Ceramic article, raw batch formulation, and method

Abstract

An impervious, virgin soda-lime glass-based ceramic article is disclosed. The impervious ceramic article of the present invention is prepared from a raw batch formulation including virgin soda-lime glass cullet and clay. The article of the present invention has aesthetic and physical properties which are precisely reproducible. A raw batch formulation for making an impervious soda-lime glass-based ceramic article is also disclosed. In a preferred embodiment, the raw batch formulation includes greater than 60 to about 85 weight percent virgin soda-lime glass cullet; from about 15 to about 40 weight percent clay; and from about 0 to about 10 weight percent flint. A method for making an impervious virgin soda-lime glass-based ceramic article is further disclosed. The method comprises dry-mixing a mixture including virgin soda-lime glass cullet and clay to form raw batch material; adding a sufficient amount of a volatilizable liquid to the raw batch material while mixing at a sufficient speed to produce granules of the raw batch material; heating the granules to remove part of the volatilizable liquid therefrom to form partially dried pellets; uniformly distributing the partially dried pellets in a die cavity of predetermined shape; uniformly applying pressure to the uniformly distributed partially dried pellets in the die cavity to form a green body compact; drying the green body compact to a moisture content of less than about 1 weight percent by weight; and firing the dried green body compact to form an impervious virgin soda-lime glass-based ceramic article of predetermined shape.

Dependencies are inferred from the claim text.