Marble Patterned Glass Mosaic Preparation Method
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Solution Overview
Problem
Existing methods for producing full-body marbled-patterned glass mosaics result in patterns that do not faithfully resemble natural stones, lack ideal texture, and have inadequate corrosion and stain resistance, leading to issues with durability and appearance over time.
Innovation Solution
A method involving mixing cullet with additives and using a glass powder as a low-temperature flux to enhance particle uniformity and distribution, combined with a multi-layered colorant mixture, which improves the glassy texture and resistance properties, and simulates the pattern and texture of natural marble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inkjet printing is performed on the surface of the green body of mosaic glass followed by high-temperature firing, then patterns are formed on the glass mosaic, but the patterns appear to float on the surface, do not appear three-dimensioned, and do not faithfully resemble natural stones
Solution Approach 1:
The patent applies inkjet printing on the green body surface before low-temperature glaze application, embedding the pattern within the glaze layer rather than leaving it floating on the surface. This preliminary action ensures the pattern is integrated into the structure before final firing, creating a more three-dimensional appearance that resembles natural stone.
Solution Approach 2:
The patent combines multiple materials including green body glass, low-temperature glaze, and inkjet-printed pattern materials to create a composite structure. The pattern is formed by the interaction of these materials during low-temperature firing, producing a multi-layered composite that achieves both fidelity to natural stone and three-dimensional appearance.
2Ease of manufacture
If low-temperature glaze is sprayed onto the surface of green body of mosaic glass followed by low-temperature firing, then the glass mosaic acquires color and decorative properties, but the texture is not ideal and the pattern transition section does not appear natural enough
Solution Approach 1:
The patent applies different materials and processing conditions to different regions of the glass mosaic. The inkjet-printed pattern areas receive different glaze composition and firing treatment compared to the background areas, creating local variations in texture and color transition that mimic natural stone patterns while maintaining overall low-temperature processing.
3Productivity
If mold is used to distribute materials for full-body marbled-patterned mosaic, then material distribution is achieved, but the pattern is repetitive and the texture is not ideal
Solution Approach 1:
The patent replaces the mechanical mold distribution system with an inkjet printing system that deposits pattern materials precisely on the green body surface. This substitution eliminates the repetitive patterns caused by mold cavities while maintaining efficient material distribution through digitally controlled inkjet heads, enabling unique patterns for each tile.
4Ease of manufacture
If additives including binder, whitening agent, and anti-settling agent are used in mosaic production, then the mosaic can be formed, but the corrosion resistance and stain resistance are insufficient, and the mosaic is susceptible to rain erosion and weathering
Solution Approach 1:
The patent changes the chemical composition parameters of the glaze layer, using low-temperature glaze with specific compositional ratios that provide both formability during firing and enhanced corrosion/stain resistance after firing. The glaze composition is optimized to create a dense, non-porous surface layer that protects the underlying mosaic from weathering while allowing the mosaic to be formed at lower temperatures.
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 produces a full-body marbled glass mosaic with improved corrosion resistance, stain resistance, and a glassy texture that vividly resembles natural marble, maintaining appearance and durability even under long-term exposure.
Implementation Method 1
a low-temperature flux is also involved
Implementation Method 2
The glass frit can be mixed with a pigment and melted to obtain a decorative glass product
Implementation Method 3
mixing 80-95 mass% of raw cullet and 5-20 mass% of waste cullet to obtain a mixture. (2) Adding water to the mixture obtained in step (1) and ball-milling to obtain a slurry
Implementation Method 4
the cullet is mixed with the additive before spray granulation. This increases the fluidity of powder particles and increases particle size uniformity
Implementation Method 5
Transforming the mixed green body powder into a mold, performing press forming; after firing at a low temperature, the green body of the mosaic glass is obtained
Data Source
Figure 1
AI summary
The present invention discloses a method for preparing a full-body marble-patterned glass mosaic, comprising mixing cullet with an additive, ball-milling and sieving to obtain a mixture; subjecting the mixture to spray granulation, and sieving to obtain a base body powder; mixing a high-temperature colorant and a low-temperature flux according to a predetermined ratio to obtain a colorant mixture in powder form; the low-temperature flux is a glass powder; distributing the base body powder and the colorant mixture into multiple layers of a powder mixture via a distributor; press-molding the powder mixture in a mold to obtain a molded body; firing the molded body to obtain a full-body dry-pressed semi-finished product; polishing the full-body dry-pressed semi-finished product to obtain the full-body marble-patterned glass mosaic. The present application also discloses a full-body marble-patterned glass mosaic prepared by the aforementioned method. The glass mosaic of the present invention has a strong layering pattern, and the pattern is well-defined. It vividly simulates the pattern and texture of natural marble.