JP7026637B2 - 含水カオリン粘土の製造方法、および前記含水カオリン粘土から製造された製品 - Google Patents
含水カオリン粘土の製造方法、および前記含水カオリン粘土から製造された製品 Download PDFInfo
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- JP7026637B2 JP7026637B2 JP2018553887A JP2018553887A JP7026637B2 JP 7026637 B2 JP7026637 B2 JP 7026637B2 JP 2018553887 A JP2018553887 A JP 2018553887A JP 2018553887 A JP2018553887 A JP 2018553887A JP 7026637 B2 JP7026637 B2 JP 7026637B2
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- Prior art keywords
- kaolin clay
- less
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- fine
- kaolin
- Prior art date
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 title claims description 650
- 239000005995 Aluminium silicate Substances 0.000 title claims description 641
- 235000012211 aluminium silicate Nutrition 0.000 title claims description 641
- 239000004927 clay Substances 0.000 title claims description 449
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- 239000002245 particle Substances 0.000 claims description 147
- 239000000203 mixture Substances 0.000 claims description 79
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- 238000009472 formulation Methods 0.000 claims description 38
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- 239000003973 paint Substances 0.000 claims description 27
- 229910052878 cordierite Inorganic materials 0.000 claims description 23
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims description 23
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- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 claims description 7
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- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 5
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- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 14
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- 239000012043 crude product Substances 0.000 description 13
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 12
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 8
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- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 7
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- FQENQNTWSFEDLI-UHFFFAOYSA-J sodium diphosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])([O-])=O FQENQNTWSFEDLI-UHFFFAOYSA-J 0.000 description 5
- 235000019818 tetrasodium diphosphate Nutrition 0.000 description 5
