A patent of Slip casting of sanitaryware

8/19/2019 A patent of Slip casting of sanitaryware

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US 2 0 0 6 0 0 5 7 8 4 6 A 1

1 2 )Paten t Appl ica t ion Publ ica t ion 1 0 )P u b . N 0 . :US 2 0 0 6 / 0 0 5 7 8 4 6A 11 9 )Uni ted S t a t e s

I sh ikawa e t a l . 4 3 )P u b . D a t e : Mar. 1 6 , 2 0 0 6

( 5 4 ) COMPOSITION FOR USE AS SANITA RYEARTHENWARE MATERIAL, METHOD FORPRODUCTION THEREOF, METHOD FORMANUFACTURING SANITARYEARTHENWARE USING S A I DCOMPOSITION

7 5 ) I n v e n t o r s :H i d e m iI s h i k a w a ,K i t a k y u s h u - S h iJ P ) ;K a t s u h i r oK a w a k a m i ,K i t a k y u s h u - S h iJ P ) ;T s u y o s h iO z e k i ,K i t a k y u s h u - S h iJ P ) ;T a k a c h i k aA r a k a w a ,

K i t a k y u s h u - S h iJ P ) ;M i t s u y o s h iM a c h i d a ,K i t a k y u s h u - S h iJ P )

C o r r e s p o n d e n c eA d d r e s s :HELLER EHRMAN WHITE & MCAULIFFELLP1 7 1 7 RHODE I S L A N D AVE, NW

WASHINGTON,DC 0 0 3 6 - 3 0 0 1( U S )7 3 ) A s s i g n e e :TOTO LT D . ,K i t a k y u s h u - S h iJ P )

2 1 ) A p p l .N o . : 1 0 / 5 2 8 , 0 9 9

2 2 ) PCT i l e d : S e p . 2 6 ,2 0 0 3

( 8 6 ) PCT o . : P C T / J P 0 3 / 1 2 3 7 1

3 0 ) F o r e i g nA p p l i c a t i o nP r i o r i t yD a t a

Sep. 2 7 , 2 0 0 2 ( J P ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 0 0 2 - 2 8 3 9 6 5

M a r. 28, 2 0 0 3 ( JP ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 0 0 3 - 0 9 0 8 6 4

P u b l i c a t i o n C l a s s i ? c a t i o n

5 1 ) I n t .C l .H01L 2 1 / 3 0 2 ( 2 0 0 6 . 0 1 )H01L 2 1 / 4 6 1 ( 2 0 0 6 . 0 1 )

( 5 2 ) Us. 0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 4 3 8 / 6 8 9

5 7 ) ABSTRACT

Disclosed a r e a composi t ion f o r a s a n i t a r y Ware body o r usei n s l i pc a s t i n g ,p o s s e s s i n g e x c e l l e n tl o n g - t e r ms t o r a g es t ab i l i t y ,t r a n s p o r t a b i l i t ya n d s l u r r yr e g e n e r a t i o n ,a p r o d u c t i o np r o c e s s o f t h e s a m e , and a p r o d u c t i o n p r o c e s so f a s a n i t a r yWare u s i n g t h e c o m p o s i t i o nf o r a s a n i t a r y Ware b o d y . T h i s

c o m p o s i t i o nf o r as a n i t a r yWa r eb o d yc o m p r i s e sa g g l o m e ra te o f a raW a t e r i a l poWder o r s a i d s a n i t a r y Ware body andh a s a W a t e r c o n t e n t o f 0 ( Z e r o ) t o 2 5 by W e i g h ta n d a 5 0a v e r a g e p a r t i c l e d i a m e t e r o f 1 t o 15 pm on a n u m b e r b a s i so f t h e poWder. Aslurry o f a raW m a t e r i a l f o r a s a n i t a r y Wareb o d yf o ru s e i n s l i pc a s t i n g c a n b e p r e p a r e db y a d d i n gWa t e rt o t h e c o m p o s i t i o nf o r a s a n i t a r y W a r ebody a n d s t i r r i n gt h em i x t u r e .


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P a t e n t A p p l i c a t i o nP u b l i c a t i o n Mar. 1 6 , 2 0 0 6 S h e e t 2 0 f 2 US 2 0 0 6 / 0 0 5 7 8 4 6A 1

FIG.3


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US 2006/0057846 A 1

COMPOSITION FOR USE AS SANITARYEARTHENWARE MATERIAL, METHOD FOR

PRODUCTION THEREOF, METHOD FORMANUFACTURING SANITARY EARTHENWARE

USING S A I D COMPOSITION

BACKGROUND OF THE INVENTION

[ 0 0 0 1 ] 1 . F i e l d o f t h e I n v e n t i o n

[ 0 0 0 2 ] The p r e s e n t i n v e n t i o nr e l a t e st o a c o m p o s i t i o nf o ra s a n i t a r y Ware body f o r u s e i n s l i pc a s t i n g , a p r o c e s s f o rp r o d u c i n gt h e s a m e , a n da p r o c e s s f o r p r o d u c i n ga s a n i t a r yW a r eu s i n g s a i d c o m p o s i t i o n .

[ 0 0 0 3 ] 2 . B a c k g r o u n dA r t

[ 0 0 0 4 ] I n t h ep r o d u c t i o no f s a n i t a r yWa r e s ,s l i pc a s t i n gi sg e n e r a l l ya d o p t e df o rt h ep r o d u c t i o n o f g r e e nb o d i e s . T h i s i sb e c a u s e s a n i t a r y Wares a r e r e l a t i v e l y l a r g e a n d h a v e ac o m p l i c a t e ds h a p e .S l i pc a s t i n gi s , f o re x a m p l e ,c a r r i e do u ta s f o l l o W s .A u i t a b l e a m o u n t of Water i s a d d e d t o t h e raWm a t e r i a l f o r a s a n i t a r y Ware body t o r e n d e r t h e raW m a t e r i a l? u i d . N e x t , t h e raW a t e r i a l , t o Which a t e r h a s been a d d e d ,i s mixed and ground i n a b a l l m i l l o r t h e l i k e t o p r e p a r e as l u r r y .The s l u r r y t h u s o b t a i n e d a s s u c h i s p o u r e di n t o a s l i pc a s t i n g m o l d . I n t h i s W a y , t h e raW m a t e r i a l f o r a s a n i t a r yWare body f o r u s e i n s l i pc a s t i n g i s s l u r r i e d a n d , i n t h i s s t a t eW i t h o u t b e i n g s o l i d i ? e d , i s t h e n u s e d i n t h e s t e po f s l i pc a s t i n g .

[ 0 0 0 5 ] On t h e o t h e r h a n d , i n t h e p r o d u c t i o no f p o t t e r y o rc e r a m i c W h i t e W a r e ,s u c h a s t i l e s ,i n Which a g r e e n body i sp r e p a r e db y p l a s t i cp r e s s i n g , t h e r a Wm a t e r i a l f o r ap o t t e r yo r c e r a m ic W h i t e W a r ebody s s u b j e c t e d t o t h e s t e p o f p l a s t i cp r e s s i n g i n t h ef o r mo f a p l a s t i cp r e s s i n gb o d yp r e p a r e db yd e h y d r a t i n ga s l u r r y o f t h e raW m a t e r i a l , t h a ti s , i n t h e f o r mof a s o l i d .

[ 0 0 0 6 ] J a p a n e s e P a t e n t L a i d - O p e n N o . 4 0 7 7 7 / 1 9 9 6d i sc l o s e s a method i n Which a s l u r r y c o m p o s i t i o nf o r p l a s t i cs h a p i n gi s d e h y d r a t e dt o p r e p a r e a b o d yf o r p l a s t i cs h a p i n gWhich s t h e n s u b j e c t e dt o p l a s t i c s h a p i n gs u c h a s e x t r u s i o no r poWer j i g g e r i n g t o p r e p a r e a g r e e n b o d y .

SUMMARY OF THE INVENTION

[ 0 0 0 7 ] The p r e s e n t i n v e n t o r s h a v e n o W f o u n d t h a t ,i n as l u r r y o f a raW m a t e r i a l f o r a s a n i t a r y Ware body f o r u s e i ns l i pc a s t i n g ,r e d u c i n g t h e Wa t e r c o n t e n t t o 0 ( Z e r o ) t o 2 5by W e i g h t c a nr e a l i Z e s t a b l e s t o r a g e o f t h e raW m a t e r i a l f o ra l o n g p e r i o d o f t i m e , s i g n i ? c a n t r e d u c t i o ni n a l o a d on raWm a t e r i a l t r a n s f e ra n d s t o r a g e , a n d i m m e d i a t er e g e n e r a t i o no fa s l u r r y f o r a s a n i t a r y Ware body i n a v e r y s i m p l e mannerW h i c hi s t h e n u s e d f o rs l i pc a s t i n g .

[ 0 0 0 8 ] A c c o r d i n g l y , a no b j e c t o f t h e p r e s e n t i n v e n t i o ni s t op r o v i d e a c o m p o s i t i o nf o r a s a n i t a r y Ware body f o r u s e i ns l i pc a s t i n g ,p o s s e s s i n ge x c e l l e n tl o n g - t e r ms t o r a g es t a b i l i t y ,t r a n s p o r t a b i l i t ya n d s l u r r yr e g e n e r a t i o n ,a p r o d u c t i o n p r oc e s s of h e same, and a production r o c e s s of s a n i t a r y Wareu s i n g t h e c o m p o s i t i o nf o r as a n i t a r y W a r e b o d y .

[ 0 0 0 9 ] A c c o r d i n gt o o n e a s p e c t o f t h ep r e s e n t i n v e n t i o n ,t h e r e i s p r o v i d e d a c o m p o s i t i o nf o r a s a n i t a r y Ware body o ru s e i n s l i p c a s t i n g , c o m p r i s i n g a g g l o m e r a t eso f a raWm a t e r i a l poWder f o rs a i d s a n i t a r y W a r e body a n d h a v i n gaWa t e r c o n t e n t o f 0 ( Z e r o ) t o 2 5 by We i g h t , W h e r e i n

M a r . 1 6 ,2 0 0 6

[ 0 0 1 0 ] s a i d poWder a s a 5 0 a v e r a g ep a r t i c l ed i a m e t e ro f1 t o 1 5 pm on a n u m b e r b a s i s .

[ 0 0 1 1 ] A c c o r d i n gt o a n o t h e r a s p e c t o f t h ep r e s e n t i n v e nt i o n ,t h e r e i s p r o v i d e da p r o c e s sf o r p r o d u c i n ga c o m p o s i t i o nf o r a s a n i t a r y Ware body o r u s e i n s l i pc a s t i n g , s a i d p r o c e s sc o m p r i s i n gt h e s t e p so f :

[ 0 0 1 2 ] p r o v i d i n ga raW m a t e r i a l f o r a s a n i t a r y Ware b o d y ;

[ 0 0 1 3 ]b o d y ;[ 0 0 1 4 ] g r i n d i n g t h e raW m a t e r i a l f o r a s a n i t a r y Ware bodyW i t h Wa t e ra d d e d t h e r e t o t o p r e p a r e a s l u r r y f o r s l i pc a s t i n g ;a n d

adding Water o t h e raW a t e r i a l f o r a s a n i t a r y Ware

[ 0 0 1 5 ]d e h y d r a t i n ga n d / o rd r y i n gt h es l u r r yf o rs l i pc a s t i n gt o p r e p a r e t h e c o m p o s i t i o nf o r a s a n i t a r y Ware b o d y .

[ 0 0 1 6 ] A c c o r d i n gt o a f u r t h e r a s p e c t o f t h e p r e s e n t i n v e nt i o n ,t h e r e i s p r o v i d e d a p r o c e s s f o r p r o d u c i n ga s a n i t a r yWa r e , c o m p r i s i n gt h e s t e p s o f :

[ 0 0 1 7 ] a d d i n g Wa t e r t o t h e a b o v e c o m p o s i t i o nf o r a s a n it a r y W a r e body a n d s t i r r i n gt h e m i x t u r e t o r e g e n e r a t e t h es l u r r y ;

[ 0 0 1 8 ] p o u r i n g t h e s l u r r y i n t o as l i p c a s t i n gm o l d a n da l l o W i n gt h e s l u r r y t o c a s t on t h e m o l d ;

[ 0 0 1 9 ][ 0 0 2 0 ][ 0 0 2 1 ][ 0 0 2 2 ]

t a k i n g t h e r e s u l t a n tg r e e n b o d yo u t o f t h em o l d ;

d r y i n gt h eg r e e n b o d y ;

c o a t i n g g l a Z e o n t o t h ed r i e d g r e e n b o d y ; a n d

? r i n g t h eg l a Z e - c o a t e dg r e e n b o d y.

BRIEF DESCRIPTION OF THE DRAWINGS

[ 0 0 2 3 ] FIG. 1 i s a p e r s p e c t i v e vieW o f a We s t e r n - s t y l et o i l e tboWl as p r e p a r e d i n Examples 6 a n d 7 a n dComparat i v eE x a m p l e2 ;

[ 0 0 2 4 ] FIG. 2 i s a s i d e vieW o f t h e We s t e r n - s t y l et o i l e tboWl shoWn i n FIG. 1 ; a n d

[ 0 0 2 5 ] FIG. 3 i s a f r o n t vieW o f t h e We s t e r n - s t y l e t o i l e tboWl shoWn i n FIG. 1 .

