WO2018217180A2 - Ceramic composition - Google Patents

Ceramic composition Download PDF

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Publication number
WO2018217180A2
WO2018217180A2 PCT/TR2017/050493 TR2017050493W WO2018217180A2 WO 2018217180 A2 WO2018217180 A2 WO 2018217180A2 TR 2017050493 W TR2017050493 W TR 2017050493W WO 2018217180 A2 WO2018217180 A2 WO 2018217180A2
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Prior art keywords
composition
ceramic
ceramic composition
strength
deformation
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PCT/TR2017/050493
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French (fr)
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WO2018217180A3 (en
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Sefik Baran TARHAN
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Kaleseramik Canakkale Kalebodur Seramik Sanayi Anonim Sirketi
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Publication of WO2018217180A3 publication Critical patent/WO2018217180A3/en

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    • C04B33/00Clay-wares
    • C04B33/32Burning methods
    • C04B33/34Burning methods combined with glazing
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16Shaped 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
    • C04B35/18Shaped 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
    • C04B35/185Mullite 3Al2O3-2SiO2
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    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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    • C04B2235/3418Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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    • C04B2235/3427Silicates other than clay, e.g. water glass
    • C04B2235/3463Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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    • C04B2235/9607Thermal properties, e.g. thermal expansion coefficient
    • C04B2235/9615Linear firing shrinkage

