WO2000058236A1 - Method of treating ceramic materials and natural minerals and use of quartz and silicate-like material in the method - Google Patents
Method of treating ceramic materials and natural minerals and use of quartz and silicate-like material in the method Download PDFInfo
- Publication number
- WO2000058236A1 WO2000058236A1 PCT/FI2000/000243 FI0000243W WO0058236A1 WO 2000058236 A1 WO2000058236 A1 WO 2000058236A1 FI 0000243 W FI0000243 W FI 0000243W WO 0058236 A1 WO0058236 A1 WO 0058236A1
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- WO
- WIPO (PCT)
- Prior art keywords
- quartz
- silicate
- treatment
- substrate material
- advantageously
- Prior art date
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
- C04B41/5035—Silica
Definitions
- the present invention relates to a method for strengthening and/or sealing ceramic materials and natural minerals.
- the invention further relates to the use of quartz and a silicate-like solids in the method.
- ceramic mate ⁇ als are generally categorized as compositions formed from metal oxides and silicates. This definition is very broad and, accordingly, ceramic compositions are known in the art in plural variations (including glasses). The properties of a ceramic material are not determined by the components of its composition alone, but rather the same components can be the starting materials of different compositions depending on the values of kinetic and temperature-related variables during the formation of the composition.
- the bonding mechanism in the silicon dioxide elementary unit and the formation of the Si tetrahedron, as well as the tendency of the tetrahedrons to undergo a complex polymerization into chains, planes and lattice structures are the basic concepts that must be elaborated to understand the structures of ceramic compositions and glass formation, as well as material properties of ceramic materials.
- the partially ionic or covalent nature of bonds in a silicon dioxide material determine its physical-chemical properties, wherein a covalent bond is substantially stronger than an ionic bond.
- Covalent bonds in silicate glass are the basis of its polymerized structure. If other substances are added to the lattice structure of the Si tetrahedrons, they may disrupt or modify the lattice (modifying agents) or bond with the lattice structure so as to modify only the material properties. Na, Ca and Fe ions are all capable of affecting the stability of the Si tetrahedron lattice structure so as to allow these ions to change the material properties. The change of basic material properties is different depending on whether the ions form bridges between the tetrahedrons or whether the modifying effect is simply caused by the bonding of ions to the lattice structure through disruption of the covalent bonds of the structure.
- the structure formations in, e.g., quartz, tridymite and cristobalite are based on the different variations of the same tetrahedral scheme.
- the tetrahedrons may be connected to each other by different angles thus forming varying lattice structures.
- the formation of a glass-like material is not dependent on the components alone that are selected for the preparation of the composition, but rather, the molecular structure (lattice) determines the glass properties.
- Si, Ti, Ge, N, and other elements may act as the glass- forming atoms, the overwhelmingly most common being Si.
- the Si-O bond is may be characterized as about 50 % ionic and by 50 % covalent.
- elements capable of forming a lattice have at least about 50 % ionic character.
- silicon dioxide and different silicates can form a variety of different glasses.
- the different additives modify glass properties.
- addition of Na ions disrupts the lattice, see FIG. 1.
- the Ca ions act as typical bridging elements that are bonded to the lattice by two oxygen bonds.
- the bonding is affected by the size of the ions.
- the lattice properties are modified, whereby the lattice structure can accommodate tetrahedrons by a varying density so that, e.g., the lattice may become less dense (by Na addition) or denser (by Ca addition), see FIG. 2.
- the lattice structure over the entire molar ratio scale is glass-like, see FIGS. 3 and 4.
- the Si0 2 system may form different lattice structures known as quartz, cristobalite and tridymite. These structures have different molar ratios of Na ions. Quartz occurring as a natural mineral is a very hard material. In this type of so-called acid glass, the Na ion can have an inhibitory effect, e.g., on fungal growth and bacterial metabolism when the ion embedded in a ceramic structure.
- Conventional window glass compositions comprise the system CaO-Na 2 0- Si0 2 .
- the Ca ion acts as a bridging element in the system, its higher content in the composition increases the ionic nature of the system.
