WO2004013066A1 - Fully vitrified stain free extruded porcelain stoneware tiles, slabs and profiles - Google Patents

Fully vitrified stain free extruded porcelain stoneware tiles, slabs and profiles Download PDF

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Publication number
WO2004013066A1
WO2004013066A1 PCT/IN2003/000134 IN0300134W WO2004013066A1 WO 2004013066 A1 WO2004013066 A1 WO 2004013066A1 IN 0300134 W IN0300134 W IN 0300134W WO 2004013066 A1 WO2004013066 A1 WO 2004013066A1
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Prior art keywords
vitrified
stain
product
stain free
profiles
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PCT/IN2003/000134
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French (fr)
Inventor
Rudrapatnakeshavamurthy Venkatesha
Snehasish Ghosh
Kasturiumapathy Rao
Original Assignee
Venkatesha Rudrapatnakeshavamu
Snehasish Ghosh
Kasturiumapathy Rao
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Application filed by Venkatesha Rudrapatnakeshavamu, Snehasish Ghosh, Kasturiumapathy Rao filed Critical Venkatesha Rudrapatnakeshavamu
Priority to AU2003242981A priority Critical patent/AU2003242981A1/en
Publication of WO2004013066A1 publication Critical patent/WO2004013066A1/en

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/24—Manufacture of porcelain or white ware
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3201—Alkali metal oxides or oxide-forming salts thereof
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3272—Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472—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
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5463—Particle size distributions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6021—Extrusion moulding

Definitions

  • This invention in general relates to the field of ceramic technology.
  • this invention relates to a Vitrified Stain Free Extruded Porcelain Tiles and Shapes herein described generally as Products used for industrial (chemical industry, food process industry), commercial complexes and other heavy duty areas.
  • the object of the invention is to get vitrified stain free ceramic products which have been used in the building industries.
  • the need for a vitrified stain free product arises due to requirement of markets.
  • Vitrified Stain Proof Porcelain Stoneware is a ceramic material made from selected raw materials fired at high temperatures to get hard and resistant to wear. In particular it is well known for its susceptibility to staining.
  • Porcelain Stoneware is difficult to keep clean as dirt usually adhere to its stone surface.
  • the polishing process cause the surface to become more microporus and this makes it susceptible to penetrating type of grim which are absorbed deep into material.
  • Stains of this type are caused by Coffee, Bear, Wine, Soft drink, Fountain Pen Ink, Ink and Shampoo to name a few and these may be so completely absorbed that they are virtually impossible to remove.
  • the majority of the ceramic raw materials are inorganic, non-metallic and non-ferrous in. nature. They do not react with organic materials at all.
  • the phenomenon of the staining in the ceramic tile is mainly physical where the foreign particles go inside the pores of the surface of contract. Since the ceramic surfaces are not essentially pore free, the staining problem is inherent. The staining particles are mostly very fine in nature and they find an easy go in the pores of the ceramic surface.
  • the cleaning agents are normally being water or water solutions of different acid or alkalies, have inherent surface tension which does not allow the agent to go deep inside the pores to remove the staining particles out.
  • the staining is generated by two-fold activity. They go to the pores inside and remain there permanent due to their inability to come out.
  • a general process of manufacturing vitrified tiles and profiles is a subject matter for a invention for which we have applied for a patent though the patent of manufacturing the vitrified tiles are novel, there exist the problem of staining associated with surface of the tiles.
  • the Research and Development has been carried out in order to over come the problem of staining in the tiles.
  • the object of invention is to explain the ingredients of the formulation and the process involved leading to manufacturing stain proof tiles and profiles.