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- XTEGARKTQYYJKE-UHFFFAOYSA-M Chlorate Chemical compound [O-]Cl(=O)=O XTEGARKTQYYJKE-UHFFFAOYSA-M 0.000 description 4
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- 235000019982 sodium hexametaphosphate Nutrition 0.000 description 4
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- 239000000377 silicon dioxide Substances 0.000 description 3
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 description 3
- SUKJFIGYRHOWBL-UHFFFAOYSA-N sodium hypochlorite Chemical compound [Na+].Cl[O-] SUKJFIGYRHOWBL-UHFFFAOYSA-N 0.000 description 3
- 238000001179 sorption measurement Methods 0.000 description 3
- 239000000454 talc Substances 0.000 description 3
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- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 2
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 2
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 2
- RNIHAPSVIGPAFF-UHFFFAOYSA-N Acrylamide-acrylic acid resin Chemical compound NC(=O)C=C.OC(=O)C=C RNIHAPSVIGPAFF-UHFFFAOYSA-N 0.000 description 2
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 2
- 239000004606 Fillers/Extenders Substances 0.000 description 2
- 239000005642 Oleic acid Substances 0.000 description 2
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- 229920000388 Polyphosphate Polymers 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
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- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
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- 239000000314 lubricant Substances 0.000 description 2
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 2
- 150000002894 organic compounds Chemical class 0.000 description 2
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- JVBXVOWTABLYPX-UHFFFAOYSA-L sodium dithionite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])=O JVBXVOWTABLYPX-UHFFFAOYSA-L 0.000 description 2
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- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
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- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium peroxydisulfate Substances [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 1
- VAZSKTXWXKYQJF-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)OOS([O-])=O VAZSKTXWXKYQJF-UHFFFAOYSA-N 0.000 description 1
