Abstract: A resin composition comprising melt blending a polyamide resin such as nylon MXD6 with a polyphenoxy resin. The polyamide resin and the polyphenoxy resin may be combined prior to or after melting and can be sandwiched between two PET layers in a perform mold to form an article capable of blow molding to form a container with improved delamination resistance. Also, intercalated layered materials are prepared by co-intercalation of an onium ion, an aromatic polyamide oligomer or polymer, e.g., nylon MXD6, and a polyphenoxy oligomer or polymer between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The co-intercalated layered materials are combined with the aromatic polyamide and polyphenoxy resin to form a nanocomposite composition for sandwiching between PET layers to form containers having improved delamination resistance.

Abstract: The present invention relates to coarse calcined kaolin slurries having a high solids content. The invention also relates to methods of making such slurries. The resulting slurries can have a solids content of at least about 58% by weight wherein at least about 40% by weight of the calcined kaolin particles has a particle size of at least about 1 ?m. The slurries can be stabilized where the solids show little settling from suspension. The slurries have many uses, including fillers or extenders in paint and coating compositions for paper or paper board. More generally, the inventive products may be used wherever calcined kaolins are used. The present invention also related to coarse calcined kaolin slurries having a multimodal particle size distribution and a high solids content.

Abstract: The instant invention relates to cationic alkoxyamines, which are useful as polymerization initiators/regulators in a controlled stable free radical polymerization process to produce intercalated and/or exfoliated nanoparticles from natural or synthetic clays. The invention also relates to improved nanocomposites produced by this process and to the use of these nanocomposite compositions as, for example, coatings, sealants, caulks, adhesives and as plastic additives.

Abstract: Barrier coating mixtures contain in a carrier liquid, (a) a non-elastomeric substantially polymerized acrylic polymer; (b) an exfoliated layered platelet-like silicate filler which has been acid treated and having an aspect ratio greater than 25; and (c) at least one additive, wherein the total solids content is less than 30% and the amount of filler is between 5% to about 60% of the total solids content. Coated articles and containers, freestanding films and packaging films are produced using the barrier coating mixtures. Methods of manufacturing such coated products and coating mixtures are also encompassed.

Abstract: A swellable layer silicate is described based on smectite or sepiolite/palygorskite for use in media containing di- or polyvalent cations that reduce swellability, characterized by a swelling volume of about 5 to 50 mL, measured by addition of 2 g layer silicate (air-dried) to 100 mL water, and by a fineness of maximum 5 wt. % >40 ?m and maximum 20% >20 ?m, as dry sieve residue.

Abstract: A method of making a polymeric compound with nanofiller of a predetermined grade. The method includes the steps of providing a base grade of the polymeric material, and mixing a nanofiller concentrate material with the base grade polymeric material in a ratio sufficient to render the predetermined grade of filled polymeric compound, the ratio being nanofiller concentrate material to base grade polymeric material. A method for making the nanofiller concentrate material includes the steps of mixing a high flow carrier resin and a nanofiller to form a mixture, extruding the mixture, and pelletizing the extruded mixture. The mixture may advantageously include colorants, such as pigments or dyes.

Abstract: Processes for modifying the surface chemistry of a clay are disclosed. In one embodiment, there is provided a process for modifying the surface chemistry of a clay, wherein the process comprises: providing a clay dispersion comprising at least one unmodified clay wherein said clay has a first exchangeable cation; adding a second cation to the clay dispersion, wherein at least a portion of the second cation exchanges with at least a portion of the first cation to form a modified clay dispersion; and combining at least one polar containing agent with the modified clay dispersion to provide a modified clay.

Abstract: The invention provides nanocomposites comprising a clay and an organic compound, in which the clay is a clay bridged by a metal compound, preferably iron oxide and/or aluminum oxide. The organic compound is preferably a polymer. The clay-based nanocomposites of the invention have good mechanical properties and good heat resistance. The invention also provides cables comprising such a nanocomposite, preferably in their sheath or outer coating. Finally, the invention provides a process for producing said nanocomposite.

