Process and apparatus for hot-forging synthetic ceramic

Abstract

The embodiments of the invention are directed to a synthetic ceramic comprising pyroxene-containing crystalline phase, a clast, and a glass phase, wherein at least a portion of the synthetic ceramic is plastically deformable in a certain temperature range. Other embodiments of the invention relate to a method of making a synthetic ceramic, comprising heating a green ceramic material to 900-1400° C., to a temperature sufficient to initiate partial melting of at least a portion of the green ceramic material, transferring the heated green ceramic material to a press, pressing the heated green ceramic material in a die at 1,000 to 10,000 psi, and transferring the heated, pressed green ceramic material to a furnace for cooling to form the synthetic ceramic.

Description

RELATED APPLICATIONS[0001]This application is related to U.S. Ser. No. 11 / 213,218, filed Aug. 25, 2005, entitled “Synthesized Hybrid Rock Composition, Method, and Article Formed by the Method,” which is incorporated herein by reference. This application is also related to U.S. Ser. No. 09 / 596,271, now U.S. Pat. No. 6,547,550, issued on Apr. 15, 2003, entitled “Apparatus for hot vacuum extrusion of ceramics,” U.S. Ser. No. 10 / 382,765, filed Mar. 5, 2003, entitled “Method and apparatus for hot vacuum extrusion of ceramics,” all of which are incorporated herein by reference.FIELD OF INVENTION[0002]Embodiments of the invention relate to the field of advanced ceramics, particularly to the composition and manufacture of synthetic ceramic (also referred herein as a “hybrid rock material” or as “manufactured stone”) such as ceramic tile of a ceramic composite that is plastically deformable at high temperature, and otherwise strong, with low porosity.BACKGROUND[0003]“Uniaxial hot pressing” a...

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Benefits of technology

[0075]Another advantage of the present invention is that the solid compositions and corresponding articles of manufacture are impermeable without the need for glazing. The invention's impermeability is directly related to the fact that, unlike conventional synthetic rock materials, the composition and articles contain essentially zero open porosity, due to the continuous glass matrix structure surrounding crystallites distributed throughout therein. With the exception of certain rare vitreous expensive clay products, such as porcelain, conventional synthetic rock and ceramic products require glazing to achieve impermeability.

[0076]The synthetic ceramics of the embodiments of the invention contain substantially zero open porosity (less than 0.5% open porosity), which results in less porous and more impermeable articles as compared to conventional ceramic materials. Surprisingly, voids (closed pores) may be induced in applicant's invention to result in a lighter weight construction-type material, without compromising the invention's impermeable characteristics.

[0077]The feedstock materials used for the synthetic ceramics of the embodiments of the invention are typically waste materials or manufacturing byproducts that are particulate in their texture. Examples include fine particle residues from crushed rock quarries and fine grained fly-ash powder from coal burning power plants. Microscopic examination of these materials with the aid of a scanning electron microprobe instrument reveals very fine angular grains or clasts of various mineral components in the case of the pulverized quarry fines (FIG. 1) or spherical-shaped microscopic glass beads in the case of the fly-ash materials (FIG. 2). Incompletely melted remnants of these particulate or clastic sedimentary feedstock materials comprise the “aggregate” phase of the synthetic ceramics of the embodiments of the invention (FIGS. 3 and 4).

[0078]FIG. 1 shows a microscopic view of fine grained angular particles or clasts of a pulverized mineral and rock sediments found in crushed rock quarry fines and mine tailings. The particles seen here are composed of both single mineral grains and multi-mineral rock fragments. FIG. 2 shows a microscopic view of the fine grained fly-ash material largely composed of spherical-shaped glass beads with a smaller quantity of angular residual quartz. FIG. 3 shows a microscopic view of the incompletely melted remnants of the fine grained mineral and rock particles of the sedimentary feedsto

Problems solved by technology

Graphite parts oxidize over time and are highly susceptible to wear, which makes the hot pressing process expensive and only in use for manufacture of high-cost specialized parts.

The conventional ceramic tiles are rigid, brittle and cured to a permanently set (thermosetting) composition.

Thus, the conventional ceramic tiles cannot be recycled by and reformed by heati

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