  • the objective is to build more reliable product with overall better property tile at lower cost.
  • This novel process according to invention is significant because the presence of different oxides in the product which will melt at a particular stage in the firing where the body will get melt by eutectic reaction and give the surface free from all defects.
  • Monitoring of the parameters such as temperature and firing cycle (soaking period) must therefore be exceptionally accurate in the critical sections of the kiln etc. those sections involving the first and second phases of vitrification.
  • composition of stain free body have always had the common objective of simplifying the technological process as much as possible to overcome all market problems.
  • the percentage of the oxides in the clay and feldspar are the parameters play the most important role in the body formulation.
  • An important salient feature of the invention is that the vitrified stain free products is suitable for laying in the floor and elevation in the market.
  • novel stain free process according to invention can infact work in continuous modes according to production requirements or in the event of unexpected stoppages. It has suitable high loading strength with a great advantages to take a heavier load on the surface.
  • the nature of the invention and the manner in which is to performed is clearly described in the following description.
  • the invention is a Vitrified Stain Free Porcelain Stoneware Products which is unique.
  • the products available in the market are susceptible to stain.
  • the root cause of the staining problem was identified to be the presence of micropores in the surface. Therefore to overcome, the problem of staining in product, we have to produce essentially a porefree ceramic.
  • the generation of the micropores is a function of the following: a) Particle size distribution of the different raw materials used. b) Particle size distribution of the formulated body. c) Behaviour of the different raw materials at elevated temperature. d) Characteristics of different product which come into existence at high temperature. e) Behaviour of the high temperature product in cooling. In making the stain free product all the above mentioned points have been dealt with to achieve the optimum condition. To attain these a robust design is done to formulate the batch composition to produce the desired results.
  • a continuos grading is done in such a way that a progressively finer particle size fraction is available to go to the interstices to reduce the interstitial gap formed by the primary particles. For this reason a five component system is adopted to achieve an almost 99% close packing density. The rest 1% is achieved in the process of vitrification.
  • the prepared / formulated body is given a shape of a salable product and fired at 1180 - 1200 ° C. During the firing process densification of the particles occur through a liquid phase reaction sintering process. During this phenomenon the particles at the eutectic contact point melt, reacts to the grain boundary of the other particles and a highly viscous amorphous phase evolves. This amorphous material flows and fills all the pores.
  • raw materials are all of natural occurrence. Because of natural weathering effect and leaching, the chemical composition may vary from mine to mine. However, the above mentioned data may be taken for calculations.
  • LOI Loss on ignition
  • the formulation is done progressively in such a way that one component is placed in the tetrahedral interstice of the other four component particles.
  • the essence of the invention is in the developing of a novel composition of raw materials leading to a specific formulation based on the raw materials and their proportion of each constituent material shown in the following table.
  • the raw materials are wet milled and final particle size should be 99% ⁇ 63 ⁇
  • the particle size distribution in the formulated body is in the ran e as follows:
  • Tre product does not at ail get stained with the house hold chemicals for example - water solution of tea extract, water solution of the coffee extract etc.
  • Fig. 1 of the drawings shows a conventional Vitrified Tiles and Profiles which is susceptible to stain.
  • Fig. 2 of the drawings shows novel Vitrified Tiles and Profiles which is stain proof.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

