Abstract: A method of making ceramic articles includes compounding ceramic precursor batch components that include hydrous clay. The hydrous clay includes particle components having a platy geometry. The crystallite size of the platy hydrous clay particle components is greater than a predetermined amount. Controlling such crystallite size can result in reduced shrinkage of green ware during the clay dehydroxylation stage of firing.

Abstract: A method of making ceramic articles includes compounding ceramic precursor batch components that include hydrous clay. The hydrous clay includes particle components having a platy geometry. The crystallite size of the platy hydrous clay particle components is less than a predetermined amount. Controlling such crystallite size can result in fired ceramic articles with a lower coefficient of thermal expansion and improved thermal shock resistance.

Abstract: Cellular ceramic materials, for example closed cell glass ceramic materials, for use in construction of buildings comprising a clay material, carbon, and water used to form the cellular ceramic blocks, slabs and beams by expansion of the particles inside the ware. The cellular ceramic materials are produced by first mixing the clay, carbon and about 40% to about 70% water by weight of the clay in the mixture, allowing the mixture to cure, drying the cured mixture, then firing the dried mixture at a temperature and for a period of time sufficient to melt the surface of the mixture. The clay material can be, for example, surface clays, ball clays, kaolin, shale, fly ash and/or bentonite. In another embodiment a mixture of volcanic ash, carbon and water can be formed and layered with the mixture of clay, carbon and water.

Abstract: A method of making a building block from clay-containing compounds, which includes employing a major amount of such clay-containing material in combination with a calciferous additive and water to cure the shape the same under the influence of controlled pressure and temperature for a pre-determined time to create building block which is characterized by a mineralogical crystalline phase. The clay-containing compound includes a mixture of fine particulate material and coarser particulate material. The product produced by the method is also disclosed.

Abstract: A rotatable turntable tool is used in trimming wheel-thrown pottery. The turntable tool includes a base portion, a bearing member, and a cap portion which is rotatably attached to the base portion. A method of trimming an unfired clay workpiece includes steps of inverting the workpiece and placing it at a central portion of a wheel head on a potter's wheel; placing the turntable tool on top of a central portion of the inverted workpiece; pressing downwardly on the cap portion of the turntable tool while rotating said wheel head to stabilize the workpiece, whereby the base portion of the turntable tool rotates with the workpiece, while the cap portion is substantially restrained from rotating; and applying a trimming tool to an edge of the workpiece to remove unwanted clay therefrom.

Abstract: The present invention relates to a method for producing an artificial lightweight aggregate containing bottom ash. The method includes the steps of: (a) mixing 100 parts by weight of clay and 10-100 parts by weight of bottom ash to obtain a mixture; (b) extrusion-molding the mixture by using an extruder and cutting the extrusion-molded mixture to form a molded article; (c) drying the molded article by using a rotary drier; and (d) sintering the dried article at 1050-1150° C. for 15-45 minutes to produce the artificial lightweight aggregate. The aggregate produced according to the invention is lightweight, cost-effective, and has uniform water absorption.

Abstract: The invention relates to the building material industry and to the use of labor saving tools of industrial continuous and batch brick kilns. Said invention makes it possible to develop a process for producing large-sized clay ceramic products consisting in carrying out rapid and high-quality baking and to accelerate a construction process. The inventive method for producing a clay house or another clay construction consists in forming, during construction, through and blind voids in a wall and a ceiling in such a way that they are closed with a noncombustible material from outside, in covering window and door apertures in the ready clay construction with a noncombustible material, and in baking the construction to a ceramic state in such a way that hot gas penetrates into the voids and that the body of the product is uniformly heated. During baking the construction is used in the form of a furnace (combustion chamber).

Abstract: Provided is a method for making a ceramic clay brick using waste battery powder. Valuables of the waste batteries are separated through a crushing, pyrolysis, pulverizing, and magnetic separation processes. The remaining waste battery powder is processed in order to utilize the remaining waste battery powder as a colorant in a brick making process. Clay powder is added to the processed waste battery powder to make a black-colored, dark red-colored, or dark brown-colored brick according to its contents. According to the present invention, since the waste battery powder mainly including manganese and zinc can be processed into the colorant and mixed with the clay powder to make the black-colored, dark red-colored, or dark brown-colored brick according to its contents, purchase costs MnO2 used as the colorant during the making process of the ceramic brick can be remarkably reduced. In addition, superior bricks can be made at low cost.

