Matte Ceramic Tile Glaze With Low-Toxicity Mineral Substitutes
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Solution Overview
Problem
Existing matte ceramic tile production methods involve complex processes, use toxic materials like titanium dioxide, and result in products with rough texture, poor corrosion resistance, and limited color development, posing health risks and environmental concerns.
Innovation Solution
A one-time glazing method using environmentally friendly raw materials, including recycled wastes and low-toxicity components, combined with a simplified production process that includes continuous ball milling, powder spray granulation, and controlled drying and firing, to create a matte ceramic tile with a smooth, corrosion-resistant surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional matte glaze formulations containing barium carbonate, strontium compounds, tin oxide, or titanium dioxide are used, then the glaze achieves matte finish and corrosion resistance, but the materials have different degrees of toxicity and may affect human health, with titanium dioxide specifically classified as a category 2B carcinogen
Solution Approach 1:
The patent changes the chemical composition parameters of the glaze by replacing toxic materials (titanium dioxide, barium carbonate, strontium compounds) with non-toxic alternatives (zinc oxide, potassium feldspar, sodium feldspar, dolomite, kaolin, quartz, calcium phosphate). This parameter substitution maintains the matte finish and corrosion resistance while eliminating the harmful health effects associated with the original materials.
Solution Approach 2:
The patent employs inexpensive, readily available, and non-toxic raw materials that can be easily replaced if needed. The formulation uses common ceramics and minerals (zinc oxide, feldspars, kaolin, quartz) that are cheaper and safer than precious or toxic materials like titanium dioxide, barium carbonate, or strontium compounds.
2Reliability
If titanium dioxide is included in the glaze formulation, then the glaze achieves matte finish and corrosion resistance, but the glaze contains titanium dioxide which contributes to the yellow color that appears on the glazed surface, affecting the richness of the decorative pattern
Solution Approach 1:
The patent changes the color-related parameters by removing titanium dioxide (which causes yellow discoloration) and replacing it with zinc oxide and other neutral or enhancing materials. This allows the glaze to maintain its matte finish and corrosion resistance while achieving richer, more vibrant decorative colors without the unwanted yellow tint.
3Reliability
If multiple types of barium carbonate, strontium compounds, tin oxide, or titanium dioxide are used in the glaze formulation, then the glaze achieves desired matte finish and corrosion resistance, but the preparation process becomes relatively complicated
Solution Approach 1:
The patent extracts and removes the complex, toxic components (barium carbonate, strontium compounds, tin oxide, titanium dioxide) from the glaze formulation and replaces them with a simpler set of non-toxic materials. This extraction of harmful substances simplifies the preparation process while maintaining the essential functional properties of the glaze.
Solution Approach 2:
The patent simplifies the formulation parameters by reducing the number of different material types needed. Instead of requiring multiple specialized materials (barium carbonate, strontium compounds, tin oxide, titanium dioxide), the new formulation uses a more straightforward combination of common ceramics and minerals, making the preparation process less complicated.
4Device complexity
If a one-time glazing method is used, then the consumption of glaze material is reduced and the production process is simplified, but the glaze must provide both matte finish, corrosion resistance, and color development in a single application
Solution Approach 1:
The patent uses a composite glaze formulation that integrates multiple functional components in a single material system. The glaze combines zinc oxide, potassium feldspar, sodium feldspar, dolomite, kaolin, quartz, and calcium phosphate to simultaneously achieve matte finish, corrosion resistance, and vibrant color development in one application, eliminating the need for multiple separate glazing steps.
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 reduces production complexity, minimizes health and environmental impact, and produces tiles with a smooth, stain-resistant, and chemically durable surface that meets high-quality standards, with improved resistance to wear and ease of cleaning.
Implementation Method 1
a blank material for the ceramic tile consists of the following components in percentage by weight: nepheline powder: 10%-15%; clay with a carbon content of ≥3.0 wt %: 10%-15%; clay with a carbon content of ≤0.5 wt %: 15%-22%; clay with a carbon content between 0.5 wt % and 3.0 wt %: 10%-15%; recycled waste blank: 5%-10%; sodium potassium powder: 5%-10%; sodium feldspar powder: 12%-20%; desulfurization residue: 0%-7%; waste from edging and polishing: 15%-26%; waste porcelain powder: 5%-10%; liquid gel remover: 0.3%-1.0%; liquid reinforcing agent: 0.2%-0.8%
Implementation Method 2
The method involves a one-time glazing method, which reduces the consumption of glaze material, reduces the likelihood of developing product defects, simplifies the production process, and reduces production difficulty
Implementation Method 3
combined with a simplified production process that includes continuous ball milling, powder spray granulation, and controlled drying and firing
Implementation Method 4
controlled drying and firing
Data Source
AI summary
A blank material for a ceramic tile consists of the following components in percentage by weight: nepheline powder: 10%-15%; clay with a carbon content of ≥3.0 wt %: 10%-15%; clay with a carbon content of ≤0.5 wt %: 15%-22%; clay with a carbon content between 0.5 wt % and 3.0 wt %: 10%-15%; recycled waste blank: 5%-10%; sodium potassium powder: 5%-10%; sodium feldspar powder: 12%-20%; desulfurization residue: 0%-7%; waste from edging and polishing: 15%-26%; waste porcelain powder: 5%-10%; liquid gel remover: 0.3%-1.0%; liquid reinforcing agent: 0.2%-0.8%. Its preparation method comprises the following steps: preparing raw materials for a blank body and ball milling, powder spray granulation, aging, pressing and molding of the blank body, drying, polishing the blank body, spraying water, glazing, applying a decorative pattern, firing.