US 9,187,377 B2 · Method of forming ceramic articles from recycled aluminosilicates

Abstract

The present invention relates to a process of forming ceramic articles that contain a high percentage of recycled alumina silicate in their composition. The fabrication process includes a fusing of the base material forming a reticulated network that is in-filled with a melted additive composition. The base material gives the article dimensional stability and strength while the additive composition gives the article water resistance and toughness. In this invention, an additive powder with an engineered melting temperature is added to the recycled base material. The mixture is heated until the recycled aluminosilicate reaches the optimal fusing temperature. Heating is continued until the additive begins to melt filling the voids between the fused aluminosilicates particles. The article is then rapidly cooled to quench the fusing without cracking. The resulting article has high strength due to the fused alumina silicate particles and low water absorbance and high density due to the melted additive component filling all the pores between the fused alumina silicate particles.

Claims19

Dependent claims

A process for forming an aluminosilicate article comprising an aluminosilicate base material and an additive material, the process comprising the steps of:

optimally fusing the aluminosilicate base material at a first temperature to 50% to 85% of total fusing of the aluminosilicate base material, wherein the first temperature is an optimal fusing temperature (OFT), which is a temperature determined by:
i) preparing a sample of the aliminosilicate base material by sizing to less than a 200 mesh;
ii) placing 25 grams of the sample in a dish;
iii) heating the sample to a high temperature to melt completely;
iv) lowering the temperature stepwise in subsequent tests with fresh aluminosilicate base material until the material fuses into a structurally strong mass, with minimal shrinkage, wherein the temperature that generates the structurally strong mass is the optimal fusing temperature;
melting the additive material at a second temperature higher than the first temperature;
and
cooling the article.

5 more elements

Dependencies are inferred from the claim text.

Method of forming ceramic articles from recycled aluminosilicates

Life of this patent

Method of forming ceramic articles from recycled aluminosilicates

Life of this patent

Abstract

Claims19