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US 2022/0098112 A1Published application
Aqueous gelcasting formulation for ceramic products
AssigneeDelta Faucet Company
InventorsKurt J. Thomas, Paul A.V. Bridgett, Michael J. Veros, Joseph A. Elmer, Nathanael W. Dennis
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Abstract
The present disclosure relates to the manufacture of ceramic products by aqueous gelcasting. Exemplary ceramic products include sanitary ware, such as toilets and sinks. The process includes a slurrying step, a mixing step, a molding step involving aqueous gelcasting, a drying step, a glazing step, and a firing step.
Claims19
A ceramic product having a formulation comprising:
- at least one mineral oxide;
- at least one alkali aluminosilicate mineral configured to serve as a fluxing agent to reduce the melting point of the formulation;
- and
- colloidal silica.
1 more element
A formulation having a solid portion, the formulation comprising:
- silica, wherein at least a portion of the silica comprises colloidal silica;
- alumina, wherein the alumina constitutes at least 15 wt. % of the solid portion;
- and
- at least one fluxing agent.
1 more element
A formulation comprising:
- a majority of silica and alumina, wherein at least a portion of the silica comprises colloidal silica;
- and
- a minority of at least one fluxing agent.
A molded formulation comprising:
- at least one mineral oxide constituting about 10 wt. % to about 88 wt. % of the formulation;
- at least one alkali aluminosilicate mineral, separate from the at least one mineral oxide, configured to serve as a fluxing agent to reduce the melting point of the formulation;
- colloidal silica;
- and
- water, wherein the molded formulation is gelled in a mold and configured to maintain a solid shape in the mold.
2 more elements
Dependencies are inferred from the claim text.