DETAILED DESCRIPTION OF THEINVENTION

[ 0 0 2 6 ] D e ? n i t i o n

[ 0 0 2 7 ] The t e r m “ W a t e rc o n t e n t ” a s used h e r e i n r e f e r s t ot h e f r a c t i o n o f t h e amount o f Wa t e r i n t h e t o t a lW e i g h to f t h e

W h o l eWa t e r - c o n t a i n i n gs o l i dW h i c hi s c a l c u l a t e d b y t h ef o l l o W i n ge q u a t i o n :Z = [ ( W — W D ) / W D ] > < 1 O O

W h e r e i n

[ 0 0 2 8 ] Z : Wa t e r c o n t e n t , ;

[ 0 0 2 9 ] W: m a s s o f s a m p l eb e f o r e d r y i n g , g ; a n d

[ 0 0 3 0 ] WD: m a s s o f s a m p l ea f t e rd r y i n gf o r 2 4 h r a t 1 1 0 °C . ,g .

[ 0 0 3 1 ] I n t h e p r e s e n t i n v e n t i o n ,t h e e x p r e s s i o n “50a v e r a g e p a r t i c l e d i a m e t e r on a n u m b e r b a s i s ” r e f e r s t o t h ed i a m e t e r o f p a r t i c l e s a t t h e t i m e When t h e c u m u l a t i v enumber o f s m a l l p a r t i c l e s a s c o u n t e df r o m s m a l l e r p a r t i c l e s


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US 2006/0057846 A 1

s i d e h a s r e a c h e d 5 0 o f t h e t o t a lnumber o f p a r t i c l e s a sdetermined based on d a t a on t h e p a r t i c l e s i Z e d i s t r i b u t i o nm e a s u r e dW i t h a l a s e rd i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b ut i o n a n a l y Z e r .

[ 0 0 3 2 ] I n t h e p r e s e n t i n v e n t i o n ,t h e e x p r e s s i o n “50a v e r a g e p a r t i c l e d i a m e t e r on a W e i g h tb a s i s ” r e f e r s t o t h ed i a m e t er o f p a r t i c l e s a t t h e t i m e When h e c u m u l a t i v eW e i g h to f s m a l l p a r t i c l e s a s m e a s u r e df r o m s m a l l e r p a r t i c l e s s i d eh a s r e a c h e d 5 0 o f t h e t o t a lW e i g h t o f p a r t i c l e s a s d e t e rm i n e d based on d a t a on t h e p a r t i c l e diameter d i s t r i b u t i o n ona W e i g h tb a s i s m e a s u r e dby a s i e v i n g m e t h o d .I n t h e p r e s e n ti n v e n t i o n , t h e p a r t i c l e d i a m e t e r d i s t r i b u t i o n on a W e i g h tb a s i s may e m e a s u r e dW i t h a d r y s i e v i n g a p p a r a t u sa c c o r di n g t o J I S Z 8 8 1 5 ( 1 9 9 4 ) . T h i s J I S ,t o g e t h e r W i t h E n g l i s ht r a n s l a t i o n t h e r e o f ,i s e a s i l ya v a i l a b l ef r o m J a p a n e s e S t a nd a r d s A s s o c i a t i o n 1 - 2 4 ,A k a s a k a 4 - c h o m e , M i n a t o - k u ,T o k y o ,J a p a n ) . S p e c i ? c a l l y ,a s i e v i n ga p p a r a t u se q u i p p e dW i t h t e s ts i e v e s s p e c i ? e d i n J I S Z 8801 i s p r o v i d e d , a n d as i n g l e t e s ts i e v e o r a p l u r a l i t y o f t e s ts i e v e s p u t on t o p o f e a c h

o t h e r i s v i b r a t e d f o r s i e v i n g . The s i e v i n g t i m e i s t h e t i m eWhich h a s e l a p s e d b e t W e e nt h e s t a r to f t h e s i e v i n g a n d t h et i m e When h e mass f a g r o u po f p a r t i c l e s Which a s p a s s e dt h r o u g ht h e s i e v e p e r m i n u t e r e a c h e s n o t more t h a n 0 .1 o ft h e m a s s f t h e c h a r g e ds a m p l e .The o t a lo f t h e m a s s f e a c ho v e r s i Z e and t h e mass o f u n d e r s i Z eo f t h e s m a l l e s t a p e r t u r es i e v e a s m e a s u r e da f t e rt h e c o m p l e t i o no f t h e s i e v i n g s h o u l db e W i t h i n1 2 o f t h e mass o f t h e c h a r g e ds a m p l e . P a r t i c l e sW h i c hc l o g m e s h e sa r er e m o v e db y t u r n i n g t h es i e v e u p s i d edoWn s o t h a tt h e b a c k s i d e o ft h e s i e v i n g n e t f a c e s u p W a r d ,a n d r e m o v i n gt h ep a r t i c l e sb y a c l o g g i n ge l i m i n a t i n gb r u s h .The p a r t i c l e s Which c a u s e c l o g g i n g o f t h e meshes a r er e g a r d e d a s t h e o v e r s i Z e .

[ 0 0 3 3 ] C o m p o s i t i o nf o rs a n i t a r yWa r eb o d y

[ 0 0 3 4 ] The c o m p o s i t i o nf o r as a n i t a r y W a r ebody a c c o r di n g t o t h e p r e s e n t i n v e n t i o ni s a c o m p o s i t i o nWhich a n formi n t o a raW a t e r i a l s l u r r y f o r a s a n i t a r y Ware body by a d d i n gWa t e r t o t h e c o m p o s i t i o na n d s t i r r i n gt h e m i x t u r e . Thec o m p o s i t i o n f o r a s a n i t a r y W a r e body a c c o r d i n g t o t h ep r e s e n t i n v e n t i o ni s u s a b l e i n s l i pc a s t i n g .T h i s c o m p o s i t i o nc o m p r i s e s a g g l o m e r a t e so f a raW m a t e r i a l poWder f o r t h es a n i t a r y Ware body a n d h a s a W a t e r c o n t e n t o f 0 ( Z e r o ) t o25 b y W e i g h t .T h e p o W d e rc o n s t i t u t i n gt h ea g g l o m e r a t eh a s a 50 a v e r a g e p a r t i c l e diameter o f 1 t o 1 5 pm on anumber b a s i s .T h i s c o m p o s i t i o nf o r a s a n i t a r y Ware bodya c c o r d i n gt o t h e p r e s e n t i n v e n t i o n e n a b l e sa raW m a t e r i a l f o ra s a n i t a r y W a r ebody f o r s l i pc a s t i n g t o b e s t a b l y s t o r e d f o ra l o n g p e r i o d o f t i m e . F u r t h e r , a burden on raW m a t e r i a lt r a n s f e r a n d s t o r a g e c a n b e s i g n i ? c a n t l y r e d u c e d . F u r t h e rm o r e , a s l u r r y f o r a s a n i t a r y Ware body can be immediatelyr e g e n e r a t e df rom t h e c o m p o s i t i o nf o r - a s a n i t a r y Ware bodyby a v e r y s i m p l e method a n d c a n b e u s e d f o r s l i pc a s t i n g .

[ 0 0 3 5 ] S p e c i ? c a l l y, s i n c et h ec o m p o s i t i o nf o r as a n i t a r yWare body a c c o r d i n g to t h e p r e s e n t i n v e n t io n h a s a loWWa t e r c o n t e n t o f 0 ( Z e r o ) t o 2 5 b y We i g h t , a s comparedW i t h t h e s l u r r y b e f o r e t h e s o l i d i ? c a t i o n , t h e volume a n d t h eWeight c a n be s i g n i ? c a n t l y r e d u c e d . T h e r e f o r e , a burden onraW m a t e r i a l t r a n s f e r and s t o r a g e c a n b e s i g n i ? c a n t l yr e d u c e d ,a n d t h e e f ? c i e n c y o ft h e t r a n s f e r a n d s t o r a g e c a n b ei n c r e a s e d . The Wa t e r c o n t e n t o f t h e s l u r r y i s g e n e r a l l ya b o u t4 0 t o 60 .

[ 0 0 3 6 ] The c o m p o s i t i o nf o r as a n i t a r y W a r ebody a c c o r di n g t o t h e p r e s e n t i n v e n t i o ni s n o t a s l u r r y a n d , t h u s ,i s f r e e

M a r . 1 6 ,2 0 0 6

from a p r o b l e m ,Which i s l i k e l y t o o c c u r in t h e s l u r r y ,t h a ti s , a c h a n g ei n s l u r r yp r o p e r t i e s d u r i n g s t o r a g e f o r al o n gp e r i o d o f t i m e ,f o re X a m p l e ,p r e c i p i t a t i o no f s o l i d m a t t e r .That i s , t h e raW m a t e r i a l f o r a s a n i t a r y Ware body can b e

s t a b l y s t o r e d f o r a l o n g p e r i o d o ft i m e . The Wa t e r c o n t e n t o fp o W d e rp r o v i d e da f t e rd r y i n gmay s o m e W h a t? u c t u a t e d u ri n g s t o r a g e a n d k e e p i n g .The ? u c t u a t i o n i n Wa t e r c o n t e n t o ft h ep o W d e r , h o W e v er ,p o s e s n o p r o b l e mb e c a u s e , i n r e s l u rr y i n g , Wa t e r i s a d d e d t o t h e poWder o r e g u l a t e t h e amounto f Wa t e r i n t h er e g e n e r a t e d s l u r r y .

[ 0 0 3 7 ] F u r t h e r , i n t h e c o m p o s i t i o nf o r as a n i t a r y W a r eb o d ya c c o r d i n gt o t h ep r e s e n t i n v e n t i o n ,t h ep o W d e rc o n s t it u t i n g t h e a g g l o m e r a t eh a s a 5 0 a v e r a g e p a r t i c l ed i a m e t e ro f 1 t o 15 pm on a n u m b e r b a s i s . T h i s p a r t i c l e d i a m e t e rd i s t r i b u t i o nc o r r e s p o n d st o t h e p a r t i c l ed i a m e t e rd i s t r i b u t i o nWhich s commonly o s s e s s e d b y a s l u r r y f o r a s a n i t a r y W a r ebody o ru s e i n s l i pc a s t i n g .By v i r t u e o f t h i s ,b e f o r e u s e i ns l i p c a s t i n g , a s l u r r y f o r a s a n i t a r y Ware body c a n b ei m m e d i a t e l yr e g e n e r a t e df r o mt h ec o m p o s i t i o na c c o r d i n gt ot h e p r e s e n t i n v e n t i o n by a v e r y s i m p l e method i n WhichW a t e r i s a d d e d a n dt h e m i X t u r ei s s t i r r e d .T h e r e f o r e ,u n l i k et h e c a s e Where raW m a t e r i a l s f o r a s a n i t a r y Ware body s u c ha s p o t t e r y s t o n e , f e l d s p a r , and l a y a r e s t o r e d a s t h e y a r e ,t h ec o m p o s i t i o na c c o r d i n gt o t h ep r e s e n t i n v e n t i o nc a n r a p i d l ycope With a sudden i n c r e a s e i n a demand .

[ 0 0 3 8 ] The raW m a t e r i a l f o r a s a n i t a r y Ware body a c c o r di n g t o t h e p r e s e n t i n v e n t i o ni s n o t p a r t i c u l a r l y l i m i t e d s o f a ra s t h e m a t e r i a l i s a body m a t e r i a l c o m m o n l y u s e d i n t h ep r o d u c t i o n o fs a n i t a r yWa r e s , a n d e X a m p l e st h e r e o f i n c l u d ep o t t e r ys t o n e ,s i l i c ar o c k ,f e l d s p a r ,k a o l i n ,a n d c l a y .

[ 0 0 3 9 ] The m i X i n gr a t i oo f i n g r e d i e n t s i n t h e r a Wm a t e r i a lf o r a s a n i t a r y Ware body i s n o t p a r t i c u l a r l y l i m i t e d . Ap r e f e r r e d e X a m p l et h e r e o f i s a s f o l l o W s .

I n g r e d i e n t s P r e f e r r e dr a n g e More p r e f e r r e d r a n g e

P o t t e r y s t o n e : 35 to 70 Wt 50 to 55 Wt

k a o l i n ,s e r i c i t e ,p y r o p h y l l i t e ,e t c . )F l u x : 10 to 40 Wt 20 to 30 Wt

a l b i t e ,p o t a s hf e l d s p a r ,n e p h e l i n e ,p e t a l i t e ,d o l o m i t e ,e t c . )C l a y : 1 0 t o 5 0 Wt 2 0 t o 2 5 Wt

[ 0 0 4 0 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,t h e W a t e r c o n t e n t o f t h e c o m p o s i t i o nf o r a s a n i t a r y Ware

b o d yi s 0 ( Z e r o ) t o 9 b y We i g h t , m o r ep r e f e r a b l y 3 t o 7by We i g h t . W h e n t h e Wa t e r c o n t e n t i s W i t h i n t h e a b o v ede?ned W a t e r c o n t e n t r a n g e , t h e c o m p o s i t i o nh a s e X c e l l e n t? u i d i t y .F u r t h e r ,When a s l u r r yi s r e g e n e r a t e d f r o m t h ec o m p o s i t i o n a n d u s e di n s l i pc a s t i n g , a s a t i s f a c t o r yc a s t i n gt h i c k n e s s can be e n s u r e d . A ater c o n t e n t i n t h e r a n g e o f 3t o7 y We i g h ti s a d v a n t a g e o u si n t h a td u s t i n gi s l e s s l i k e l yt o o c c u r a n d , W h e n a s l u r r y i s r e g e n e r a t e d f rom t h e c o mp o s i t i o n , t h ev i s c o s i t yo f t h e s l u r r yb e f o r e t h es o l i d i ? c a t i o nc a n b e r e a l i Z e d by s i m p l y a d d i n gWa t e r .

