Process for the production of spherical particles of ceramics

Claim 2

A process for the production of spherical ceramic particles, comprising the steps of: forming capsules comprising a particulate ceramic-based core and a shell of polymeric material covering said core by dispersing an aqueous phase containing powdered ceramics in an oily phase containing the polymeric material to form a water-in-oil type emulsion; dispersing said water-in-oil type emulsion in another aqueous phase to form a water-in-oil-in-water type emulsion containing capsules of said ceramic-containing aqueous phase covered with a coating of said polymeric material-containing oily phase dispersed in said another aqueous phase; solidifying said polymeric material of said oily phase; and separating the resulting capsules, each having a shell of hardened polymeric material from said emulsion; and removing said shell of polymeric material from said capsules to obtian said spherical ceramic particles.

Claim 3

The process according to claim 1, wherein said aqueous phase containing powdered ceramics is an aqueous slurry of ceramics.

Claim 4

The process according to claim 2, wherein said aqueous slurry of ceramics is a slurry of calcium phosphate.

Claim 5

The process according to calim 3, wherein a solid content of said calcium phosphate slurry is 7 to 35 w/v %.

Claim 6

The process according to calim 3, wherein a solid content of said calcium phosphate slurry is 7 to 35 w/v %.

Claim 7

The process according to claim 3, wherein said calcium phosphate slurry is prepared by adding water to powdered calcium phosphate to obtain a mixture, milling said mixture, to obtain a milled product, and mixing said milled product with an emulsifying agent.

Claim 8

The process according to claim 1, wherein said oily phase containing the polymeric material is a solution of a water-insoluble polymeric material in a hydrophobic solvent.

Claim 9

The process according to claim 6, wherein said water-insoluble polymeric material is selected from the group consisting of polystyrene, polyacrylate and other water-insoluble polymeric resins.

Claim 10

The process according to claim 6, wherein said hydrophobic solvent is a chlorinated hydrocarbon solvent.

Claim 11

The process according to claim 6, wherein a content of said water-insolule polymeric material in a solution thereof is 5 to 25 w/v %.

Claim 12

The process according to claim 6, wherein said coating of said polymeric material of said oily phase is solidified by heating said water-in-oil-in-water type emulsion at a high temperature which is sufficient to cause volatilization of said hydrophobic solvent from said oily phase.

Claim 13

The process according to claim 10, wherein said emulsion is heated at a temperature of from 30° C. to 40° C.

Claim 14

The process according to claim 1, wherein said shell of polymeric material is removed from each of said capsules by baking said capsules at an elevated temperature sufficient to cause decomposition and perfect combustion of said polymeric material, thereby burning off only said shell of polymeric material.

Claim 15

The process according to claims 1, which further comprises the step of calcinating the spherical ceramic particles after removing each said shell.

Claim 16

A process for the production of spherical ceramic particles comprising the steps of: pouring an aqueous slurry of ceramics into a solution of a water-insoluble polymeric resin in a hydrophobic solvent to form a water-in-oil type emulsion in which said aqueous slurry of ceramics in the form of spheres is dispersed in said solution of water-insoluble polymeric resin; pouring said water-in-oil type emulsion into an aqueous phase to form a water-in-oil-in-water type emulsion in which spherical particles of said aqueous slurry of ceramics covered with a coating of said solution of the polymeric resin are dispersed in said aqueous phase; solidifying said coating of said solution to form a shell of said polymeric resin covering said aqueous slurry of ceramics; separating the resulting spherical particles, each having a solidified coating forming a shell from said water-in-oil-in-water type emulsion; and baking said spherical particles to remove only said shell therefrom to obtain said spherical ceramic particles.

Claim 17

A process for the production of spherical ceramic particles comprising the steps of: pouring an aqueous slurry of ceramics into a solution of a water-insoluble polymeric resin in a hydrophobic solvent to form a water-in-oil type emulsion in which said aqueous slurry of ceramics in the form of spheres is dispersed in said solution of water-insoluble polymeric resin; pouring said water-in-oil type emulsion into an aqueous phase to form a water-in-oil-in-water type emulsion in which spherical particles of said aqueous slurry of ceramics covered with a coating of said solution of the polymeric resin are dispersed in said aqueous phase; solidifying said coating of said solution to form a shell of said polymeric resin covering said aqueous slurry of ceramics; separating the resulting spherical particles, each having a solidified coating forming a shell from said water-in-oil-in-water type emulsion; and baking said spherical particles to remove only said shell therefrom to obtain said spherical ceramic particles.

Claim 18

The process according to claim 14, wherein said aqueous slurry of ceramics is an aqueous slurry of calcium phosphate.

Claim 19

The process according to claim 15, wherein said aqueous slurry of calcium phosphate is prepared by adding water to powdered calcium phosphate to obtain a mixture, milling the mixture in a ball mill, and mixing the milled mixture with an emulsifying agent.

Claim 20

The process according to claim 15, wherein a solid content of said slurry of calcium phosphate is 7 to 35 w/v %.

Claim 21

The process according to claim 14, in which a content of said polymeric resin in said solution thereof is 5 to 25 w/v %.