Mica-resin composite material

Claim 1

The method of forming a composite body composed of ion-exchanged, synthetic mica crystals and an organic resin which comprises the steps of, providing in flocculated form an ion-exchanged, synthetic, lithium and/or sodium, crystalline mica, the mica being selected from the group of fluorhectorite, hydroxyl hectorite, boron fluorphlogopite, hydroxyl boron phlogopite, and solid solutions among those and between those and other structurally-compatible species selected from the group of talc, fluortalc, fluorpolylithioinite, polylithionite, phlogopite, and fluorphlogopite, converting the floc to particulate form, mixing the particulate floc with an organic resin in particulate form and in such amount that the processed composite has a greater mechanical strength than similarly processed floc alone, and contains at least 50% floc dispersing the mixture in a solvent, drying the dispersed mixture, and pressing the dried mixture to desired form at an elevated temperature and pressure.

Claim 2

The method of forming a composite body composed of ion-exchanged, synthetic mica crystals and an organic resin which comprises the steps of, providing in flocculated form an ion-exchanged, synthetic, lithium and/or sodium, crystalline mica, the mica being selected from the group of fluorhectorite, hydroxyl hectorite, boron fluorphlogopite, hydroxyl boron phlogopite, and solid solutions among those and between those and other structurally-compatible species selected from the group of talc, fluortalc, fluorpolylithioinite, polylithionite, phlogopite, and fluorphlogopite, converting the floc to particulate form, mixing the particulate floc with an organic resin in particulate form and in such amount that the processed composite has a greater mechanical strength than similarly processed floc alone, and contains at least 50% floc dispersing the mixture in a solvent, drying the dispersed mixture, and pressing the dried mixture to desired form at an elevated temperature and pressure.

Claim 11

The method of forming a composite body composed of ion-exchanged, synthetic mica crystals and an organic resin which comprises the steps of forming a fully or predominantly crystalline body containing crystals consisting essentially of a synthetic, lithium and/or sodium, water-swelling mica selected from the group of fluorhectorite, hydroxyl hectorite, boron fluorphlogopite, hydroxyl boron phlogopite, and solid solutions among those and between those and other structurally-compatible species selected from the group of talc, fluortalc, fluorpolylithionite, polylithionite, phlogopite, and fluorphlogopite, contacting the body with a polar liquid to cause the body to swell and disintegrate into platelets having a high aspect ratio which disperse in the liquid and form a gel, mixing the gel with a donor of a larger cation whereby the larger cation exchanges with the lithium and/or sodium ions of the mica to form ion-exchanged particles which flocculate, converting the floc thus formed to a particulate form, mixing the particulate floc with an organic resin in particulate form and in such amount that the processed composite has a greater mechanical strength than similarly processed floc alone while the floc constitutes at least 50% of the composite, adding a coupling agent, dispersing the mixture in a solvent, drying the dispersed mixture to a powder form, pressing the powdered mixture to desired form at an elevated temperature and pressure.

Claim 12

The method of forming a composite body composed of ion-exchanged, synthetic mica crystals and an organic resin which comprises the steps of forming a fully or predominantly crystalline body containing crystals consisting essentially of a synthetic, lithium and/or sodium, water-swelling mica selected from the group of fluorhectorite, hydroxyl hectorite, boron fluorphlogopite, hydroxyl boron phlogopite, and solid solutions among those and between those and other structurally-compatible species selected from the group of talc, fluortalc, fluorpolylithionite, polylithionite, phlogopite, and fluorphlogopite, contacting the body with a polar liquid to cause the body to swell and disintegrate into platelets having a high aspect ratio which disperse in the liquid and form a gel, mixing the gel with a donor of a larger cation whereby the larger cation exchanges with the lithium and/or sodium ions of the mica to form ion-exchanged particles which flocculate, converting the floc thus formed to a particulate form, mixing the particulate floc with an organic resin in particulate form and in such amount that the processed composite has a greater mechanical strength than similarly processed floc alone while the floc constitutes at least 50% of the composite, adding a coupling agent, dispersing the mixture in a solvent, drying the dispersed mixture to a powder form, pressing the powdered mixture to desired form at an elevated temperature and pressure.

Claim 18

A method in accordance with c1aim 10 wherein the coupling agent is added in an amount up to 2% of the solids content.

Claim 19

A method in accordance with c1aim 10 wherein the coupling agent is added in an amount up to 2% of the solids content.