[ 0 0 4 1 ] I n a n o t h e r p r e f e r r e d e m b o d i m e n to f t h e p r e s e n ti n v e n t i o n , t h e Wa t e rc o n t e n t o ft h e c o m p o s i t i o nf o r a s a n i t a r yW a r ebody s p r e f e r a b l yi n t h e r a n g e o f1 5 t o 2 5 by e i g h t .When t h e W a t e r c o n t e n t i s i n t h e above-de?ned Water


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c o n t e n t r a n g e , t h e s t e p o f d r y i n g , Which r e q u i r e s a l o t o ft i m e , c a n b e o m i t t e d i n t h e p r o d u c t i o n o ft h e c o m p o s i t i o n .F u r t h e r , When t h e s l u r r y i s d e h y d r a t e dby a ? l t e rp r e s s t op r e p a r e t h e c o m p o s i t i o n , t h e r e i s no need t o u s e h i g h

p r e s s u r e . T h e r e f o r e ,a burden on ? l t e r c l o t h and mach ine canb e r e d u c e d . F u r t h e r , s i n c e t h e c o m p o s i t i o ni s l e s sl i k e l yt o b ep r o v i d e d i n a l a r g e mass f o r m , Wo r k a b i l i t ya t t h e t i m e o fs t o r i n g a n d d i s s o l u t i o n a t t h e t i m e o f r e s l u r r y i n g a r e e x c e ll e n t .

[ 0 0 4 2 ] I n t h e c o m p o s i t i o nf o r as a n i t a r y W a r ebody a c c o r di n g t o t h e p r e s e n t i n v e n t i o n , t h e 5 0 a v e r a g e p a r t i c l ed i a m e t e r on a number b a s i s o f t h e poWder c o n s t i t u t i n g t h ea g g l o m e r a t ei s 1 t o 1 5 pm, p r e f e r a b l y 1 t o10 pm, morep r e f e r a b l y 5 t o 1 0 pm. I n a p r e f e r r e d embodiment o f t h ep r e s e n t i n v e n t i o n , p r e f e r a b l y4 5 t o 70 , m o r ep r e f e r a b l y5 0t o 6 5 , o f t h eW h o l ep o W d e rc o n s t i t u t i n g t h ea g g l o m e r a t ehas a s i Z e of not m o r e than 1 0 pm on a n u m b e r b a s i s . Thisp a r t i c l ed i a m e t e r d i s t r i b u t i o n c o r r e s p o n d st o a p a r t i c l ediame t e rd i s t r i b u t i o nW h i c hi s commonly p o s s e s s e d b y a s l u r r y

f o r as a n i t a r y W a r ebody u s e d i n s l i pc a s t i n g .By i r t u eo ft h i s ,b e f o r e u s e i n s l i pc a s t i n g , a s l u r r y f o r a s a n i t a r y Wareb o d yc a n b e i m m e d i a t e l yr e g e n e r a t e df r o m t h ec o m p o s i t i o na c c o r d i n gt o t h e p r e s e n t i n v e n t i o nby v e r y s i m p l e methodi n Which Wa t e r i s added and t h e m i x t u r e i s s t i r r e d .

[ 0 0 4 3 ] I n t h e c o m p o s i t i o nf o r as a n i t a r y W a r ebody a c c o r di n g t o t h e p r e s e n t i n v e n t i o n , t h e 5 0 a v e r a g e p a r t i c l ediameter on a n u m b e r a s i s o f t h e raW m a t e r i a l poWder f o ra s a n i t a r yW a r eb o d ya n d t h ep r o p o r t i o no f p a r t i c l e sh a v i n ga s i Z e of not m o r e than 1 0 pm can be m e a s u r e d a s f o l l o W s .At t h e o u t s e t , W a t e r i s added t o t h e c o m p o s i t i o n f o r as a n i t a r y W a r eb o d y , a n d t h e m i x t u r e i s s t i r r e d t od i s i n t e g r a t et h ea g g l o m e r a t e . T h u s ,a s l u r r yc o n t a i n i n gh o m o g e n e o u s l yd i s p e r s e d raW m a t e r i a l poWder f o r a s a n i t a r y Ware body i sp r e p a r e d . N e x t , t h ep a r t i c l e s i Z ed i s t r i b u t i o no f t h e s l u r r yt h u s o b t a i n e d i s measured W i t h a l a s e r d i f f r a c t i o n - t y p ep a r t i c l e s i Z ed i s t r i b u t i o na n a l y Z e r .T h e 5 0 a v e r a g ep a r t i c l ed i a m e t e ron a number a s i s , t h a t i s , t h e d i a m e t e r o fp a r t i c l e sa t t h e t i m e W h e n t h e c u m u l a t i v enumber o f ?ne p a r t i c l e s a sc o u n t e df r o m s m a l l e r p a r t i c l e s s i d e h a s r e a c h e d 5 0 o f t h et o t a l n u m b e r o f p a r t i c l e s , i s determined based on t h e m e as u r e d d a t a on t h e p a r t i c l e s i Z e d i s t r i b u t i o n . F u r t h e r , t h ep r o p o r t i o no f p a r t i c l e s h a v i n ga s i Z e o f n o t more t h a n 1 0 pmon a number b a s i s i n t h e Whole poWder c o n s t i t u t i n g t h ea g g l o m e r a t ecan a l s o b e l e a r n e d f rom t h e measured d a t a ont h ep a r t i c l e s i Z e d i s t r i b u t i o n .

[ 0 0 4 4 ] I n a p r e f e r r e d embodiment f t h ep r e s e n t i n v e n t i o n ,t h e 5 0 a v e r a g e p a r t i c l e d i a m e t e r on a W e i g h tb a s i s o f t h ec o m p o s i t i o nf o r a s a n i t a r y W a r e body p e r s e , t h a ti s , t h ea g g l o m e r a t e ,i s 1 t o 10 mm, more p r e f e r a b l y 2 t o 8 mm.W h e n h e 5 0 a v e r a g ep a r t i c l ed i a m e t e ro f t h e a g g l o m e r a t ei s i n t h e above-de?ned r a n g e , d u s t i n g i s l e s s l i k e l y t o o c c u r .T h e r e f o r e , a l o W e r i n gi n r e c o v e r y and a d e t e r i o r a t i o n i nWork e n v i r o n m e n t c a n b ep r e v e n t e d . The W o r k a b i l i t ya t t h et i m e o f t r a n s f e r a n d r e s l u r r y i n g i s a l s o e x c e l l e n t . The 5 0a v e r a g e p a r t i c l e d i a m e t e r on a W e i g h tb a s i s o f t h e agglome r a t e i s m e a s u r e dW i t h a d r y s i e v i n g d e v ic e a c c o r d i n gt o J I SZ 8 8 1 5 ( 1 9 9 4 ) .

[ 0 0 4 5 ] P r o d u c t i o np r o c e s s o f c o m p o s i t i o nf o r s a n i t a r yWare body

[ 0 0 4 6 ] I n t h e p r o d u c t i o np r o c e s s o f a c o m p o s i t i o nf o r as a n i t a r y W a r eb o d ya c c o r d i n gt o t h ep r e s e n t i n v e n t i o n , Wa t e ra s a d i s p e r s i o n m e d i u m i s ? r s t added t o t h e above raW

M a r . 1 6 ,2 0 0 6

m a t e r i a l f o r a s a n i t a r y Ware b o d y . The raW m a t e r i a l f o r as a n i t a r y Ware body s t h e n ground i n t h e W a t e r t o p r e p a r e as l u r r yf o rs l i pc a s t i n g .

[ 0 0 4 7 ] The amount o f Wa t e r a d d e d i s n o t p a r t i c u l a r l yl i m i t e d . P r e f e r a b l y , h o W e v e r , W a t e r i s a d d e d i n s u c h a namount t h a t t h e W a t e r c o n t e n t o f t h e r e s u l t a n t s l u r r y i s 4 0 t o60 b y W e i g h t .

[ 0 0 4 8 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,i n a d d i n g Wa t e r , f o r e x a m p l e ,a s o l u b l e s a l tma y b e f u r t h e radded a s a d e ? o c c u l a n t .T h i s can modi fy t h e v i s c o s i t y o f t h eraW m a t e r i a l s l u r r y .P r e f e r r e d e x a m p l e s o f s o l u b l e s a l t si n c l u d e s o d i u ms i l i c a t e ,s o d i u mh y d r o x i d e ,s o d i u mc a r b o na t e ,a n d p h o s p h o r i ce s t e r s .The s o l u b l e s a l ti s a l s o a d v a n t ag e o u s i n t h a tc l o g g i n go f t h e ? l t e ra n d d e p o s i t i o n o f ?occ u l a t e c a n b e p r e v e n t e d a n d t h a t t h e p r e s s e d c a k e c a n b ee a s i l y removed f r o m t h e ? l t e r .

[ 0 0 4 9 ] I n a p r e f e r r e d embodiment o f t h e i n v e n t i o n , t h eraW m a t e r i a l s l u r r y t o Which W a t e r and o p t i o n a l l y a s o l u b l es a l t o r t h e l i k e a s a de?ucculant have been added s groundWith a conventional g r i n d i n g mach ine such a s a b a l l m i l l t op r o v i d e a 50 a v e r a g e p a r t i c l e d i a m e t e r o f 1 t o 1 5 pm on anumber b a s i s .

[ 0 0 5 0 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,t h e v i s c o s i t y o f t h e g r o u n draW a t e r i a l s l u r r y i s modi?ed oa v a l u e s u i t a b l e f o r a s l u r r y f o r s l i pc a s t i n g , f o r e x a m p l e ,t oa v i s c o s i t y i n t h e r a n g e o f 2 0 0 t o 1000 mpa-s a s measu redW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m .

[ 0 0 5 1 ] N e x t , t h e r e s u l t a n t s l u r r y f o rs l i pc a s t i n gi s d e h yd r a t e d a n d / o r d r i e d t o p r e p a r e a c o m p o s i t i o nf o r a s a n i t a r yWare b o d y .

[ 0 0 5 2 ] The s l u r r yc a n b e d e h y d r a t e dby a c o n v e n t i o n a ld e h y d r a t e r such a s a ? l t e r p r e s s o r a c e n t r i f u g e Without

p a r t i c u l a rl i m i t a t i o n .P r e f e r a b l y ,h o We v e r ,t h ed e h y d r a t i o ni sc a r r i e d o u t b y a ? l t e r p r e s s . I n t h e ? l t e r p r e s s , a ? l t e rs e p a r a t e s t h e s l u r r y i n t o s o l i d m a t t e r a n d Wa t e r .

[ 0 0 5 3 ] E x a m p l e so f p r e f e r r e dd r y i n g m e t h o d s i n c l u d es p r a y d r y i n g , s o l a rd r y i n g , Warm i r d r y i n g , a n d l y o p h i l i Z at i o n .More p r e f e r r e d i s s p r a y d r y i n g .S p r a y d r y i n g u s i n gas p r a y d r y e r i s a d v a n t a g e o u si n t h a tt h ep r o d u c t i v i t y i s h i g hb y v i r t u eo f h i g h d r y i n gs p e e d ,t h e p a r t i c l ed i a m e t e r o fa g g l o m e r a t eo f t h ec o m p o s i t i o n p r o v i d e da f t e rd r y i n gi s e a s yt o c o n t r o l , a n d , f u r t h e r ,t h e Wa t e rc o n t e n t o f t h e c o m p o s i t i o nc a n b e c o n s i d e r a b l y l o We r e d .A s compared W i t h t h e ? l t e rp r e s s , s p r a y d r y i n gc a n more e f f e c t i v e l y p r e v e n t t h e l o s s o ft h e s o l u b l e s a l tc o n t a i n e d i n t h e s l u r r y and t h u s c a n b e s a i dt o b e a

m o r e d e s i r e ds o l i d i ? c a t i o n

methodf o r

r e s l u r r y i n g .

[ 0 0 5 4 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,t h e s l u r r y i s d r i e d t o g i v e a c o m p o s i t i o n h a v i n ga Wa t e rc o n t e n t o f 0 ( Z e r o )t o 9 by e i g h t , more r e f e r a b l y3 t o 7b y We i g h t .

