Self-Glazed Ceramic Composite from Waste Materials

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Solution Overview

Problem

Existing methods for manufacturing glazed ceramic composites are energy-intensive, costly, and not environmentally friendly, as they require high temperatures and separate preparation of glazes, while ceramic and glass wastes are often disposed of in landfills or used inefficiently.

Innovation Solution

A method using ceramic and colored glass wastes, along with silica sand, to produce a self-glazed composite through a process involving grinding, mixing, pressing, and sintering at lower temperatures, eliminating the need for separate glaze application and reducing waste disposal issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional separate glaze preparation and application method is used, then glazed ceramic composite can be obtained, but energy consumption is very high and manufacturing cost increases

Engineering Contradiction:

Improvemechanical propertiesVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention merges the ceramic body and glaze into a single integrated composite material. The glaze components (glass powder, ceramic waste, silica sand) are mixed with ceramic body materials (clay, fly ash, ceramic waste) to form a homogeneous mixture that is molded and sintered as one piece, eliminating the separate glaze application step and reducing energy consumption.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ceramic waste serves multiple functions simultaneously: it acts as both the ceramic body material and the glaze material. By incorporating ceramic waste (30-70 wt%) into the composite, it provides structural support while also forming the glazed surface after sintering, reducing the need for separate glaze materials.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional separate glaze preparation and application method is used, then glazed ceramic composite can be obtained, but manufacturing cost increases

Engineering Contradiction:

Improvemechanical propertiesVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention recovers and reuses ceramic waste that would otherwise be discarded in landfills. By incorporating 30-70 wt% ceramic waste into the composite, it transforms waste material into a valuable resource, eliminating disposal costs and reducing the need for virgin raw materials, thereby lowering manufacturing costs.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The invention converts the harmful waste material (ceramic waste) into a beneficial component of the composite. The ceramic waste, which would normally require expensive disposal, is now used as both structural and surface-forming material, turning an environmental problem into an economic advantage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of substance

If ceramic and glass wastes are disposed of in landfills, then waste management is achieved, but environmental harm and high disposal costs occur

Engineering Contradiction:

Improvewaste disposalVSAvoidenvironmental harm

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The invention converts the harmful waste material (ceramic and glass waste) into a beneficial component of the composite. The ceramic waste (30-70 wt%) and glass powder (5-20 wt%) that would normally be disposed of in landfills are now used to create valuable glazed ceramic composites with improved mechanical properties, eliminating environmental harm and disposal costs.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention recovers and reuses ceramic waste and glass waste that would otherwise be discarded. By incorporating these waste materials into the composite formulation, it eliminates the need for landfill disposal and transforms waste into a resource, achieving both waste management and environmental protection.

Inventive Principle:

Principle #34Discarding and recovering

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 resulting composite exhibits improved mechanical and chemical properties, such as enhanced micro-hardness and durability, while being environmentally friendly and cost-effective, with potential for recycling and reuse in construction materials.

Implementation Method 1

The raw materials are sintered at lower temperature to obtain self glazed composite

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

an optional addition of vitrification aids such as silica

Methodology Applied

Scientific EffectVitrification: Vitrification

Data Source

PatentUS10570049B2Self glazed ceramic/glass composite and method for manufacturing the same

Publication Date: 2020.02.25 KING ABDULAZIZ CITY FOR SCIENCE AND TECHNOLOGY

AI summary

The invention provides a glazed composite manufactured using waste materials, wherein the waste materials are capable of producing ceramic forming oxides, glass modifying oxides and ceramic modifying oxides. The waste materials include ceramic waste and colored glass waste. The invention also provides a method for manufacturing composition of the glazed composite.