Toto Ltd.

Akio Matsumoto

Haruyuki Ito

Yoshinori Yamashita

Toshiya Nishikawa

Yoshifumi Misumi

Naoki Koga

Takeshi Sato

Noboru Kishima

Katsuhiro Hasebe

Masaki Taneo

Akira Hirayama

Akira Kawakami

Hiroyuki Suzuki

Tatsuhiro Kosugi

Yutaka Tomioka

Shogo Shimada

Shingo Kasahara

Motoshi Yasuda

Fumio Hongo

Masato Otsu

Masao Yamasaki

Takazi Naotsuka

Tatsuya Goto

Toshiaki Nogami

Minoru Inoue

Mitsuru Saka

Shozo Tateyama

A composite material according to the invention includes X parts by volume of boron carbide, Y parts by volume of silicon carbide, and Z parts by volume of silicon as main components, wherein 10&#x3c;X&#x3c;60, 20&#x3c;Y&#x3c;70, and 5&#x3c;Z&#x3c;30 are satisfied, and grains of 10 &#x3bc;m or more of the boron carbide and the silicon carbide are 10-50 parts by volume.

Composite material and method of manufacturing the same

A wet-type compacting method of a ceramic powder using a solvent, wherein the ceramic powder is coated with a high polymer organic substance which is substantially insoluble in the solvent so that homogeneity of a compact is kept, while generating no problem during each process and excellent plasticity and/or strength are exhibited by the compact, and if a sintering process follows a compacting process, sintering characteristics are improved.

Method of producing a carbide sintered compact

A slip casting mold includes a water absorption layer having self water absorption capability and substantial water resistance. With the water saturation percentage of the water absorption layer being controlled, a slurry layer is deposited in the slip casting mold mainly under capillary attractive forces of the slip casting mold. The water absorption layer comprises an open porous body which is manufactured by stirring a mixture of an epoxy compound having at least one epoxy ring in one molecule, a hardener for reacting with the epoxy compound to harden the epoxy compound, a filler for developing self water absorption capability and mold releasability, and water into an O/W-type emulsion slurry, and casting the emulsion slurry into a mold impermeable to water, hardening the emulsion slurry in the mold while containing water.

Mold for use in slip casting method, and method of manufacturing open porous body for use in mold

Ceramics with a glaze applied to the surface of ceramic blank, the bending strength of which ceramic blank is,Mpa or higher or the firing shrinkage rate is 7% or higher and the porosity is 7.5% or higher.

Ceramics, ceramic blank, manufacturing method thereof, sanitary earthenware and manufacturing method thereof

Method of slip casting powdery material, using a water resistant mold

A method for preparing high strength and high thermal shock-resistant china for ceramic whiteware which comprises the steps of molding a china-forming raw material which mainly comprises a natural ore material capable of forming corundum through firing or a material obtained by calcining the natural ore material to form corundum, a natural ore material capable of forming mullite through firing or a material obtained by calcining the natural ore material to form mullite, a clayey material and a flux such as feldspar, nepheline or dolomite; and then firing the molded china-forming raw material. The method permits the production of cheaper china for ceramic whiteware having high strength and excellent thermal shock resistance as compared with those prepared by the conventional techniques.

Method for preparing high strength and high thermal shock-resistant

A mold for pressure-cast-molding a ceramic article having a filter material made of an open-cell porous material. The open-cell porous material is prepared by stirring a mixture of a resin material, a microballoon, a curing agent and water to provide an emulsion slurry, casting the slurry in a water-impermeable mold and curing the slurry in the water-containing state. The portions occupied by the water during the preparation of the porous material mainly form open pores.

Mold for pressure-cast-molding a ceramic article formed from an

A ceramic article such as a sanitary pottery ware is produced by slip casting using a porous composite mold. A green ceramic body of a part such as a trap of sanitary ware is separately formed in advance by, for example, slip casting. The green ceramic body is placed in the mold cavity of the porous composite mold. Then, a slip as the material of the main part of the sanitary ware is supplied into the mold cavity to form deposit integral with the green ceramic body, whereby an integral sanitary ware is obtained by slip casting.

