WO2005049527A2 - Microcellular ceramic material, method for preparing it, and products obtained with the material and the method - Google Patents

Microcellular ceramic material, method for preparing it, and products obtained with the material and the method Download PDF

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Publication number
WO2005049527A2
WO2005049527A2 PCT/EP2004/012018 EP2004012018W WO2005049527A2 WO 2005049527 A2 WO2005049527 A2 WO 2005049527A2 EP 2004012018 W EP2004012018 W EP 2004012018W WO 2005049527 A2 WO2005049527 A2 WO 2005049527A2
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WIPO (PCT)
Prior art keywords
ceramic material
mixture
material according
facing
sludges
Prior art date
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PCT/EP2004/012018
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French (fr)
Other versions
WO2005049527A3 (en
Inventor
Franco Billi
Original Assignee
Cooperativa Ceramica D'imola S.R.L.
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Application filed by Cooperativa Ceramica D'imola S.R.L. filed Critical Cooperativa Ceramica D'imola S.R.L.
Publication of WO2005049527A2 publication Critical patent/WO2005049527A2/en
Publication of WO2005049527A3 publication Critical patent/WO2005049527A3/en

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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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    • C04B33/13—Compounding ingredients
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    • C04B33/1321—Waste slurries, e.g. harbour sludge, industrial muds
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    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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Definitions

  • the present invention relates to a microcellular ceramic material, to the method for preparing it, and to the products obtained with the material and the method.
  • the material is suitable for providing articles for applications in the field of building, in which thermal and acoustic insulation characteristics and aesthetic finishing characteristics are required.
  • thermoacoustic insulating materials widely uses synthetic insulating materials, such as polyurethanes and polystyrenes, generally structured as sheets; mineral wools, structured as mats; and expanded clay as loose material.
  • an object of the present invention is to provide a microcellular ceramic material obtained by means of a production process that allows to utilize highly competitive innovative solutions.
  • an object of the present invention is to provide a product by means of low-cost raw materials that are easily commercially available.
  • Another object is to provide a material that has good thermal and acoustic insulation characteristics and high fire resistance.
  • Another object is to provide a material that allows to manufacture products that have good mechanical strength characteristics.
  • a further object is to provide products that have high-level aesthetic characteristics and are particularly suitable for use in building.
  • microcellular ceramic material characterized in that it is obtained by using, as a basic product, sludge from the facing of porcelain stoneware, which is a waste of the ceramic tile sector, mixed with clayey plastic material, having the following chemical composition:
  • the method used consists in grinding the raw material or the porcelain stoneware facing sludge mixed with clayey plastic material and fluxes, until a fine particle size is obtained; in granulating or atomizing the mixture; in pressing or filling containment trays; in firing in a continuous kiln at a temperature comprised between 900 and 1250° C, with a firing cycle comprised between 30 and 180 minutes.
  • the resulting product is a panel that is characterized by high thermal, acoustic and mechanical strength and by an aesthetically valid finishing surface that can be further finished by depositing, before firing, one or more layers of material prepared for aesthetic purposes.
  • the sludges that originate from the facing of porcelain stoneware contain, as their main ingredient, the fragments that originate from the surface layers of the faced tiles, approximately 80% dried sludge, and as a smaller fraction fragments of the abrasive grinding wheel, equal to 20% of the dried sludge.
  • the material that constitutes the abrasive grinding wheel is a mixture of magnesium cement and silicon carbide in a fine powder of controlled particle size.
  • the facing sludge which contains large amounts of water, is subjected to filter pressing (thus reducing the water content to 20-40% by weight) and then dried if required.
  • filter pressing thus reducing the water content to 20-40% by weight
  • the mixture is prepared by appropriately mixing and homogenizing three fundamental types of raw material: clayey plastic material; facing sludges; fluxes.
  • the mixture is then finally ground down to a particle size of less than 50 ⁇ m and is granulated or atomized to particle sizes comprised between 100 and 500 ⁇ m.
  • the production process has two alternative methods of embodiment: a. traditional pressing of the mixture, in a manner similar to the production of conventional tiles, deposition on layers of refractory r , material, drying and firing of the product; b. filling of refractory trays for containment and subsequent firing.
  • the finishing surface is produced before firing, by depositing a plurality of layers of granulated material containing coloring oxides, distributed so as to provide various geometries and aesthetic solutions.
  • thermal treatments firing gradients in a continuous industrial kiln with temperatures between 900 and 1250° C and cycles between 30 and 180 minutes are used. Dry and wet grinding and cutting techniques are used during finishing.
  • Panels of the described type can be used advantageously in providing fire doors and barriers and in any application where a lightweight material with high-level characteristics of thermal insulation, fire protection and acoustic insulation is required. From what has been described and illustrated, it is evident that the intended aim and all the objects have been achieved, and that in particular a ceramic material has been provided which allows to obtain panels that have high-level thermal and acoustic insulation characteristics as well as excellent mechanical characteristics, starting from waste materials and with a low-cost method.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Building Environments (AREA)
  • Finishing Walls (AREA)
  • Treatment Of Sludge (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Abstract

