Self glazed ceramic/glass composite and method for manufacturing the same

Abstract

The invention provides a glazed composite manufactured using waste materials, wherein the waste materials are capable of producing ceramic forming oxides, glass modifying oxides and ceramic modifying oxides. The waste materials include ceramic waste and colored glass waste. The invention also provides a method for manufacturing composition of the glazed composite.

What is claimed is: 
     
         1 . A method for manufacturing a glazed composite, the method comprising:
 grinding each raw material of a set of raw materials independently, wherein the set of raw materials comprises ceramic waste and colored glass waste;   sieving each raw material of the set of raw materials independently to filter out particles having diameter more than about 90 microns;   mixing the set of raw materials to obtain a homogenous mixture;   sieving the homogenous mixture for filtering out particles having diameter more than about 90 microns;   pressing the homogenous mixture admixed with water in response to sieving, wherein 1 ml of water is added per 10 g of the homogenous mixture; and   firing the homogenous mixture at a temperature of about 700 degree C. (° C.) to 1200° C.   
     
     
         2 . The method of  claim 1 , wherein each raw material of the set of raw materials is ground in a ball mill with a speed of about 400 revolutions per minute for a period of 30 minutes. 
     
     
         3 . The method of  claim 1 , wherein each raw material and the homogenous mixture are sieved for filtering out particles having diameter more than about 50 microns. 
     
     
         4 . The method of  claim 1 , wherein the set of raw materials is mixed in a dry ball mill to obtain a homogenous mixture. 
     
     
         5 . The method of  claim 1 , wherein the homogenous mixture is pressed using one of uniaxially cold pressing, biaxial cold pressing, dry pressing, semi-dry pressing, compacting, cold isostatic pressing, hot pressing, extrusion molding, injection molding, compression molding, gel casting, slip casting and tape casting. 
     
     
         6 . The method of  claim 1 , wherein the homogenous mixture is fired at a temperature of about 700° C. to about 1200° C. with a rate of about 5° C. per minute to about 20° C. per minute for a period of about 15 minutes to about 2 hours 30 minutes. 
     
     
         7 . The method of  claim 1 , wherein the set of raw materials comprises about 35 wt % to about 65 wt % of ceramic waste and about 15 wt % to about 85 wt % of colored glass waste. 
     
     
         8 . The method of  claim 1 , wherein the set of raw materials further comprises silica sand. 
     
     
         9 . The method of  claim 8 , wherein the set of raw materials comprises about 25 weight percent (wt %) to about 46 wt % of silica sand, about 10 wt % to about 47 wt % of ceramic waste and about 25 wt % to about 46 wt % of colored glass waste. 
     
     
         10 . A composition of a glazed composite comprises about 62 wt % to about 90 wt % of silicon dioxide (SiO 2 ), about 2 wt % to about 17 wt % of alumina (Al 2 O 3 ), about 5 wt % to about 10 wt % of calcium oxide (CaO), about 2 wt % to about 14 wt % of sodium oxide (Na 2 O), about 2 wt % to about 4 wt % of potassium oxide (K 2 O), about 0. 5 wt % to about 1. 0 wt % of titanium dioxide (TiO 2 ) and about 0.1 wt % to about 5 wt % of ferric oxide (Fe 2 O 3 ). 
     
     
         11 . The composition of  claim 10 , wherein raw materials for preparing the composition of the glazed composite comprises about 35 wt % to about 65 wt % of ceramic waste and about 15 wt % to about 85 wt % of colored glass waste. 
     
     
         12 . The composition of  claim 10 , wherein raw materials for preparing the composition of the glazed composite comprises about 25 wt % to about 46 wt % of silica sand, about 10 wt % to about 47 wt % of ceramic waste and about 25 wt % to about 46 wt % of colored glass waste.