BINDER FOR WHITEWARE CERAMIC MIXTURE AND METHOD OF USING SAME

• US 20090156387A1
• Filed: 10/21/2008
• Published: 06/18/2009
• Est. Priority Date: 12/13/2007
• Status: Active Grant

• Current Assignee: Covia Holdings Corp. (Scr-Sibelco Nv)
• Original Assignee: Unimin Corporation (Covia Holdings LLC)
• Inventors: Collins, Clayton
• Granted Patent: US 8,097,078 B2
• Time in Patent Office: Days
• US Class Current: 501/148
• CPC Class Codes: C03C 14/004 the non-glass component being in the form of particles or flakes
• CPC Class Codes: C04B 2235/3272 Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
• CPC Class Codes: C04B 2235/3472 Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/72 Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
• CPC Class Codes: C04B 2235/721 Carbon content
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 2235/9615 Linear firing shrinkage
• CPC Class Codes: C04B 33/1305 Organic additives
• CPC Class Codes: C04B 33/1315 Non-ceramic binders
• CPC Class Codes: C04B 33/14 Colouring matters
• CPC Class Codes: C04B 33/24 Manufacture of porcelain or white ware
• CPC Class Codes: C04B 35/6261 Milling

Abstract

An improvement in a mixture for forming into a body that is to be fired into a “whiteware ceramic product” wherein the mixture is a compound of clay and other minerals with a ferric oxide content of less than about 5.0% by weight of the dry mixture. The improvement includes adding to the mixture a binder in the form of a combination of protein and a vegetable flour with an equivalent gram strength of at least 30 grams and a protein content of 20-50% of the binder, where the binder is in the range of 0.05% to 0.50% by weight of the dry mixture.

Claims

1. The improvement in a mixture for forming into a body that is to be fired into a whiteware ceramic product, said improvement includes adding to said mixture a binder in the form of a combination of collagen protein and vegetable flour with an equivalent gram strength of at least about 30 grams and a protein content of about 30-50% of said binder, said binder having a particle size of less than about 20 mesh.

2. The improvement as defined in claim 1 wherein said vegetable flour is corn flour.

3. The improvement as defined in claim 2 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

4. The improvement as defined in claim 1 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

5. The improvement as defined in claim 2 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

6. The improvement as defined in claim 1 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

7. The improvement as defined in claim 2 wherein said binder is in the range of 0.10 to 0.20 percent by weight of the total dry weight of said mixture.

8. The improvement as defined in claim 1 wherein said binder is in the range of 0.10 to 0.20 percent by weight of the total dry weight of said mixture.

9. The improvement as defined in claim 8 wherein said mixture includes 0-30 percent by weight of silica.

10. The improvement as defined in claim 2 wherein said mixture includes 0-30 percent by weight of silica.

11. The improvement as defined in claim 1 wherein said mixture includes 0-30 percent by weight of silica.

12. The improvement as defined in claim 11 wherein said mixture also includes nepheline syenite and/or feldspar.

13. The improvement as defined in claim 8 wherein said mixture also includes nepheline syenite and/or feldspar.

14. The improvement as defined in claim 5 wherein said mixture also includes nepheline syenite and/or feldspar.

15. The improvement as defined in claim 6 wherein said mixture also includes nepheline syenite and/or feldspar.

16. The improvement as defined in claim 2 wherein said mixture also includes nepheline syenite and/or feldspar.

17. The improvement as defined in claim 1 wherein said mixture also includes nepheline syenite and/or feldspar.

18. The improvement as defined in claim 2 wherein the moisture content of said binder is less than about 15% by weight of said binder.

19. The improvement as defined in claim 17 wherein said equivalent gram strength is in the general range of 30-80 grams.

20. The improvement as defined in claim 2 wherein said equivalent gram strength is in the general range of 30-80 grams.

21. The improvement as defined in claim 1 wherein said equivalent gram strength is in the general range of 30-80 grams.

22. The improvement as defined in claim 2 wherein the ferric oxide content of said mixture is less than about 5.0 percent by weight of said mixture.

23. The improvement as defined in claim 1 wherein the ferric oxide content of said mixture is less than about 5.0 percent by weight of said mixture.

24. The improvement as defined in claim 2 wherein the modulus of rupture of said mixture before firing is increased by at least about 15 percent over the same mixture without said binder.

25. The improvement as defined in claim 24 wherein said increase in modulus of rupture of said mixture before firing is in the range of about 18-35 percent over the same mixture without said binder.

26. The improvement as defined in claim 1 wherein the modulus of rupture of said mixture before firing is increased by at least about 15 percent over the same mixture without said binder.

27. The improvement as defined in claim 26 wherein said increase in modulus of rupture of said mixture before firing is in the range of about 18-35 percent over the same mixture without said binder.

28. The improvement as defined in claim 1 wherein the ferric oxide content of said mixture is less than about 5.0 percent by weight of said mixture.

29. The improvement as defined in claim 4 wherein the whiteware ceramic product is a generally flat tile.

30. The improvement as defined in claim 2 wherein the whiteware ceramic product is a generally flat tile.

31. The improvement as defined in claim 1 wherein the whiteware ceramic product is a generally flat tile.

32. A naturally occurring clay for use in a mixture to produce a fired whiteware body, said clay including a binder in the form of a combination of collagen protein and a vegetable flour, said binder being 0. 10 to 5.0 percent by weight of said clay.

33. A naturally occurring clay as defined in claim 32 wherein said vegetable

34. A naturally occurring clay as defined in claim 35 wherein said binder has an equivalent gram strength of at least 30 grams and a protein content of at least 30 percent by weight of said binder.