A microcellular ceramic material obtained starting from raw materials constituted predominantly by sludges from the facing of porcelain stoneware, the chemical composition of the material being substantially as follows: (I). The mixture is prepared by grinding and is then granulated and atomized. The mixture is shaped by pressing or by filling containment trays. The product thus prepared is fired in a continuous kiln at temperatures comprised between 900 and 1250° C, with cycles comprised between 30 and 180 minutes. It is also possible to provide a surface finishing layer with aesthetic characteristics.

Description

MICROCELLULAR CERAMIC MATERIAL, METHOD FOR PREPARING IT, AND PRODUCTS OBTAINED WITH THE MATERIAL AND THE METHOD Technical Field The present invention relates to a microcellular ceramic material, to the method for preparing it, and to the products obtained with the material and the method. In particular, the material is suitable for providing articles for applications in the field of building, in which thermal and acoustic insulation characteristics and aesthetic finishing characteristics are required. Background Art The field of thermoacoustic insulating materials widely uses synthetic insulating materials, such as polyurethanes and polystyrenes, generally structured as sheets; mineral wools, structured as mats; and expanded clay as loose material. All these materials do not have a definite structure of their own, since they do not have an appreciable mechanical strength in the case of synthetic insulating materials, are constituted by filament-like mats in the case of mineral wools, and are granular in the case of expanded clays. In addition to this, synthetic insulation materials and mineral wools are materials that have toxicity problems and are scarcely fire-resistant. As an alternative to these materials, materials such as cellular glass have been provided which, in addition to having good thermal and acoustic insulation characteristics, has good fire resistance and high mechanical strength and therefore can be shaped into sheets and/or panels. Products of this kind, and a method for manufacturing them, are disclosed for example in EP-480,929 and in US-3 ,945,816. However, these cellular glasses have the drawback of requiring a very expensive production process, which affects the cost of the finished product, limiting its diffusion and marketability. Disclosure of the Invention The aim of the present invention is to provide a microcellular ceramic material obtained by means of a production process that allows to utilize highly competitive innovative solutions. Within this aim, an object of the present invention is to provide a product by means of low-cost raw materials that are easily commercially available. Another object is to provide a material that has good thermal and acoustic insulation characteristics and high fire resistance. Another object is to provide a material that allows to manufacture products that have good mechanical strength characteristics. A further object is to provide products that have high-level aesthetic characteristics and are particularly suitable for use in building. This aim and these and other objects that will become better apparent hereinafter are achieved by a microcellular ceramic material, characterized in that it is obtained by using, as a basic product, sludge from the facing of porcelain stoneware, which is a waste of the ceramic tile sector, mixed with clayey plastic material, having the following chemical composition:
Figure imgf000003_0001
The method used consists in grinding the raw material or the porcelain stoneware facing sludge mixed with clayey plastic material and fluxes, until a fine particle size is obtained; in granulating or atomizing the mixture; in pressing or filling containment trays; in firing in a continuous kiln at a temperature comprised between 900 and 1250° C, with a firing cycle comprised between 30 and 180 minutes. The resulting product is a panel that is characterized by high thermal, acoustic and mechanical strength and by an aesthetically valid finishing surface that can be further finished by depositing, before firing, one or more layers of material prepared for aesthetic purposes. Further characteristics and advantages of the invention will become better apparent from the following detailed description of the material and of the method, given by way of non-limiting example in order to explain the characteristics and advantages of the invention. Ways of carrying out the Invention The sludges that originate from the facing of porcelain stoneware contain, as their main ingredient, the fragments that originate from the surface layers of the faced tiles, approximately 80% dried sludge, and as a smaller fraction fragments of the abrasive grinding wheel, equal to 20% of the dried sludge. The material that constitutes the abrasive grinding wheel is a mixture of magnesium cement and silicon carbide in a fine powder of controlled particle size. The facing sludge, which contains large amounts of water, is subjected to filter pressing (thus reducing the water content to 20-40% by weight) and then dried if required. Chemical analysis of the facing sludges, expressed as a percentage over the material dried at 105° C, is given in the following table:
Figure imgf000004_0001
The mixture is prepared by appropriately mixing and homogenizing three fundamental types of raw material: clayey plastic material; facing sludges; fluxes. The mixture is then finally ground down to a particle size of less than 50 μm and is granulated or atomized to particle sizes comprised between 100 and 500 μm. After this treatment, the production process has two alternative methods of embodiment: a. traditional pressing of the mixture, in a manner similar to the production of conventional tiles, deposition on layers of refractory r, material, drying and firing of the product; b. filling of refractory trays for containment and subsequent firing. The finishing surface is produced before firing, by depositing a plurality of layers of granulated material containing coloring oxides, distributed so as to provide various geometries and aesthetic solutions. As regards the thermal treatments, firing gradients in a continuous industrial kiln with temperatures between 900 and 1250° C and cycles between 30 and 180 minutes are used. Dry and wet grinding and cutting techniques are used during finishing. By means of the described material, it is possible to provide thermally insulating panels for external cladding. Said panels have considerable thermal insulation characteristics and a surface that makes them suitable to be used as a finishing cladding with excellent aesthetic characteristics. Likewise, it is possible to provide thermally insulating panels for internal claddings and for false ceilings. In view of their considerable mechanical strength and shape stability, it is also possible to provide supporting structural panels for partitions and modules for prefabricated internal or external walls. Excellent results are also achieved in applications such as sound- absorbing barriers and thermal and acoustic insulations for ovens and refrigeration chambers. Panels of the described type can be used advantageously in providing fire doors and barriers and in any application where a lightweight material with high-level characteristics of thermal insulation, fire protection and acoustic insulation is required. From what has been described and illustrated, it is evident that the intended aim and all the objects have been achieved, and that in particular a ceramic material has been provided which allows to obtain panels that have high-level thermal and acoustic insulation characteristics as well as excellent mechanical characteristics, starting from waste materials and with a low-cost method. It is of course possible to use different raw materials that have, however, equivalent characteristics by starting from the same inventive concept, and the panels may have different shapes, dimensions and finishes. The disclosures in Italian Patent Application No. PD2003A000266 from which this application claims priority are incorporated herein by reference.

