Patent: US 20140228211 A1. Method for producing light ceramic materials

Autores:  Tadeusz Von Rymon Lipinski, Bruno Keller, Frank Beissmann, Peter Neugebauer, Ruth Kernke, Dirk Poppe

The present invention relates to a novel process for producing ceramic materials, in particular refractory materials having a reduced relative density. In particular, the invention relates to a process for producing light, refractory materials having non-contiguous pores based on shaped and unshaped materials. These materials can be used as working lining in high-temperature applications. The process is based on the production of spherical, closed and isolated pores in the microstructure of the material. The pores having a pore diameter which can be set in a targeted manner are generated by use of polymer particles, in particular polymethacrylates, in particular polymers or copolymers prepared by means of suspension polymerization, as pore formers which can be burnt out. The polymers or copolymers are present in the form of small spheres having a defined diameter. The introduction of isolated spherical pores allows the production of ceramic materials having a sometimes significantly reduced relative density and improved corrosion resistance and better mechanical strength compared to the prior art. The specific, closed pore system at the same time contributes to reducing the thermal conductivity of the ceramic materials. In addition, the novel process has the advantage that there is no risk of formation of undesirable black cores, even in the production of thick-walled ceramic products.

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