- Silicates are typical glass formers. The number of different glasses has been estimated at about 600. Glass may occur in a stable state also in a structure resembling an undercooled liquid, wherein Si atoms are assumed to be arranged in a tetrahedral-like configuration but having a nonorganized order in the bonding of the tetrahedrons with each other, because the kinetic cooling dynamics have not given the structure enough time to assume a fully ordered lattice configuration.
- glass is defined to refer to a transparent material, whereby the word glass itself does not reveal the materials included in the composition or its properties.
- Glass-like materials must thus be understood to be composed as a combination of oxide and silicate lattices resulting in a very complex structure. Hence, the exact background of glass formation phenomena in ceramic materials is very difficult to explain in theoretical terms.
- the glass-like skeleton formed by the tetrahedral lattice structure of silicates is the backbone of hardness in ceramic materials. Glass-like materials and coatings are charac- terized by brittle breaking under a blow. Breaking takes place along the crystalline grain borders of the oxide inclusions of the silicate skeleton.
- a ceramic material also contains separate oxide components that form the softer, nonglassy portion of the material having a tinted or white colour.
- Ceramic materials typically those of the man- made variety, are characterized by a high content of pores. Also a natural material is porous, but yet denser than pottery or concrete, for instance. Due to its inherent permeability to water, a ceramic material generally needs some type of coating treatment: glazing, gel-coating, painting, silicate compound application and the like. Glaze may be applied by melting, silane treatment, growth from an aqueous solution, etc. Aqueous solutions have also been used as paint additives. Traditionally, the goal has been to achieve a water- resistant coating.
- a repairing posttreatment of a glaze has not normally been carried out as the means thereto have been lacking.
- a glass-like coating is advantageous, because the silicate lattice adheres to the substrate material in a natural manner via chemical bonds and its lacera- tion has not been a similar problem as that occurring in a separately applied coating made using a noncompatible material. Glaze makes porous ceramics water-resistant and gives good protection against corrosion.
- ceramic materials have been coated by glaze layers of different types and thicknesses.
- Walls do not generally require a thick coating, while horizontal surfaces such as floors are more demanding. Thereon, the coating must endure varying blows and imposed pressures. Also the corners and edges of wall surfaces are subject to forces imposed by the inherent weight of the material and stresses from thermal expansion.
- the joints between ceramic tiles are porous as well as subject to break down under abrasion, and they gather dirt.
- the water-impervious glaze does not "breathe" so that gaseous substances could escape through the tile, the rear of the tile cannot dry up thus supporting fungal growth.
- the ceramic substrate material can absorb different liquids such as oils, acids from foodstuffs, aqueous solutions, etc., that are difficult to clean away. This may be one of the reasons why glazes are not renewed. Bacteria and microorganisms can pass through the joints and cracks thus making worn surfaces and joints unhygienic.
- EU directives have posed new requirements in terms of, e.g., hygienics, a problem that is aggravated in hospitals by contaminants.
- a further problem hampering the use of ceramic materials has been their tendency to crack due to their structure which prevents their use under conditions specified for good resistance to pressure and impact loads. The same applies to ceramic coatings, too.
- a glass-like glaze is a good choice in terms of water resistance and corrosion protection as long as it remains intact. Problems arise from damage to the glaze. The glaze breaks due to its brittle nature thus being weak under mechanical wear, pressure and impact loads. The major problems herein are traced to the filtration of calcium salts through the structure and the activity (hydrolyzation) of the calcium salts, as well as from the soaking of the structure by different liquids.
- Glazes are made by a heat treatment process (melting), hardening a silicate frit, silane treatment and deposition from an aqueous sol.
- Aqueous sols have also been used as binders in paint systems. The use of aqueous sols is based on the capability of silicates and oxides to hydrolyze thus being capable of becoming incorporated in a lattice structure when the sol is dried.
- a thin glaze is often sufficient on vertical surfaces (such as walls), a thin glaze is often sufficient. Ceilings are coated by different compounds. Floor surfaces need a thick glazing (on tiles), whereby the joints remain more problematic.
- the requirements posed on utensils and articles vary depending on whether the objects are used as decoration or as cooking utensils (enameled kettles), glasses, cups, pots, etc. In addition to water resistance, some of the objects are also expected to have good durability under temperature changes. Hence, the selection of a glaze is combined with the selection of ceramic materials from a group of alternatives of widely varying porosities.
