Strontium Aluminosilicate Glass-Ceramic Tile Coatings
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Solution Overview
Problem
Traditional ceramic tile glazes face limitations in wear resistance, particularly with darker colors, due to high production costs and restricted visual characteristics, and often result in deformation or defects from mismatched thermal expansion coefficients between the coating and the tile substrate.
Innovation Solution
A strontium-containing aluminosilicate glass-ceramic coating is applied to ceramic tiles, comprising a crystallizing component with strontium, aluminum, and silicon, and an optional flux component, which can be tailored for aesthetic and functional properties, including slip resistance, applied as a dry or wet glaze, and optionally with an underlayer glaze to enhance wear resistance and thermal expansion matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional glass-ceramic coatings are used to improve wear resistance, then abrasion resistance is improved, but the coefficient of thermal expansion mismatch causes deformation or coverage defects
Solution Approach 1:
The patent modifies the chemical composition parameters of the glass-ceramic coating by incorporating specific oxides (Al2O3, SiO2, CaO, MgO, K2O, Na2O, P2O5, ZnO, B2O3) in controlled proportions to adjust the coefficient of thermal expansion. This parameter adjustment enables the coating to match the thermal expansion characteristics of the ceramic tile substrate, preventing deformation and coverage defects while maintaining high wear resistance.
Solution Approach 2:
The invention creates a composite glass-ceramic material system that combines multiple oxide components to achieve both wear resistance and thermal expansion compatibility. The composite nature of the coating, integrating various ceramic oxides in specific ratios, allows simultaneous optimization of mechanical properties (wear resistance) and thermal properties (coefficient of thermal expansion matching).
2Strength
If glass-ceramic coatings with high refractive indices are used to improve wear resistance, then durability is improved, but opacity increases limiting visual characteristics
Solution Approach 1:
The patent optimizes the refractive index parameter of the glass-ceramic coating by controlling the composition and crystalline phase content. By adjusting the ratio of crystalline to glassy phases and selecting specific oxide combinations, the coating achieves a balanced refractive index that provides adequate wear resistance while maintaining sufficient transparency to preserve the visual characteristics and color vibrancy of the underlying tile decoration.
3Strength
If lighter colored glazes are used to achieve better wear resistance, then abrasion resistance is improved, but product design is limited to light colors
Solution Approach 1:
The invention employs a composite glass-ceramic system where the wear resistance is derived from the crystalline phase structure rather than relying on light color. The multi-oxide composition creates a robust crystalline network that provides inherent abrasion resistance independent of color, enabling the coating to protect tiles across the full spectrum of colors including dark hues, thereby expanding product design freedom.
4Strength
If alternative glaze technologies are used to provide improved wear resistance, then abrasion resistance is improved, but production costs increase
Solution Approach 1:
The patent optimizes the firing process parameters including temperature profile, heating rate, and hold time to achieve complete crystallization and densification of the glass-ceramic coating. By precisely controlling these thermal parameters, the coating achieves maximum wear resistance and coating-substrate bonding strength, eliminating the need for additional post-processing steps or quality rework, thereby reducing overall production costs despite the sophisticated composition.
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 coating achieves high abrasion resistance across a range of colors, minimizing wear resistance impairment with darker colors and reducing manufacturing costs through a fast-fire process, while maintaining transparency and visual appeal, and preventing deformation or defects.
Implementation Method 1
the crystallizing component comprises strontium, aluminum, and silicon... forms into a strontium-containing aluminosilicate glass-ceramic composition during the manufacturing firing cycle
Implementation Method 2
some of these systems have coefficients of thermal expansion that are lower than those observed for ceramic tiles. This mismatch between the coating and the tile substrate can result in deformation of the tile or coverage defects such as crazing or crawling
Data Source
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AI summary
The various embodiments of the present invention are directed to wear resistant coatings, tiles having the wear resistant coatings disposed thereon, and to methods of making the coatings and tiles. A wear resistant coating generally includes a strontium aluminosilicate glass-ceramic composition that is formed from a glaze. The glaze can include a crystallizing component, which itself can include strontium, aluminum, and silicon, but also comprises less than about 2 weight percent each of lithium, boron, barium, sodium, iron, titanium, zirconium, and carbon, based on a total weight of the crystallizing component.