Abstract: Described herein are polymeric composites that can include a kaolin filler dispersed within a thermoplastic polymer matrix. The kaolin filler can exhibit an aspect ratio of from 20 to 50, as measured by laser scattering, a mean particle size of from 0.75 microns to 2 microns e.s.d., as measured by Sedigraph, or a combination thereof. In some embodiments, the kaolin filler exhibits a ratio of aspect ratio to mean particle size ranges from 4 to 5, as measured by laser scattering. In some embodiments, less than 30% by weight of the kaolin filler exhibits a particle size of less than 0.5 microns e.s.d., as measured by Sedigraph. The composites can exhibit improved mechanical properties such as flexural strength, tensile strength, and heat deflection temperature. The composites can be used to form articles, for example, by thermoforming.

Abstract: A method of producing a spray-dried, hydrous kaolin clay is disclosed that includes mixing a hydrous kaolin clay with water, an ammonium polyacrylate or polyacrylic acid, ammonium hydroxide, and a propanolamine selected from the group consisting of 2-amino-2-methyl-1-propanol, 2-methylamino-2-methyl-1-propanol, 1-amino-2-propanol, or mixtures thereof, to produce a viscosity stable dispersed slurry, and spray drying the slurry to produce the spray-dried, hydrous, kaolin clay. A spray-dried, hydrous kaolin clay is also disclosed.

Abstract: A method of producing a spray-dried, hydrous kaolin clay is disclosed that includes mixing a hydrous kaolin clay with water, an ammonium polyacrylate or polyacrylic acid, ammonium hydroxide, and a propanolamine selected from the group consisting of 2-amino-2-methyl-1-propanol, 2-methylamino-2-methyl-1-propanol, 1-amino-2-propanol, or mixtures thereof, to produce a viscosity stable dispersed slurry, and spray drying the slurry to produce the spray-dried, hydrous, kaolin clay. A spray-dried, hydrous kaolin clay is also disclosed.