Process for making thick-walled ceramic bodies from synthetic mi

Details Process for making thick-walled ceramic bodies from synthetic mi Process for making thick-walled ceramic bodies from synthetic mi

1985-05-16

1986-11-11

Schor, Kenneth M.

Glass manufacturing

Processes

With shaping of particulate material and subsequent fusing...

65 17, 501 12, C03B 1906

Patent

active

046220577

ABSTRACT:
The instant invention is directed to the production of boards and other relatively thick-walled shapes of various configurations from inorganic silicates. The method for preparing such products involves five general steps: first a fully or predominantly crystalline body is formed containing crystals consisting essentially of a lithium and/or sodium water-swelling mica selected from the group of fluorhectorite, boron fluorphlogopite, and solid solutions therebetween; second, that body is contacted with a polar liquid, customarily water, to cause swelling and disintegration of the body accompanied with the formation of a gel; third, the gel is contacted with a source of large cations to effect an ion exchange reaction between the large cations and the Li.sup.+ and/or Na.sup.+ ions in the gel and to cause flocculation of the gel; fourth, the floc is substantially separated from the polar liquid and a shape of a desired geometry formed therefrom; and, fifth, the shaped body is fired at a temperature in excess of 700.degree. C., but below about 1100.degree. C., to minimize the normal hygroscopic tendencies in the materials.

REFERENCES:
patent: 2268589 (1942-01-01), Heany
patent: 3678144 (1972-07-01), Shoup
patent: 4239519 (1980-12-01), Beall et al.
patent: 4293439 (1981-10-01), Corbett et al.
patent: 4442175 (1984-04-01), Flannery et al.
patent: 4443239 (1984-04-01), Biswas et al.
patent: 4472185 (1984-09-01), Wu

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