- Patent publication EP 0 952 127 A1 discloses a method in which a thin glass- like surface film is deposited from an aqueous solution.
- the aqueous solution is used in the same manner as a glazing paint to form the thin glass-like film on vertical surfaces of a building material.
- the surface On porous substrates, the surface must be treated 5 times to form a nonporous film on the substrate surface.
- the method is proposed for forming a coating on the walls of a swimming pool. Obviously, the method is not applicable to the treatment of horizontal surfaces.
- the method according to the invention offers improved protection to the substrate material against bacterial attack and other similar factors causing hygienic problems.
- the goal of the invention is achieved by way of utilizing a novel approach in which impregnation is used in lieu of a conventional surface treatment.
- the method according to the invention is characterized in that strengthening and/or sealing steps in the method are carried out principally by virtue of impregnating quartz and silicate-like solids into the substrate material, most advantageously into the pores, crystalline grain borders and cracks thereof.
- the present invention is characterized by strengthening and sealing of ceramic materials and natural minerals by virtue of impregnating an aqueous quartz-silicate composition into the pores, crystalline grain borders and cracks of the substrate material.
- the water resistance of ceramic materials has been sought from the use of various coatings.
- the selection of such coatings is determined by the application. If the objective is not set as to form a continuous watertight film or coating on the substrate material, but rather, to modify the inherent properties of the substrate material by way of, e.g., sealing the material structure, a number of benefits are gained over coatings.
- the composition of the impregnating solids is matched with that of the hardest component (quartz) in the ceramic substrate material, the hardness and durability of the treated ceramic substrate can be improved substantially. Then, a structure is obtained equivalent to natural stone materials that have a lower porosity.
- quartz as an aggregate of the material gives the more strength the greater its relative proportion in the impregnant and the deeper the composition is impregnated. In comparison, the inherent water absorption capability of concrete is quite high.
- the impregnating solids are complemented with Na silicate as an aqueous solution, generally known as water glass
- this so-called acid glass improves the hygienic nature of the material in three different ways.
- the sodium acts as an acidic element inhibiting fungal growth and occurrence of bacteria.
- the reduced porosity prevents the material from being soaked with such liquids (water and other liquids) that can promote fungal growth and bacterial metabolism.
- the material capability of "breathing" is not lost thus permitting natural drying of the material.
- the need for sealing depends on the water absorption capability of the sub- strate material. If the material is inherently impervious or has been glazed on its surface, its water absorption rate is so slow that a separate treatment is needed for improving the absorption rate.
- a diluted aqueous solution of ammonium bifluoride can be used for etching the structure of a glaze. This so-called pore-opening treatment is a precondition for the posttreatment of materials already put in use.
- a renovation treatment such as made on, e.g., soiled floors having calcium salts already diffused onto its surface
- the area must be cleaned prior to the pore-opening treatment.
- Acetic acid and hydrochloric acid may be used for dissolving the oxides of the substrate material, thus allowing the surface to be both made porous for its softer components and cleaned free from different contaminants, a part of which may be organic by nature.
- the cleaning operation can be performed using commercial detergents, but they are not always effective in dissolving calcium salts that have already diffused onto the substrate surface.
- the floor surface is advantageously given an antislip treatment.
- an antislip treatment Conventionally, this has been carried out by an acid treatment using hydrochloric acid, for instance.
- the goal of the antislip treatment is to make the substrate surface microscopically rough to increase the coefficient of friction and prevent water from forming a slippery film.
- This goal is more advantageously attained using a glass-etching compound, whereby the antislip effect is gained with much milder etching than by using hydrochloric acid, for instance.
- This technique is based on etching the microcracks of the material surface that have a sharper and more durable structure.
- a glazed surface is its slipperiness.
- the material is sealed using the above-described method, its surface will not become as slippery as a glazed surface, whereby the antislip treatment is not needed over the entire floor surface.
- the antislip treatment of the floor is performed by etching the glass-like coating, its tendency to accumulate soil is reduced from that achievable by way of an antislip treatment performed by etching the softer components of the material.
- the overall durability of a material treated by the present method becomes much more resistant to washing cycles so that the material can be cleaned without damage using pressurized water jet washers.