Claims

CLAIMS 1. A microcellular ceramic material, characterized in that it has a composition that is the result of the combination of at least:
— clayey plastic material (clay); ~ porcelain stoneware facing sludges;
~ fluxes.
2. The microcellular ceramic material according to claim 1, characterized in that it has a composition that is the result of the combination of at least:
~ clayey plastic material (clay): 10÷60%;
~ porcelain stoneware facing sludges: 10÷80%;
~ fluxes: 10÷70%.
3. The microcellular ceramic material according to claim 1, characterized in that it has a composition that is the result also of the combination of at least: glass waste, waste from stoneworking, foundry waste, or equivalents, alone or in combination.
4. The ceramic material according to claim 1, characterized in that it has the following chemical formulation:
Figure imgf000007_0001
5. The ceramic material according to claim 1, characterized in that said porcelain stoneware facing sludges have the following chemical formulation:
Figure imgf000008_0001
6. The ceramic material according to claims 1 and 5, characterized by the use of porcelain stoneware facing sludges.
7. The ceramic material according to claims 1 and 3, characterized by the use of glass waste, stoneworking waste, foundry waste, or equivalents, alone or in combination.
8. A method for providing a ceramic material according to claim 1, characterized in that it comprises the following operating steps: grinding the raw material, i.e., the porcelain stoneware facing sludges mixed with clayey plastic materials and fluxes, until a fine particle size is achieved; granulating or atomizing the mixture; pressing or filling containment trays; firing in a continuous kiln at a temperature comprised between 900 and 1250° C, with a firing cycle comprised between 30 and 180 minutes.
9. The method according to claim 8, characterized in that said facing sludges are filter pressed beforehand, until a water content comprised between 20 and 40% by weight is obtained.
10. The method according to claim 8, characterized in that the mixture is finally ground down to a particle size of less than 50 μm.
11. The method according to claim 8, characterized in that after grinding, the mixture is atomized down to a particle size comprised between 100 and 500 μm.
12. The method according to claim 8, characterized in that said mixture is pressed, by way of a method similar to the one used to produce traditional tiles, by deposition on sheets of refractory material for firing or directly on the rollers of a kiln.
13. The method according to claim 8, characterized in that said mixture is deposited inside trays made of refractory material before being fired.
14. The method according to claim 8, characterized in that one or more coating layers containing colored oxides is deposited on the pressed mixture or on the mixture deposited in refractory trays.
15. The method according to claims 8 and 14, characterized in that said coating oxide layers are treated superficially so as to provide designs or aesthetic geometries.
16. A product obtained with the ceramic material according to claims 1 to 7 and with the method according to claims 8 to 15, characterized in that it is a thermally insulating panel for external cladding.
17. A product obtained with the ceramic material according to claims 1 to 7 and with the method according to claims 8 to 15, characterized in that it is a false ceiling panel.
18. A product obtained with the ceramic material according to claims
1 to 7 and with the method according to claims 8 to 15, characterized in that it is a structural panel for partitions.
19. A product obtained with the ceramic material according to claims 1 to 7 and with the method according to claims 8 to 15, characterized in that it is a module for prefabricated internal or external walls.
20. A product obtained with the ceramic material according to claims 1 to 7 and with the method according to claims 8 to 15, characterized in that it is used to provide panels used in making fire doors and barriers, and in any application requiring a lightweight material with high-level thermal insulation, fire protection and acoustic insulation characteristics.
PCT/EP2004/012018 2003-10-30 2004-10-22 Microcellular ceramic material, method for preparing it, and products obtained with the material and the method WO2005049527A2 (en)