Abstract: The invention relates to a porous mold for use in a pressure casting process, which mold is manufactured of a polymeric material forming a matrix into which a clay and a block copolymer or a graft copolymer have been incorporated, wherein the block copolymer or graft copolymer comprises one or more first structural units (A), which are compatible with the clay, and one or more second structural units (B), which are compatible with the polymeric matrix. The invention further relates to a process for producing said mold and to the use of said mold in a pressure casting process.

Abstract: It is an object of the present invention to provide a polyolefin resin composition excellent in flame retardancy, in particular capable of manifesting excellent flame retardancy owing to a shape retaining effect upon combustion, and excellent also in mechanical strength and thermal characteristics, a thermoplastic resin for cable jacketing or sheathing which comprises the above resin composition, and an insulated cable. The present invention relates to a polyolefin resin composition comprising 100 parts by weight of a polyolefin resin and 0.1 to 100 parts by weight of a layered silicate, wherein a combustion residue thereof obtained by combusting said polyolefin resin composition by heating for 30 minutes under heating condition of 50 kW/m2 shows a yield point stress of not less than 4.9×103 Pa when compressed at a rate of 0.1 cm/s.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay treated in situ with an intercalation agent and a non-aqueous, chemically reactive, organic intercalation facilitating agent, wherein the amount of intercalation facilitating agent is sufficient to facilitate intercalation and to disperse said inorganic clay. The thermosetting inorganic clay nanodispersions comprise an inorganic clay dispersed in an intercalating agent and an intercalation facilitating agent. Thermosetting inorganic clay nanodispersions are used to prepare thermosetting nanocomposite articles.

Abstract: A method for modifying a high-density polyethylene (HDPE)-clay nanocomposite is disclosed. The method comprises shearing a melt of the nanocomposite at an effective shear rate. The modified nanocomposite shows significantly increased complex melt viscosity, storage modulus, and loss modulus.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay and at least one organometallic compound. The thermosetting inorganic clay nanodispersions are used to prepare thermosetting articles.

Abstract: A polyolefin-based nanocomposite and a method of preparing the same are disclosed. The polyolefin-based nanocomposite is prepared by melt kneading a mixture including (A) 40-99.8% by weight of a matrix polymer of polyolefin; (B) 0.1-30% by weight of a polyolefin compatilizer containing polar reactive groups; and (C) 0.1-30% by weight of a layered clay material having a quaternary ammonium ion bonded to the surface thereof. The quaternary ammonium ion contains (I) at least one alkyl group having at least 15 carbon atoms; and (ii) a substitutent having —Si—O—Si—linkage and at least one terminal reactive group.

Abstract: The invention relates to a nanocomposite material on the basis of a clay having a layered structure and a cation exchange capacity of from 30 to 250 milliequivalents per 100 gram, a polymeric matrix and a block copolymer or a graft copolymer, which block copolymer or graft copolymer comprises one or more first structural units (A), which are compatible with the clay, and one or more second structural units (B), which are compatible with the polymeric matrix.

Abstract: An article comprising a matrix polymer and clay wherein said clay is intercalated with a block copolymer, wherein said block copolymer comprises a hydrophilic block capable of intercalating said clay and a matrix compatible block compatible with said matrix polymer.

Abstract: The present invention provides phyllosilicate-polymer compositions which are useful as liquid crystalline composites. Phyllosilicate-polymer liquid crystalline compositions of the present invention can contain a high percentage of phyllosilicate while at the same time be transparent. Because of the ordering of the particles liquid crystalline composite, liquid crystalline composites are particularly useful as barriers to gas transport.

Abstract: A process for preparing a ball clay slurry with a casting rate of at least about 50, a modulus of rupture of at least 500 pounds per square inch, and from about 0.1 to about 1.0 weight percent of organic polyelectrolyte. In this process, a digested lignite material is mixed with a lignitic coarse clay, a nonlignitic coarse clay, a lignitic fine clay, and a polyelectrolyte dispersing agent.