35. A naturally occurring clay as defined in claim 32 wherein said binder has an equivalent gram strength of at least 30 grams and a protein content of at least 30 percent by weight of said binder.

36. A naturally occurring clay as defined in claim 33 wherein the moisture content of said binder is less than 15 percent of said binder.

37. A naturally occurring clay as defined in claim 32 wherein the moisture content of said binder is less than 15 percent of said binder.

38. A method of producing a mixture for making “

green”

body to be fired into a whiteware ceramic product, said method comprising;

(a) combining clay with at least one other mineral;

(b) adding to said mineral combination a protein binder in an amount of at least about 0.05 percent by weight of said mineral combination; and

,

(c) mixing said mineral combination and said binder by a mechanical mixer.

39. A method as defined in claim 38 wherein said mixer is a ball mill

40. A method as defined in claim 38 wherein said binder increases the modulus of rupture by about 15 percent.

41. A method as defined in claim 38 wherein said mixture has a ferric oxide content of less than about 5.0 percent.

42. A method as defined in claim 41 wherein said binder is at least in the range of 0.05 to 0.50 percent of said total dry mixture.

43. A method as defined in claim 40 wherein said binder is at least in the range of 0.05 to 0.50 percent of said total dry mixture.

44. A method as defined in claim 39 wherein said binder is at least in the range of 0.05 to 0.50 percent of said total dry mixture.

45. A method as defined in claim 38 wherein said binder is at least in the range of 0.05 to 0.50 percent of said total dry mixture.

46. A method as defined in claim 39 including:

(d) adding said binder to said clay before said mixing operation; and

,

(e) mixing said binder and clay before said aforementioned mixing operation.

47. A method as defined in claim 38 including:

(d) adding said binder to said clay before said mixing operation; and

,

(e) mixing said binder and clay to said clay before said aforementioned mixing operation.

48. A method as defined in claim 47 wherein the modulus of rupture of said mixture is increased by at least about 15 percent over the same mixture without said binder.

49. A method as defined in claim 38 wherein the modulus of rupture of said mixture is increased by at least about 15 percent over the same mixture without said binder.

50. A method as defined in claim 38 wherein said whiteware ceramic product is a generally flat tile.

51. A method as defined in claim 38 wherein said protein binder includes a vegetable flour.

52. A method as defined in claim 51 wherein said protein binder is selected from the class consisting of collagen protein and vegetable protein.

53. A method as defined in claim 38 wherein said protein binder is selected from the class consisting of collagen protein and vegetable protein.

54. A method as defined in claim 51 wherein said vegetable flour is selected from the class consisting of corn flour and starch.

55. The improvement in a mixture for forming into a body to be fired to make a whiteware ceramic product, said improvement comprises adding a binder in the form of a protein and a vegetable flour with an equivalent gram strength of at least about 30 grams and a protein content of 20-50% of said binder, said binder having a particle size of greater than 20 mesh.

56. The improvement as defined in claim 55 wherein said particle size of said binder is in the range of about 20-150 mesh.

57. The improvement as defined in claim 55 wherein said protein is selected from the class comprising collagen protein and vegetable protein.

58. The improvement as defined in claim 55 wherein said protein is collagen protein.

59. The improvement as defined in claim 55 wherein said vegetable flour is selected from the class consisting of corn flour and starch.

60. The improvement as defined in claim 55 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

61. The improvement as defined in claim 55 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

62. The improvement as defined in claim 55 wherein said binder is in the range of 0.10 to 0.20 percent by weight of the total dry weight of said mixture.

63. The improvement as defined in claim 55 wherein the moisture content of said binder is less than about 15% by weight of said binder.

64. The improvement as defined in claim 55 wherein said equivalent gram strength is in the general range of 30-80 grams.

65. The improvement as defined in claim 55 wherein the ferric oxide content of said mixture is less than about 5.0 percent by weight of said mixture.

66. The improvement as defined in claim 55 wherein the modulus of rupture of said mixture before firing is increased by at least about 15 percent over the same mixture without said binder.

67. The improvement as defined in claim 66 wherein said increase in modulus of rupture of said mixture before firing is in the range of about 18-35 percent over the same mixture without said binder.

68. The improvement in a mixture for forming into a body that is to be fired into a whiteware ceramic product, said improvement includes adding to said mixture a binder in the form of a protein with a protein content of 30-50% of said binder, said binder having a particle size of less than about 20 mesh and greater than about 200 mesh.

69. The improvement as defined in claim 68 wherein said binder is a combination of protein selected from the class consisting of collagen protein and vegetable protein and a vegetable flour selected from the class consisting of corn flour and starch.

70. The improvement as defined in claim 68 wherein said protein is collagen protein.

71. The improvement as defined in claim 69 wherein said binder has an equivalent gram strength of at least about 30 grams.

72. The improvement as defined in claim 68 wherein said binder has an equivalent gram strength of at least about 30 grams.

73. The improvement as defined in claim 72 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

74. The improvement as defined in claim 69 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

75. The improvement as defined in claim 68 wherein said binder is at least about 0.05 percent of the total dry weight of said mixture.

76. The improvement as defined in claim 75 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

77. The improvement as defined in claim 72 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

78. The improvement as defined in claim 69 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

79. The improvement as defined in claim 68 wherein said binder is in the range of 0.05 to 0.50 percent by weight of the total dry weight of said mixture.

80. The improvement as defined in claim 68 wherein the carbon content of the binder is less than 0.2% of the total mixture.