Polymeric binders for enhancing green strength of pressed ceramics
First Claim
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1. A method for preparing a ceramic material, which comprises:
- mixing a ceramic powder with an aqueous solution containing a substantially hydrolyzed copolymer of an ester and an amide to produce a slurry, said ester being of the formula;
##STR7## wherein R1 is an unsaturated acyclic hydrocarbon group having about 2 to about 4 carbon atoms, and R2 is an alkyl group having 1 to about 4 carbon atoms, and said amide being of the formula;
##STR8## wherein R3 is hydrogen or an alkyl group having 1 to about 4 carbon atoms, R4 is an unsaturated acyclic hydrocarbon group having about 2 to about 4 carbon atoms, and R5 is hydrogen or an alkyl group having 1 to about 4 carbon atoms;
drying the slurry by a process selected from the group consisting of filter pressing, fluidized bed spray drying and tape casting to produce particles which include said copolymer;
compacting the particles by a process selected from the group consisting of dry pressing, extrusion, jiggering and slip casting to produce an aggregate structure; and
heating the aggregate structure to produce a fired ceramic material.
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Abstract
A composition suitable for use as a binder of ceramic materials and a method for preparing a ceramic material which provides relatively greater green ceramic strength is disclosed. The improved binder contains substantially hydrolyzed copolymer made from monomers having ester or amide functional groups, poly(vinyl amine), poly(vinyl formamide) or a copolymer of vinyl alcohol and vinyl amine. The binder is combined with an aqueous solution containing a ceramic powder to make a slurry, and the slurry is subsequently spray dried, pressed and heated to make a ceramic.
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Citations
15 Claims
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1. A method for preparing a ceramic material, which comprises:
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mixing a ceramic powder with an aqueous solution containing a substantially hydrolyzed copolymer of an ester and an amide to produce a slurry, said ester being of the formula;
##STR7## wherein R1 is an unsaturated acyclic hydrocarbon group having about 2 to about 4 carbon atoms, and R2 is an alkyl group having 1 to about 4 carbon atoms, and said amide being of the formula;
##STR8## wherein R3 is hydrogen or an alkyl group having 1 to about 4 carbon atoms, R4 is an unsaturated acyclic hydrocarbon group having about 2 to about 4 carbon atoms, and R5 is hydrogen or an alkyl group having 1 to about 4 carbon atoms;drying the slurry by a process selected from the group consisting of filter pressing, fluidized bed spray drying and tape casting to produce particles which include said copolymer;
compacting the particles by a process selected from the group consisting of dry pressing, extrusion, jiggering and slip casting to produce an aggregate structure; and
heating the aggregate structure to produce a fired ceramic material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for preparing a ceramic material, which comprises:
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mixing a ceramic powder with an aqueous solution containing a salt of a copolymer having repeating units to produce a slurry, said polymer being of the formula;
##STR9## wherein R2 is an alkyl group having 1 to about 4 carbon atoms, R3 is hydrogen or an alkyl group having 1 to about 4 carbon atoms, R5 is hydrogen or an alkyl group having 1 to about 4 carbon atoms, the sum of n and q is in the range of about 2 to about 100, the sum of p and r is in the range of about 98 to about 0 the ratio r/p is about 0 to about 0.67, and the range the ratio q/n is about 0 to about 20;drying the slurry by a process selected from the group consisting of filter pressing, fluidized bed spray drying and tape casting to produce particles which include said copolymer;
compacting the particles by a process selected from the group consisting of dry pressing, extrusion, jiggering and slip casting to produce an aggregate structure; and
heating the aggregate structure to produce a fired ceramic material. - View Dependent Claims (11, 12, 13)
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14. A method for preparing a ceramic material which comprises:
mixing a ceramic powder with an aqueous solution containing a polymer selected from the group consisting of polyvinyl amine, polyvinyl formamide and poly(vinyl alcohol/vinyl amine) to form a slurry;
drying the slurry by a process selected from the group consisting of filter pressing, fluidized bed spray drying and tape casting to produce particles which include said polymer;
compacting the particles by a process selected from the group consisting of dry pressing, extrusion, jiggering and slip casting to produce an aggregate structure; and
heating the aggregate structure to produce a fired ceramic material.- View Dependent Claims (15)
Specification