Abstract: A method of forming bricks, tiles, and the like by treating clay, shale or other clay ceramic raw materials containing pyrite is disclosed. Such clay, ceramic raw materials may be ground, and then mixed with an oxidizer in a pre-oxidation step to disperse the oxidizer within the clay to expose the maximum amount of clay surface to the oxidizer. One oxidizer that may be used is an aqueous solution of hydrogen peroxide. Clay is shaped into clay products and then heated to elevated temperatures. Pyrite within the clay is oxidized, thereby removing sulfur-containing compounds such as sulfur dioxide from the clay. The application of the invention may assist in preventing efflorescense by ensuring complete or nearly complete removal of pyrite from products oxidation treatment and subsequent firing at elevated temperatures. Similarly, by enhancing the oxidation of pyrite, faster firing cycles may be possible which facilitates reduced fuel consumption and faster process time.

Abstract: A method of forming bricks, tiles, and the like by treating clay, shale or other clay ceramic raw materials containing pyrite is disclosed. Such clay ceramic raw materials may be ground, and then mixed with an oxidizer in a pre-oxidation step to disperse the oxidizer within the clay to expose the maximum amount of clay surface to the oxidizer. One oxidizer that may be used is an aqueous solution of hydrogen peroxide. Clay is shaped into clay products and then heated to elevated temperatures. Pyrite within the clay is oxidized, thereby removing sulfur-containing compounds such as sulfur dioxide from the clay. The application of the invention may assist in preventing efflorescense by ensuring complete or nearly complete removal of pyrite from products oxidation treatment and subsequent firing at elevated temperatures. Similarly, by enhancing the oxidation of pyrite, faster firing cycles may be possible which facilitates reduced fuel consumption and faster process time.

Abstract: Flux calcined kaolin clay especially useful as a pigment for low sheen paints is obtained by mixing hydrous kaolin with an aqueous solution of alkaline flux, spray drying, pulverizing, calcining and repulverizing.

Abstract: An improved process for transforming clays that cannot be utilized in commercial pigment production to low-viscosity pigment for commercial application is described whereby a treated clay is produced having a reduced viscosity as compared to the initial clay when compared at equivalent solids content. The process comprises the steps of: drying the clay; mixing the dried clay with an aqueous solution of an alkali metal salt wherein the alkali metal salt is selected from the group consisting of lithium, potassium, rubidium and cesium salts; extruding the material obtained from alkali metal salt treatment; heat-treating the extruded material and high-shear blunging of the heat-treated material. Typically, a high viscosity clay that has been treated with this five-step procedure will exhibit a viscosity that is about 10% to about 20% of the viscosity of the starting clay.

Abstract: A method of producing a porous inorganic particulate material which comprises treating a particulate aluminosilicate material with a leaching agent which chemically reacts with or solubilizes aluminum and thereby leaches aluminum from the aluminosilicate material, wherein the particulate aluminosilicate material is a particulate hydrous aluminosilicate material which has been flash calcined.

Abstract: Flux calcined kaolin clay especially useful as a pigment for low sheen paints is obtained by mixing hydrous kaolin with an aqueous solution of alkaline flux, spray drying, pulverizing, calcining and repulverizing.

Abstract: Paper making processes, including microparticulate processes, which utilise bentonite are provided with bentonite in the form of a concentrate, or a dilute dispersion made by diluting the concentrate, wherein the concentrate is a dispersion of 15 to 40% by weight bentonite in water containing citrate and has a viscosity below 5000 cps and is a stable fluid. The concentrates are novel. They are preferably made by mixing alkaline earth bentonite with water and sodium citrate.

Abstract: Alkaline earth bentonite can be activated by the use of sodium citrate or other organic sequestering agent as activator. Dry blends of the activator and the bentonite can be provided.

