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A lightweight ceramic material is provided, useful for example as thermal insulation, kiln furniture or for metallurgical applications. Accordingly, a lightweight fired ceramic material comprises a set porous material in the form of a freeze-gelled ceramic sol composition containing hollow microsphe

A lightweight ceramic material is provided, useful for example as thermal insulation, kiln furniture or for metallurgical applications. Accordingly, a lightweight fired ceramic material comprises a set porous material in the form of a freeze-gelled ceramic sol composition containing hollow microspheres bonded together in a ceramic matrix. A method of making a lightweight fired ceramic shaped product is also provided in which a freeze-gellable ceramic sol composition is formed containing hollow microspheres, the composition is placed in a tool (21) of high thermal conductivity, the tool is cooled to irreversibly gel the sol composition, the monolith so formed is demoulded and allowed to thaw and is then fired to form a product comprising the microspheres bonded in a ceramic matrix.

대표청구항 ▼

A method of making a lightweight fired shaped ceramic product in which a freeze-gellable ceramic sol composition is formed containing hollow microspheres, the composition is placed in a mould having a cavity of the desired shape of said product, the mould comprising a tool of high thermal conductivi

A method of making a lightweight fired shaped ceramic product in which a freeze-gellable ceramic sol composition is formed containing hollow microspheres, the composition is placed in a mould having a cavity of the desired shape of said product, the mould comprising a tool of high thermal conductivity made by flame-spraying metal onto a replica of the desired shape, and the tool is cooled at a rate sufficient to irreversibly gel the sol composition to form a monolith, the monolith is demoulded, thawed and fired to form a product comprising the microspheres bonded in a ceramic matrix.