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- SNXYIOIMZXSIDC-UHFFFAOYSA-A hexadecasodium;phosphonato phosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])([O-])=O.[O-]P([O-])(=O)OP([O-])([O-])=O.[O-]P([O-])(=O)OP([O-])([O-])=O.[O-]P([O-])(=O)OP([O-])([O-])=O SNXYIOIMZXSIDC-UHFFFAOYSA-A 0.000 description 1
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Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/40—Compounds of aluminium
- C09C1/42—Clays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/16—Clays or other mineral silicates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C1/00—Apparatus or methods for obtaining or processing clay
- B28C1/02—Apparatus or methods for obtaining or processing clay for producing or processing clay suspensions, e.g. slip
-
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Description
本願においては、含水カオリン粘土製品の製造方法が開示される。前記方法は、(a)白い粗粒の粗製カオリン粘土を精製して、第一の配合成分として精製された白い粗粒のカオリン粘土を形成することを含み得る。前記の白い粗粒のカオリン粘土を、白亜紀の白い粗粒の粗製カオリン粘土から誘導できる。そのような白亜紀の粗粒の白い粗製物は、中央ジョージアのカオリン鉱床中で見つけることができる。白い粗粒の粗製カオリン粘土の精製は、遠心分離および磁気分離を含み得る。精製された白い粗粒のカオリン粘土は、少なくとも80質量%の粒子が直径2μm以下を有する粒子を含み得る。いくつかの実施態様において、精製された白い粗粒のカオリン粘土は、X線回折(XRD)を使用して測定した際に微結晶の平均サイズ600Å~950Åを示すことができる。精製された白い粗粒のカオリン粘土の酸化鉄含有率は、白い粗粒のカオリン粘土の質量に対して0.3質量%~0.5質量%であり得る。いくつかの実施態様において、前記方法は、精製された白い粗粒のカオリン粘土を離層することを含み得る。
本願内で使用される用語「含む(comprising)」およびその変化形は、用語「含む(including)」およびその変化形と同義的に使用されており、且つ、開放型の、限定されない用語である。用語「含む(comprising)」および「含む(including)」は、本願内で様々な実施態様を記載するために使用されているのだが、用語「本質的に~からなる」および「からなる」は、「含む(comprising)」および「含む(including)」の代わりに使用されてより特定の実施態様を提供することがあり、且つ、それも開示されている。この開示および付属の特許請求の範囲内で使用される際、単数形は、特段記載されない限り、複数の指示対象を含む。本願内のパーセントの範囲および他の範囲の開示は、その範囲の端点およびその範囲内でもたらされる任意の整数の開示を含む。
精製された白い粗粒のカオリン粘土(精製された白い離層された粗粒のカオリン粘土を含む)を、白い粗粒のカオリン粗製物、例えば白い板状の粗粒のカオリン粘土から、本願内で記載される方法を使用して誘導できる。「精製された白い粗粒のカオリン粘土」との用語は、本願内で「白い粗粒のカオリン粘土」とも称され、且つ、「精製された白い離層された粗粒のカオリン粘土」との用語は、本願内で「白い離層された粗粒のカオリン粘土」とも称される。「精製された白い粗粒のカオリン粘土」は、「精製された白い粗粒のカオリン粘土」が離層されていても離層されていなくてもよいのに対し、「精製された白い離層された粗粒のカオリン粘土」は離層されているという点で、「精製された白い離層された粗粒のカオリン粘土」とは異なる。従って、「精製された白い粗粒のカオリン粘土」との記載は、「精製された白い離層された粗粒のカオリン粘土」にも関する。
精製された微細な含水カオリン粘土を、本願内に記載される方法を使用して、第三紀の微細な粗製カオリン粘土から誘導できる。精製された微細な含水カオリン粘土を、本願において、微細な含水カオリン粘土とも称する。第三紀の微細な粗製カオリン粘土を、第三紀の粗製物鉱床から採掘できる。カオリン粗製物は、それらが形成された年代を反映する物理的特性を有する。第三紀の粗製物は典型的には、他の年代に堆積された粘土より微細なサイズであり、異なる微量元素のプロファイル、例えばより高いFe2O3含有率を有し、且つ、より高い密度を有する。第三紀の鉱床に基づく粘土は、典型的には白亜紀の粘土(元々、6500万~13600万年前に堆積)を含み、それは3700万~5300万年前に侵食され且つ再堆積された。それらの微細に散在するカオリン粗製物は、カオリンの形成時代および不純物の種類および水準に依存して、灰色、クリーム色、白、茶色、赤またはピンクにわたる色を伴い得る。いくつかの実施態様において、第三紀の微細な粗製カオリン粘土は、中央ジョージア、東ジョージアまたはそれらの組み合わせから採掘された粘土を含み得る。