[ 0 0 5 5 ] I n a n o t h e r p r e f e r r e d e m b o d i m e n to f t h e p r e s e n ti n v e n t i o n , t h e s l u r r y c a n b e d e h y d r a t e dt o g i v e a p r e s s e dc a k e h a v i n ga r e d u c e d Wa t e rc o n t e n t o f20 o 30 by e i g h t ,W h i c hi s s t i l l? u i d , f o l l o We db y d r y i n gt o g i v e a c o m p o s i t i o nh a v i n g a Wa t e r c o n t e n t o f 0 ( Z e r o ) t o 9 by We i g h t , morep r e f e r a b l y3 t o 7 b y We i g h t .

[ 0 0 5 6 ] I n a n o t h e r p r e f e r r e d e m b o d i m e n to f t h e p r e s e n ti n v e n t i o n , a method may a l s o b e a d o p t ed W h e r e i nt h e s l u r r y


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i s d e h y d r a t e dt o g i v e a p r e s s e d c a k e h a v i n g a Wa t e r c o n t e n to f 1 5 t o 2 5 by W e i g h tWhich s t h e n u s e d a s a c o m p o s i t i o nf o r a s a n i t a r y W a r eb o d y . F u r t h e r , t h e p r e s s e d c a k e may b ep a s s ed t h r o u g ha p e l l e t e r o r t h e l i k e t os h a p e t h e c a k e i n t o

?akes o r n o o d l e s Which can improve w o r k a b i l i t y and cans h o r t e n r e s l u r r y i n g t i m e . The c o m p o s i t i o ni n t h e f o r m o f? a k e s o r noodles can b e d r i e d t o reduce t h e Water c o n t e n t t o

0 ( Z e r o ) t o 9 y e i g h t . I n t h i sc a s e , a f u r t h e r r e d u c t i o n i nvolume a n d W e i g h t c a n b er e a l i Z e d , a n d , a t t h e same t i m e ,s i n c e t h e c o m p o s i t i o ni s s e p a r a t e d i n as m a l l e r s i Z e ,t h et r a n s f e r e f f i c i e n c y c a n b e e n h a n c e d .

[ 0 0 5 7 ] P r o d u c t i o np r o c e s s o f s a n i t a r y W a r eu s i n g compos i t i o n f o rs a n i t a r y W a r ebody

[ 0 0 5 8 ] I n t h e p r o d u c t i o n p r o c e s s o f a s a n i t a r y Warea c c o r d i n g t o t h e p r e s e n t i n v e n t i o n , a t t h e o u t s e t ,a t l e a s tW a t e r i s a d d e d t o t h e c o m p o s i t i o nf o r a s a n i t a r y Ware b o d y ,a n d t h e m i x t u r e i s s t i r r e d t or e g e n e r a t e a s l u r r y f o r s l i pc a s t i n g .

[ 0 0 5 9 ] P r e f e r a b l y, t h ea m o u n to f Wa t e r a d d e d i s p r o p e r l yd e t e r m i n e d s o a s t o g i v e p r o p e r s l u r r y c o n c e n t r a t i o n andv i s c o s i t y d e p e n d i n gu p o nc o n d i t i o n s o fa k i l nu s e d , m o l d i n gc o n d i t i o n s s u c h a s t y p e o f a s l i pc a s t i n g mold a n d t h e l i k e .F o r e X am p l e ,a method m a y e a d o p t e dW h e r e i nt h e amounto f Wa t e r n e c e ss a r yf o r p r o v i d i n g a p r e d e t e r m i n e ds l u r r yc o n c e n t r a t i o n i s p r e v i o u s l y c a l c u l a t e df rom t h e W a t e r cont e n t o f t h e c o m p o s i t i o nand h i samount f W a t e ri s added t ot h e c o m p o s i t i o nf o r a s a n i t a r y W a r eb o d y .

[ 0 0 6 0 ] M i x i n ga n d s t i r r i n gm e t h o d sa r e n o t p a r t i c u l a r l yl i m i t e d ,a n d e X a m p l e st h e r e o f i n c l u d es t i r r i n gd e v i c e s s u c ha s s t i r r e r sa n d b l u n g e r s .

[ 0 0 6 1 ] W a t e r u s e d f o rr e s l u r r y i n g i s n o t p a r t i c u l a r l yl i mi t e d .P r e f e r a b l y , h o W e v e r ,a l a r g e amount o f i o n s Which

c a u s e c o a g u l a t io nand p r e c i p i t a t i o n , s u c h a s c h l o r i d e i o n s( C l ‘ ) o r s u l f a t e i o n s (SO 2 - ) ,a r e n o t c o n t a i n e d .W h e n a t e ru s e d f o r r e s l u r r y i n g c o n t a i n s a l a r g e amount o f t h e s e i o n s ,p r e f e r a b l y , t h e W a t e r i s s u b j e c t e d t o d i s t i l l a t i o no r i o ne X c h a n g et r e a t m e n t t o g i v e d i s t i l l e dWa t e r o r i o n - e x c h a n g e dWa t e r Which i s t h e n u s e d f o r r e s l u r r y i n g .

[ 0 0 6 2 ] I n a p r e f e r r e d embodiment f t h ep r e s e n t i n v e n t i o n ,i n r e s l u r r y i n g , a n a d d i t i o n a l raW a t e r i a l poWder s added i no r d e r t o c o n t r o l s h r i n k a g ea t t h e t i m e o f ? r i n g o r c a s t i n g r t ea t t h et i m e o f s l i pc a s t i n g .S p e c i ? c a l l y , When g r e e n b o d i e sa r e ? r e d i n a p l u r a l i t y o f k i l n s , t h e s h r i n k a g e i s n o t o f t e ne v e n d e p e n d i n gupon c o n d i t i o n so f t h e k i l n s u s e d . I n d e p e nd e n t l y o f t h e c o n d i t i o n s o f t h e k i l n su s e d , ? r e d p r o d u c t sh a v i n g a g i v e n s h r i n k a g e c a n b e p r e p a r e d b y a d d i n g a na d d i t i o n a l raW m a t e r i a l poWder o t h e r e g e n e r a t r e ds l u r r y t o

c o n t r o l t h e s h r i n k a g ea t t h e t i m e o f ? r i n g . S i n c e t h e s a n i t a r yWare i n c l u d e s m a n y t y p e s a n d s h a p e s , t h e t h i c k n e s s o f t h eb o d ys h o u l d b es u i t a b l e f o rt h e s h a p e a n d t y p e .The t h i c kn e s s o f c a s t i n g body a t t h e t i m e o f s l i p c a s t i n g c a n b er e g u l a t e d t o a p r o p e r l e v e l d e p e n d i n gupon t h e t y p e a n ds h a p e o f t h e s a n i t a r y W a r e by a d d i n g t h e a d d i t i o n a l raWm a t e r i a l p o W d e r .I n p a r t i c u l a r , i nt h e c a s e o f s a n i t a r y Wa r e s ,t h e r e a r e v a r i o u s t y p e s a n d s h a p e s s u c h a s t o i l e tb o W l s ,u r i n a l s ,W a s h b o W l s , a n dh a n d Wash a s i n s .T h e r e f o r e , t h ea b o v e c o n t r o l o f t h e c a s t i n g t h i c k n e s s i s e f f e c t i v e .

[ 0 0 6 3 ] I n a p r e f e r r e d embodiment f t h ep r e s e n t i n v e n t i o n ,a t l e a s to n e m a t e r i a l s e l e c t e d from f e l d s p a r , d o l o m i t e , a n dn e p h e l i n e m a y be used a s t h e a d d i t i o n a l raW m a t e r i a lpoWder. These raW m a t e r i a l poWders f u n c t i o n a s a ? u X i n a

M a r . 1 6 ,2 0 0 6

raW m a t e r i a l f o r a s a n i t a r y Ware and t h u s l o W e rt h e m e l t i n gi n i t i a t i o nt e m p e r a t u r eo f t h e g r e e nbody t t h e t i m e o f ? r i n g .T h e r e f o r e , When t h e raW m a t e r i a l poWder i s added t o t h er e g e n e r a t e d s l u r r y ,a p r o p e r s h r i n k a g ec a n b e r e a l i Z e d i n

? r i n g u s i n g a k i l n h a v i n g a l o W? r i n g t e m p e r at u r e .[ 0 0 6 4 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,a t l e a s t one m a t e r i a l s e l e c t e d from o t t e r y s t o n e , s i l i c ar o c k ,and alumina may be used a s t h e a d d i t i o n a l raW m a t e r i a lpoWder. These raW m a t e r i a l poWders f u n c t i o n a s an a g g r eg a t e i n a raW m a t e r i a l f o r a s a n i t a r y Ware and t h u s i n c r e a s et h e m e l t i n g i n i t i a t i o nt e m p e r a t u r e o f t h e g r e e n body a t t h et i m e o f ? r i n g . T h e r e f o r e ,When t h e raW m a t e r i a l poWder sadded t o t h e r e g e n e r a t e d s l u r r y ,a p r o p e r s h r i n k a g ec a n b er e a l i Z e d i n ? r i n g u s i n g a k i l nh a v i n ga h i g h ? r i n g t e m p e r at u r e .

[ 0 0 6 5 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,a t l e a s to n e m a t e r i a l s e l e c t e d from c h i n a c l a y ,b a l l c l a y ,a n dp l a s t i c c l a y m a y b e u s e d a s t h e a d d i t i o n a l raW m a t e r i a lp o W d e r .T h e s e raW m a t e r i a l p o W d e r sf u n c t i o n m a i n l y t oc o n t r o l t h e amount o f c a s t i n g a t t h e t i m e o f s l i pc a s t i n g a n dt o c o n t r o l p l a s t i c i t ya t t h e t i m e o f s h a p i n g . T h e s e a d d i t i o n a lraW m a t e r i a l poWders m a y a l s o b e a d d e d f o r v i s c o s i t ym o d i ? c a t i o n p u r p o s e sa t t h e t i m e o f s l u r r y i n g . A c c o r d i n g l y ,t h e a d d i t i o n o f t h e s e raW m a t e r i a l poWders t o t h e r e g e n e ra t e d s l u r r yc a n r e a l i Z e abody a v i n g p r o p e rs l u r r yv i s c o s i t ya n d p l a s t i c i t y a n d c a n r e a l i Z e a body t h i c k n e s s s u i t a b l e f o rt h e s h a p e a n dt y p e o f t h e s a n i t a r y W a r e t o b e p r o d u c e d .

[ 0 0 6 6 ] I n a p r e f e r r e de m b o d i m e n to f t h ep r e s e n t i n v e n t i o n ,t h e amount o f t h e a d d i t i o n a l raW m a t e r i a l poWder added i s0 . 0 1 t o 1 0 p a r t s by We i g h t ,more p r e f e r a b l y0 . 0 1 t o 6 p a r t sb y We i g h t ,b a s e d o n 1 0 0 p a r t sb y W e i g h to f t h ec o m p o s i t i o nf o r a s a n i t a r y Ware b o d y . When h e amount f t h e a d d i t i o n a lraW m a t e r i a l poWder added i s i n t h e above-de?ned r a n g e ,d e s i r e d e f f e c t s s u c h a s c o n t r o l o f t h e m e l t i n g i n i t i a t i o nt e m p e r a t u r e c a n b e a t t a i n e d W h i l e m a i n t a i n i n gt h e h i g hs t r e n g t ho f t h e? r e d p r o d u c t .

[ 0 0 6 7 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,i n r e s l u r r y i n g , a s o l u b l e s a l t i s a d d e d f o r s l u r r y v i s c o s i t ymodi?cation p u r p o s e s .The r e a s o n f o r t h i s i s a s f o l l o W s .Thev i s c o s i t yo f t h er e g e n e r a t e ds l u r r yi s s o m e t i m e ss o m e W h a th i g h e r t h a nt h ev i s c o s i t y o f t h e s l u r r yb e f o r e t h es o l i d i ? c at i o n .Although t h e r e a s o n f o r t h i sh a s n o t b e e n f u l l y e l u c id a t e d y e t ,one o f t h e r e a s o n s f o r t h i s phenomenon s b e l i e v e dt o r e s i d e i n t h a t a s m a l l amount o f t h e s o l u b l e s a l to r i g i n a l l yc o n t a i n e d i n t h e raW m a t e r i a l f o r a s a n i t a r y Ware body s l o s td u r i n gd e h y d r a t i o no r d r y i n gl e a d i n g t o a n i n c r e a s e i n s l u r r yv i s c o s i t y . The a d d i t i o n o f a s o l u b l e s a l t a t t h e t i m e o fr e s l u r r y i n gc a n p r e v e n t t h e i n c r e a s e i n v i s c o s i t y t o p r o v i d e

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s u i t a b l e f o rs l i pc a s t i n g ,[ 0 0 6 8 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,a t l e a s t one m a t e r i a l s e l e c t e d f rom sod ium s i l i c a t e ,sod iumh y d r o X i d e ,sodium a r b o n a t e , a n d a p h o s p h o r i ce s t e rmay eused a s t h e s o l u b l e s a l t .I n t h e s l u r r y o f t h e raW m a t e r i a l f o ra s a n i t a r y Ware, t h e s e s o l u b l e s a l t s a r e adsorbed t o t h e raWm a t e r i a l p a r t i c l e s t o h a v e e l e c t r i cc h a r g e s , a n d t h i sr e s u l t si nt h ed e v e l o p m e n to f e l e c t r i cr e p u l s i o n among h ep a r t i c l e s .T h e r e f o r e , t h e s o l u b l e s a l t sf u n c t i o n a s a d i s p e r s a n t i n t h es l u r r y ,a n d t h e a d d i t i o n o f t h e s o l u b l es a l t s t ot h e r e g e n e r a t e ds l u r r y c a n r e a l i Z et h e c o n t r o l o f t h e v i s c o s i t y o f t h e s l u r r ytoWard a loWer v a l u e .

