Ceramic products, raw batch formulations, and method

• US 7,169,725 B2
• Filed: 10/08/2002
• Issued: 01/30/2007
• Est. Priority Date: 10/18/2001
• Status: Expired due to Fees

• Current Assignee: Michael J. Haun
• Original Assignee: Michael J. Haun
• Inventors: Haun, Michael J.
• Primary Examiner(s): GROUP, KARL E
• Application Number:
  US10/493,072
• Publication Number:
  US 20040255621A1
• Time in Patent Office: 1,575 Days
• Field of Search: 50/2, 50/5, 501/55, 65/173, 65/175, 65/27, 156/155
• US Class Current: 501/155
• CPC Class Codes: C03B 19/06 by sintering, e.g. by cold isostatic pressing of powders and subsequent sintering, by hot pressing of powders, by sintering slurries or dispersions not undergoing a liquid phase reaction
• CPC Class Codes: C03C 1/002 Use of waste materials, e.g. slags
• CPC Class Codes: C03C 10/0063 containing waste materials, e.g. slags
• CPC Class Codes: C03C 14/004 the non-glass component being in the form of particles or flakes
• CPC Class Codes: C03C 2214/04 Particles; Flakes
• CPC Class Codes: C03C 2214/20 Glass-ceramics matrix
• CPC Class Codes: C04B 2235/36 Glass starting materials for making ceramics, e.g. silica glass
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/604 Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 2235/9653 Translucent or transparent ceramics other than alumina
• CPC Class Codes: C04B 33/13 Compounding ingredients C04B33/36, C04B35/71 take precedence ; pigments for ceramics C09C1/0009
• CPC Class Codes: C04B 33/132 Waste materials; Refuse; ResiduesC04B33/16 takes precedence; waste glass C04B33/13
• CPC Class Codes: C04B 33/14 Colouring matters
• CPC Class Codes: C04B 33/20 for dry-pressing C04B33/13 takes precedence
• CPC Class Codes: C04B 33/34 combined with glazing
• CPC Class Codes: C04B 33/36 : Reinforced clay-wares
• CPC Class Codes: C04B 35/63 : using additives specially adapted for forming the products , e.g.. binder binders
• CPC Class Codes: C04B 35/634 : Polymers C04B35/636 takes precedence
• CPC Class Codes: C04B 35/63488 : Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]
• CPC Class Codes: C04B 35/653 : Processes involving a melting step
• CPC Class Codes: C04B 35/82 : Asbestos; Glass; Fused silica
• CPC Class Codes: Y02P 40/60 : Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Abstract

The invention provides a method to transform large quantities of waste glass into useful ceramic products by a low-cost manufacturing process. The method improves green strength compared to previous methods, and does not require water or any other liquid solvent. Only one firing step is needed with a low peak firing temperature of about 700° C.to about 1000° C. The method conserves energy and natural resources compared to clay-based traditional ceramic manufacturing. High-quality impervious ceramic products can be produced by the invention.

Claims

1. A method for making a ceramic product from waste glass, comprising:

heating a solid organic binder to form a liquid organic binder;

mixing the waste glass with the liquid organic binder to form a liquid-binder-coated glass mixture;

cooling the liquid-binder-coated-glass mixture to form a solid-binder-coated-glass mixture;

forming the solid-binder-coated-glass mixture into a green ceramic article;

heating the green ceramic article to burnout the organic binder; and

firing the green ceramic article to sinter the green ceramic article into the ceramic product.

2. The method according to claim 1, wherein the waste glass is selected from the group consisting of container glass waste, flat glass waste, fiber glass waste, and specialty glass waste.

3. The method according to claim 1, wherein the waste glass is provided in a glass powder form.

4. The method according to claim 1, wherein the waste glass is provided in a dry-processed glass powder form.

5. The method according to claim 1, wherein about 90 to about 99 weight percent of the solid-binder-coated-glass powder is comprised of the waste glass and about 1 to about 10 weight percent of the solid-binder-coated-glass powder is comprised of the solid organic binder.

6. The method according to claim 1, wherein the waste glass includes a filler.

7. The method according to claim 1, wherein the waste glass includes a filler selected from the group consisting of ceramic raw materials and colorants.

8. The method according to claim 1, wherein the waste glass includes a filler comprised of coarse-sized particles.

9. The method according to claim 1, wherein about 0.1 to about 40 weight percent of the waste glass is comprised of a filler.

10. The method according to claim 1, further including mixing the waste glass with the solid organic binder, before heating the solid organic binder to form a liquid organic binder.

11. The method according to claim 1, further including heating the waste glass to above the melting temperature of the solid organic binder, before mixing the waste glass with the liquid organic binder to form a liquid-binder-coated-glass mixture.

12. The method according to claim 1, further including crushing the solid-binder-coated-glass mixture to break up agglomerates and reduce the particle size of the solid-binder-coated-glass mixture.

13. The method according to claim 1, further including seiving the solid-binder-coated-glass mixture to control the particle size of the solid-binder-coated-glass mixture.

14. The method according to claim 1, wherein the forming comprises pressing or extrusion.

15. The method according to claim 1, wherein the firing comprises heating the green ceramic article to a maximum temperature of about 700°

C. to about 1000°

C.

16. The method according to claim 1, wherein the ceramic product comprises tile or brick.

17. The method according to claim 1, wherein the firing comprises partial crystallization of the ceramic product.

18. The method according to claim 1, wherein the ceramic product has a smooth glossy surface.

19. The method according to claim 1, wherein the ceramic product has a textured surface.

20. The method according to claim 1, wherein the ceramic product is further processed by applying a glaze thereon.