Abstract: The present invention provides a fine ?-alumina particle having a degree of ?-transformation of not less than 95%, a BET specific surface area of not less than 10 m2/g, a degree of necking of not more than 30%, and a total content of Si, Fe, Cu, Na and Mg of not more than 500 ppm.

Abstract: Dry compound from clay, quartz sand, starch as binding addition agent is prepared, 20% of water solution of sodium hydroxide is added to it, the obtained mixture is formed and exposed to bake for 1.5 hour under 960-1050 deg. C., at that, the ratio of quartz sand and clay is 2.33:1, and the ratio of dry compound and solution of sodium hydroxide is 6.25:1. Thus, the method is simplified, the obtained bricks have low heat transfer and low gravity, but are solid, cold, heat and chemical-resistant.

Abstract: A method of making a building block from clay-containing compounds, which includes employing a major amount of such clay-containing material in combination with a calciferous additive and water to cure the shape the same under the influence of controlled pressure and temperature for a pre-determined time to create building block which is characterized by a mineralogical crystalline phase. The clay-containing compound includes a mixture of fine particulate material and coarser particulate material. The product produced by the method is also disclosed.

Abstract: This invention relates to a method for manufacturing an artificial ultra-lightweight aggregate having a specific gravity of 0.8-0.9 using raw sewage sludge. According to the invention, raw sewage sludge and water-free waste are mixed into a blend having a water content that allows the optimal extrusion, whereby excellent ultra-lightweight aggregate which has low water absorption rate and, low slump loss can be produced. In addition, the collective treatment of waste and the mass production of recycled products are possible without addition of a drying process for raw sewage sludge, and thus excellent ultra-lightweight aggregate can be supplied at low cost.

Abstract: A sintering apparatus for silver clay wherein a silver clay composition can be readily and easily sintered by exposing a silver clay composition obtained by molding to a flame of a solid alcohol fuel.

Abstract: Methods and compositions are provided for making low temperature sintering ceramic bodies that have very low thermal expansion and low porosity.

Abstract: A process of manufacturing a sulfoaluminate or ferroaluminate cement, and an apparatus for the manufacture. The cement is manufactured from a mixture containing CaCO3, Al3 and/or Al(OH)3, CaSO4, SiO2 and/or a product containing silica or silicates such as clay, these compounds being present in the anhydrous or hydrated form. In this process, the mixture is treated up to clinkering by movement in a center of a kiln, in a sheet with approximately constant thickness, at approximately constant speed, along a treatment path having a positive temperature gradient, and for a treatment time during which the mixture remains below its melting temperature. The mixture is clinkered to produce a clinkered mixture that is cooled upon exit from the treatment path.

Abstract: A novel process for manufacturing fully vitrified flat extruded ceramic glazed, unglazed tiles and profiles includes the following steps: mixing of raw materials in predetermined ratios; wet milling in ball mills; mechanical filter pressing to get cakes; shredding of cake to obtain noodles like structure; using a de-airing pug mill machine to produce proper mixing by removing of air the body; drawing a column of clay body through a die for required shapes; drying in three layer horizontal drier and chamber drier; coloring in a appropriate glazing line; firing in a appropriate roller kiln; sorting line; packing and palletizing machine; and using a sawing and glueing machine for smaller size tiles to make patterns and for border tiles. The invention also includes a system for carrying out the invented process so as to achieve high quality fully vitrified ceramic tiles and profiles.

Abstract: A method of making a product which is generally impervious to water including the steps of making a generally homogenous mixture of slate particles and clay, wetting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed mixture and subjecting the dried formed mixture to a temperature of at least 1100° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.

Abstract: FIGS. 25 and 26 show in sequence a 270° bending of a tile predisposed on a bottom surface thereof in which surface a straight groove has been made at a position where a bend is to be performed. FIG. 5 is a detailed illustration showing the groove after having been filled following bending. In the illustrated example, the bend of the tile is obtained, after making the groove in the opposite surface to the upper surface, by subjecting the tile to overall or localized heating as it is resting on a support made of refractory material which support has two surfaces which are reciprocally perpendicular and inclined with respect to a vertical, at a suitable angle for the tile to be stable thanks to a part thereof resting on the surface, and a projecting part of the tile to be able, when softened, to fall by gravity until it reaches and rests perfectly on the other surface 10″ of the support.

