Modified Swellable Clay Plasticizer for Ceramic Tiles
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Solution Overview
Problem
The existing processes for producing ceramic tiles face challenges with the addition of organic additives, which lead to black coring issues and require laboratory testing for inorganic plasticizers like bentonites, and aqueous slurries have limited shelf-life and are not suitable for dry processes.
Innovation Solution
A modified swellable clay, reacted with a small quaternary ammonium salt, is used in powder form, acting as a plasticizer with predictable behavior and minimal viscosity impact, allowing for its use in both wet and dry processes without the need for laboratory testing or liquid forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If organic additives are added to increase plasticity and binding capacity, then the capacity to change permanently in size and shape during forming is improved, but black coring problems occur due to increased organic matter content
Solution Approach 1:
The patent changes the chemical composition parameters by using inorganic plasticizers (specific clays like ball clays, illite-chlorite, and illite-kaolinite) instead of organic additives. This substitution maintains the plasticity and binding capacity needed for forming while eliminating the organic matter that causes black coring during firing.
Solution Approach 2:
The patent employs readily available inorganic clay materials that serve their plasticizing function during forming and then completely burn out or vitrify during firing, leaving no harmful residues. These inorganic additives are effectively 'consumed' in a clean manner compared to organic additives that leave carbon residues causing black coring.
2Strength
If inorganic plasticizers like bentonites are used to increase green and dry strength, then the strength of tile bodies is improved, but laboratory testing and careful control are required due to variation in chemistry and effect on viscosity
Solution Approach 1:
The patent specifies precise chemical composition ranges for the inorganic plasticizers (e.g., SiO2: 40-70 wt%, Al2O3: 15-30 wt%, Fe2O3: 0.5-3 wt%, CaO: 0.5-3 wt%, MgO: 0.5-3 wt%) to standardize their behavior. This parameter control reduces variability in viscosity effects and eliminates the need for extensive laboratory testing while maintaining predictable plasticizing performance.
Solution Approach 2:
The patent develops inorganic plasticizer compositions that work universally across different ceramic raw material formulations and grinding processes (both wet and dry). The standardized composition provides consistent plasticity and binding properties regardless of the specific clay type or processing method, simplifying plant-wide implementation.
3Object-affected harmful factors
If aqueous slurries of swellable clay are used as plasticizers, then black coring is avoided and predictable behavior is achieved, but shelf-life is limited and they are not suitable for dry processes
Solution Approach 1:
The patent transforms the plasticizer from aqueous slurry form to dry powder form while maintaining its plasticizing functionality. This phase transition from liquid to solid state extends shelf-life indefinitely, eliminates storage and handling complications associated with liquids, and enables use in both wet and dry processing routes without requiring process modifications.
Solution Approach 2:
The patent modifies the physical state parameter of the inorganic plasticizer from liquid slurry to dry powder, and adjusts the chemical composition to optimize performance in both wet and dry environments. This dual-state capability allows the same material to function as a plasticizer whether water is present or absent during processing.
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 modified swellable clay enhances green and dry strength of ceramic tiles, avoids black coring, and is easily mixed with other additives, making it suitable for all ceramic tile production processes without affecting viscosity or requiring significant process modifications.
Implementation Method 1
Plasticizers are added for the specific purpose of increasing the capacity of the slips to change permanently in size and shape during the forming of the tiles
Implementation Method 2
swelling clays, such as the bentonites, exhibit plasticity and binding properties and that their addition to the ceramic raw materials, in the manufacture of tiles, increases both the green and the dry strength
Implementation Method 3
a modified swellable clay, reacted with a small quaternary ammonium salt, is used in powder form, acting as a plasticizer with predictable behavior and minimal viscosity impact
Data Source
AI summary
The present disclosure relates to a process for making ceramic tiles characterized by the addition to the ceramic raw materials of a composition comprising a swellable clay modified with small quaternary ammonium salts.