Abstract: Kaolin clays are conditioned for the removal of colored titaniferous impurities by (A) first mixing the kaolin clay with a collector to condition the impurities, in the absence of a dispersant, but in the presence of sufficient water to yield a mixture having a solids content of at least 65 percent by weight and (B) then deflocculating the kaolin clay mixture at a pH of at least 4.0 with a dispersant in amounts sufficient to yield a kaolin clay slurry which is suitable for subsequent processing to remove colored titaniferous impurities.

Abstract: There is disclosed a process for improving one or more properties of kaolin comprising:(a) providing an aqueous suspension of particulate kaolin clay;(b) introducing into the aqueous suspension a first reagent comprising a source of alkaline earth metal ions and a second reagent comprising a source of carbonate ions to precipitate an alkaline earth metal carbonate in the said aqueous suspension of the said particulate kaolin clay whereby the said particulate kaolin clay present at the start of the process becomes entrained by and bonded to the alkaline earth metal carbonate to form a composite particulate product which may be used in paper making or paper coating or as a filler or extender in compositions for other applications. The alkaline earth metal ions may be calcium ions provided by calcium hydroxide obtained by slaking lime either in the aqueous suspension or separately. The carbonate ions may be provided by carbon dioxide.

Abstract: A process for improving the rheological properties of an aqueous suspension of a particulate inorganic material which comprises the steps of: (a) forming an aqueous suspension of the particulate inorganic material and an effective amount of an anionic polyelectrolyte dispersing agent; (b) diluting the suspension formed in step (a) with water while maintaining the particulate in the dispersed state of step (a) to give a solids concentration of not less than 20% by weight of the particulate inorganic material; and (c) reconcentrating the diluted suspension formed in step (b) to give a solids concentration of at least 50% by weight of the particulate inorganic material.

Abstract: Clay materials, such as kaolin, containing expandable layer-silicates are chemically treated with a source of magnesium cations, followed by a pH adjustment, to provide a slurry product having improved rheological properties.

Abstract: Kaolin clays are conditioned for the removal of colored titaniferous impurities by (A) first mixing the kaolin clay with a collector to condition the impurities, in the absence of a dispersant, but in the presence of sufficient water to yield a mixture having a solids content of at least 65 percent by weight and (B) then deflocculating the kaolin clay mixture at a pH of at least 4.0 with a dispersant in amounts sufficient to yield a kaolin clay slurry which is suitable for subsequent processing to remove colored titaniferous impurities.

Abstract: A process for intercalating potassium acetate molecules in kaolin clay particles to achieve delamination has been developed by mixing kaolin clay particles, potassium acetate and water. A maximum intercalation, and hence a maximum degree of delamination, can be achieved with potassium acetate levels between 10% and 75% by weight, based on the weight of kaolin clay particles, and 5% and 50% water by weight, based on the weight of potassium acetate.

Abstract: A method for preparing high solids suspensions of calcined clay which are stable without the necessity of adding a colloidal thickening agent and have minimal dilatancy. A calcined kaolin clay pigment, substantially free of anionic dispersant, is dispersed in water by addition of alkali to provide a neutral to mildly alkaline aqueous slurry. To the dispersed slurry, a water-soluble cationic organic polymer is added in minor amounts, to partially flocculate and thicken the slurry, thereby stabilizing the slurry against sedimentation.

Abstract: The invention relates to new curable inorganic resins based on alkali metal boroaluminosilicates, which, before curing, include inorganic elements in the reactive state, in the following proportions, expressed as their molar ratio of oxides:2.ltoreq.SiO.sub.2 /Al.sub.2 O.sub.3 .ltoreq.41.3.ltoreq.X.sub.2 O/Al.sub.2 O.sub.3 .ltoreq.3.810.ltoreq.H.sub.2 O/Al.sub.2 O.sub.3 .ltoreq.280.5<B.sub.2 O.sub.3 /Al.sub.2 O.sub.3 .ltoreq.2.0X.sub.2 O denoting one or more alkali metal oxides chosen from Na.sub.2 O, K.sub.2 O, Li.sub.2 O, and optionally fillers.The invention also relates to the process for the preparation of these new inorganic resins.The cured resins obtained are very useful for manufacturing heat protection materials.

