation allows the antimicrobial minerals to be applied without mixing them into the base glaze, thereby avoiding the defects and property alterations that occur when minerals are added during glaze formulation. Each layer can be optimized independently - the base glaze for its aesthetic and functional properties, and the surface layer for antimicrobial efficacy.
Solution Approach 2:
The base glaze is applied and fired first, creating a stable foundation layer. Then, the antimicrobial minerals are applied as a surface coating before a second firing. This preliminary action of establishing the base glaze first allows the antimicrobial minerals to be applied in a controlled manner on a prepared surface, preventing them from causing defects in the base glaze composition while still achieving surface-level antimicrobial effectiveness.
2Reliability
If a thick glaze layer is used to combine antimicrobial additives, then antimicrobial effect is achieved, but cost increases significantly
Solution Approach 1:
The patent applies antimicrobial minerals specifically as a surface coating layer rather than distributing them throughout a thick glaze layer. This local quality approach concentrates the expensive antimicrobial minerals exactly where they are needed - at the surface interface where bacteria contact the ceramic - rather than wasting material throughout the entire glaze thickness. The base glaze can be applied as a thin, cost-effective layer, while only the necessary amount of antimicrobial minerals is applied to the surface.
Solution Approach 2:
The patent extracts the antimicrobial function from the bulk glaze material and separates it as a distinct surface coating layer. This extraction allows the expensive antimicrobial minerals to be applied in minimal quantities only where needed for surface protection, rather than being distributed throughout a thick glaze layer where much of the material would be wasted. The base glaze can be applied economically as a thin layer, with only the essential amount of antimicrobial minerals added to the surface coating.
3Reliability
If antimicrobial minerals are mixed into the glaze, then antimicrobial effect is achieved, but most minerals are lost in the depth of the glaze where they cannot affect bacteria on the surface
Solution Approach 1:
The patent segments the glaze structure into a base glaze layer and a separate surface coating layer containing antimicrobial minerals. This segmentation ensures that the antimicrobial minerals remain concentrated at the surface where bacteria contact the ceramic, rather than being distributed throughout the glaze depth where they would be ineffective. The base glaze can be applied as a thin layer, with the antimicrobial minerals concentrated in the surface coating that directly interfaces with the bacterial environment.
Solution Approach 2:
The patent applies local quality by concentrating antimicrobial minerals specifically in the surface coating layer rather than distributing them uniformly throughout the glaze. This ensures maximum effectiveness at the critical interface where bacteria contact the ceramic surface, while minimizing the total amount of minerals required. The base glaze can be applied as a thin, cost-effective layer, with only the necessary amount of antimicrobial minerals applied to the surface coating.
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
Achieves effective antimicrobial protection with minimal impact on glaze properties and reduced material usage, ensuring surface efficacy while maintaining aesthetic and functional integrity.
Implementation Method 1
applying an antimicrobial composition on top of an outermost surface of a glazed ceramic article, wherein the antimicrobial composition comprises an antimicrobial additive
Data Source
AI summary
A method of treating a glazed ceramic article comprises applying an antimicrobial composition on top of an outermost surface of a glazed ceramic article. The antimicrobial composition comprises an antimicrobial additive. The antimicrobial composition further comprises a carrier medium. The antimicrobial additive is selected from the group consisting of Bi2O3, ZnO, Ag2CO3, Ag2O, Zn, Bi, Ag, and a combination thereof.