- the treatment is particularly advantageous on floor surfaces having the tile joints treated by the impregnant. Initially, the thick glaze of the tiles can take the pressurized water jet washing but not so the joints. Additionally, the present treatment makes the tile material more durable than it was originally. The attained strength is determined by the depth to which the impregnation is or can be performed, this being dependent on the outcome of the substrate surface etching.
- the substrate material need not be treated by its full depth in all cases, particularly not when the strength specifications are less demanding.
- the required depth of treatment is determined by the following factors: amount of solids in the aqueous treatment solution, duration of impregnation, duration of pore-opening treatment, drying temperature, effectiveness of cleaning and inherent water wicking capability of substrate material, and the amount of micropheres possibly used.
- the material is subjected to the necessary steps of the above-given four-step list.
- Acid solutions with the substances dissolved therein are removed by vacuum suction after the completion of each treatment step.
- the surface is rinsed with abundant water and allowed to dry between the successive treatment steps.
- the substrate material is allowed to dry for 24 h prior to being subjected to loads.
- the acids (acetic acid, hydrochloric acid, other necessary solvents) are used in a concentration as diluted as possible so that the acid concentration at the most soiled areas is increased as required.
- the acid is allowed to work for a few minutes and the surface is rubbed with a squeegee or mop. Respectively, the concentration of the ammonium bifluoride solution is kept as low as possible.
- the working time of the applied fluoride solution is determined by the degree of surface roughness and user's experience.
- the treatment agents are applied directly to the surface to be treated.
- the impregnation step is carried out in the same fashion as described above, but now the time allowed for impregnation is substantially longer when a nonporous or glazed material is to be treated.
- the surface After the impregnation step, the surface must be rinsed carefully to clean the surface free from the impregnation composition.
- the method is particularly suited for treating essentially horizontal surfaces. Treatment of entirely vertical surfaces is rather difficult by virtue of the method, since aqueous solutions tend to fall away along the surface and the time for impregnation remains short. Porous materials having a good water wicking capability can be treated in a satisfactory manner.
- Example 1 Cleaning and repair treatment of ceramic tile surfaces of a swimming pool and its sanitary spaces.
- Example 1 Treatment is performed as in Example 1 without the antislip treatment step.
- the amount of NaO is 35 %, whereby the amount of Si0 2 will be 65 %. (It must be noted that the acid nature rendered by NaO inhibits microorganism cultures, whereby its proportion may even be increased.)
- the liquid is impregnated into the inner surface by allowing the liquid to stay in the pot. Rinsing and drying as above.
- the pot may be surface-treated (painting, glazing) after thorough drying.
- Strengthening treatment of a concrete floor required to have a good mechani- cal resistance to wear (imposed by, e.g., cars or machines continuously moving on the floor).
- the liquid is impregnated into the concrete for, e.g., 15 min (depending on the local circumstances) and is allowed to dry for 24 h.
- a plurality of different materials can be treated, e.g.:
- Grouting concrete (requires use of microspheres in the treatment), marble (advantageously using the ammonium bifluoride treatment), bricks, soapstone and the like ceramic/porous materials.
- the amount of quartz in the quartz-silicate composition used in the method according to the invention is adjusted according to the material to be treated and/or the final properties required therefrom.
- the proportion of quartz to be used in the quartz-silicate composition varies according to the particular application, especially according to the desired strength, whereby the quartz percentage in the composition may rise up to almost 100 %, advantageously up to 50 - 95 %, particularly advantageously up to 60 - 75 %.
- sodium oxide may be added to the quartz-silicate composition by an amount rising up to 50 %, while advantageously an amount of 20 - 30 % is used.
- the impregnation depth of the quartz-silicate composition in the substrate material to be impregnated is determined by the intended application and requirements specified for the substrate material. In most cases, the impregnation depth is selected based on empirical data. Hence, the depth to which the substrate must be impregnated varies starting from an essential surface strengthening and/or sealing of the material being treated to full-depth impregnation of the entire substrate material. In other words, the goal is to adjust the depth of the impregnation treatment with the quartz- silicate composition such that an essential strengthening and/or sealing effect is attained. While any fixed limits are difficult to define, an advantageous impregnation depth is 5 - 95 %, preferredly 10 - 70 %, of the total thickness of the substrate material.
- the essential feature of the invention is that composition is impregnated into the substrate material.