Abstract: A highly versatile method for manufacturing ceramic tiles of different formats, a plant for its implementation, and tiles obtained thereby includes the following operational stages. First, a single panel is dry-formed within a ceramic mold by compressing at least one ceramic material in powder form. At least two tiles are then separated from said panel, after the formation of the panel but before a firing process of said panel. The plant for implementing the method incorporates a press of relatively large power with which there is associated a single-exit ceramic mold arranged to form a starting panel of large dimensions, and at least one sectioning unit provided downstream of the press to obtain at least one tile of the desired format from said starting panel.

Abstract: A method of forming bricks, tiles, and the like by treating clay, shale or other clay ceramic raw materials containing pyrite is disclosed. Such clay ceramic raw materials may be ground, and then mixed with an oxidizer in a pre-oxidation step to disperse the oxidizer within the clay to expose the maximum amount of clay surface to the oxidizer. One oxidizer that may be used is an aqueous solution of hydrogen peroxide. Clay is shaped into clay products and then heated to elevated temperatures. Pyrite within the clay is oxidized, thereby removing sulfur-containing compounds such as sulfur dioxide from the clay. The application of the invention may assist in preventing efflorescense by ensuring complete or nearly complete removal of pyrite from products oxidation treatment and subsequent firing at elevated temperatures. Similarly, by enhancing the oxidation of pyrite, faster firing cycles may be possible which facilitates reduced fuel consumption and faster process time.

Abstract: A method for manufacturing an artificial reef based on industrial waste is disclosed. Industrial wastes, including red mud, blast furnace slag, the sludges from the factories of refining raw ore, broken pieces of glass, the stone powders from the anti-pollution facilities equipped in stone- or aggregate-extracting spots, the slurries from the terminal treatment plants of water and sewage, the ashes from the incinerators for household wastes, the pulp sludges and slurries from paper mills, the coal ashes from thermoelectric power plants, and the side-products produced upon coal mining, are utilized, alone or in combination with a plasticizer and a mineralizer, in constructing artificial fishing reeves through pug-milling, molding and thermal treatment processes. The artificial fishing reef, through which the industrial wastes are converted into environment-affinitive resources, have advantages of being economically favorable and producing no pollution of the environment.

Abstract: Building bricks and tiles are made by mixing 60% to 75% clay, 20% to 40% sludge and 1% to 10% sand, all percentages being by weight of the total composition. This process utilizes industrial waste products to provide building materials which are lighter and stronger than conventional materials.

Abstract: A method of making a product which is generally impervious to water including the steps of making a generally homogenous mixture of slate particles and clay, setting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed mixture and subjecting the dried formed mixture to a temperature of at least 1145° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.

Abstract: A method for manufacturing ceramic boards for use as finishing construction materials is provided, which includes the steps of: blending raw materials at predetermined ratios; mixing the blended raw materials with water to prepare a mixture; kneading the mixture to remove bubbles; molding the bubble-free kneaded mixture into planar wares having a face; engraving a predetermined pattern on the face of the planar wares and then filling the patterns with a colored inlay material to form inlaid surfaces; drying the engraved and inlaid wares; polishing the inlaid surfaces to expose the patterns; primarily calcining the wares having exposed patterns at a temperature of 800° C. to 900° C. for a predetermined period to prepare primary ceramic boards; coating a glaze mixture composed of components at fixed ratios on the faces having the exposed patterns to prepare glazed wares and then drying; and secondary calcining the glazed wares at a temperature of 1250° C. to 1350° C. for a predetermined period.

Abstract: A method for providing improved compaction, green density, green strength and surface finish properties in simulated stone and mineral-like materials from ceramic green bodies, based on addition of selected polymer additives during ceramic processing, is disclosed. Polymer additives having weight-average molecular weights from 30,000 to 1,000,000, glass transition temperatures from −50 to +90° C., and low hygroscopicity are particularly useful in providing enhanced properties of ceramic products involving processing of large-size granule intermediates.