Definitions

  • the invention is related to a ceramic composition.
  • the invention is specifically related to a ceramic composition that has a water absorption rate above 0.5%,that is forty percent lighter than the similar ceramic compositions having the same volume, that has high strength and that has a low deformation rate.
  • Ceramic is a building material that is preferred in many areas since its melting point is high, it is harder than traditional products, it is resistant to corrosion and it can be easily accessed. Ceramic is an inorganic material that comprises a plurality of components. Some of its properties and its structure change depending on the proportion of the components. Ceramic is usually used in vitrified products. It's most common applications are sinks, bathroom utilities and floor tiles. The main reason why it is preferred in these areas is that its water absorption rate is less than the alternatives and its successful at staying clean. Ceramic gains some of these properties by glazing. Glazing is the glassification of the ceramic as a result of being fired at high temperatures.
  • the formula of the said invention having absorption value lower than 0.5% is given as (component ratio by weight) S1O2 42-59%, AI2O3 35 - 52%, Na2O 0,5-2%, K2O 0,5-2%, T1O2 0,5-4%, UO2 ⁇ 2%, CaO ⁇ 4%, MgO ⁇ 4%, Fe 2 O 3 ⁇ 4%.
  • the formula of the said invention having absorption value higher than 0.5% is given as (component ratio by weight) S1O2 50 - 65%, AI2O3 30 - 50%, Na2O 0,5 - 2%, K2O 0,5 - 2%, MgO or CaO 0.5 - 4%, T1O2 0,5 - 2%, LiO 2 ⁇ 2%, ZrO 2 Fe 2 O 3 ⁇ 4%.
  • the formula of the said invention is given as (component ratio by weight) SiO2 18-35%, AI2O3 54-76%, Na 2 O 0,5-2%, K2O 0,5-2%, T1O2 0- 4%, U2O 0-7%, CaO 0-1 %, MgO 0-5%, Fe 2 O 3 0-2%, B2O3 0-6%, BaO 0-4%.
  • composition in the invention is given as (component ratio by weight) AI2O3 45-60%, S1O2 24-33%, B2O3 2,4-3,3%, Na 2 O 1 ,2-1 ,65%, K2O 0,8-1 ,1 %, CaO 3,2-4,4%, MgO 1 ,2-1 ,65%, PbO 7,2-9,9%.
  • a slip composition prescription to be used in ceramic sanitary devices is mentioned and the materials used in the invention are 3-1 1 % feldspar, 6-16% quartz, 25-30% clay, 25-35% kaolin, 15-20% alumina and 2-8% wollastonite.
  • the water absorption value is ⁇ 4% and dry strength is 30-40 kg/cm 2 and the fired strength is 900-1000 kg/cm 2 .
  • the invention is related to a ceramic composition that enables production of products that are lighter, that have improved strength and lower deformation rate, that are thinner and longer.
  • the strength of the composition is increased by decreasing the amount of aluminum oxide and silicon oxide with respect to the known state of the art.
  • the present invention is related to a ceramic composition that is forty percent lighter than similar ceramic compositions having the same volume, that has high strength and a low deformation rate in order to eliminate the above mentioned disadvantages and that brings new advantages to the related technical field.
  • the main object of the invention is to enable production of thinner and lighter ceramic based products.
  • the present invention is a ceramic composition. Accordingly, it comprises;
  • Table 1 shows the range of component ratios of the ceramic composition relative to the total weight.
  • Table 2 shows the ratios of the components of an exemplary ceramic composition relative to the total weight.
  • the invention is related to a ceramic composition that has a water absorption rate above 0.5%, that is approximately forty percent lighter than other similar ceramic compositions having the same volume, and that has high strength and a low deformation rate.
  • AI2O3 ratio is held between 30-49,9%. According to the Hooke's Law, as the Young's Modulus increases the tensile stress required to stretch the material also increases.
  • tensile stress
  • E Young's modulus
  • strain
  • Young's modulus for AI2O3 is 360 GPa. Since the Young's modulus of AI2O3 is higher than other components, as AI2O3 ratio increases the tensile stress and strength of which the composition resists increases as well.
  • Mullite is a crystal structure comprising 3AI2O32S1O2 that is found in the ceramic composition. As the mullite crystals form, the strength of the composition increases. Thus, along with the mullite compound that is formed as the ratio of AI2O3 increases, a stronger composition is obtained.
  • Quartz may comprise of very pure S1O2. As the temperature increases, cracks form around the quartz due to the differences in the thermal expansion coefficients. Said cracks increase tendency towards fracture. In the composition, quartz phase transformation is decreased by lowering the S1O2 ratio and accordingly the loss of strength is minimized.
  • feldspar minerals are used as fluxes to perform the melting operation.
  • Said feldspar minerals are albite and orthoclase.
  • the formula of the albite is NaAISisOs and the formula of the orthoclase is KAIS13O8.
  • the ratio of Na20 is decreased and the ratio of K2O is increased by decreasing the ratio of the albite and increasing the ratio of the orthoclase.
  • K2O is increased, the permanent deformations at high temperatures named as pyroplastic deformation are decreased. Pyroplastic deformation makes it harder to produce long and thin ceramic tools. As the length of the work piece increases, the probability of deformation also increases.
  • the ratio of components used in the composition has made the strength, shrinkage and deformation values approach the ideal level.
  • the ratio of the components of the exemplary composition relative to total weight is as given in Table 2.
  • the raw materials used for creating the ceramic composition are first dissolved in water by using fast mixers.
  • the residue of the sieve must be maximum 3% for 63 microns.
  • the prepared slip is left to rest for 3 days after being passed through a 120-micron sieve.
  • the casting operation is performed by pouring the slip into a plaster or resin mold. After the casting process, the product is placed into a dryer and the dried products are glazed and fired at 1 200°C- 1300°C.
  • Strength measurement is carried out according to a 3-point bending test.
  • the prepared slip is poured into a plaster mold having the dimensions 12x2x1 ,5 cm.
  • One day later the molds are opened and under normal conditions they are dried at 1 1 0°C for 1 more day in a drying oven.
  • the dried products are fired in a process kiln and its strength is tested by a 3-point bending test.
  • the 3-point bending test determines the maximum bending load that can be resisted when said load is applied by a component such as a piston or the like to a material positioned between 2 supports.
  • the strength is determined as 790 kg/cm 2 as the result of the test.
  • the water absorption test is performed according to TS EN 997:2012. In said test, 3 parts of composition of which one side is glazed and the other side is not, that have a surface area of 30 cm 2 is left in a drying oven for 180 minutes at 1 00°C and cooled in a desiccator. Following this, the measurements are performed in a measurement device with 0.05 gr precision. Afterwards, the composition is left in boiling water for 120 minutes and left in the same water for 20 more hours after the boiling ends. Finally, the measurements are again performed in a measurement device with 0.05 gr precision. The water absorption percentage is found by dividing the difference between the last and the first measurements by one hundred. Accordingly, when said composition is subjected to the water absorption test, 0.60% value is obtained.
  • Another test performed on the composition is the deformation test.
  • the slip formed from said composition is poured into bar shaped plaster molds and left to wait for 3 hours. After 3 hours, the plaster molds are opened and the deformation samples are dried in a drying oven for a day at 100°C. The dried material is compressed between two supports such that a certain part of it protrudes therefrom. It is fired at 1220°C for 16 hours. After this time, the change in deformation on the material is measured. The sample compositions exhibited 15 mm change when subjected to the deformation test. In standard vitrified products, this value goes up to 35 mm.
  • Another test performed on the composition is the firing shrinkage test. Said test determines the linear shrinkage rate of the material after firing with respect to the pre-fired condition. It is determined that the sample composition has shrunk 10.1 % when compared to the first length after being subjected to the said water shrinkage test.