- the treatment compositions include Na silicates and quartz, but in principle the filling of the substrate material pores is not limited to any particular selection of the solids used herein, whereby also other glass-like components can be added to the water- or solvent-based composition.
- quartz has the highest hardness and is the most cost-effective choice when the treatment is specified to improve the substrate material hardness.
- the treatment has a very slight tinting effect on the substrate material colour as the glass-like filler component has a different coefficient of refraction.
- the treatment composition may be complemented with colour-rendering oxides as additives.
- the premises in which the invention may be practiced include industrial spaces, hospitals, sports activity halls, foodstuff industry premises, exterior wall surfaces, brick walls and washing and shower spaces needing the sealing of building structures.
- the method can be applied for protecting objects such as marble surfaces, decoration and statues against decay, improving the wear resistance of, e.g., marble tile floors and treating surfaces in concrete-walled basins and the like. More generally, the method is suited for improving the properties of porous materials mentioned in the above description of the invention by virtue of impregnating solids into the substrate material matrix.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Aftertreatments Of Artificial And Natural Stones (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP00914211A EP1183219A1 (en) | 1999-03-25 | 2000-03-24 | Method of treating ceramic materials and natural minerals and use of quartz and silicate-like material in the method |
AU35615/00A AU3561500A (en) | 1999-03-25 | 2000-03-24 | Method of treating ceramic materials and natural minerals and use of quartz and silicate-like material in the method |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FI990661A FI990661A0 (en) | 1999-03-25 | 1999-03-25 | Method for treating slabs of rock and soil and use of mineral polymer material in the method |
FI990661 | 1999-03-25 | ||
FI992140 | 1999-10-05 | ||
FI19992140 | 1999-10-05 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000058236A1 true WO2000058236A1 (en) | 2000-10-05 |
Family
ID=26160721
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/FI2000/000243 WO2000058236A1 (en) | 1999-03-25 | 2000-03-24 | Method of treating ceramic materials and natural minerals and use of quartz and silicate-like material in the method |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1183219A1 (en) |
AU (1) | AU3561500A (en) |
WO (1) | WO2000058236A1 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4037653A1 (en) * | 1990-11-27 | 1992-06-04 | Stephan Dipl Ing Schuettpelz | Preserving natural or synthetic stone - using aq. soln. based on potassium water-glass for protection against damage due to environment |
WO1996038396A1 (en) * | 1995-06-02 | 1996-12-05 | Stonetec Anstalt/Stonetec Establishment | Agent for impregnating stone and shaped stonework or for the production of modelable compounds and compounds containing said agent and mineral solids |
US5928775A (en) * | 1994-04-29 | 1999-07-27 | Mcdonnell Douglas Corporation | Surface protection of porous ceramic bodies |
EP0952127A1 (en) * | 1997-12-15 | 1999-10-27 | Joseph E. Dipl.-Ing. Doumet | Method of producing a waterrepellent product, and product and method for waterproofing a surface of a building material |
-
2000
- 2000-03-24 WO PCT/FI2000/000243 patent/WO2000058236A1/en not_active Application Discontinuation
- 2000-03-24 EP EP00914211A patent/EP1183219A1/en not_active Withdrawn
- 2000-03-24 AU AU35615/00A patent/AU3561500A/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4037653A1 (en) * | 1990-11-27 | 1992-06-04 | Stephan Dipl Ing Schuettpelz | Preserving natural or synthetic stone - using aq. soln. based on potassium water-glass for protection against damage due to environment |
US5928775A (en) * | 1994-04-29 | 1999-07-27 | Mcdonnell Douglas Corporation | Surface protection of porous ceramic bodies |
WO1996038396A1 (en) * | 1995-06-02 | 1996-12-05 | Stonetec Anstalt/Stonetec Establishment | Agent for impregnating stone and shaped stonework or for the production of modelable compounds and compounds containing said agent and mineral solids |
EP0952127A1 (en) * | 1997-12-15 | 1999-10-27 | Joseph E. Dipl.-Ing. Doumet | Method of producing a waterrepellent product, and product and method for waterproofing a surface of a building material |
Also Published As
Publication number | Publication date |
---|---|
EP1183219A1 (en) | 2002-03-06 |
AU3561500A (en) | 2000-10-16 |
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