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WO2006049444A1 (en) 2004-11-04 2006-05-11 Lg Chem, Ltd. Super light weight ceramic panel and process for preparing the same
WO2008080371A1 (en) * 2007-01-05 2008-07-10 Karel Palla Use of grinding swarfs of conglomerated stone production as an ingredient of clay raw material for brickware, earthenware and similar ceramic products
ITPD20110104A1 (en) * 2011-04-07 2012-10-08 Cooperativa Ceramica D Imola S C PROCEDURE FOR THE CONSTRUCTION OF CERAMIC SHEETS OF LARGE SIZE
US20140243182A1 (en) * 2012-12-21 2014-08-28 Università di Padova Glass-ceramic composition and method for manufacturing the same
CN107698237A (en) * 2016-12-01 2018-02-16 张晓辉 Silicide additive, silicon protect stone series of plates and its processing technology
CN109232024A (en) * 2018-10-19 2019-01-18 肇庆乐华陶瓷洁具有限公司 A kind of preparation method of multi-functional full space of a whole page dark color ceramic tile
CN116655400A (en) * 2023-08-02 2023-08-29 抖梦空间传媒科技(天津)有限公司 Ceramic product with solid waste as raw material, production process and application thereof

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EP0128966A1 (en) * 1983-06-15 1984-12-27 Georg Dr. Fritsch Process for the disposal of industrial sludges
US5928773A (en) * 1994-02-15 1999-07-27 Vitric Corporation Foamed glass articles and methods of making same and methods of controlling the pH of same within specific limits
US20030075841A1 (en) * 1996-11-30 2003-04-24 Digive Limited Method of making a product

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006049444A1 (en) 2004-11-04 2006-05-11 Lg Chem, Ltd. Super light weight ceramic panel and process for preparing the same
EP1807260A1 (en) * 2004-11-04 2007-07-18 LG Chem, Ltd. Super light weight ceramic panel and process for preparing the same
EP1807260A4 (en) * 2004-11-04 2010-06-23 Lg Chemical Ltd Super light weight ceramic panel and process for preparing the same
WO2008080371A1 (en) * 2007-01-05 2008-07-10 Karel Palla Use of grinding swarfs of conglomerated stone production as an ingredient of clay raw material for brickware, earthenware and similar ceramic products
CZ302929B6 (en) * 2007-01-05 2012-01-18 Palla@Karel Use of grinding swarfs of conglomerated stone production as an ingredient of clay raw material for brickware, earthenware and similar ceramic products
ITPD20110104A1 (en) * 2011-04-07 2012-10-08 Cooperativa Ceramica D Imola S C PROCEDURE FOR THE CONSTRUCTION OF CERAMIC SHEETS OF LARGE SIZE
WO2012137066A1 (en) * 2011-04-07 2012-10-11 Cooperativa Ceramica D'imola S.C. Method for providing large sized ceramic slabs
US20140243182A1 (en) * 2012-12-21 2014-08-28 Università di Padova Glass-ceramic composition and method for manufacturing the same
CN107698237A (en) * 2016-12-01 2018-02-16 张晓辉 Silicide additive, silicon protect stone series of plates and its processing technology
CN109232024A (en) * 2018-10-19 2019-01-18 肇庆乐华陶瓷洁具有限公司 A kind of preparation method of multi-functional full space of a whole page dark color ceramic tile
CN109232024B (en) * 2018-10-19 2021-07-30 肇庆乐华陶瓷洁具有限公司 Preparation method of multifunctional full-plate-surface dark-color ceramic tile
CN116655400A (en) * 2023-08-02 2023-08-29 抖梦空间传媒科技(天津)有限公司 Ceramic product with solid waste as raw material, production process and application thereof

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