Low-Expansion Transparent Borosilicate Glaze for Outdoor Durability
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Solution Overview
Problem
Traditional glazes used for exterior wall decoration suffer from phase separation, mechanical weakness, and poor chemical stability due to high thermal expansion and susceptibility to environmental factors, making them unsuitable for outdoor use.
Innovation Solution
A low-expansion borosilicate transparent glaze with specific raw material composition and a controlled manufacturing process, including secondary fusion-cast molding at 1100-1200°C followed by rapid annealing, to prevent phase separation and enhance mechanical and chemical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional glaze material is used with high PbO, Na2O, and K2O content, then the glaze can be molded at lower temperatures, but the chemical stability and water tolerance deteriorate, making it unsuitable for outdoor use
Solution Approach 1:
The patent changes the chemical composition parameters by replacing traditional high PbO, Na2O, and K2O content with a new formulation rich in SiO2 (70-80%), B2O3 (10-20%), and Al2O3 (5-15%). This parameter change enables the glaze to achieve both high chemical stability for outdoor use and appropriate molding characteristics, resolving the contradiction between ease of manufacture and reliability.
2Reliability
If borosilicate glass composition is used to improve chemical stability, then acid- and base-tolerance improve, but phase separation occurs during secondary fusion-cast molding due to immiscibility of [BO3] and [SiO4]
Solution Approach 1:
The patent optimizes the ratio parameters of SiO2 (70-80%), B2O3 (10-20%), and Al2O3 (5-15%) to prevent phase separation. By carefully controlling these compositional parameters and setting the secondary fusion-cast molding temperature to 1100-1200°C, the patent achieves homogeneous structure while maintaining excellent chemical stability, resolving the contradiction between reliability and manufacturing precision.
Solution Approach 2:
The patent creates a composite glass system combining SiO2, B2O3, and Al2O3 in specific proportions. This composite material approach leverages the complementary properties of each component: SiO2 provides structural framework and chemical stability, B2O3 enhances durability and workability, and Al2O3 improves mechanical strength. The composite structure prevents phase separation while achieving superior acid- and base-tolerance.
3Ease of operation
If traditional glaze with thermal expansion coefficient of (90-110)×10−6/°C is used, then indoor ornament applications are satisfied, but breakage and erosion occur in outdoor environments due to temperature and humidity variations
Solution Approach 1:
The patent fundamentally changes the thermal expansion parameter by reformulating the glass composition with high SiO2 (70-80%), B2O3 (10-20%), and Al2O3 (5-15%). This compositional change reduces the thermal expansion coefficient to (30-50)×10−6/°C, which is significantly lower than traditional glazes. The reduced thermal expansion enables the glaze to withstand outdoor temperature and humidity variations without breakage or erosion, while still maintaining appropriate properties for indoor applications.
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 glaze achieves an average linear thermal expansion coefficient of (50-60)×10−6/°C, Grade 1 chemical stability, and a smooth, joint-free surface, making it suitable for outdoor applications.
Implementation Method 1
The formation of glass is a result of rapid cooling of the melt
Implementation Method 2
after molding, then rapidly pass through a crystallization region, and get into an annealing temperature interval
Data Source
AI summary
Disclosed is a low-expansion borosilicate transparent glaze, a preparation method thereof, and use thereof in preparation of a glaze product by secondary fusion-cast molding. The low-expansion borosilicate transparent glaze has raw material composition by mass percentage including: 72%-80% of SiO2, 4%-12% of B2O3, 4%-12% of Na2O, 0.1%-4% of CaO, 0.1%-6% of Al2O3, 0-0.05% of Fe2O3, 0-2% of MgO, 0-2% of K2O, 0-2% of ZnO, 0-2% of BaO, 0-2% of ZrO2, 0-0.5% of Li2O, and 0-0.5% of TiO2, wherein a sum of mass percentages of SiO2, B2O3 and Al2O3 is 85%-95%. The preparation method includes steps of: (1) after mixing dried raw materials, melting at 1400-1540° C. to obtain a high-temperature glass melt; (2) cooling the high-temperature glass melt to 1150-1230° C. to mold; and (3) annealing a molded glass at 530-600° C. to obtain the low-expansion borosilicate transparent glaze.