Abstract: An improved process for producing a aggregated composite pigment having desired physical and optical characteristics when used as a coating, filler or pigment in paper. The aggregated pigment is produced by contacting a substantially dry fine particle size mixture of kaolin and one or more additional feed minerals with a previously hydrolyzed organic silicon compound, such as hydrolyzed tetraethoxysilane, and then recovering the aggregated composite pigment.

Abstract: A coating pigment for coating printing media, especially paper and cardboard, is made with at least one swellable layer silicate which can be fixed on the printing medium essentially without binders, where the amount of swellable layer silicate is at least 30 weight percent and the swelling volume of the coating pigment is 5 to 30 ml, based on suspension of 2 g coating pigment in 100 ml water. A water-based coating which contains such a coating pigment and a printing medium that is coated on one or both sides with the coating pigment or coating are also described. The deinkability of printed printing media coated with the coating pigment is improved.

Abstract: A method for preparing a time-stable, low viscosity, pumpable high solids aqueous bentonite slurry which has good application properties upon dilution and use. An aqueous solution of at least first and second salt components is prepared in which there is dispersed at least 8% by weight of the resultant slurry of a powdered bentonite. The first salt component is selected to give if used alone an acceptably low viscosity to the slurry at said high solids and at least good application properties upon the dilution and use. The second salt component is selected to act in combination with the first salt component to substantially further decrease the acceptably low viscosity at a specified high solids content or to enable increase of the solids content while maintaining the acceptably low viscosity, while not substantially impairing the application properties. The high solids pumpable slurry product is also claimed.

Abstract: A process for increasing the brightness of Minnesota kaolin clay containing chlorite and siderite mineral impurities comprising treating the clay with a strong mineral acid preferably in combination with magnetic separation.

Abstract: An improved process for producing a aggregated kaolin pigment having desired physical and optical characteristics when used as a coating, filler or pigment in paper. The aggregated pigment is produced by contacting a substantially dry fine particle size kaolin with a previously hydrolyzed organic silicon compound, such as hydrolyzed tetraethoxysilane, and then recovering the aggregated kaolin pigment.

Abstract: A smectite clay is provided as an elevated solids aqueous slurry e.g. up to 50% solids, which is composed of the smectite clay slurried or dispersed in water containing an effective concentration of a monovalent salt. When such a salt is present in the clay slurry, the clay does not swell appreciably, is essentially inactive, and the slurry can be shipped and stored without creating a gelling problem. When this slurry is diluted with fresh water at the point of application to make it of the desired solids content for use, the smectite clay is activated and exhibits the desired properties, such as viscosity, retention, etc.

Abstract: A process for upgrading a crude bentonite ore such that it can be used advantageously to prepare unusually high aqueous solution viscosities. This sequence comprises initially subjecting the crude ore to a working or shearing stage, followed by a drying step to about a 5% moisture level. Na.sub.2 CO.sub.3 is then dry-blended with the material, and the sequence is completed by subjecting the mix to a pulverizing step.

Abstract: Adducts of clay, especially of the smectite variety, most especially bentonite, are prepared with an effective amount of at least one activated mixed metal oxide or oxy-hydroxide (AHMMO) formed by dehydrating hydrotalcite or a mixture comprising magnesium oxide and aluminum oxide, or a crystalline mixed metal hydroxide conforming substantially to the formulaLi.sub.m D.sub.d T(OH).sub.(m+2d+3+n.a) (A.sup.n).sub.a. xH.sub.2 Owhere m is zero to one, D is a divalent metal, d is from zero to 4, T is a trivalent metal, A represents at least one anion or negative-valence radical of valence n, where n is 1 or more, (m+2d+3+n.a) is equal to or greater than 3, (m+d) is greater than zero, and xH.sub.2 O represents excess waters of hydration. These adducts are useful, e.g., in drilling muds and in viscosity modification of a wide variety of fluids.