[ 0 0 6 9 ] I n a p r e f e r r e d embodiment f t h e p r e s e n t i n v e n t i o n ,t h e amount o f t h e s o l u b l e s a l ta d d e d i s 0 . 0 0 1 t o 0 . 2 p a r t by


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W e i g h tb a s e d o n 1 0 0 p a r t sb y W e i g h to f t h ec o m p o s i t i o nf o ra s a n i t a r y Ware b o d y . When h e amount o f t h e s o l u b l e s a l ta d d e d i s i n t h e a b o v e - d e ? n e dr a n g e , t h e v i s c o s i t y o f t h es l u r r y c a n b e l o w e r e dW i t h o u tc a u s i n gt h e c o a g u l a t i o ne f f e c t .

[ 0 0 7 0 ] I n a p r e f e r r e d embodiment f t h ep r e s e n t i n v e n t i o n ,a method i s a d o p t e d W h e r e i n ,b e f o r e t h e p r e p a r a t i o n o f as a n i t a r y Ware u s i n g t h e c o m p o s i t i o nf o r a s a n i t a r y Wareb o d y , a t e s tp i e c e o f a s a n i t a r y W a r e i s p r e v i o u s l yp r e p a r e du s i n g t h e r e g e n e r a t e d s l u r r y u n d e r t h e same p r o c e s s a n dc o n d i t i o n s a s i n t e n d e d t o b e u s e d i n t h e p r e p a r a t i o n o f t h es a n i t a r y W a r ea n d i s s u b j e c t e d t o measurement o f s h r i n k a g eo r t h e l i k e t o p r o v i d e measured d a t a based on Which t h er e g e n e r a t e ds l u r r yi s s l i g h t l yc o n t r o l e d .T h e s l i g h tc o n t r o lc a n b e c a r r i e d o u t by p r o p e r l y a d d i n gv a r i o u s raW m a t e r i a lp o W d e r si n r e s l u r r y i n g t h e c o m p o s i t i o nf o r as a n i t a r y W a r eb o d y .F o r e X a m p l e ,When h ep r e v i o u s l ym e a s u r e ds h r i n k a g el e v e l o f t h e t e s tp i e c e i s s m a l l , a raW m a t e r i a l poWder s u c ha s f e l d s p a r , d o l o m i t e , o r n e p h e l i n e a s a ? u X componen t f o ri n c r e a s i n g t h e s h r i n k a g ea t t h e t i m e o f ? r i n g i s a d d e d t o t h es l u r r y t o r e n d e r t h e s l u r r y s u i t a b l e f o r p r o v i d i n g a p r o p e rs h r i n k a g e .On h eo t h e r h a n d , When h ep r e v i o u s l ym e a s u r e ds h r i n k a g e l e v e l o f t h e t e s tp i e c e i s l a r g e , a raW m a t e r i a lpoWder such a s p o t t e r y s t o n e , s i l i c a r o c k and alumina a s a na g g r e g a t ef o rr e d u c i n gt h es h r i n k a g e a t t h et i m e o f ? r i n g i sa d d e dt o t h e s l u r r y t o r e n d e r t h e s l u r r y s u i t a b l e f o rp r o v i d i n ga p r o p e rs h r i n k a g e . I n o r d e r t o p r o v i d e a body h a v i n gs l u r r yv i s c o s i t y ,b o d y t h i c k n e s s ,a n d p l a s t i c i t ys u i t a b l ef o r t h es h a p e a n dt y p e o f a s a n i t a r y Ware t o b e p r e p a r e d b a s e dond a t a on c a s t i n g amount a n d p l a s t i c i t y a s measured i n t h ep r e p a r a t i o n o f t h e g r e e n body t e s t p i e c e , a raW m a t e r i a lp o W d e rs u c ha sc h i n ac l a y , b a l l c l a y ,a n d p l a s t i cc l a y i s a d d e dt o t h e s l u r r y .

[ 0 0 7 1 ] T h e r e g e n e r a t e ds l u r r yt h u so b t a i n e di s p o u r e di n t oa s l i pc a s t i n g mold o f gypsum o r a r e s i n ,a n d , a f t e rc a s t i n g ,t h e r e s u l t a n t g r e e n body i s p u l l e d o u t f r o m t h e m o l d . Theg r e e n body i s d r i e d a n d i s t h e n c o a t e d W i t hg l a Z e i n i t sd e s i r e d p a r t .The g l a Z e d g r e e nbody i s ? r e d t o p r o v i d e as a n i t a r y W a r e .

[ 0 0 7 2 ] S t e p s a f t e rs l i pc a s t i n gmay b e t h o s ec o m m o n l yused i n t h e p r o d u c t i o n o fs a n i t a r y Wares and a r e n o t p a rt i c u l a r l yl i m i t e d . Any o n v e n t i o n a lg l a Z emay e u s e d a s t h eg l a Z e W i t h o u t l i m i t a t i o n s o f a r a s i t i s s u i t a b l e f o r t h ep r o d u c t i o no f s a n i t a r y Wa r e s . T h e ? r i n g t e m p e r at u r ei s n o tl i m i t e d s o f a r a s t h e t e m p e r a t u r e i s s u i t a b l e f o r t h e product i o n o f s a n i t a r y Wa r e s . I n g e n e r a l , h o W e v e r ,t h e ? r i n g t e mp e r a t u r e i s 1100 t o 1 2 0 0 ° C .

EXAMPLES

C o m p a r a t i v eE x a m p l e1

[ 0 0 7 3 ] A aW m a t e r i a l , f o r a s a n i t a r y Ware b o d y , c o n t a i ni n g p o t t e r y s t o n e ,f e l d s p a r ,c l a y a n d t h el i k eW a sp r o v i d e d .T h i s raW m a t e r i a l f o r as a n i t a r y W a r ebody 8 0 0 k g ) , 260 kgo f Wa t e r , 1 k g o f s o d i u ms i l i c a t e ,a n d 7 2 0 k g o f g r i n d i n gb a l l s Were p l a c e d i n a 1 - t c y l i n d e r , and t h e m i x t u r eWas a l lm i l l e d f o r a b o u t 20 r t o p r e p a r e s l u r r y A f t h e raW m a t e r i a lf o rt h eb o d y .

[ 0 0 7 4 ] The c o n t e n t o f Wa t e r i n s l u r r y A as r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t

M a r . 1 6 ,2 0 0 6

55.3 by e i g h t o f t h e p a r t i c l e s h a d a d i a m e t e r o fn o t moret h a n 1 0 pm and t h e 50 a v e r a g e p a r t i c l e d i a m e t e r Was 8 . 3pm n a n u m b e r b a s i s .

[ 0 0 7 5 ] F u r t h e r ,t h e v i s c o s i t y o f s l u r r yA Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 4 6 0 mPa~s.

[ 0 0 7 6 ] S l u r r y A Was t h e n p o u r e d i n t o ap l a s t e rm o l d ,f o l l o W e db y s l i p c a s t i n g t o p r e p a r e a p l a t e - s h a p e d g r e e nbody h a v i n g a l e n g t h o f 2 5 0 m m , a Width o f 30 m m , and at h i c k n e s s o f 10 mm. T h i s g r e e n body Was d r i e d a t 4 5 ° C .o v e r n i g h t ( a b o u t1 6 h r ) .T h e d r i e d g r e e n b o d yWas ? r e d a t1100 t o 1200° C . f o r 2 4 h r t o p r e p a r e a ?red p r o d u c t .

[ 0 0 7 7 ] The d i m e n s i o no f t h e ? r e d p r o d u c tWas m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 1 . 5 .

[ 0 0 7 8 ] The t i m e W h i c hh a d e l a p s e d b e t W e e nt h ei n i t i a t i o no f t h e p r e p a r a t i o n o f t h e raW m a t e r i a l a n d t h e p r o v i s i o n o ft h e s l u r r y f o rs l i pc a s t i n g Was a b o u t 3 0 h r .

C o m p a r a t i v eE X a m p l e2

[ 0 0 7 9 ] S l u r r yA r e p a r e d i n C o m p a r a t i v eE X a m p l e1 W a sp o u r e di n t o ap l a s t e r mold o rm o l d i n ga We s t e r n - s t y l et o i l e tb o W l , f o l l o We db y s l i pc a s t i n g .T h eg r e e nb o d yt h u so b t a i n e dWas d r i e d a t 4 5 ° C . o v e r n i g h t ( a b o u t1 6 h r ) a n d Was t h e ng l a Z e d .The l a Z e d g r e e nbody Was ? r e d a t 1 1 0 0 t o 1 2 0 0 ° C .f o r 24 h r t o p r e p a r e a W e s t e r n - s t y l et o i l e tboWl. I n t h e s a m emanner a s d e s c r i b e d a b o v e ,10 W e s t e r n - s t y l e t o i l e tboWlsWere p r e p a r e d . FIG. 1 i s a p e r s p e c t i v e vieW o f a Westerns t y l e t o i l e tboWl 1 p r e p a r e di n t h i sm a n n e r ,FIG. 2 i s a s i d evieW f t h e We s t e r n - s t y l et o i l e tboWl , a n d FIG. 3 i s a f r o n t

vieW o f t h e We s t e r n - s t y l et o i l e tboWl 1 .[ 0 0 8 0 ] F o r e a c h o f t h e 1 0 We s t e r n - s t y l e t o i l e tb o W l sp r e p a r e d b y t h e? r i n g ,t h ed i m e n s i o n s ,i . e . ,l e n g t h ,W i d t h ,and h e i g h t , Were measured t o c o n ? r m Whether o r n o t t h ed i m e n s i o n sa r e W i t h i n s p e c i ? c a t i o n s i n c l u d i n gt h e t o l e r a n c eo f t h e p r o d u c t . The l e n g t h a shoWn i n FIG. 2 Was measureda s t h e l e n g t h . The l e n g t h b shoWn i n FIG. 3 Was measureda s t h e W i d t h , and t h e l e n g t h c s h o W n n FIG. 2 Was measu reda s t h e h e i g h t . A s a r e s u l t ,f o r a l l t h e W e s t e r n - s t y l e t o i l e tb o W l s ,a l l t h e l e n g t h , W i d t h a n dh e i g h t v a l u e s W e r e l o c a t e di ns u b s t a n t i a l l y t h em i d d l eo f t h es p e c i ? c a t i o n s , a n d ,t h u s ,a l lt h e We s t e r n - s t y l e t o i l e tb o W l s p a s s e d t h e d i m e n s i o n a li n s p e c t i o n .

[ 0 0 8 1 ] F u r t h e r ,f o re a c h o f t h e1 0 s a m p l e s , t h eh e i g h t o f

t h eg r e e n b o d y i m m e d i a t e l y

a f t e rt h e s l i pc a s t i n g Was

c o m p a r e dW i t ht h e h e i g h t o ft h e ? r e d p r o d u c tt o c a l c u l a t e t h ep e r c e n t a g e s h r i n k a g e . A s a r e s u l t ,t h e a v e r a g e o f t h e p e rc e n t a g e s h r i n k a g e sWas 1 2 . 4 . The l e n g t h c shoWn i n FIG.2 Was measured a s t h e h e i g h t .

E X a m p l e1

[ 0 0 8 2 ]S l u r r yA a b o u t2 0 0 k g )p r e p a r e di n C o m p a r a t i v eEXample 1 Was r o v i d e d . T h i s s l u r r y AWa s i n t r o d u c e di n t oa s p r a y d r y e r a n d Was d r i e d a n d g r a n u l a t e db y a t o m i Z i n gt h es l u r r y a t a n ambient t e m p e r a t u r e o f 8 0 °C o p r e p a r e a b o u t1 2 0 k g o f a g r a n u l a rc o m p o s i t i o n c o m p r i s i n ga g g l o m e r a t e so f t h e poWder o f t h e raW m a t e r i a l f o r t h e b o d y . The Wa t e rc o n t e n t o f t h e c o m p o s i t i o nWas measured and found t o b e


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5.5 by We i g h t . The 5 0 a v e r a g e p a r t i c l e d i a m e t e r o n aW e i g h t b a s i s o f t h e c o m p o s i t i o nWas m e a s u r e dby a d r ys i e v i n g a p p a r a t u sa c c o r d i n gt o 1 1 5 Z 8 8 1 5 ( 1 9 9 4 )a n d f o u n dt o b e 2 . 1 mm.

[ 0 0 8 3 ] T h e c o m p o s i t i o n 2 . 5k g ) t h u s o b t a i n e d ,1 k g o fWa t e r , a n d 4 kg o f g r i n d i n g b a l l s Were p l a c e d i n a 6k g - e a r t h e n W a r ep o t a n d W e r emixed t o g e t h e r a n d s t i r r e di na b a l l m i l l f o r a b o u t 1 0 min o p r e p a r e r e g e n e r a t e ds l u r r y B .About 3 0 min Was t a k e n t o o b t a i n t h e s l u r r y f o r s l i pc a s t i n gu s i n g t h e s o l i dm a t e r i a l a f t e rt h es p r a y d r y i n g .