本願内で記載されるとおり、含水カオリン粘土製品は、白い粗粒のカオリン粘土のみ、微細な含水カオリン粘土のみ、または白い粗粒のカオリン粘土と微細な含水カオリン粘土との配合物を含み得る。前記配合物は、少なくとも80質量%が直径2μm以下を有する粒子を含み得る。例えば、前記配合物は、少なくとも90質量%、少なくとも93質量%、少なくとも96質量%、または少なくとも98質量%が直径2μm以下を有する粒子を含み得る。いくつかの実施態様において、前記配合物は、80質量%~98質量%、90質量%~98%質量%、または93質量%~94質量%が直径2μm以下を有する粒子を含み得る。配合されたカオリン粘土の不純物プロファイルは、0.1質量%以下のNa2O、0.25質量%以下のK2O、1.5質量%以下のTiO2、1質量%以下のFe2O3、0.1質量%以下のCaO、0.1質量%以下のP2O5を含み得る。
含水カオリン粘土製品の製造方法をここに開示する。開示される方法は、含水カオリン粘土の効率的な製造を可能にする。本願内で記載されるとおり、含水カオリン粘土を、白い粗粒のカオリン粘土のみ、微細な含水カオリン粘土のみ、または白い粗粒のカオリン粘土と微細な含水カオリン粘土との配合物から製造できる。配合物が使用される場合、粗粒のカオリン成分と微細なカオリン成分との配合を、カオリン粘土の採掘および加工の間の任意の点で行うことができる。例えば、噴霧乾燥前、または噴霧乾燥後に、粗粒のカオリン成分と微細なカオリン成分とを配合できる。正味の結果が、この文献内で概説される特性を有する配合物を製造できる2種のカオリン成分の添加である限り、粗粒のカオリン成分および微細なカオリン成分を、個々の成分としてコージエライト原料バッチに添加してもよい。カオリン試料の配合前に、前記方法は、白い粗粒の粗製カオリン粘土を精製して、白い粗粒のカオリン粘土を製造すること、および/または第一のアルカリ含有率を有する第三紀の微細な粗製カオリン粘土を精製して、微細な含水カオリン粘土を製造することを含み得る。
本願内で開示される含水カオリンを、カオリンが使用され得る任意の用途において使用することもできる。例えば、含水カオリン粘土製品を、コージエライト組成物中で有利に用いることができる。本願内で記載される含水カオリン粘土製品を、熱特性が強化されたコージエライトセラミックハニカムの焼結における原料成分として使用できる。本願内で記載されるとおり、含水カオリン粘土製品は、白い粗粒の含水カオリン粘土および微細な含水カオリン粘土を含み得る。それら2つの材料の組み合わせは、最終製品中でのコージエライトの結晶配向の程度を操作するための機構を作り出すことによって、コージエライトハニカムの熱機械的特性を強化すると予測される。
例1は、超微細な粒子サイズのカオリン流を得るための粗粒および微細な粗製物の製造方法を概説する。粗粒のカオリン粘土は、中央ジョージアの鉱床中に見出される白い粘土を含み得る。微細な粘土は、中央ジョージアから採掘された第三紀のカオリン、または東ジョージア地域から採掘された第三紀のカオリンを含み得る。微細に散在するカオリン粗製物は、カオリンの形成時代および不純物の種類および水準に依存して、灰色、クリーム色、白、茶色、赤、ピンク色にわたる色のものであってよい。
離層されたおよび微細な粒子サイズのカオリン流の配合物を図2に示すとおりに製造した。対照の試料を上記の例に記載したように製造した。粗粒の離層された流は、中央ジョージア地域の2つの異なる源の粗粒の粘土から得られた。微細な粘土は、中央ジョージア地域から採掘された第三紀のカオリンからなった。表3は、例2から得られた最終的なカオリン微細流の物理的特性を示す。対照および例示的な微細流におけるXRFの結果を表4に示す。
質量分析法を使用して、セラミック基材について、対照の含水カオリン製品および本発明の微細な含水カオリン製品において有機物分析を行った。製造された2つ(対照および本発明の製品)の試料を、Phenomenex ZB-5MSiカラムにおいて、1マイクロリットル容積のスプリットレス式の注入を用いて直接的に分析した。質量分析は、有機物の水準に関する限りは、試験された2つの試料のクロマトグラムにおいて顕著な相違はないことを示した。実際に、分析結果によれば、本発明の微細なカオリン製品は、より清浄な誘導抽出物をもたらした。従って、新たに開発された方法が、セラミック基材について同様の微細なカオリン製品をもたらし得ることが、質量分析法により確認される。
例3は、粗粒のカオリン粗製物からの粗い粒子サイズのカオリン製品の製造方法を概説する(図5にも描く)。この例において使用される粗粒のカオリン粗製物は典型的には、中央ジョージアのカオリン鉱床中で見つけられる白い色であり得る。
例4は、図6の工程フローシートに示されるとおり、粗粒および微細な粗製物からの微細な粒子サイズのカオリン顔料の製造を記載する。
例5は、粗粒および微細な粗製物からの超微細な粒子サイズのカオリン顔料の製造方法を記載する(図7に示される工程フローシート)。微細な流および粗粒の流は(配合前に)例4に記載されるように得られた。微細な流および粗粒の流を配合し、公称93~94質量%が2μm未満の粒子サイズを有する、つまり、粗粒のカオリン流と微細なカオリン流とを質量比25/75で合わせた。一般に、微細な流と粗粒の流とを配合して、80~96質量%が2μm未満である公称粒子サイズにすることができる。その配合物を次に、ディスクノズル遠心分離機(AlphaLaval)を使用して遠心分離して、少なくとも70質量%が0.3μm未満の粒子サイズを有する超微細な流が得られた。