This invention relates to novel stain proof tiles. This invention comprises the process, the formulation, the raw material, the oxides, means of drying, preheating, means of heating, soaking period, cooling period in the novel process. The vitrified stain free extruded porcelain stone ware tiles, slabs and profiles will have the following composition. Raw material and percentage of composition: A. Clay-I, 20-25; B. Clay-II; 15-25; C. Clay-III, 10-15; D. Feldspar-A, 30-35; E. Feldspar-, 10-20.

Description

FULLY VITRIFIED STAIN FREE EXTRUDED PORCELAIN STONEWARE TILES,SLABS AND PROFILES.
This invention in general relates to the field of ceramic technology. In particular this invention relates to a Vitrified Stain Free Extruded Porcelain Tiles and Shapes herein described generally as Products used for industrial (chemical industry, food process industry), commercial complexes and other heavy duty areas.
The particular usage of ceramics was in the field of roofing, flooring and wall cladding. In all the cases the ceramics is expected to last long, give " an aesthetic view. Though the traditional ceramics offer good aesthetic view, they particularly fall to stain proofness. The products are highly prone to staining when used in floor. When the floor in different areas are used with acids, alkalies and different other chemicals, when cleaned leave a permanent mark, (stained) which does not leave the ' surface even after. repeated wash. This creates a permanent blemish causing heavily on the aesthetics.
Therefore to have a blemish free ceramic for a long time, a product is required which is essentially pore free and stain proof.
The object of the invention is to get vitrified stain free ceramic products which have been used in the building industries. The need for a vitrified stain free product arises due to requirement of markets.
The vitrified stain free is one of the product properties achieved in the process of manufacturing vitrified extruded glazed, unglazed tiles, slabs and profiles. Vitrified Stain Proof Porcelain Stoneware is a ceramic material made from selected raw materials fired at high temperatures to get hard and resistant to wear. In particular it is well known for its susceptibility to staining.
Porcelain Stoneware is difficult to keep clean as dirt usually adhere to its stone surface. However, the polishing process cause the surface to become more microporus and this makes it susceptible to penetrating type of grim which are absorbed deep into material.
Stains of this type are caused by Coffee, Bear, Wine, Soft drink, Fountain Pen Ink, Ink and Shampoo to name a few and these may be so completely absorbed that they are virtually impossible to remove.
The majority of the ceramic raw materials are inorganic, non-metallic and non-ferrous in. nature. They do not react with organic materials at all.
The phenomenon of the staining in the ceramic tile is mainly physical where the foreign particles go inside the pores of the surface of contract. Since the ceramic surfaces are not essentially pore free, the staining problem is inherent. The staining particles are mostly very fine in nature and they find an easy go in the pores of the ceramic surface.
The cleaning agents are normally being water or water solutions of different acid or alkalies, have inherent surface tension which does not allow the agent to go deep inside the pores to remove the staining particles out.
Therefore, the staining is generated by two-fold activity. They go to the pores inside and remain there permanent due to their inability to come out.
The interest of those working in the ceramic sector is, in any case, directed towards fast firing technology because, in the final analysis, this technology leads to a considerable simplication of the production machinery and equipment as well as the technological process.
A general process of manufacturing vitrified tiles and profiles is a subject matter for a invention for which we have applied for a patent though the patent of manufacturing the vitrified tiles are novel, there exist the problem of staining associated with surface of the tiles. The Research and Development has been carried out in order to over come the problem of staining in the tiles. We have achieved the novel formulation of raw materials when subjected to our novel process mentioned in earlier patent application results in strain proof tiles and profiles.
The object of invention is to explain the ingredients of the formulation and the process involved leading to manufacturing stain proof tiles and profiles.
We have applied for a patent for a novel process for producing fully vitrified flat extruded ceramic glazed and unglazed tiles and profiles by an application no.2133/MAS/98 dated 23/9/1998.
The objective, therefore, is to build more reliable product with overall better property tile at lower cost.
At that time, the necessity to mechanise the technological process prevailed without particular attention being paid to the stain free products. The different interest of technicians in the importance of the process operation in determining the stain free porcelain stone ware products.
This novel process according to invention is significant because the presence of different oxides in the product which will melt at a particular stage in the firing where the body will get melt by eutectic reaction and give the surface free from all defects. Monitoring of the parameters such as temperature and firing cycle (soaking period) must therefore be exceptionally accurate in the critical sections of the kiln etc. those sections involving the first and second phases of vitrification.
In any case, composition of stain free body have always had the common objective of simplifying the technological process as much as possible to overcome all market problems. The percentage of the oxides in the clay and feldspar are the parameters play the most important role in the body formulation. An important salient feature of the invention is that the vitrified stain free products is suitable for laying in the floor and elevation in the market.
The novel stain free process according to invention can infact work in continuous modes according to production requirements or in the event of unexpected stoppages. It has suitable high loading strength with a great advantages to take a heavier load on the surface.
Accordingly it is a primary object of the invention to invent a vitrified stain free porcelain stoneware products which is unique.