Slip casting method for manufacturing ceramic articles

A vitreous china comprises, as principal components, 25 to 70% by weight of a glass phase and 75 to 30% by weight of a crystalline phase, the glass phase comprising, as principal chemical components, 4 to 12% by weight of K.sub.2 O+Na.sub.2 O, 50 to 75% by weight of SiO.sub.2 and 17 to 40% by weight of Al.sub.2 O.sub.3 while the total amount of the glass phase is defined to be 100% by weight, and the crystalline phase comprising, as principal mineral components, 10 to 60% by weight of .alpha.-alumina, 0 to 20% by weight of quartz and 2 to 20% by weight of mullite while the total amount of the vitreous china is defined to be 100% by weight. The vitreous china and the method for preparing the same may permit the marked improvement of the mechanical strength of the vitreous china. The mechanical strength may be improved without adversely affecting other physical properties (such as high temperature deformation, resistance to thermal shock and firing temperature). This vitreous china can be applied to sanitary-wares, large-sized pottery plates and various kinds of engineering ceramics. Moreover, the present invention provides a glaze which has excellent compatibility with vitreous china having high alumina contents and which is thus applied to a large-sized product formed from vitreous china having such a high alumina content.

Vitreous china, method for preparing the vitreous china, sanitary-ware

A powder molding is manufactured from various powdery materials including an inorganic material, an organic material, a metallic material, etc., according to a wet forming process. A powdery material and a solvent are mixed into a mixture so that the mixture exhibits a dilatant flow. The mixture is molded into a molding of desired shape, and then the molding is dried.

Method of manufacturing powder molding

A method of producing a porous material having open pores including stirring a mixture including (i) an epoxy compound having at least one epoxy ring in the compound, (ii) a hardener capable of reacting with the epoxy compount to harden the epoxy compound, (iii) a filler and (iv) water to form an emulsion slurry having a low viscosity and containing the soluble salts uniformly dispersed therein, casting the resulting emulsion slurry in a water impermeable mold and then hardening the slurry while maintaining the water content thereof, and wherein the soluble salts are added to the mixture. The method makes it possible to produce a large scale porous material having open pores and a complicated shape whose shrinkage factor during hardening and water and air permeabilities are controlled to desired levels respectively while scattering thereof is reduced.

Method of producing porous material having open pores

A mold, used in pressure casting ceramic articles, includes a plurality of mold parts set and clamped in combination. Each of the mold parts includes: a porous body forming a filter layer with a generally even thickness and a plurality of channels formed in the inside or outside surface thereof and most running in parallel with the molding surface of the mold for allowing water and air to flow therethrough; a reinforcing iron frame for fitting the porous body therein; and a filler filling up the space between the porous body and the iron frame.

Mold used in pressure casting ceramic articles

A method of making a porous mold for pressure slip casting. A surface porous layer is cast which has an average pore diameter of at most 20 microns and a thickness of 5 to 40 mm. An adhesive is applied in a pattern to the rear surface of the surface porous layer to leave an unapplied portion on the rear surface. A coarse porous layer is applied to the adhesive applied and unapplied portions of the rear surface of the surface porous layer which is made of a mixture of liquid resin and a filler of a particle diameter of 0.1 to 5.0 mm at a volume ratio of 15 to 50:100. The coarse porous layer has a thickness of 5 to 30 mm. A sealing adhesive is applied to the surface of the coarse porous layer and means is applied for passage of water from and air into the coarse porous layer.

Method for making porous mold for pressure slip casting

Herein disclosed is a mold used in pressure casting ceramic articles, which includes a plurality of mold parts set and clamped in combination. Each of the mold parts includes: a porous body forming a filter layer with a generally even thickness and a plurality of channels formed in the inside or outside surface thereof and most running in parallel with the molding surface of the mold for allowing water and air to flow therethrough; a reinforcing iron frame for fitting the porous body therein; and a filler filling up the space between the porous body and the iron frame.

A porous mold for pressure slip casting, which includes: a surface porous layer having an average pore diameter of at most 20 microns and a thickness of 5 to 40 mm; an adhesive applied in a pattern to the rear surface of the surface porous layer to leave an unapplied portion on the rear surface; a coarse porous layer covering the adhesive applied and unapplied portions of the rear surface of the surface porous layer and made of a mixture of a liquid resin and a filler of a particle diameter of 0.1 to 5.0 mm at a volume ratio of 15 to 50:100, the coarse porous layer having a thickness of 5 to 30 mm; a sealing adhesive covering substantially the outer surface of the coarse porous layer; and a passage for water from and air into the coarse porous layer.

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Fukuoka, Japan

Akio Matsumoto