Imerys Kaolin, Inc.

Imerys Pigments, Inc.

Tommy L Adkins

Edward J Sare

Stephen C Raper

Julie Figlar

Curtis L Manning

John D Sagurton

The present invention relates to a composition comprising calcined kaolin having a narrow particle size distribution. The composition can have many uses, such as fillers or extenders in paint, plastics, polymers, papermaking, and coating compositions. More generally, the inventive products may be used wherever calcined kaolins are used.

Unusually narrow particle size distribution calcined kaolins

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 &#x3bc;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.

High solids, large particle, calcined kaolin slurries

A method of method of making a formed ceramic body, comprising casting or jiggering a composition comprising a mullite-rich calcined kaolin obtained from a hydrous kaolin. Also provided is a method of modifying/increasing the casting rate of a formed body formulation comprising hydrous kaolin, the method comprising substituting at least 10% of the hydrous kaolin in the formulation with a mullite-rich calcined kaolin. Also provided is a ceramic body filter cake comprising a mullite-rich calcined kaolin, wherein the mullite-rich calcined kaolin is obtained from a hydrous kaolin and a method of modifying/increasing the filtration rate of a ceramic body filter cake comprising hydrous kaolin, the method comprising substituting at least 10% of the hydrous kaolin in the ceramic body filter cake with a mullite-rich partially calcined kaolin. Also provided are dried greenware products and final ware products comprising a mullite-rich calcined kaolin, wherein the mullite-rich calcined kaolin is obtained from a hydrous kaolin.

Mullite-rich calcined kaolin compositions and methods for improved casting rates in cast ceramic bodies

The present invention relates to calcined kaolin products, their production, and use. More specifically, the invention relates to calcined kaolin-containing products having a median diameter particle size of from about 0.5 &mgr;m to about 10 &mgr;m, and a multimodal particle size distribution defined herein. The calcined kaolin products of the invention possess a combination of physical properties and applied properties not previously seen together in calcined kaolin pigments. The products according to the invention find use as flattening (or matting) agents, and as fillers or extenders in paint and coating compositions. More generally, the inventive products may be used wherever calcined kaolins are used.

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Cochran, GA, United States of America

Tommy L Adkins