[ 0 0 8 4 ] The c o n t e n t o f W a t e r i n s l u r r y B Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t5 4 . 8 by W e i g h to f t h e p a r t i c l e s h a d a d i a m e t e r o fn o t moret h a n 1 0 pm and t h e 50 a v e r a g e p a r t i c l e d i a m e t e r Was 8 . 4pm n a n u m b e r b a s i s .

[ 0 0 8 5 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r yB Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 620 m p a - s .

[ 0 0 8 6 ] S l u r r y B Was p o u r e di n t o a p l a s t e rm o l d , f o l l o W e db y s l i pc a s t i n gt o p r e p a r e a p l a t e - s h a p e d g r e e nb o d yh a v i n ga l e n g t h o f 2 5 0 mm, a Width o f 30 mm, and a t h i c k n e s s o f10 m m . T h i s g r e e n body Was d r i e d a t 4 5 ° C . o v e r n i g h t( a b o u t 1 6 h r ) . The d r i e d g r e e n body Was ? r e d a t 1 1 0 0 t o1200° C . f o r 2 4 h r t o p r e p a r e a ? r e d p r o d u c t .

[ 0 0 8 7 ] The d i m e n s i o no f t h e? r e d p r o d u c t Was m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 1 . 2 .

E x a m p l e2

[ 0 0 8 8 ]S l u r r yA a b o u t2 0 0 k g )p r e p a r e di n C o m p a r a t i v eExample 1 Was r o v i d e d . T h i s s l u r r y AWa s i n t r o d u c e di n t oa s p r a y d r y e r a n d Was d r i e d a n d g r a n u l a t e dby a t o m i Z i n gt h es l u r r y a t a n a m b i e n t t e m p e r a t u r e o f8 0 ° C . t o p r e p a r e a b o u t1 2 0 k go f a g r a n u l a rc o m p o s i t i o n c o m p r i s i n ga g g l o m e r a t e so f t h e poWder o f t h e raW m a t e r i a l f o r t h e b o d y . The Wa t e rc o n t e n t o f t h e c o m p o s i t i o nWas measured and found t o be7.0 by We i g h t . The 5 0 a v e r a g e p a r t i c l e d i a m e t e r o n aW e i g h t b a s i s o f t h e c o m p o s i t i o nWas m e a s u r e dby a d r ys i e v i n g a p p a r a t u sa c c o r d i n gt o 1 1 5 Z 8 8 1 5 ( 1 9 9 4 )a n d f o u n dt o b e 2 . 3 mm.

[ 0 0 8 9 ] T h e c o m p o s i t i o n 2 . 5k g ) t h u so b t a i n e d ,1 k g o fWa t e r , 0 . 5g ( 0 . 0 2 ) o f s o d i u ms i l i c a t e ,a n d 4 k g o f g r i n d i n gb a l l s Were p l a c e d i n a 6 k g - e a r t h e n W a r ep o t and Were mixedt o g e t h e r and s t i r r e d i n a b a l l m i l l f o r a b o u t 10 min o p r e p a r er e g e n e r a t e ds l u r r y C . About 30 min Was t a k e n to o b t a i n t h es l u r r y f o rs l i pc a s t i n gu s i n g t h ec o m p o s i t i o na f t e rt h es p r a yd r y i n g .[ 0 0 9 0 ] The c o n t e n t o f Wa t e r i n s l u r r y C Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t55 .7 by W e i g h to f t h e p a r t i c l e s h a d a d i a m e t e r o fn o t moret h a n 1 0 pm and t h e 50 a v e r a g e p a r t i c l e d i a m e t e r Was 8 . 2pm n a n u m b e r b a s i s .

[ 0 0 9 1 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r yC Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 588 m P a ~ s .

M a r . 1 6 ,2 0 0 6

[ 0 0 9 2 ] S l u r r y C Was o u r e d i n t o ap l a s t e rm o l d , f o l l o W e db y s l i pc a s t i n gt o p r e p a r e a p l a t e - s h a p e dg r e e nb o d yh a v i n ga l e n g t h o f 2 5 0 mm, a Width o f 30 mm, and a t h i c k n e s s o f10 m m . T h i s g r e e n body Was d r i e d a t 4 5 ° C . o v e r n i g h t

( a b o u t 1 6 h r ) .The d r i e d g r e e n body Was ? r e d a t 1 1 0 0 t o1200° C . f o r 2 4 h r t o p r e p a r e a ? r e d p r o d u c t .

[ 0 0 9 3 ] The d i m e n s i o no f t h e ? r e d p r o d u c t Was m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 1 . 3 .

E x a m p l e3

[ 0 0 9 4 ]S l u r r yA a b o u t2 0 0 k g )p r e p a r e di n C o m p a r a t i v eExample 1 Was r o v i d e d . T h i s s l u r r y AWa s i n t r o d u c e di n t oa ? l t e r p r e s s a p p a r a t u s . The s l u r r y Was r e s s e d a t a p r e s s u r eo f 1 0 kg /cm2 a n d Was h e l d i n t h i s s t a t e f o r 30 min t od e h y d r a t e t h e s l u r r y .T h u s , a p r e s s e d c a k e h a v i n ga Wa t e r

c o n t e n t o f a b o u t 2 2 by W e i g h tWas o b t a i n e d . The p r e s s e dc a k e Was e d i n t oa p e l l e t e r d i ed i a m e t e r 1 0 m m ) o p r o v i d ea b o u t 160 kg o f n o o d l e s o f t h e s e m i - s o l i d raW m a t e r i a l f o rt h e b o d y . The W a t e r c o n t e n t o f t h e n o o d l e s Was measureda n d f o u n dt o b e 2 1 b y We i g h t .

[ 0 0 9 5 ] T h en o o d l e s 2 . 5k g ) t h u s o b t a i n e d,7 0 0 g o f W a t e r ,0 . 3 g ( 0 . 0 1 ) o f s o d i u ms i l i c a t e ,a n d 4 k g o f g r i n d i n gb a l l sWere p l a c e d i n a 6 k g - e a r t h e n W a r ep o t and Were mixedt o g e t h e r and s t i r r e d i n a b a l l m i l l f o r a b o u t 20 min o p r e p a r er e g e n e r a t e ds l u r r y D . About 5 0 min Was t a k e n t o o b t a i n t h es l u r r y f o rs l i pc a s t i n gu s i n g t h en o o d l e s .

[ 0 0 9 6 ] The c o n t e n t o f Wa t e r i n s l u r r y D Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t56 .2 o f t h e p a r t i c l e s had a d i a m e t e r o f n o t more t h a n 10 pmand t h e 50 average p a r t i c l e diameter Wa s 8 . 0 pm on anumber b a s i s .

[ 0 0 9 7 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r yD Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 5 0 0 mPa~s.

[ 0 0 9 8 ] S l u r r y Was p o u r e di n t o ap l a s t e rm o l d , f o l l o W e db y s l i pc a s t i n gt o p r e p a r e a p l a t e - s h a p e dg r e e nb o d yh a v i n ga l e n g t h o f 2 5 0 mm, a Width o f 30 mm, and a t h i c k n e s s o f10 m m . T h i s g r e e n body Was d r i e d a t 4 5 ° C . o v e r n i g h t( a b o u t 1 6 h r ) .The d r i e d g r e e n body Was ? r e d a t 1 1 0 0 t o1200° C . f o r 2 4 h r t o p r e p a r e a ? r e d p r o d u c t .

[ 0 0 9 9 ] The d i m e n s i o no f t h e ? r e d p r o d u c t Was m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 1 . 0 .

E x a m p l e4

[ 0 1 0 0 ]S l u r r yA a b o u t2 0 0 k g )p r e p a r e di n C o m p a r a t i v eExample 1 Was r o v i d e d . T h i s s l u r r y AWa s i n t r o d u c e di n t oa s p r a y d r y e r a n d Was d r i e d a n d g r a n u l a t e db y a t o m i Z i n gt h es l u r r y a t a n a m b i e n t t e m p e r a t u r e o f8 0 ° C . t o p r e p a r e a b o u t1 2 0 k g o f a g r a n u l a rc o m p o s i t i o n c o m p r i s i n ga g g l o m e r a t e so f t h e poWder o f t h e raW m a t e r i a l f o r t h e b o d y . The Wa t e rc o n t e n t o f t h e c o m p o s i t i o nWas measured and found t o b e7.0 by We i g h t . The 5 0 a v e r a g e p a r t i c l e d i a m e t e r on a


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W e i g h t b a s i s o f t h e c o m p o s i t i o nWas m e a s u r e dby a d r ys i e v i n g a p p a r a t u sa c c o r d i n gt o 1 1 5 Z 8 8 1 5 ( 1 9 9 4 )a n d f o u n dt o b e 2.2 mm.

[ 0 1 0 1 ] T h e c o m p o s i t i o n 2 . 5k g ) t h u s o b t a i n e d ,1 k g o fWa t e r , 0 . 5g ( 0 . 0 2 ) o f s o d i u ms i l i c a t e ,4 k g o f g r i n d i n gb a l l s ,a n d 1 2 5 go f f e l d s p a r W e r ep l a c e d i n a 6 k g - e a r t h e nWare p o t and Were mixed t o g e t h e r and s t i r r e d i n a b a l l m i l lf o r a b o u t 1 0 min o p r e p a r e r e g e n e r a t e ds l u r r y E . About 3 5min Was t a k e n t o o b t a i n t h e s l u r r y f o rs l i pc a s t i n g u s i n g t h ec o m p o s i t i o na f t e rt h es p r a y d r y i n g .

[ 0 1 0 2 ] The c o n t e n t o f Wa t e r i n s l u r r y E Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t5 5 . 0 f t h e p a r t i c l e s had a d i a m e t e r o f n o t more t h a n 10 pmand t h e 50 a v e r a g e p a r t i c l e diameter Wa s 8 . 0 pm on anumber b a s i s .

[ 0 1 0 3 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r yE Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 5 4 0 m P a ~ s .

[ 0 1 0 4 ] S l u r r y E Was p o u r e di n t o a p l a s t e rm o l d , f o l l o W e db y s l i pc a s t i n gt o p r e p a r e a p l a t e - s h a p e d g r e e nb o d yh a v i n ga l e n g t h o f 2 5 0 mm, a Width o f 30 mm, and a t h i c k n e s s o f10 m m . T h i s g r e e n body Was d r i e d a t 4 5 ° C . o v e r n i g h t( a b o u t 1 6 h r ) . The d r i e d g r e e n body Was ? r e d a t 1 1 0 0 t o1200° C . f o r 2 4 h r t o p r e p a r e a ? r e d p r o d u c t .

[ 0 1 0 5 ] The d i m e n s i o no f t h e? r e d p r o d u c t Was m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 2 . 2 .

E x a m p l e5

[ 0 1 0 6 ]S l u r r yA a b o u t2 0 0 k g )p r e p a r e di n C o m p a r a t i v eExample 1 Was r o v i d e d . T h i s s l u r r y AWa s i n t r o d u c e di n t oa s p r a y d r y e r a n d Was d r i e d a n d g r a n u l a t e dby a t o m i Z i n gt h es l u r r y a t a n a m b i e n t t e m p e r a t u r e o f8 0 ° C . t o p r e p a r e a b o u t1 2 0 k go f a g r a n u l a rc o m p o s i t i o n c o m p r i s i n ga g g l o m e r a t e so f t h e poWder o f t h e raW m a t e r i a l f o r t h e b o d y . The Wa t e rc o n t e n t o f t h e c o m p o s i t i o nWas measured and found t o be7.0 by We i g h t . The 5 0 a v e r a g e p a r t i c l e d i a m e t e r o n aW e i g h t b a s i s o f t h e c o m p o s i t i o nWas m e a s u r e dby a d r ys i e v i n g a p p a r a t u sa c c o r d i n gt o 1 1 5 Z 8 8 1 5 ( 1 9 9 4 )a n d f o u n dt o b e 2 . 1 mm.

[ 0 1 0 7 ] T h e c o m p o s i t i o n 2 . 5k g ) t h u so b t a i n e d ,1 k g o fWa t e r , 1 . 5g ( 0 . 0 6 ) o f s o d i u ms i l i c a t e ,a n d 4 k g o f g r i n d i n gb a l l s Were p l a c e d i n a 6 k g - e a r t h e n W a r ep o t and Were mixedt o g e t h e r and s t i r r e d i n a b a l l m i l l f o r a b o u t 10 min o p r e p a r er e g e n e r a t e ds l u r r y F .About 35 min Was t a k e n t o o b t a i n t h es l u r r y f o rs l i p c a s t i n gu s i n g t h e p o W d e ra f t e rt h e s p r a yd r y i n g .[ 0 1 0 8 ] The c o n t e n t o f Wa t e r i n s l u r r y F Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t5 5 . 7 f t h e p a r t i c l e s had a d i a m e t e r o f n o t more t h a n 10 pmand t h e 50 a v e r a g e p a r t i c l e diameter Wa s 8 . 2 pm on anumber b a s i s .

[ 0 1 0 9 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r yF Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 4 6 0 mPa~s.