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
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Abstract

The invention is related to a ceramic composition that enables production of ceramics that are resistant to deformation, that have high strength value and that are thin and light and it is also related to the component ratios in the composition.

Description

DESCRIPTION
CERAMIC COMPOSITION TECHNICAL FIELD
The invention is related to a ceramic composition.
The invention is specifically related to a ceramic composition that has a water absorption rate above 0.5%,that is forty percent lighter than the similar ceramic compositions having the same volume, that has high strength and that has a low deformation rate.
PRIOR ART
Ceramic is a building material that is preferred in many areas since its melting point is high, it is harder than traditional products, it is resistant to corrosion and it can be easily accessed. Ceramic is an inorganic material that comprises a plurality of components. Some of its properties and its structure change depending on the proportion of the components. Ceramic is usually used in vitrified products. It's most common applications are sinks, bathroom utilities and floor tiles. The main reason why it is preferred in these areas is that its water absorption rate is less than the alternatives and its successful at staying clean. Ceramic gains some of these properties by glazing. Glazing is the glassification of the ceramic as a result of being fired at high temperatures.
The most important disadvantage of working with ceramic is that its strength gets lower as its dimension gets larger and the deformation caused by firing increases Due to problems caused by decreasing strength of the ceramic, the products produced from ceramic are produced to be thicker and thus heavier. The ceramics that is produced to be thicker narrows the working field of the designers. The products having the desired designs are prevented. Besides, increasing the amount of raw materials reflects on the costs of production negatively.
In the German Patent and Trademark Office document with application Numbered DE1 0145537, a ceramic composition that comprises silicon dioxide, aluminum oxide and potassium oxide which is used in sanitary and other small items is mentioned. The invention is given in two separate compositions as having a water absorption rate below 0.5% and above 0.5%. In these studies, the strength and impact test results are given, but the test results for cure temperature deformation are not given. In order to produce thinner products, lack of this value is a disadvantage. The formula of the said invention having absorption value lower than 0.5% is given as (component ratio by weight) S1O2 42-59%, AI2O3 35 - 52%, Na2O 0,5-2%, K2O 0,5-2%, T1O2 0,5-4%, UO2≤ 2%, CaO≤ 4%, MgO < 4%, Fe2O3≤ 4%. The formula of the said invention having absorption value higher than 0.5% is given as (component ratio by weight) S1O2 50 - 65%, AI2O3 30 - 50%, Na2O 0,5 - 2%, K2O 0,5 - 2%, MgO or CaO 0.5 - 4%, T1O2 0,5 - 2%, LiO2< 2%, ZrO2 Fe2O3≤ 4%.
In the World Intellectual Property Organization (WIPO) document with application Numbered WO20141 39993, a ceramic material is mentioned. In order to obtain an amorphous phase in the ceramic compositions, the fluxes are melted with S1O2 at high temperatures and fritted by being poured into cold water. After being ground, the fritted composition is added into the slip and slip casting operation is started to produce porous ceramic. The formula of the said invention is given as (component ratio by weight) SiO2 18-35%, AI2O3 54-76%, Na2O 0,5-2%, K2O 0,5-2%, T1O2 0- 4%, U2O 0-7%, CaO 0-1 %, MgO 0-5%, Fe2O3 0-2%, B2O3 0-6%, BaO 0-4%.
In the document with application Number EP0332457, multi-layered ceramic sublayers and a method for production thereof is mentioned. The formula of the composition in the invention is given as (component ratio by weight) AI2O3 45-60%, S1O2 24-33%, B2O3 2,4-3,3%, Na2O 1 ,2-1 ,65%, K2O 0,8-1 ,1 %, CaO 3,2-4,4%, MgO 1 ,2-1 ,65%, PbO 7,2-9,9%.
In the Turkish Patent Office document with application Number TR 2014/1 5838, a slip composition prescription to be used in ceramic sanitary devices is mentioned and the materials used in the invention are 3-1 1 % feldspar, 6-16% quartz, 25-30% clay, 25-35% kaolin, 15-20% alumina and 2-8% wollastonite. In the invention that is directed towards lowering firing temperatures of the products and increasing the strength, the water absorption value is < 4% and dry strength is 30-40 kg/cm2 and the fired strength is 900-1000 kg/cm2.
As a result, all of the abovementioned problems make it necessary to bring a novelty to the related field. BRIEF DESCRIPTION OF THE INVENTION
The invention is related to a ceramic composition that enables production of products that are lighter, that have improved strength and lower deformation rate, that are thinner and longer. In this invention, the strength of the composition is increased by decreasing the amount of aluminum oxide and silicon oxide with respect to the known state of the art. By changing the ratio and type of the flux feldspar and decreasing the MgO and CaO ratios, the pyroplastic based problems are minimized through decreasing the high temperature viscosity.
