Aqueous gelcasting formulation for ceramic products

Abstract

The present disclosure relates to the manufacture of ceramic products by aqueous gelcasting. Exemplary ceramic products include sanitary ware, such as toilets and sinks. The process includes a slurrying step, a mixing step, a molding step involving aqueous gelcasting, a drying step, a glazing step, and a firing step.

What is claimed is: 
     
         1 . A ceramic product having a formulation comprising:
 at least one mineral oxide;   at least one alkali aluminosilicate mineral configured to serve as a fluxing agent to reduce the melting point of the formulation; and   colloidal silica.   
     
     
         2 . The ceramic product of  claim 1 , wherein the at least one mineral oxide of the formulation includes silica and alumina. 
     
     
         3 . The ceramic product of  claim 1 , wherein the at least one alkali aluminosilicate mineral of the formulation includes Feldspar or Nepheline Syenite. 
     
     
         4 . The ceramic product of  claim 1 , wherein the formulation is a slurry comprising water. 
     
     
         5 . The ceramic product of  claim 4 , wherein the at least one mineral oxide of the formulation constitutes about 10 wt. % to about 88 wt. % of the slurry. 
     
     
         6 . A formulation having a solid portion, the formulation comprising:
 silica, wherein at least a portion of the silica comprises colloidal silica;   alumina, wherein the alumina constitutes at least 15 wt. % of the solid portion; and   at least one fluxing agent.   
     
     
         7 . The formulation of  claim 6 , wherein the at least one fluxing agent is sourced from an alkali aluminosilicate mineral. 
     
     
         8 . The formulation of  claim 7 , wherein the alkali aluminosilicate mineral is Feldspar. 
     
     
         9 . The formulation of  claim 7 , wherein a portion of the silica and a portion of the alumina is sourced from the alkali aluminosilicate mineral. 
     
     
         10 . The formulation of  claim 6 , wherein the formulation is a slurry further comprising a liquid portion. 
     
     
         11 . A ceramic product having the formulation of  claim 6 . 
     
     
         12 . A formulation comprising:
 a majority of silica and alumina, wherein at least a portion of the silica comprises colloidal silica; and   a minority of at least one fluxing agent.   
     
     
         13 . The formulation of  claim 12 , wherein silica is a primary component and alumina is a secondary component. 
     
     
         14 . The formulation of  claim 12 , wherein the at least one fluxing agent comprises sodium oxide, potassium oxide, and calcium oxide. 
     
     
         15 . The formulation of  claim 12 , wherein the formulation consists essentially of the silica, the alumina, and the at least one fluxing agent. 
     
     
         16 . A ceramic product having the formulation of  claim 12 . 
     
     
         17 . A molded formulation comprising:
 at least one mineral oxide constituting about 10 wt. % to about 88 wt. % of the formulation;   at least one alkali aluminosilicate mineral, separate from the at least one mineral oxide, configured to serve as a fluxing agent to reduce the melting point of the formulation;   colloidal silica; and   water, wherein the molded formulation is gelled in a mold and configured to maintain a solid shape in the mold.   
     
     
         18 . The molded formulation of  claim 17 , wherein the formulation is chemically gelled or freeze gelled. 
     
     
         19 . A molded object formed from the molded formulation of  claim 17 , wherein the molded object is removed from the mold and dried to remove at least a portion of the water from the molded formulation.