M a r . 1 6 ,2 0 0 6

[ 0 1 1 0 ] S l u r r y F Was p o u r e di n t o a p l a s t e rm o l d , f o l l o W e db y s l i pc a s t i n gt o p r e p a r e a p l a t e - s h a p e dg r e e nb o d yh a v i n ga l e n g t h o f 2 5 0 mm, a Width o f 30 mm, and a t h i c k n e s s o f10 m m . T h i s g r e e n body Was d r i e d a t 4 5 ° C . o v e r n i g h t

( a b o u t 1 6 h r ) .The d r i e d g r e e n body Was ? r e d a t 1 1 0 0 t o1200° C . f o r 2 4 h r t o p r e p a r e a ? r e d p r o d u c t .

[ 0 1 1 1 ] The d i m e n s i o no f t h e ? r e d p r o d u c tWas m e a s u r e da n d Was compared W i t h t h e d i m e n s i o no f t h e g r e e n bodyi m m e d i a t e l ya f t e rt h es l i pc a s t i n g t oc a l c u l a t et h ep e r c e n t a g es h r i n k a g e . A s a r e s u l t ,i t Was f o u n d t h a t t h e p e r c e n t a g es h r i n k a g eWas 1 1 . 4 .

E x a m p l e6

[ 0 1 1 2 ] S l u r r y G 1 2 t ) Was r e p a r e d i n t h e same manner a si n C o m p a r a t i v eE x a m p l e1 ,e x c e p t t h a tt h ep r o p o r t i o n o ft h ecomponen t s i n t h e raW a t e r i a l f o r a s a n i t a r y Ware body Wa sv a r i e d . T h i s s l u r r y G Was i n t r o d u c e d i n t o a s p r a y d r y e r a n dWas d r i e d a n d g r a n u l a t e d by a t o m i Z i n g t h e s l u r r y a t a n

ambient t e m p e r a t u r e o f8 0 ° C . t o p r e p a r e a b o u t 1 1 t o f ag r a n u l a rc o m p o s i t i o n c o m p r i s i n ga g g l o m e r a t eo ft h ep o W d e ro f t h e raW m a t e r i a l f o r t h e b o d y . The W a t e r c o n t e n t o f t h epoWder Was m e a s u r e da n d f o u n dt o b e 4.5 by e i g h t . The5 0 a v e r a g e p a r t i c l e d i a m e t e r on a W e i g h t b a s i s o f t h ec o m p o s i t i o nWas m e a s u r e d b y a d r y s i e v i n g a p p a r a t u sa c c o r d i n gt o J I S Z 8815 ( 1 9 9 4 ) a n d f o u n dt o b e 2 . 1 m m .

[ 0 1 1 3 ] T h e c o m p o s i t i o n 5 . 0 t ) t h u s o b t a i n e d , 2 . 0t o fWa t e r , 1 . 0k g ( 0 . 0 2 ) o f s o d i u ms i l i c a t e ,a n d 4 8 0 0 k g o fg r i n d i n g b a l l s Were p l a c e d i n a 5 t - c y l i n d e r a n d Were mixedt o g e t h e r a n d s t i r r e di n a c y l i n d e r m i l l f o r a b o u t 30 min t op r e p a r e r e g e n e r a t e ds l u r r y H . About 55 min Was t a k e n t oo b t a i nt h e s l u r r y f o rs l i pc a s t i n gu s i n g t h ec o m p o s i t i o na f t e rt h es p r a y d r y i n g .

[ 0 1 1 4 ] The c o n t e n t o f Wa t e r i n s l u r r y H Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l es i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t53 .6 o f t h e p a r t i c l e s had a d i a m e t e r o f n o t more t h a n 10 pmand t h e 50 average p a r t i c l e diameter Wa s 8 . 6 pm on anumber b a s i s .

[ 0 1 1 5 ] F u r t h e r ,t h e v i s c o s i t y o f s l u r r yH Was m e a s u r e dW i t h a Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g s p e e d o f 60r p m and Wa s found t o be 4 8 4 mPa~s.

[ 0 1 1 6 ] S l u r r y H Was o u r e d i n t o t h e same p l a s t e r mold a su s e d i n C o m p a r a t i v eE x a m p l e2 , f o l l o We db y s l i pc a s t i n g .The g r e e n body t h u s o b t a i n e d Was d r i e d and Was t h e ng l a Z e d .The l a Z e d g r e e nbody Was ? r e d a t 1 1 0 0 t o 1 2 0 0 ° C .f o r 24 h r t o p r e p a r e a W e s t e r n - s t y l et o i l e tboWl. I n t h e s a m emanner a s d e s c r i b e d a b o v e ,10 W e s t e r n - s t y l e t o i l e tboWlsWere p r e p a r e d .

[ 0 1 1 7 ] F o r e a c ho f t h e 1 0 We s t e r n - s t y l et o i l e tb o W l sp r ep a r e d b y t h e ? r i n g , t h ed i m e n s i o n s ,i . e . ,l e n g t h ,W i d t h ,a n dh e i g h t , Were measu red i n t h e s a m e m a n n e r a s i n C o m p a r at i v e Example 2 t o c o n ? r m Whether o r n o t t h e dimensions a r eW i t h i ns p e c i ?c a t i o n s i n c l u d i n gt h et o l e r a n c eo f t h ep r o d u c t .A s a r e s u l t ,a l l t h e We s t e r n - s t y l et o i l e tb o W l sp a s s e d t h ed i m e n s i o n a li n s p e c t i o n ,a l t h o u g ha l l t h e l e n g t h ,W i d t h a n dh e i g h t v a l u e s Were t h o s e c l o s e t o t h e r e s p e c t i v e u p p e r l i m i t so f t h es p e c i ?c a t i o n s i n c l u d i n gt h e t o l e r a n c e .

[ 0 1 1 8 ] F u r t h e r , i n t h e same manner a s i n ComparativeE x a m p l e2 , f o re a c h o f t h e 1 0 s a m p l e s , t h e h e i g h t o f t h e


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g r e e nb o d yi m m e d i a t e l ya f t e rt h es l i pc a s t i n gW a sc o m p a r e dW i t h t h e h e i g h t o f t h e .? r e d p r o d u c t t o c a l c u l a t e t h e p e rc e n t a g es h r i n k a g e .A s r e s u l t ,t h e a v e r a g e o f t h e p e r c e n t a g es h r i n k a g e s Was 1 1 . 3 .

[ 0 1 1 9 ]E x a m p l e7[ 0 1 2 0 ] C h i n ac l a y( 2 0 0 k g ) ,5 0 k g o f g a i r o m ec l a y ,a n d 5 0kg f f e l d s p a r poWder e r e a d d e dt o 5 . 0 t o f t h e c o m p o s i t i o np r e p a r e d b y t h es p r a y d r y e r i n E x a m p l e6 . T h e m i x t u r e ,

M a r . 1 6 ,2 0 0 6

g r e e nb o d yi m m e d i a t e l ya f t e rt h es l i pc a s t i n gW a sc o m p a r e dW i t h t h e h e i g h t o f t h e ? r e d p r o d u c t t o c a l c u l a t e t h e p e r c e n ta g e s h r i n k a g e . A s a r e s u l t ,t h e a v e r a g e o f t h e p e r c e n t a g es h r i n k a g e s Was 1 2 . 2 .

RESULTS

[ 0 1 2 6 ] Va r i o u sm e a s u r e dv a l u e sf o rC o m p a r a t i v eE x a m p l e1 and Examples 1 t o 5 a r e shoWn i n T a b l e 1 .

TABLE

Comp. E x . 1 E x . 1 E x . 2 E x . 3 E x . 4 E x . 5

Water c o n t e n t o f composition 5 . 5 7 . 0 2 1 . 0 7 . 0 7 . 0

S l u r r y p r e p a r a t i o nt i m e 3 0 h r 3 0 min 3 0 min 5 0 min 3 5 min 3 5 min

P r o p e r t i e so fs l u r r y

P a r t i c l e d i a m e t e r < 1 0 [ u m 55 .3 54 .8 55 .7 56 .2 55 .0 55 . 7

50 v e r a g e p a r t i c l e d i a m e t e r 8 . 3 , u m 8 . 4 [ u r n 8 . 2 , u m 8 . 0 [ u r n 8 . 0 , u m 8 . 2 , u mVi s c o s i t y 460 mPa s 620 mPa s 588 mPa s 500 mPa s 540 mPa s 460 mPa s

F i r i n g t i m e 24 h r 24 h r 24 h r 24 h r 24 h r 24 h r

F i r i n g s h r i n k a g e 1 1 . 5 1 1 . 2 1 1 . 3 1 1 . 0 1 2 . 2 1 1 . 4

t o g e t h e r W i t h 2 . 0 t o f Wa t e r , 1 . 0k g ( 0 . 0 2 ) o f s o d i u ms i l i c a t e ,a n d 4800 kg o f g r i n d i n g b a l l s W e r e p l a c e d i n a 5t - c y l i n d e r a n d Were mixed t o g e t h e r a n d s t i r r e d i na c y l i n d e rm i l l f o r a b o u t 30 min o p r e p a r e r e g e n e r a t e ds l u r r y J . About6 0 m i n Was t a k e n t o o b t a i n t h es l u r r y f o rs l i pc a s t i n g u s i n gt h ec o m p o s i t i o na f t e rt h es p r a y d r y i n g .

[ 0 1 2 1 ] The c o n t e n t o f Wa t e r i n s l u r r y J Was r e g u l a t e d t o4 0 b y We i g h t . T h e r e a f t e r , t h ep a r t i c l ed i a m e t e r o f t h es l u r r y Was m e a s u r e dW i t h a l a s e r d i f f r a c t i o n - t y p e p a r t i c l e

s i Z e d i s t r i b u t i o n a n a l y Z e r . A s a r e s u l t ,i t Was found t h a t54 .9 f t h e p a r t i c l e s had a d i a m e t e r o f n o t more t h a n 10 pmand t h e 50 a v e r a g e p a r t i c l e diameter Wa s 8 . 2 pm on anumber b a s i s .

[ 0 1 2 2 ] F u r t h e r , t h ev i s c o s i t y o f s l u r r y JWas e a s u r e dW i t ha Brook?eld v i s c o m e t e ra t a r o t o r r o t a t i n g speed o f 60 r p mand Was found t o be 598 mPa~s.

[ 0 1 2 3 ] S l u r r y J Was p o u r e d i n t o t h e same p l a s t e r mold a su s e d i n C o m p a r a t i v eE x a m p l e2 , f o l l o We db y s l i pc a s t i n g .The g r e e n body t h u s o b t a i n e d Was d r i e d and Was t h e ng l a Z e d .The l a Z e d g r e e n body Was ? r e d a t 1 1 0 0 t o 1 2 0 0 ° C .f o r 24 h r to p r e p a r e a W e s t e r n - s t y l et o i l e tb o W l .I n t h e s a m emanner a s d e s c r i b e d a b o v e , 10 W e s t e r n - s t y l e t o i l e tboWlsWere p r e p a r e d .

[ 0 1 2 4 ] F o r e a c h o f t h e 1 0 We s t e r n - s t y l e t o i l e tb o W l sp r e p a r e db y t h e? r i n g ,t h ed i m e n s i o n s ,i . e . ,l e n g t h ,W i d t h ,and h e i g h t , Were measured i n t h e s a m e m a n n e r a s i n

Comparative Example 2 t o c o n ? r m W h e t h e r o r n o t t h ed i m e n s i o n sa r e W i t h i n s p e c i ? c a t i o n s in c l u d i n gt h e t o l e r a n c eo f t h e p r o d u c t . A s a r e s u l t ,f o r a l l t h e We s t e r n - s t y l et o i l e tb o W l s ,a l l t h e l e n g t h , W i d t h a n dh e i g h t v a l u e s W e r e l o c a t e di n s u b s t a n t i a l l yt h em i d d l eo f t h es p e c i ? c a t i o n s , a n d ,t h u s ,a l lt h e We s t e r n - s t y l e t o i l e tb o W l s p a s s e d t h e d i m e n s i o n a li n s p e c t i o n .

[ 0 1 2 5 ] F u r t h e r , i n t h e same manner a s i n ComparativeE x a m p l e2 , f o re a c h o f t h e 1 0 s a m p l e s , t h eh e i g h t o f t h e

[ 0 1 2 7 ] The f o l l o W i n gf a c t s c a n b e s e e n f rom t h e r e s u l t sshoWn i n T a b l e 1 . F o r Examples 1 t o 5 , t h e p r o p e r t i e s o fs l u r r yr e g e n e r a t e d f r o m t h eg r a n u l a rc o m p o s i t i o n sa n d t h ep e r c e n t a g e s h r i n k a g e o ft h e s a m p l e s p r e p a r e d u s i n g t h er e g e n e r a t e d s l u r r i e sW e r e s u b s t a n t i a l l ye q u a l t o t h o s e o fa s - p r e p a r e ds l u r r i e si n C o m p a r a t i v eE x a m p l e1 W h i c hh a dn o t b e e n b r o u g h ti n t o g r a n u l a r c o m p o s i t i o n .T h i s demons t r a t e st h a t t h e c o m p o s i t i o nf o r a s a n i t a r y Ware body a c c o r di n g t o t h e p r e s e n t i n v e n t i o n h a s a h i g h l e v e l o f s u i t a b i l i t yf o rs l u r r yr e g e n e r a t i o n a n d c a n b e a d v a n t a g e o u s l yu s e d i n s l i p

c a s t i n go f s a n i t a r yWa r e s . F u r t h e r ,c o m p a r i s o no f t h e s l u r r yp r e p a r a t i o n t i m ei n C o m p a r a t i v eE x a m p l e1 W i t h t h es l u r r yp r e p a r a t i o n t i m e i n Examples 1 t o5 shoWs h a tt h e p r e s e n ti n v e n t i o nc a n 1 5 s i g n i ? c a n tl y s h o r t e nt h e s l u r r yp r e p a r a t i o nt i m e .