OBJECTS OF THE INVENTION
The present invention is related to a ceramic composition that is forty percent lighter than similar ceramic compositions having the same volume, that has high strength and a low deformation rate in order to eliminate the above mentioned disadvantages and that brings new advantages to the related technical field.
The main object of the invention is to enable production of thinner and lighter ceramic based products.
Another object of the invention is to prevent deformation due to the decreasing viscosity of the amorphous phase that occurs at high temperatures. Yet another object of the invention is to decrease the costs by providing a ceramic composition structure that is lighter in comparison to other same sized sinks and that can reach higher impact resistance values. In order to achieve the abovementioned objects that will be apparent from the detailed description given below, the present invention is a ceramic composition. Accordingly, it comprises;
• S1O2 35 - 49,9%, Silicon dioxide or silica
· AI2O3 30 - 49,9%, aluminum (III) oxide or alumina
• Na20 0 - 0,1 %, sodiumoxide
• K2O 2 - 10%, potassiumoxide
• T1O2 0 - 2%, titaniumoxide
• L12O 0 - 2%, lithiumoxide
· CaO 0 - 0,5%, calciumoxide
• MgO 0 - 0,5%, magnesiumoxide
• Fe203 0 - 3%, iron(lll)oxide
• B2O3 0 - 2,4%, bortrioxide
• BaO 0 - 2%, bariumoxide at the ratios given above. Thus, it is enabled to produce ceramic that has a water absorption value above 0.5 percent, that is resistant to deformation and that has high strength value, and that is thinner and lighter. DESCRIPTION OF THE TABLES
Table 1 shows the range of component ratios of the ceramic composition relative to the total weight. Table 2 shows the ratios of the components of an exemplary ceramic composition relative to the total weight. DETAILED DESCRIPTION OF THE INVENTION
In this detailed description, a ceramic composition of the invention is described through non-limiting examples to provide a better understanding of the matter.
The invention is related to a ceramic composition that has a water absorption rate above 0.5%, that is approximately forty percent lighter than other similar ceramic compositions having the same volume, and that has high strength and a low deformation rate.
In Table 1 , the component ratio ranges of the ceramic composition of the invention are given relative to the total weight.
Figure imgf000006_0001
As seen in the formula provided above, AI2O3 ratio is held between 30-49,9%. According to the Hooke's Law, as the Young's Modulus increases the tensile stress required to stretch the material also increases.
In the Hooke Elasticity Law, σ= E x ε formula is given. In this formula, σ is tensile stress, E is Young's modulus and ε is strain. Young's modulus for AI2O3 is 360 GPa. Since the Young's modulus of AI2O3 is higher than other components, as AI2O3 ratio increases the tensile stress and strength of which the composition resists increases as well. Mullite is a crystal structure comprising 3AI2O32S1O2 that is found in the ceramic composition. As the mullite crystals form, the strength of the composition increases. Thus, along with the mullite compound that is formed as the ratio of AI2O3 increases, a stronger composition is obtained.
During firing of the ceramic composition, a part of the quartz already in the composition passes onto the amorphous phase and a part of crystal quartz stay in the final product, depending on the composition. Quartz may comprise of very pure S1O2. As the temperature increases, cracks form around the quartz due to the differences in the thermal expansion coefficients. Said cracks increase tendency towards fracture. In the composition, quartz phase transformation is decreased by lowering the S1O2 ratio and accordingly the loss of strength is minimized.
In the compositions of the invention, feldspar minerals are used as fluxes to perform the melting operation. Said feldspar minerals are albite and orthoclase. The formula of the albite is NaAISisOs and the formula of the orthoclase is KAIS13O8. In the composition, the ratio of Na20 is decreased and the ratio of K2O is increased by decreasing the ratio of the albite and increasing the ratio of the orthoclase. As K2O is increased, the permanent deformations at high temperatures named as pyroplastic deformation are decreased. Pyroplastic deformation makes it harder to produce long and thin ceramic tools. As the length of the work piece increases, the probability of deformation also increases.
One of the main reasons of pyroplastic deformation is the low viscosity of the amorphous phase formed at high temperatures. Alkaline earth oxidizes lower the viscosity of the composition rapidly. In the invention, rapid decreasing of the viscosity value in the amorphous phase is prevented by keeping the amount of CaO and MgO alkaline oxidizers as low as possible. Thus, high temperature viscosity is increased. Said amount of CaO and MgO is less than 0.5 percent with respect to the total weight.