Further objects of the invention will be clear from the ensuing description. The invention is described in detail in the following pages of the complete specification.
DESCRIPTION OF THE VITRIFIED STAIN FREE PROCESS USING A NOVEL FORMULATION:
The nature of the invention and the manner in which is to performed is clearly described in the following description. The invention is a Vitrified Stain Free Porcelain Stoneware Products which is unique. The products available in the market are susceptible to stain.
The root cause of the staining problem was identified to be the presence of micropores in the surface. Therefore to overcome, the problem of staining in product, we have to produce essentially a porefree ceramic. The generation of the micropores is a function of the following: a) Particle size distribution of the different raw materials used. b) Particle size distribution of the formulated body. c) Behaviour of the different raw materials at elevated temperature. d) Characteristics of different product which come into existence at high temperature. e) Behaviour of the high temperature product in cooling. In making the stain free product all the above mentioned points have been dealt with to achieve the optimum condition. To attain these a robust design is done to formulate the batch composition to produce the desired results.
When particles of same equivalent diametrical dimension are studied under gravity, it is found that interstices are formed between the particles. These interstices are in turn play host to the crevices to attract staining.
Operation:
A continuos grading is done in such a way that a progressively finer particle size fraction is available to go to the interstices to reduce the interstitial gap formed by the primary particles. For this reason a five component system is adopted to achieve an almost 99% close packing density. The rest 1% is achieved in the process of vitrification. The prepared / formulated body is given a shape of a salable product and fired at 1180 - 1200 ° C. During the firing process densification of the particles occur through a liquid phase reaction sintering process. During this phenomenon the particles at the eutectic contact point melt, reacts to the grain boundary of the other particles and a highly viscous amorphous phase evolves. This amorphous material flows and fills all the pores. In this process all the pores in the ceramic form are eradicated giving rise to a pore free product. This reaction process being an irreversible one, does not allow the melt to settle in any particular place, in turn the cooling of the ceramic takes place so. fast that the viscosity of the melt becomes so high, for all practical purposes it becomes solid. When the ceramic is cooled to the room temperature, the whole reaction product gives rise to a monolithic, pore free and homogenous ceramic. This ceramic when tested under heavy staining condition, shows exceptionally good stain proofness.
To achieve the above mentioned qualities in ceramics raw materials are carefully choosen and a batch is formulated in such a way so as to produce the required properties after reactions are over.
Raw Materials:
Following are the general chemical formula of the raw materials.
Clay AI2Si2H4O8 Feldspar KNiAbSiδde
Above- mentioned raw materials are all of natural occurrence. Because of natural weathering effect and leaching, the chemical composition may vary from mine to mine. However, the above mentioned data may be taken for calculations.
During the various stages of production the chemical changes in the product occurs only when the products are fired. In other stages of process, the raw materials are changed physically with respect to their grain size, water content of the slip etc.
Raw material stoichiometric details
Figure imgf000010_0001
Note: LOI stands for Loss on ignition. The Traditional ceramic has the batch composition as per the following:
Clay 50 - 60%
Quartz 20 - 25%
Feldspar 20 - 25%
' In the present case, the formulation is done progressively in such a way that one component is placed in the tetrahedral interstice of the other four component particles.
The essence of the invention is in the developing of a novel composition of raw materials leading to a specific formulation based on the raw materials and their proportion of each constituent material shown in the following table.
,
Figure imgf000011_0001
The raw materials are wet milled and final particle size should be 99% < 63 μ The particle size distribution in the formulated body is in the ran e as follows:
Figure imgf000012_0001
Oxide Chemical Composition of the ceramic
Figure imgf000012_0002
The novel stain free process has many advantages which are as follows:
α The product does not get stained with impurities in the cleaning household cleaning agents muriatic acid.
α The product does not get stained when the cleaning agent contains high concentration of alkalies.
□ The product does not get stained when the cleaning agent contains high concentration of acids except hydrofluoric acid.
□ Tre product does not at ail get stained with the house hold chemicals for example - water solution of tea extract, water solution of the coffee extract etc.
α The product does not at all get stained with the methylene blue and fountain pen ink .
□ Maintaining uniform temperature within the kiln for controlling percentage of moisture and stain absorption in the products. Complete flexibility is ensured with the plant both upstream and down stream
It will be understood that the foregoing descriptions are only illustrative of the present invention and it is not intended that the intention be limited thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure.
All substitution, alterations and modifications of the present invention which come with in the scope of the following claims are to which the present invention is readily susceptible without departing from the spirit of the invention.
Fig. 1 of the drawings shows a conventional Vitrified Tiles and Profiles which is susceptible to stain.
Fig. 2 of the drawings shows novel Vitrified Tiles and Profiles which is stain proof.
Further extensive test has been carried out on this novel stain proof tiles using wide varieties of staining material ranging from ordinary ball pen marks to wet mud. The results of the test conducted at the end of 12 hours and 24 hours respectively are tabulated and shown in the following table. OF STAIN RESISTANCE TEST
Figure imgf000015_0001
Figure imgf000016_0001
L0
L5
Figure imgf000017_0001