Abstract: An improved process for producing a aggregated kaolin pigment having desired physical and optical characteristics when used as a coating, filler or pigment in paper. The aggregated pigment is produced by mixing an aqueous slurry of a fine particle kaolin with a previously hydrolyzed organic silicon compound, such as hydrolyzed tetraethoxysilane, and then spray drying the mixture to form a dry, chemically aggregated kaolin pigment.

Abstract: A process for producing a high brightness, high solids kaolin clay aqueous slurry. An aqueous low solids suspension of crude kaolin clay is degritted, and subjected to a particle size classification. The aqueous suspension of the fine particle fraction is acidified to a pH of 5.0 or lower to produce an acid flocculated suspension which is treated with a bleaching agent to reduce ferric ion impurities to ferrous ion impurities. A ferrous ion chelating agent is added to the bleached acid flocculated suspension after which an alkaline agent is added to raise the pH to a level greater than 5.0 to form a dispersed aqueous suspension of the beneficiated kaolin. The dispersed suspension is then subjected to membrane filtration to partially dewater same, and additional water is thermally evaporated from the partially dewatered dispersed kaolin suspension to produce the high solids product suspension.

Abstract: Novel hydrous kaolin pigments comprising a major weight percent of a conventional hydrous kaolin pigment and a minor amount of a specific form of added discrete iron oxide, specifically magnetite, uniformly physically admixed therewith. Pigments of the invention have brightness values of about 78% to 85% and "b" values in the range of -1 to +4.

Abstract: A process is disclosed for producing high brightness kaolin from ore containing silica, other types of clays, minerals such as ilmenite micas, feldspars and various metal silicates as well as organic matter. The process consists of sizing, a double floatation step, magnetic separation, leaching and oxidative brightening steps. This is a novel combination of conventional unit operations and in particular the use of a double floatation step to remove quartz and various trace minerals that interfere with achieving high optical brightness for kaolin.

Abstract: A method of producing a high opacifying kaolin pigment by separating from one or more iron-stained titania-containing crude kaolins having a titania content of from about 1 to 2 weight percent, one or more titania-enriched kaolin fractions which contain the titania in an amount of above 2 weight percent; subjecting the fraction(s) to media grinding; dewatering and drying the media ground fraction(s); blending the fraction(s) with a fine particle size unground kaolin having a titania content less than 2%, in proportions to provide a calciner feed having at least 2% titania; and calcining the feed at a temperature in the range of 1500.degree. to 2200.degree. F.

Abstract: A mixture of swellable clay, such as bentonite, is charged with an additive which provides an excess of single-charged cations which tend to neutralize the deleterious effects of double-charged cations which are naturally present in seawater and industrial waste. The mixture is deposited on and carried by a sheet to facilitate its uses as a pond liner or a foundation sealant.

Abstract: The present invention relates to slurries of synthetic alkali metal silicates with fine particles kaolin clay. The slurries consists of at least 50% solids which solids comprise an approximately 50:50 combination of the fine kaolin clay and the synthetic alkali metal silicate (SAMS). The integrated composition of the SAMS products is an entity having an overall composition ofxM.sub.2 O:Al.sub.2 O.sub.3 :ySiO.sub.2 Owhere x is the number of moles of alkali metal oxide and is an integer from 0.01 to 2.0, M is an alkali metal, y is the number of miles of SiO.sub.2 in the unique SAMS composition, and z is the number of moles of bound water and is an integer ranging from 1.0 to 5.0. The composition essentially comprises altered kaolin clay platelets with an integral rim or protuberance of essentially amorphous alkali metal silicate-kaolin reaction product. The slurry is useful in latex paint systems.

Abstract: An opacifying pigment with enhanced light scattering properties for use as a paper coating or filler material is produced by reacting kaolin in the presence of water with sodium hydroxide or potassium hydroxide at a temperature in excess of 60.degree. C. The kaolin is reacted with the hydroxide in a concentration to produce a molality of at least 0.1.