The results obtained in the tests performed on the composition of the invention are as follows;
Water absorption rate 0,5-3,5 %
Fired shrinkage value 9,5-1 0,5 %
Strength: 600-810 kg/cm2
Single support deformation value: 1 3-21 mm.
According to test results, the ratio of components used in the composition has made the strength, shrinkage and deformation values approach the ideal level.
EXAMPLE 1
The ratio of the components of the exemplary composition relative to total weight is as given in Table 2.
Figure imgf000008_0001
Table 2
The raw materials used for creating the ceramic composition are first dissolved in water by using fast mixers. The residue of the sieve must be maximum 3% for 63 microns. The prepared slip is left to rest for 3 days after being passed through a 120-micron sieve. After the slip has rested, the casting operation is performed by pouring the slip into a plaster or resin mold. After the casting process, the product is placed into a dryer and the dried products are glazed and fired at 1 200°C- 1300°C.
Strength measurement is carried out according to a 3-point bending test. The prepared slip is poured into a plaster mold having the dimensions 12x2x1 ,5 cm. One day later the molds are opened and under normal conditions they are dried at 1 1 0°C for 1 more day in a drying oven. The dried products are fired in a process kiln and its strength is tested by a 3-point bending test. The 3-point bending test determines the maximum bending load that can be resisted when said load is applied by a component such as a piston or the like to a material positioned between 2 supports. The strength is determined as 790 kg/cm2 as the result of the test.
Another test performed on the composition is the water absorption test. The water absorption test is performed according to TS EN 997:2012. In said test, 3 parts of composition of which one side is glazed and the other side is not, that have a surface area of 30 cm2 is left in a drying oven for 180 minutes at 1 00°C and cooled in a desiccator. Following this, the measurements are performed in a measurement device with 0.05 gr precision. Afterwards, the composition is left in boiling water for 120 minutes and left in the same water for 20 more hours after the boiling ends. Finally, the measurements are again performed in a measurement device with 0.05 gr precision. The water absorption percentage is found by dividing the difference between the last and the first measurements by one hundred. Accordingly, when said composition is subjected to the water absorption test, 0.60% value is obtained.
Another test performed on the composition is the deformation test. In said test, the slip formed from said composition is poured into bar shaped plaster molds and left to wait for 3 hours. After 3 hours, the plaster molds are opened and the deformation samples are dried in a drying oven for a day at 100°C. The dried material is compressed between two supports such that a certain part of it protrudes therefrom. It is fired at 1220°C for 16 hours. After this time, the change in deformation on the material is measured. The sample compositions exhibited 15 mm change when subjected to the deformation test. In standard vitrified products, this value goes up to 35 mm. Another test performed on the composition is the firing shrinkage test. Said test determines the linear shrinkage rate of the material after firing with respect to the pre-fired condition. It is determined that the sample composition has shrunk 10.1 % when compared to the first length after being subjected to the said water shrinkage test.
The protection scope of the invention is defined in the appended claims and in no way, can it be limited by what is described in this detailed description for illustration. Also, it is apparent that a person skilled in the art can present similar embodiments in the light of what is described above without departing from the main theme of the invention.

Claims

1 . The invention is a ceramic composition that enables production of ceramics that has a water absorption value above 0.5 percent, that has a single support deformation value between 14-23 mm, that has high strength value, that is thin and light, characterized in that comprises,
• Si02 35 - 49,9%,
Figure imgf000011_0001
• Na20 0 - 0,1 %,
Figure imgf000011_0002
• T1O2 0 - 2%,
Figure imgf000011_0003
• CaO 0 - 0,5%,
• MgO 0 - 0,5%
Figure imgf000011_0004
• BaO 0 - 2%
by weight.
2. A ceramic composition according to Claim 1 , characterized in that comprises less than 0.5% MgO by weight in order to prevent the viscosity from decreasing rapidly in the amorphous phase.
3. A ceramic composition according to Claim 1 , characterized in that comprises less than 0.5% CaO by weight in order to prevent the viscosity from decreasing rapidly in the amorphous phase.
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