Ceramic products, of glass, fly ash and clay and methods of making the same

Abstract

A ceramic kiln-fired product which comprises glass, fly ash, and a clay binder. Further provided is a method for preparing raw material suitable for forming a shaped, kiln-fired, ceramic product. The method comprises mixing glass, fly ash, and a clay binder with from about 10 wt. % to about 15 wt. % water, on a dry weight basis, to form an aqueous mixture, separating the aqueous mixture using a mesh of from about 10 to about 12 screen into first and second portions, the first portion comprising the aqueous mixture which does not pass through the mesh and the second portion comprising the aqueous mixture which passes through the mesh, and drying the second portion until the moisture content of the second portion is less than about 0.5 wt. % to form the raw material. The present invention also provides a tile glazing formulation which may be used with the ceramic product of the present invention, as well as a method of using the formulation. The glazing formulation comprises, on a dry weight basis, about 70 wt. % to about 75 wt. % frit, about 8 wt. % to about 11 wt. % clay, about 2 wt. % to about 6 wt. % feldspar, about 1 wt. % to about 2 wt. % flint, about 6 wt. % to about 8 wt. % zinc oxide, about 6 wt. % to about 8 wt. % alumina.

Dependencies are inferred from the claim text.