# US 5,705,118 A · Process for producing a ceramic body

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- Number: US 5,705,118 A
- Document ID: US5705118A
- Status: Granted
- Kind: A
- Application number: 08/216,480
- Filed: 1994-03-22
- Granted: 1998-01-06
- Earliest claimed: 1992-08-27
- Assignees: PolyCeramics, Inc.
- Inventors: Kevin G. Hayes; Peter A. Roberts; Frank R. Spitulnik
- Web page: https://patentgrep.com/patent/US5705118A

## CPC

- A61F 2/28: Bones
- A61L 27/56: Porous materials, {e.g. foams or sponges}
- B28B 1/32: by projecting, e.g. spraying (spraying in general B05B, B05D)
- B28B 1/50: specially adapted for producing articles of expanded material, e.g. cellular concrete (chemical aspects {or making expanded aggregate} C04B)
- B28B 7/0064: {Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces (B28B7/36 takes precedence; producing decorative effects B44C; designs of stone surfaces B44F)}
- B28B 7/34: Moulds, cores, or mandrels of special material, e.g. destructible materials (for slip casting B28B1/26)
- C04B 35/634: Polymers (C04B35/636 takes precedence)
- F23D 3/08: characterised by shape, construction, or material, of wick
- A61F 2/3094: {Designing or manufacturing processes}
- A61F 2002/30011: {differing in porosity}
- A61F 2002/30968: {Sintering}
- A61F 2250/0023: differing in porosity
- A61F 2310/00179: Ceramics or ceramic-like structures
- F23D 2212/00: Burner material specifications
- F23D 2213/00: Burner manufacture specifications
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- A61L: METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES (preservation of bodies or disinfecting characterised by the agents employed A01N; preserving, e.g. sterilising, food or foodstuffs A23; preparations for medical, dental or toiletry purposes A61K)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- F23D: BURNERS

## Abstract

A process for preparing a ceramic body in which a ceramic mixture is formed into a green body and thereafter fired. The ceramic mixture is prepared by mixing at least about 40 weight percent of ceramic material and less than about 60 weight percent of gluten with water. At least about 90 weight percent of the particles of ceramic material are smaller than about 20 microns, and at least about 50 weight percent of the particles of ceramic material are from about 0.5 to about 2 microns. The mixture has a pH of from about 2 to about 8.

## Claims

### Claim 1

A process for preparing a ceramic body, comprising the steps of sequentially:
(a) mixing at least about 40 weight percent of ceramic material (by total weight of said ceramic material and gluten, less than about 60 weight percent of said gluten (by total weight of said ceramic material and said gluten), and from about 20 to about 80 weight percent of water (by total weight of said ceramic material, said gluten, and said water) to produce a mixture, wherein:
1. at least about 90 weight percent of the particles of said ceramic material are smaller than about 20 microns, and at least about 50 weight percent of the particles of said ceramic material are from about 0.5 to about 2 microns, and
2. said mixture has a pH of from about 2 to about 8;
(b) forming said mixture into a green body; and
(c) firing said green body until a body which contains substantially none of said gluten is produced.

### Claim 2 (depends on 1)

The process as recited in claim 1, wherein said mixture has a pH of from about 6.5 to about 7.5.

### Claim 3 (depends on 1)

The process as recited in claim 1, wherein said mixture is comprised of from about 30 to about 70 weight percent of said water (by total weight of said ceramic material, said gluten, and said water).

### Claim 4 (depends on 1)

The process as recited in claim 1, wherein said mixture is comprised of from about 45 to about 75 weight percent of said water (by total weight of said ceramic material, said gluten, and said water).

### Claim 5 (depends on 1)

The process as recited in claim 1, wherein said green body is fired while disposed within a microwave oven.

### Claim 6 (depends on 1)

The process as recited in claim 1, wherein said green body is fired until it has a density which is at least about 95 percent of its theoretical density.