Patent US4820554A successfully refreshed from Google Patents.
US4820554A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Coated paper and process
Assignee: ECC America Inc
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Filing: 1986-10-14
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Granted: 1989-04-11
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Expires: 2006-10-14
Abstract
Abstract A coated paper of improved optical and printing qualities, coated with a structured kaolinitic pigment. The pigment consists of porous aggregates of kaolin particles which are chemically bonded together. The pigment may be produced by chemically reacting a particulate kaolin with a metal chloride, such as silicon tetrachloride. The process for preparing the structured pigment is conducted under conditions such that the kaolinite structure is not impaired.
Inventors
- 👤 J. Philip E. Jones
- 👤 Rasik H. Raythatha
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 17:00
CPC Classifications
D; D21; D21H; D21H19/00; D21H19/36; D21H19/38; D21H19/40; C; C09; C09C; C09C1/00; C09C1/40; C09C1/42; C01; C01P; C01P2004/00; C01P2004/50; C01P2004/51; C01P2004/52; C01P2004/60; C01P2004/61; C01P2004/62; C01P2004/80; C01P2006/00; C01P2006/14; C01P2006/19; C01P2006/21; C01P2006/60; C01P2006/80; C01P2006/82; C01P2006/90; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31971; Y10T428/31993
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
164 words
A method for producing improved coated papers and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin; and (b) chemically reacting said feed mixture in particulate form with a metal chloride having the general formula M Cl x , where M is Si, Al or Ti; and x is 3 or 4 in accordance with M, to aggregate the kaolin particles to form the structured pigment; the moisture level present in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the said paper or paperboard product with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 2
Independent Claim
164 words
A method for producing improved coated papers and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin; and (b) chemically reacting said feed mixture in particulate form with a metal chloride having the general formula M Cl x , where M is Si, Al or Ti; and x is 3 or 4 in accordance with M, to aggregate the kaolin particles to form the structured pigment; the moisture level present in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the said paper or paperboard product with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 3
Independent Claim
171 words
A method for producing improved coated papers and paperboard and products which comprises: A. producing a structure kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin; and (b) aggregating the kaolin particles to form the structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti, and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; the moisture level present in the said feed mixture reacted in step (b) being sufficient ot at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 4
Independent Claim
171 words
A method for producing improved coated papers and paperboard and products which comprises: A. producing a structure kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin; and (b) aggregating the kaolin particles to form the structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti, and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; the moisture level present in the said feed mixture reacted in step (b) being sufficient ot at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 5
Independent Claim
216 words
A method for producing improved coated paper and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of (a) forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of any alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being present in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) chemically reacting said feed mixture in particulate form with a metal chloride having the general formula M Cl x , where M is Si, Al or Ti; and x is 3 or 4 in accordance with M, to aggregate the kaolin particles to form the structured pigment; the moisture level present in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 6
Independent Claim
216 words
A method for producing improved coated paper and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of (a) forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of any alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being present in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) chemically reacting said feed mixture in particulate form with a metal chloride having the general formula M Cl x , where M is Si, Al or Ti; and x is 3 or 4 in accordance with M, to aggregate the kaolin particles to form the structured pigment; the moisture level present in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 7
Independent Claim
226 words
A method for producing improved coated paper and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of an alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being pesnt in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) aggregating the kaolin particles to form the structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti, and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; the moisture level preesnt in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 8
Independent Claim
226 words
A method for producing improved coated paper and paperboard products which comprises: A. producing a structured kaolin pigment having enhanced light scattering and opacifying properties by a process comprising the steps of: (a) forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of an alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being pesnt in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) aggregating the kaolin particles to form the structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti, and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; the moisture level preesnt in the said feed mixture reacted in step (b) being sufficient to at least partially hydrolyze the metal chloride; and steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and B. coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 9
Independent Claim
33 words
A method in accordance with claims 1, 2, 3 or 4 wherein said metal chloride comprises silicon tetrachloride; and wherein the moisture level in said feed is below that at which the predominant
Claim 10
Independent Claim
29 words
A method as set forth in claims 1, 2, 3 or 4 including the step of heating the reactants in step (b) to temperatures not higher than 150° C.
Claim 11
Independent Claim
40 words
A method as set forth in claims 1, 2, 3 or 4 including the steps of aging the product of step (b) for a period of at least three days to enhance the scattering properties of the aggregated kaolin particles.
Claim 12
Independent Claim
29 words
A method as set forth in claims 1, 2, 3 or 4, wherein said feed kaolin has a G.E. brightness in the range of from about 80 to 92.
Claim 13
Independent Claim
41 words
A method in accordance with claims 1, 2, 3 or 4, wherein the feed mixture subjected to step (b) has a free moisture content such as to provide a water to metal chloride molar ratio of from about 1 to 10.
Claim 14
Independent Claim
33 words
A method as set forth in claims 1, 2, 3 or 4, wherein said kaolin utilized in step (a) is at least as fine as 94% by weight less than 2 micrometers E.S.D.
Claim 15
Independent Claim
36 words
A method as set forth in claims 3 or 4, wherein said aggregation enhancing agent comprises from about 0.4 to about 12% by weight of the kaolin, of a particulate alkaline earth metal carbonate or hydroxide.
Claim 16
Dependent Claim
15 words
A method as set forth in claim 11, wherein said enhancing agent comprises calcium carbonate.
Claim 17
Dependent Claim
23 words
A method as set forth in claim 12 wherein the feed mixture of kaolin and calcium carbonate is dry-milled prior to step (b).