[ 0 1 2 8 ] F o r C o m p a r a t i v eE x a m p l e2 a n d E x a m p l e s6 a n d 7 ,v a r i o u s measured v a l u e s a r e s h o W n i n T a b l e 2 .

TABLE 2

Comp. E x . 2 E x . 6 E x . 7

Wa t e r content of 4.5 4.5

c o m p o s i t i o nS l u r r y p r e p a r a t i o nt i m e 3 0 h r 5 5 min 6 0 minP r o p e r t i es o fs l u r r y

P a r t i c l e d i a m e t e r < 55.3 53.6 54.91 0 [um5 0 a v e r a g e p a r t i c l e 8 . 3 , u m 8 . 6 [ u r n 8 . 2 , u md i a m e t e rVi s c o s i t y 460 mPa s 484 mPa s 598 mPa s

F i r i n g t i m e 24 h r 2 4 h r 24 h rF i r i n gs h r i n k a g e 1 2 . 4 1 1 . 3 1 2 . 2D i m e n s i o n a li n s p e c t i o n P a s s e d P a s s e d P a s s e d

[ 0 1 2 9 ] The f o l l o W i n gf a c t s c a n b e s e e n f rom t h e r e s u l t sshoWn n T a b l e 2 . F o r E x a m p l e s6 a n d 7 , t h e p r o p e r t i e s o fs l u r r i e sr e g e n e r a t e d f r o mt h eg r a n u l a rc o m p o s i t i o n sa n d t h e? r i n g s h r i n k a g ea n d d i m e n s i o n a l a c c u r a c yo f t h e s a n i t a r yW a r e sp r e p a r e d u s i n gt h e r e g e n e r a t e ds l u r r i e sW e r es u b s t a nt i a l l ye q u a l t o t h o s e o f a s - p r e p a r e ds l u r r i e s i nC o m p a r a t i v e


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Example 2 Which h a d n o t b e e n b r o u g h t i n t oa g r a n u l a rc o m p o s i t i o n .T h i s d e m o n s t r a t e st h a tt h e c o m p o s i t i o nf o r as a n i t a r y Ware body a c c o r d i n gt o t h e p r e s e n t i n v e n t i o nh a s ah i g h l e v e lo f s u i t a b i l i t yf o rs l u r r yr e g e n e r a t i o n a n d c a n b e

a d v a n t a g e o u s l yu s e d i n s l i pc a s t i n go f s a n i t a r yWa r e s . S p ec i ? c a l l y ,When t h e c o m p o s i t i o nf o r as a n i t a r y W a r e bodya c c o r d i n gt o t h e p r e s e n t i n v e n t i o ni s u s e d i n t h e p r o d u c t i o no f a s a n i t a r y W a r e , t h e s a n i t a r y Ware c a n be produced undert h e same c a s t i n g and ? r i n g c o n d i t i o n s a s u s e d i n t h e p r od u c t i o n o f a s a n i t a r y Ware u s i n g t h e s l u r r y b e f o r e t h es o l i d i ? c a t i o n . F u r t h e r ,c o m p a r i s o no ft h es l u r r yp r e p a r a t i o nt i m e i n C o m p a r a t i v eE x a m p l e2 W i t h t h es l u r r yp r e p a r a t i o nt i m e i n Examples 6 a n d 7 shoWs h a tt h e p r e s e n t i n v e n t i o nc a n s i g n i ? c a n t l y s h o r t e nt h e s l u r r yp r e p a r a t i o n t i m e .

1 . A o n - s l u r r y c o m p o s i t i o nf o r a s a n i t a r y W a r ebody o ru s e i n p r e p a r i n g a s l u r r y f o rs l i p c a s t i n g ,c o m p r i s i n ga g g l o m e r a t e so f a raW m a t e r i a l poWder f o r s a i d s a n i t a r yWare body a n d h a v i n ga Wa t e r c o n t e n t o f 0 ( Z e r o ) t o 2 5 byWe i g h t , W h e r e i ns a i d poWder h a s a 5 0 a v e r a g e p a r t i c l ediameter of 1 t o 15 pm on a n u m b e r b a s i s .

2 . The c o m p o s i t i o nf o r a s a n i t a r y W a r ebody a c c o r d i n gt oc l a i m 1 , W h e r e i ns a i d Wa t e r c o n t e n t i s 0 ( Z e r o ) t o 9 byWe i g h t .

3 . The c o m p o s i t i o nf o r a s a n i t a r y W a r ebody a c c o r d i n gt oc l a i m 1 , W h e r e i ns a i d Wa t e r c o n t e n t i s 3 t o 7 by We i g h t .

4 . The c o m p o s i t i o nf o r a s a n i t a r y W a r ebody a c c o r d i n gt oc l a i m 1 , W h e r e i ns a i d Wa t e r c o n t e n t i s 1 5 t o 2 5 by e i g h t .

5 . The c o m p o s i t i o nf o r a s a n i t a r y W a r ebody a c c o r d i n gt oc l a i m 1 , W h e r e i nt h e 5 0 a v e r a g e p a r t i c l ed i a m e t e r o f t h eagglomerates i s 1 t o 10 mm n a Weight b a s i s .

6 . A p r o c e s sf o rp r o d u c i n ga n o n - s l u r r yc o m p o s i t i o nf o r as a n i t a r y W a r e body f o r u s e i n p r e p a r i n g a s l u r r y f o r s l i pc a s t i n g ,s a i dp r o c e s s c o m p r i s i n gt h es t e p s o f :

p r o v i d i n ga raW m a t e r i a l f o r a s a n i t a r y Ware b o d y ; a d d i n gWater t o t h e raW m a t e r i a l f o r a s a n i t a r y Ware body;

g r i n d i n g t h e raW m a t e r i a l f o r a s a n i t a r y Ware body W i t hWa t e r a d d e d t h e r e t o t o p r e p a r e a s l u r r y f o r s l i pc a s t i n g ;a n d

d e h y d r a t i n ga n d / o rd r y i n g t h es l u r r yf o rs l i pc a s t i n gt op r e p a r e t h e c o m p o s i t i o nf o r a s a n i t a r y Ware b o d y .

7 . T h e p r o c e s s a c c o r d i n gt o c l a i m 6 , W h e r e i n ,i n a d d i n gs a i d Wa t e r , a s o l u b l e s a l tf o r v i s c o s i t y o f t h e s l u r r y i s f u r t h e radded t o m a t e r i a l f o r a s a n i t a r y Ware b o d y .

8 . The p r o c e s s a c c o r d i n gt o c l a i m 7 , W h e r e i ns a i d s o l u b l es a l ti s a tl e a s t one a l t s e l e c t e d f rom t h e group c o n s i s t i n g o fs o d i u ms i l i c a t e ,s o d i u mh y d r o x i d e ,s o d i u mc a r b o n a t e , a n d ap h o s p h o r i ce s t e r .

9 . T h e p r o c e s s a c c o r d i n gt o c l a i m 6 , W h e r e i ns a i d d r y i n g

i s c a r r i e d o u t by a s p r a y d r y e r .1 0 . The p r o c e s s a c c o r d i n g t o c l a i m 6 , W h e r e i n s a i d

d e h y d r a t i o ni s c a r r i e d o u t by a ? l t e r p r e s s .1 1 . The p r o c e s s a c c o r d i n gt o c l a i m 6 a n y one o f c l a i m s 6 ,

W h e r e i nt h ev i s c o s i t y o f t h e s l u r r y f o rs l i pc a s t i n g i s 2 0 0 t o1,000 m P a ~ s a s m easu red With a Brook?eld viscometer at ar o t o rr o t a t i n g s p e e d o f 6 0 r p m .

M a r . 1 6 ,2 0 0 6

1 2 . A o m p o s i t i o nf o r a s a n i t a r y Ware b o d y , Which i sp r o d u c e db y a p r o c e s s a c c o r d i n gt o c l a i m 6 .

1 3 . A r o c e s s f o r p r o d u c i n ga s a n i t a r y Wa r e , c o m p r i s i n gt h e s t e p s o f :

a d d i n gWa t e r t o t h e c o m p o s i t i o nf o r a s a n i t a r y Ware bodya c c o r d i n gt o c l a i m 1 a n d s t i r r i n gt h e m i x t u r e t o r e g e ne r a t et h e s l u r r y ;

p o u r i n gt h es l u r r yi n t oa s l i pc a s t i n gm o l da n d a l l o W i n gt h e s l u r r y t o c a s t on t h e m o l d ;

t a k i n g t h e r e s u l t a n tg r e e nb o d yo u t o f t h em o l d ;d r y i n gt h eg r e e n b o d y ;

c o a t i n g g l a Z eo n t o t h ed r i e d g r e e n b o d y ;a n d ? r i n g t h eg l a Z e - c o a t e dg r e e n b o d y .

1 4 .T h ep r o c e s s a c c o r d i n gt o c l a i m 1 3 ,W h e r e i n ,i n a d d i n gs a i d Wa t e r , a n a d d i t i o n a l raW m a t e r i a l poWder i s f u r t h e ra d d e df o rr e g u l a t i n g t h e p e r c e n t a g e s h r i n k a g ea t t h e t i m e o fs a i d ? r i n g o r f o r r e g u l a t i n g c a s t i n gr a t ea t t h e t i m e o f s a i d

s l i pc a s t i n g .1 5 . The p r o c e s s a c c o r d i n g t o c l a i m 1 4 , W h e r e i n s a i da d d i t i o n a l raW m a t e r i a l poWder i s a t l e a s t one m a t e r i a ls e l e c t e d f r o mt h eg r o u pc o n s i s t i n g o f f e l d s p a r ,d o l o m i t e ,a n dn e p h e l i n e .

1 6 . The p r o c e s s a c c o r d i n g t o c l a i m 1 4 , W h e r e i n s a i da d d i t i o n a l raW m a t e r i a l poWder i s a t l e a s t one m a t e r i a ls e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o f p o t t e r y s t o n e , s i l i c ar o c k , a n d a l u m i n a .

1 7 . The p r o c e s s a c c o r d i n gt o c l a i m 1 4 , W h e r e i ns a i da d d i t i o n a l raW m a t e r i a l poWder i s a t l e a s t one m a t e r i a ls e l e c t e d f r o m t h eg r o u p c o n s i s t i n g o f c h i n a c l a y ,b a l lc l a y ,a n d p l a s t i cc l a y .

1 8 . The p r o c e s s a c c o r d i n g t o c l a i m 1 4 , W h e r e i n t h eamount o f t h e a d d i t i o n a l raW m a t e r i a l poWder added s 0 . 0 1

t o 1 0 p a r t s b y W e i g h t b a s e do n 1 0 0 p a r t s b y W e i g h to f t h ec o m p o s i t i o nf o r a s a n i t a r y Ware b o d y .1 9 .T h ep r o c e s s a c c o r d i n gt o c l a i m 1 4 ,W h e r e i n ,i n a d d i n g

s a i d Wa t e r , a s o l u b l e s a l ti s f u r t h e r added f o r m o d i f y i n gt h ev i s c o s i t yo f t h es l u r r y .

2 0 . The p r o c e s s a c c o r d i n g t o c l a i m 1 9 , W h e r e i n s a i ds o l u b l e s a l t i s a t l e a s t one s a l t s e l e c t e d f rom t h e groupc o n s i s t i n g o f s o d i u m s i l i c a t e ,s o d i u mh y d r o x i d e , s o d i u mc a r b o n a t e , a n d a p h o s p h o r i ce s t e r .

2 1 . The p r o c e s s a c c o r d i n g t o c l a i m 1 9 , W h e r e i n t h eamount o f t h e s o l u b l e s a l t a d d e d i s 0 . 0 0 1 t o 0 . 2 p a r t byWe i g h t b a s e do n 1 0 0 p a r t sb y W e i g h to f t h ec o m p o s i t i o nf o ra s a n i t a r y Ware b o d y .

2 2 . A a n i t a r y W a r ep r o d u c e db y t h e p r o c e s s a c c o r d i n gt oc l a i m 1 3 .

2 3 . Use o f t h e c o m p o s i t i o nf o r a s a n i t a r y Ware bodya c c o r d i n gt o c l a i m 1 , f o r t h e p r o d u c t i o no f a s a n i t a r y Wa r e .

2 4 . T h e c o m p o s i t i o nf o r as a n i t a r y W a r ebody a c c o r d i n gt o c l a i m 1 , W h e r e i ns a i d W a t e r c o n t e n t i s l e s s t h a n 2 0 byWe i g h t .

A patent of Slip casting of sanitaryware

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