Claims

1. A fully Vitrified Stain Free Extruded Porcelain Stoneware Tiles, Slabs and Profiles manufactured by a novel process wherein the composition of each of the raw material is given as follows:
Raw Material Percentage of Composition
A. Clay - I 20 - 25
B. Clay - II 15 - 25
C. Clay- III 10 - 15
D. Feldspar - A 30 - 35
E. Feldspar - B 10-20
2. A fully Vitrified Stain Free Extruded Porcelain Stoneware Tiles, Slabs and Profiles as claimed in claim 1 wherein the said product being manufactured by a novel process claimed in our earlier application for patent.
3. A fully Vitrified Stain Free Extruded Porcelain Stoneware Tiles,
Slabs and Profiles as claimed in claim 1 wherein in the novel process indicated in the claim 2 wherein the process includes maintaining uniform temperature within the kiln for controlling percentage of moisture and stain absorption in the product.
4. A Vitrified Stain ■ Free Products comprises the process, the formulation, the raw material, the oxides, means of drying, preheating, means of heating, soaking period, cooling period provided in the process.
5. A Vitrified Stain Free Products as claimed in claim - 1 , the product does not get stained with impurities in the cleaning household cleaning agents.
6. A Vitrified Stain Free Products as claimed in claim - 1 , the product does not get stained when the cleaning agent contains high concentration of alkalies.
7. A Vitrified Stain Free Products as claimed in claim - 1 , the product does not get stained when the cleaning agent contains high concentration of acids except hydrofluoric acid.
8. A Vitrified Stain Free Products as claimed in claim - 1 , the product does not at all get stained with the house hold chemicals like water solution of tea extract, water solution of the coffee extract.
9. A Vitrified Stain Free Products as claimed in claim - 1, the product does not at all get stained with the methylene blue and fountain pen ink.
10. A Vitrified Stain Free Products as described in the complete specification.
PCT/IN2003/000134 2002-08-02 2003-04-02 Fully vitrified stain free extruded porcelain stoneware tiles, slabs and profiles WO2004013066A1 (en)

Priority Applications (1)

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AU2003242981A AU2003242981A1 (en) 2002-08-02 2003-04-02 Fully vitrified stain free extruded porcelain stoneware tiles, slabs and profiles

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN581/MAS/02 2002-08-02
IN581CH2002 2002-08-02

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016193500A1 (en) 2015-06-05 2016-12-08 Cosentino Research & Development, S.L. Compacted ceramic materials with low porosity
EP3480180A3 (en) * 2017-11-06 2019-09-11 Fliesenmarkt Herberhold GmbH Stoneware tile

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60137874A (en) * 1983-11-24 1985-07-22 株式会社興人 Ceramic sheet and manufacture
US5275989A (en) * 1990-10-25 1994-01-04 Bayer Italia S.P.A. Ceramic composition for the production of the top layer of two-layered stoneware tiles
CN1278521A (en) * 1999-06-21 2001-01-03 上海斯米克建筑陶瓷有限公司 Polished fully-vitrified ceramic tile

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60137874A (en) * 1983-11-24 1985-07-22 株式会社興人 Ceramic sheet and manufacture
US5275989A (en) * 1990-10-25 1994-01-04 Bayer Italia S.P.A. Ceramic composition for the production of the top layer of two-layered stoneware tiles
CN1278521A (en) * 1999-06-21 2001-01-03 上海斯米克建筑陶瓷有限公司 Polished fully-vitrified ceramic tile

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016193500A1 (en) 2015-06-05 2016-12-08 Cosentino Research & Development, S.L. Compacted ceramic materials with low porosity
US10329188B2 (en) 2015-06-05 2019-06-25 Consentino Research & Development, S.L. Compacted ceramic materials with low porosity
EP3480180A3 (en) * 2017-11-06 2019-09-11 Fliesenmarkt Herberhold GmbH Stoneware tile

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