Claim 18
Dependent Claim
20 words
A process in accordance with claim 13, wherein the said feed mixture is dry-milled by repetitive passes through a mill.
Claim 19
Independent Claim
26 words
A method as set forth in claims 2 or 4, wherein said ammonia is added at levels from about 8 to 16 lbs/ton of feed mix.
Claim 20
Dependent Claim
20 words
A method as set forth in claim 1 or 3, wherein the step of metal chloride addition is sequentially repeated.
Claim 21
Dependent Claim
32 words
A method as set forth in claim 1 or 3, wherein the step of metal chloride addition is sequentially repeated and ammonia is added only after the second addition of metal chloride.
Claim 22
Dependent Claim
41 words
A coated paper or paperboard coated with a structured kaolinitic pigment comprising porous aggregates of kaolin particles which are chemically bonded to one another, by the process of steps (a) and (b) of any of claims 1, 2, 3 or 4.
Claim 23
Dependent Claim
21 words
The coated paper coated with a structured kaolinitic pigment by the process of any of claims 1, 2, 3 or 4.
Claim 24
Dependent Claim
58 words
A coated paper or paperboard coated with a structured kaolinitic pigment being the reaction product of a fine particle size kaolin, a metal chloride having the general formula M Cl x in which M is Si, Al or Ti and x is 3 or 4 depending on the valence of M, and water for hydrolyzing said metal chloride.
Claim 25
Dependent Claim
58 words
A coated paper or paperboard coated with a structured kaolinitic pigment being the reaction product of a fine particle size kaolin, a metal chloride having the general formula M Cl x in which M is Si, Al or Ti and x is 3 or 4 depending on the valence of M, and water for hydrolyzing said metal chloride.
Claim 26
Dependent Claim
19 words
A coated paper or paperboard as set forth in claim 20 in which said metal chloride comprises silicon tetrachloride.
Claim 27
Independent Claim
90 words
A method for improving the optical and printability properties of a paper or paperboard coated with a coating formulation of the type comprising a coating pigment component and an adhesive binder; said method comprising: substituting into the said pigment component of the said coating formulation, from about 5 to 60% by weight of said component, of a structured kaolinitic pigment comprising porous aggregates of kaolin particles which are chemically bonded to one another, by the process of steps (a) and (b) of any of claims 1, 2, 3 or 4.
Claim 28
Dependent Claim
63 words
A coated paper or paperboard, the coating of which comprises a coating pigment component and an adhesive binder, said pigment component including from 5 to 60% by weight of a structured kaolinitic pigment comprising porous aggregates of kaolin particles which are chemically bonded to one another by the process of steps (a) and (b) of any of claims 1, 2, 3, or 4.
Claim 29
Independent Claim
96 words
A method for preparing an aqueous slurry of a pigment prepared by steps (a) and (b) of any of claims 1, 2, 3, or 4, comprising dispersing said pigment to form an aqueous slurry of up to 52% solids by weight, by intermixing said pigment with water and as dispersing agents a combination of from about 0.4 to 1% of medium viscosity carboxymethylcelulose, from about 0.1 to 0.5% of tetrasodium pyrophosphate, and from about 0 to 0.5% of sodium polyacrylate salts, said percentages being expressed as weight percent of the dry pigment present in said slurry.
Claim 30
Independent Claim
39 words
A method in accordance with claims 1, 2, 3 or 4, wherein the feed mixture subjected to step (b) has a free moisture content such as to provide a water to metal chloride ratio of less than about 50.
Claim 31
Dependent Claim
231 words
In the method for imprinting paper by contact printing a pattern upon a paper provided with a kaolin pigment coating composition; the improvement enabling enhanced printing properties at a given coat weight or maintaining of printing properties while reducing coat weights comprising: utilizing in said method a coated paper prepared by a process of (a) producing a structure kaolin pigment by forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of an alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being present in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) aggregating the kaolin particles to form the said structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti; and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and (c) coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 32
Dependent Claim
231 words
In the method for imprinting paper by contact printing a pattern upon a paper provided with a kaolin pigment coating composition; the improvement enabling enhanced printing properties at a given coat weight or maintaining of printing properties while reducing coat weights comprising: utilizing in said method a coated paper prepared by a process of (a) producing a structure kaolin pigment by forming a feed mixture of a fine particle size kaolin together with an aggregation enhancing agent selected from one or more members of the group consisting of an alkaline earth metal carbonate or hydroxide, and lithium carbonate, the enhancing agent being present in quantities to provide from about 5 to 120 millimoles of the enhancing agent metal ion species per 100 parts by weight of kaolin; and (b) aggregating the kaolin particles to form the said structured pigment, by combining said feed mixture in particulate form with a metal chloride having the general formula M Cl x where M is Si, Al or Ti; and x is 3 or 4 in accordance with M; and then adding ammonia to the combined feed mixture and metal chloride; steps (a) and (b) being conducted under conditions such that the basic kaolinite crystalline structure is not altered; and (c) coating the paper with a coating composition having a pigment component wherein said structured kaolin pigment comprises from 5 to 60% by weight thereof.
Claim 33
Dependent Claim
21 words
The method of claim 26, in which in step (b) ammonia is added to the combined feed mixture and metal chloride.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-04-10 | 1992-10-10 | 1993-04-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-04-10 | 1996-10-10 | 1997-04-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-04-10 | 2000-10-10 | 2001-04-11 | $7700.00 | Window Closed / Lapsed |