Wear resistant coatings and tiles and methods of making same
View Patent ↗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.
1. A wear resistant coating, comprising a strontium aluminosilicate glass-ceramic composition that is formed from a glaze that comprises a crystallizing component, wherein the crystallizing component comprises strontium, aluminum, and silicon, and wherein the crystallizing component 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, wherein the glaze exhibits no detectable strontium aluminum silicate crystalline phase prior to firing; and
wherein the glaze further comprises a flux component, wherein the flux component comprises aluminum, silicon, sodium, calcium, potassium, and magnesium, and wherein the flux component comprises less than about 2 weight percent each of lithium, boron, barium, iron, titanium, phosphorus, zinc, and carbon.
2. The wear resistant coating of claim 1 , wherein the crystallizing component further comprises one or more of: calcium, potassium, magnesium, or zinc.
3. The wear resistant coating of claim 1 , wherein the strontium aluminosilicate glass-ceramic composition is Sr(Al 2 Si 2 O 8 ).
4. The wear resistant coating of claim 1 , wherein the flux component further comprises zirconium.
5. The wear resistant coating of claim 1 , wherein the glaze comprises about 85 to about 97 weight percent of the crystallizing component and about 3 to about 15 weight percent of the flux component, based on a dry weight of the glaze.
6. The wear resistant coating of claim 1 , wherein the wear resistant coating has an abrasion resistance of Class 4 or 5 as measured according to ASTM C1027-99 for all lightness values (L*) of greater than or equal to about 33 as measured using a CIE color space equation.
7. A coated tile, comprising: a ceramic tile; and a wear resistant coating disposed on a surface of the ceramic tile; wherein the wear resistant coating comprises a strontium aluminosilicate glass-ceramic composition that is formed from a glaze that comprises a crystallizing component; wherein the crystallizing component comprises strontium, aluminum, and silicon; and wherein the crystallizing component 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, wherein the glaze exhibits no detectable strontium aluminum silicate crystalline phase prior to firing; and
wherein the glaze further comprises a flux component, wherein the flux component comprises aluminum, silicon, sodium, calcium, potassium, and magnesium, and wherein the flux component comprises less than about 2 weight percent each of lithium, boron, barium, iron, titanium, phosphorus, zinc, and carbon.
8. The coated tile of claim 7 , wherein the crystallizing component further comprises one or more of: calcium, potassium, magnesium, or zinc.
9. The coated tile of claim 7 , wherein the strontium aluminosilicate glass-ceramic composition is Sr(Al 2 Si 2 O 8 ).
10. The coated tile of claim 7 , wherein the flux component further comprises zirconium.
11. The coated tile of claim 7 , further comprising an underlayer glaze interposed between the wear resistant coating and the surface of the ceramic tile.
12. The coated tile of claim 11 , wherein the underlayer glaze comprises silicon, aluminum, sodium, and potassium, and wherein the underlayer glaze comprises less than about 2 weight percent each of lithium, boron, barium, iron titanium, phosphorus, and magnesium.
13. The coated tile of claim 12 , wherein the underlayer glaze further comprises one or more of calcium, zinc or carbon.
14. The coated tile of claim 7 , wherein the wear resistant coating has an abrasion resistance of Class 4 or 5 as measured according to ASTM C1027-99 for all lightness values (L*) of greater than or equal to about 33 as measured using a CIE color space equation.
15. A wear resistant coating, comprising a strontium aluminosilicate glass-ceramic composition that is formed from a glaze that comprises a crystallizing component, wherein the crystallizing component comprises strontium, aluminum, and silicon, and wherein the crystallizing component comprises less than about 2 weight percent each of lithium, boron, barium, iron, titanium, zirconium, and carbon, based on a total weight of the crystallizing component; and
wherein the glaze further comprises a flux component, wherein the flux component comprises aluminum, silicon, sodium, calcium, potassium, and magnesium, and wherein the flux component comprises less than about 2 weight percent each of lithium, boron, barium, iron, titanium, phosphorus, zinc, and carbon.
16. A wear resistant coating, comprising a strontium aluminosilicate glass-ceramic composition that is formed from a glaze that comprises a crystallizing component and a flux component, wherein the crystallizing component comprises strontium, aluminum, silicon, and wherein the crystallizing component and the flux component together comprise less than about 2 weight percent each of lithium, boron, barium, iron, titanium, and carbon, based on a total weight of the crystallizing component, wherein the glaze exhibits no detectable strontium aluminum silicate crystalline phase prior to firing; and
wherein the flux component comprises sodium, calcium, potassium, and magnesium.