Polished Glazed Ceramic Tile Abrasion Resistance
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Solution Overview
Problem
Fully polished glaze ceramic tiles suffer from low abrasion resistance due to high amorphous phase content and low crystalline substance content, leading to increased scratches and abrasion over time, which limits their application in public places.
Innovation Solution
A preparation method for hard wear-resistant polished glazed ceramic tiles is developed, involving specific adjustments to the formula and application method of the fully polished glaze, including the use of corundum and hyalophane as primary crystalline substances, and silk-screen printing for precise glaze application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a low-aluminum and high-potassium-and-sodium glaze formula is used, then the glazing process is simple and the glaze surface is easy to form, but the abrasion resistance and hardness of the glaze surface are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the glaze by reducing K2O and Na2O content from the conventional high levels to 0.5-1.5% each, increasing Al2O3 to 21-25%, and adding CaO (8.5-10.5%) and MgO (4.0-6.0%). This parameter transformation maintains manufacturability while dramatically improving abrasion resistance and hardness
Solution Approach 2:
The patent creates a composite glaze system combining multiple oxide components with specific functions: Al2O3 for hardness, CaO and MgO for bond strength and resistance, ZnO for melting control, and BaO for gloss enhancement. This composite approach achieves both ease of manufacturing and superior durability
2Productivity
If the waterfall method is used for glazing, then the glaze application is simple and fast, but the amount of glaze applied is large causing increased material cost and decreased hardness and abrasion resistance
Solution Approach 1:
The patent replaces the waterfall method (gravitational flow) with silk-screen printing (controlled deposition). This substitution allows precise control of glaze thickness and quantity, reducing material waste while ensuring optimal glaze layer depth that maintains both hardness and abrasion resistance
Solution Approach 2:
The patent changes the glaze application parameters by controlling the specific weight to 1.50-1.70 g/cm³ and applying 90-140 g/m² through silk-screen printing, compared to the excessive application in waterfall method. This parameter optimization reduces material cost while improving surface hardness
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 significantly enhances the abrasion resistance of fully polished glaze ceramic tiles, achieving a Mohs hardness of 5.5 to 6.0 and abrasion resistance of class 5 (12,000 revolutions), thereby expanding their application in construction and public spaces.
Implementation Method 1
The phase composition of the fired fully polished glaze is 10 to 20 percent by weight of corundum, 20 to 30 percent by weight of hyalophane, 0.5 to 1.0 percent by weight of hematite, and 50 to 68 percent by weight of amorphous phase
Data Source
AI summary
A preparation method includes the following steps: Step (1): pressing and then drying body powder to form a green brick; Step (2): applying a ground coat on the surface of the green brick; Step (3): inkjet-printing a pattern on the surface of the green brick having the ground coat, and applying an isolation glaze; Step (4): applying a fully polished glaze on the surface of the green brick having the isolation glaze; and Step (5): drying, firing, and polishing the green brick having the fully polished glaze to obtain a hard wear-resistant polished glazed ceramic tile. The phase composition of the fired fully polished glaze is as follows: 10 to 20 percent by weight of corundum, 20 to 30 percent by weight of hyalophane, 0.5 to 1.0 percent by weight of hematite, and 50 to 68 percent by weight of amorphous phase.