Process for fast-fire ceramic tile using nepheline syenite and clay

Abstract

Abstract COMPOSITION AND PROCESS FOR MANUFACTURING FAST-FIRE CERAMIC TILE, PARTICULARLY LARGE-SIZED FLOOR AND WALL TILES OF 1/4" TO 1'' X 12" X 12" DIMENSIONS OR LARGER, COMPRISE A SYSTEM IN WHICH THE FUNCTION USUALLY PERFORMED BY THE CLAY INGREDIENT, AS THE PLASTICIZER AND BINDER IN THE FIRED WARE IN USUAL CERAMIC-FORMING COMPOSITIONS, IS PERFORMED INSTEAD BY A FUSIBLE MATERIAL, NEPHELINE SYENITE, WHICH SERVES ALSO AS THE GROG INGREDIENT IN THE PRE-FIRED STAGES, AND IN WHICH SYSTEM THE CLAY, REVERSELY, PERFORMS THE USUAL SKELETON-FORMING FUNCTION OF THE GROG IN THE FIRED WARE. THE TITLE BODY MAKING COMPOSITION CONSISTS ESSENTIALLY BY WEIGHT OF 20 TO 80% OF NEPHELINE SYENITE AND FROM 80 TO 20% OF A CLAY WHOSE INCIPIENT FUSION POINT IS SUBSTANTIALLY ABOVE THAT OF THE NEPHELINE SYENITE AND WHICH CONTAINS LESS THAN 15%, AND PREFERABLY LESS THAN 5%, BY WEIGHT OF FREE QUARTZ.THE COMPOSITION IS ESSENTIAL FOR MAKING SEMI-VITREOUS, NON-GLAZED OR GLAZED, TITLE PRODUCTS UNUSUALLY FREE OF STRUCTURAL DEFECTS, SUCH AS CRACKING, WARPAGE AND POOR DIMENSIONAL UNIFORMITY, BY MEANS OF A NOVEL FAST-FIRE PROCESS IN WHICH THE TILES ARE FIRED IN THE TEMPERATURE RANGE OF ABOUT 1800 TO 2200* F. FROM THEIR GREENWARE STATE TO MATURED, FIRED PRODUCTS IN FROM ABOUT ONE TO THREE HOURS.

Inventors

• 👤 John Everhart
• 👤 John Lawson Felder

Bibliographic Details