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Ishikawa et al.
(54)
(30)
Publication Classi?cation
(52)
(57)
Correspondence Address:
HELLER EHRMAN WHITE & MCAULIFFE
LLP
(2006.01)
(2006.01)
ABSTRACT
10/528,099
PCT/JP03/12371
mixture.
US 2006/0057846 A1
FIG.3
US 2006/0057846 A1
US 2006/0057846 A1
[0001]
[0010]
1 to 15 pm on a number basis.
[0013]
body;
?uid. Next, the raW material, to Which Water has been added,
slurry;
casting.
[0005]
of a solid.
tive Example 2;
[0007]
[0026] De?nition
[0027] The term Water content as used herein refers to
the fraction of the amount of Water in the total Weight of the
folloWing equation:
Z=[(WWD)/WD]><1OO
Wherein
US 2006/0057846 A1
tion analyZer.
[0032] In the present invention, the expression 50%
average particle diameter on a Weight basis refers to the
[0037]
the case Where raW materials for a sanitary Ware body such
as pottery stone, feldspar, and clay are stored as they are, the
Ingredients
Preferred range
Pottery stone:
35 to 70 Wt %
50 to 55 Wt %
(kaolin, sericite,
pyrophyllite, etc.)
10 to 40 Wt %
20 to 30 Wt %
10 to 50 Wt %
20 to 25 Wt %
Flux:
(albite, potash
feldspar, nepheline,
petalite, dolomite,
etc.)
Clay:
[0040]
US 2006/0057846 A1
60% by Weight.
[0048] In a preferred embodiment of the present invention,
in adding Water, for example, a soluble salt may be further
added as a de?occulant. This can modify the viscosity of the
[0049]
Z 8815 (1994).
[0046]
[0052]
by Weight.
[0055] In another preferred embodiment of the present
invention, the slurry can be dehydrated to give a pressed
cake having a reduced Water content of 20 to 30% by Weight,
Which is still ?uid, folloWed by drying to give a composition
having a Water content of 0 (Zero) to 9% by Weight, more
preferably 3 to 7% by Weight.
[0056] In another preferred embodiment of the present
invention, a method may also be adopted Wherein the slurry
US 2006/0057846 A1
casting.
[0059]
raW material for a sanitary Ware and thus loWer the melting
[0064]
[0065]
at least one material selected from china clay, ball clay, and
plastic clay may be used as the additional raW material
poWder. These raW material poWders function mainly to
control the amount of casting at the time of slip casting and
to control plasticity at the time of shaping. These additional
raW material poWders may also be added for viscosity
modi?cation purposes at the time of slurrying. Accordingly,
the addition of these raW material poWders to the regener
[0062]
tion. Although the reason for this has not been fully eluci
dated yet, one of the reasons for this phenomenon is believed
to reside in that a small amount of the soluble salt originally
contained in the raW material for a sanitary Ware body is lost
[0068]
body should be suitable for the shape and type. The thick
ness of casting body at the time of slip casting can be
regulated to a proper level depending upon the type and
shape of the sanitary Ware by adding the additional raW
material poWder. In particular, in the case of sanitary Wares,
[0063]
[0069]
US 2006/0057846 A1
[0070]
Comparative EXample 2
poWder such as china clay, ball clay, and plastic clay is added
to the slurry.
[0080]
sanitary Ware.
Comparative Example 1
[0073]
ing pottery stone, feldspar, clay and the like Was provided.
This raW material for a sanitary Ware body (800 kg), 260 kg
of Water, 1 kg of sodium silicate, and 720 kg of grinding
balls Were placed in a 1-t cylinder, and the mixture Was ball
milled for about 20 hr to prepare slurry A of the raW material
inspection.
[0081] Further, for each of the 10 samples, the height of
the green body immediately after the slip casting Was
compared With the height of the ?red product to calculate the
percentage shrinkage. As a result, the average of the per
centage shrinkages Was 12.4%. The length c shoWn in FIG.
2 Was measured as the height.
EXample 1
[0074]
of the poWder of the raW material for the body. The Water
content of the composition Was measured and found to be
US 2006/0057846 A1
Example 3
number basis.
Example 2
of the poWder of the raW material for the body. The Water
content of the composition Was measured and found to be
to be 2.3 mm.
slurry for slip casting using the composition after the spray
drying.
[0090]
Example 4
pm on a number basis.
US 2006/0057846 A1
to be 2.2 mm.
Example 6
[0112]
number basis.
of the raW material for the body. The Water content of the
Example 5
obtain the slurry for slip casting using the composition after
the spray drying.
[0114]
of the poWder of the raW material for the body. The Water
content of the composition Was measured and found to be
7.0% by Weight. The 50% average particle diameter on a
Weight basis of the composition Was measured by a dry
number basis.
to be 2.1 mm.
[0116]
The green body thus obtained Was dried and Was then
slurry for slip casting using the poWder after the spray
drying.
[0117]
[0108]
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[0119] Example 7
[0120] China clay (200 kg), 50 kg of gairome clay, and 50
RESULTS
Comp. Ex. 1
Water content of composition
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
5.5%
7.0%
21.0%
7.0%
7.0%
30 hr
30 min
30 min
50 min
35 min
35 min
55.3%
8.3 ,um
54.8%
8.4 [urn
55.7%
8.2 ,um
56.2%
8.0 [urn
55.0%
8.0 ,um
55.7%
8.2 ,um
460 mPa - s
Properties of slurry
Particle diameter < 10 [um
50% average particle diameter
Viscosity
460 mPa - s
620 mPa - s
588 mPa - s
500 mPa - s
540 mPa - s
Firing time
24 hr
24 hr
24 hr
24 hr
24 hr
24 hr
Firing shrinkage
11.5%
11.2%
11.3%
11.0%
12.2%
11.4%
[0127]
60 min Was taken to obtain the slurry for slip casting using
the composition after the spray drying.
[0121]
number basis.
[0123]
TABLE 2
Comp. Ex. 2
Ex. 6
Ex. 7
4.5%
4.5%
30 hr
55 min
60 min
55.3%
53.6%
54.9%
8.3 ,um
8.6 [urn
8.2 ,um
598 mPa - s
The green body thus obtained Was dried and Was then
Water content of
[0124]
composition
Properties of slurry
Particle diameter <
10 [um
50% average particle
diameter
460 mPa - s
484 mPa - s
Firing time
Viscosity
24 hr
24 hr
24 hr
Firing shrinkage
12.4%
11.3%
12.2%
Dimensional inspection
Passed
Passed
Passed
[0129]
inspection.
[0125]
US 2006/0057846 A1
taking the resultant green body out of the mold; drying the
green body;
coating glaZe onto the dried green body; and ?ring the
slip casting.
Weight.
nepheline.
16. The process according to claim 14, Wherein said
additional raW material poWder is at least one material
Weight.