Abstract: Composition for coloring ceramic articles obtained from ceramic mass containing TiO.sub.2 as such, in shades ranging from yellow to orange, consisting of an aqueous or hydroalcoholic solution to be applied to the surface to colored before final firing and containing soluble compounds of chromium/antimony or of chromium/zinc or chromium/zirconium or chromium/manganese mixtures.

Abstract: A method for forming ceramic tiles by means of a partially isostatic mold, comprising the following stages: loading the ceramic powder to be pressed into the mold cavity; exerting a uniform pressure on the entire surface of the ceramic powder present in the mold cavity; releasing the pressure and partially opening the mold to facilitate powder deaeration; exerting pressure on a first portion of the surface of the powder contained in the mold cavity; exerting pressure on a second portion of the surface of the powder contained in the mold cavity, while simultaneously nullifying the pressure on said first surface portion of the powder contained in the mold cavity; and alternating the exertion of pressure on said first and on said second portion alternately.

Abstract: A method for forming ceramic tiles, including those of large dimensions, comprising the following stages: loading the powder to be pressed into the mould cavity; exerting an initial pressure on the entire surface of the powder present in the mould cavity; releasing the initial pressure; exerting the compacting pressure on the entire surface of the powder contained in the mould cavity; increasing the pressure on a first portion of the surface of the powder contained in the mould cavity up to a value permitted by the press capacity; releasing the pressure on said first portion of the surface of the powder contained in the mould cavity and increasing the compacting pressure on a second portion of the surface of the powder contained in the mould cavity; alternating the exertion of pressure on said first portion and on said second portion; and interrupting the exertion of pressure.

Abstract: The invention relates to a method of making a die set for the manufacture of specially shaped ceramic tile, and the tiles formed thereby. A main component of the die set is a lower punch made of rigid material, on whose upper surface a profile is cut which is suitably shaped to form the front face of the ceramic tile, including the contoured side. The punch has a complete, continuous coating of synthetic resin or rubber bonded to it, with the punch's upper surface defining the form of the front face of the ceramic tile. The coating is continuous and covers the lateral portion of the profile that forms the shaped side, and continues on the upper most part with a horizontal edge which is turned externally with respect to the profile, upon the upper lateral surface of the body of the punch; furthermore a rigid body is fixed above the upper lateral surface, which acts to clamps the horizontal extension of the coating against the lateral surface.

Abstract: A process is provided for converting lead-contaminated soil to commercially-useful ceramic shapes, in which the lead is covalently-bonded and from which it does not leach. The soil is mixed with conventional brick or tile fabricating ingredients to form a premix which is formed into a suitable shape and fired at a temperature in the range of 150.degree. F. to 250.degree. F.

Abstract: This invention relates to synthetic granite tiles made essentially from garnite sand and a process for the production of synthetic garnite tiles essentially from garnet sand which is a by-product of beach sand from rare earths extraction, said process comprising mixing beach sand garnet, feldspar and clay thoroughly; pressing the mixture using a press at a pressure in the range of 40-80 MPa to form tiles of desired shapes and sizes; drying the tiles so formed at a temperature of 100.degree.-120.degree. C.; firing the dried tiles at a temperature in the range of 1050.degree.-1250.degree. C. with a soaking for a period ranging from 1.5 to 2.5 hours, and polishing the resultant tiles.

Abstract: An accessory tile and its manufacturing method. The accessory tile is made of preformed tile bodies of plate shape which have colored patterns on their surfaces, respectively. The preformed tile bodies are disposed on both sides of a press surface of a lower mold of a V-shaped cross section, respectively, while joint end surfaces of the preformed tile bodies are contacted closely with each other. They are pressed between the lower mold and an upper mold into one body. The pressed bodies are burnt to obtain the accessory tile as a final product.

Abstract: The invention relates to a process for manufacturing brickworks mouldings by mixing a compound containing a granular clay-containing material with a lean material and, if required, other additives from which moulding compound green products are moulded, dried and burnt. This process permits a recycling of residual materials by using as clay-containing material a residual material consisting predominantly of clay minerals, especially a dry fraction, predominantly composed of annealed clay minerals, of an ash, preferably brown coal ash, and by producing the moulding compound by mixing the fraction with the lean material and other additives as well as water, where water is used in such a quantity as to produce an earth-moist moulding compound which is then pressed in portions on a press to form individual, inherently stable green products.