Claims (15)
- 超微細な含水カオリン粘土の製造方法であって、
(i) 第三紀の微細な灰色の粗製カオリン粘土の総質量に対して0.2質量%を上回る第一のアルカリおよびアルカリ土類金属酸化物含有率を有する第三紀の微細な灰色の粗製カオリン粘土を精製すること、
ここで、前記第三紀の灰色の微細な粗製カオリン粘土の精製はポリマーで補助された選択凝集およびオゾン処理を含み、前記第一のアルカリおよびアルカリ土類金属酸化物含有率よりも低い第二のアルカリおよびアルカリ土類金属酸化物含有率を有する微細な含水カオリン粘土をもたらし、且つ
ここで、前記微細な含水カオリン粘土は、少なくとも70質量%が直径0.3μm以下を有し且つ微結晶の平均サイズが400Å以下である粒子を含む、
および
(ii) 前記微細な含水カオリン粘土を、超微細な含水カオリン粘土に加工すること、
ここで、前記超微細な含水カオリン粘土は、前記超微細な含水カオリン粘土の0.2質量%以下の全アルカリおよびアルカリ土類金属酸化物含有率を有する、
を含む、前記製造方法であって、
前記超微細な含水カオリン粘土の製造方法は遠心分離処理を含む、
前記方法。 - 前記第三紀の微細な灰色の粗製カオリン粘土の精製が、さらに、凝集、漂白、ろ過、再分散、噴霧乾燥、微粉砕またはそれらの組み合わせを含む、請求項1に記載の方法。
- 超微細な含水カオリン粘土の製造方法であって、
(a) 白い粗粒の粗製カオリン粘土を精製して、少なくとも80質量%の粒子が直径2μm以下を有する粒子を有する精製された白い粗粒のカオリン粘土を製造すること、
(b) 第一のアルカリおよびアルカリ土類金属酸化物含有率を有する第三紀の微細な粗製カオリン粘土を精製して、少なくとも90質量%の粒子が直径1μm以下を有する粒子を有する精製された微細な含水カオリン粘土を製造すること、
ここで、第三紀の微細な粗製カオリン粘土の精製は選択凝集を含み、微細な含水カオリン粘土成分の総質量に対して0.2質量%以下のNa 2 O、K 2 O、MgOおよびCaOの合計の含有率を有する精製された微細な含水カオリン粘土をもたらす、
(c) 前記精製された白い粗粒のカオリン粘土と前記精製された微細な含水カオリン粘土とを、質量比95:5~5:95で配合して、少なくとも80質量%の粒子が直径2μm未満を有する配合物を製造すること、
(d) 前記配合物を遠心分離して、超微細な含水カオリン流をもたらすこと、および
(e) 前記超微細な含水カオリン流を精製して、超微細な含水カオリン粘土にすること、
ここで、精製は、凝集、漂白、ろ過、再分散、噴霧乾燥、微粉砕またはそれらの組み合わせを含み、且つ、前記超微細な含水カオリン粘土は、前記超微細な含水カオリン粘土の総質量に対して0.2質量%以下のNa 2 O、K 2 O、MgOおよびCaOの合計の含有率を有する、
を含む、前記方法。 - 高分子量のアニオン性ポリマーが、前記選択凝集に使用される、請求項3に記載の方法。
- 前記超微細な含水カオリン流は、少なくとも70質量%の粒子が直径0.3μm以下を有する粒子を含む、請求項3または4に記載の方法。
- 前記配合物は、90~98質量%の粒子が直径2μm以下を有する粒子を含む、請求項3から5までのいずれか1項に記載の方法。
- 前記配合物は、微結晶の平均サイズ300Å~600Åを示す、請求項3から6までのいずれか1項に記載の方法。
- 前記微細な含水カオリン粘土と、精製され離層された粗粒のカオリン粘土とを配合することをさらに含み、ここで、前記精製され離層された粗粒のカオリン粘土は、少なくとも80質量%の粒子が直径2μm以下を有する粒子を有する、請求項1から7までのいずれか1項に記載の方法。
- 前記微細な含水カオリン粘土と前記精製され離層された粗粒のカオリン粘土との間の質量比は5:95~95:5である、請求項8に記載の方法。
- 前記超微細な含水カオリン粘土は、前記超微細な含水カオリン粘土の総質量に対して0.15質量%以下のNa 2 O、K 2 O、MgOおよびCaOの合計の含有率を有する、請求項1から9までのいずれか1項に記載の方法。
- 前記超微細な含水カオリン粘土は、前記超微細な含水カオリン粘土の総質量に対して、酸化ナトリウム含有率0.05質量%以下、および酸化カリウム含有率0.10質量%以下を有する、請求項1から10までのいずれか1項に記載の方法。
- 前記微細な含水カオリン粘土中の粒子は、微結晶の平均サイズ200Å~400Åを示す、請求項1から11までのいずれか1項に記載の方法。
- 請求項1から12までのいずれか1項に記載の方法により製造された超微細な含水カオリン粘土を含むコージエライトセラミック組成物であって、前記組成物の前駆体のコージエライトバッチ組成物が10~30質量%の前記超微細な含水カオリン粘土を含む、前記組成物。
- 前記コージエライトセラミック組成物が、熱膨張率(25℃~800℃)1.25×10-6/℃以下を示す、請求項13に記載のコージエライトセラミック組成物。
- 請求項1から12までのいずれか1項に記載の方法により製造された超微細な含水カオリン粘土を含む組成物であって、前記組成物が、高光沢塗料、半光沢塗料、エッグシェル塗料または艶無し塗料から選択される塗料である、前記組成物。
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