WO2002016509A1 - Kaolin products and their use - Google Patents

Kaolin products and their use Download PDF

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Publication number
WO2002016509A1
WO2002016509A1 PCT/GB2001/003707 GB0103707W WO0216509A1 WO 2002016509 A1 WO2002016509 A1 WO 2002016509A1 GB 0103707 W GB0103707 W GB 0103707W WO 0216509 A1 WO0216509 A1 WO 0216509A1
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WO
WIPO (PCT)
Prior art keywords
kaolin
calcium carbonate
composition according
composition
particle size
Prior art date
Application number
PCT/GB2001/003707
Other languages
French (fr)
Inventor
Marielle Lorusso
Original Assignee
Imerys Minerals Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imerys Minerals Limited filed Critical Imerys Minerals Limited
Priority to AU2001282288A priority Critical patent/AU2001282288A1/en
Priority to US10/312,448 priority patent/US7413601B2/en
Publication of WO2002016509A1 publication Critical patent/WO2002016509A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
    • D21H17/68—Water-insoluble compounds, e.g. fillers, pigments siliceous, e.g. clays
    • 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
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/54—Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/10—Mixtures of chemical and mechanical pulp
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
    • D21H17/675—Oxides, hydroxides or carbonates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/71—Mixtures of material ; Pulp or paper comprising several different materials not incorporated by special processes
    • D21H17/73—Mixtures of material ; Pulp or paper comprising several different materials not incorporated by special processes of inorganic material
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
    • D21H21/52—Additives of definite length or shape

Definitions

  • the present invention relates to kaolin products and blends or compositions containing them.
  • it relates to particulate kaolin products and blends containing them for use as fillers in making uncoated, e.g. supercalendered (SC) papers and their production.
  • SC supercalendered
  • Mineral fillers are used in the production of most papers for printing or writing applications.
  • the incorporation of such fillers together with cellulose fibres in a paper making composition reduces the overall cost of the raw materials and can improve optical and printing properties of the paper.
  • adding fillers causes reduction in the strength of the paper, so there is a practical limit " "'- . to the amount of fillers normally used in the paper making composition.
  • Suitable smoothness, gloss, density per unit area and printing ink porosity can be achieved by multiple calendering of the filled paper sheets.
  • the well known process of calendering involves passing the sheets of paper between rollers to compress the sheets .
  • SC supercalendered
  • Kaolin materials have been widely used in the prior art as fillers for making papers, especially SC papers.
  • One purpose of the present invention is to provide hydrous kaolin materials suitable for use as improved fillers in the production of uncoated writing and printing grade papers, especially SC papers .
  • a particulate kaolin suitable for use as a filler material in compositions for making uncoated paper the kaolin having a mean particle size of between 0.7 ⁇ m and 3 ⁇ m and a shape factor of at least 60.
  • mean particle size and all other particle size properties are as determined for a fully dispensed dilute aqueous suspension of the particulate material in question by sedimentation using a SEDIGRAPHTM 5100 machine, (supplied by the Micromeritics Corporation) in a well-known manner.
  • the mean particle size of the kaolin product may be from 0.9 ⁇ m to 2.5 ⁇ m, especially from 0.9 ⁇ m to 1.2 ⁇ m, or from 1.2 ⁇ m to 1.7 ⁇ m.
  • the powder brightness of the particulate kaolin according to the first aspect may be at least 80 ISO units, preferably at least 83 ISO units measured in a well-known manner according industry (TAPPI) standard procedures .
  • the shape factor of the particles of the particulate kaolin according to the invention is at least 60, preferably at least 65, in some cases at least 70 or more.
  • ⁇ shape factor' as used herein means the average value (on a weight average basis) of the ratio of mean particle diameter to particle thickness for a population of particles of varying size and shape (i.e.
  • 'Mean particle diameter' is here defined as the diameter of a circle, which has the same area as the largest face of the particle.
  • the shape factor of the particles under test is calculated from the two conductivity measurements.
  • the particulate kaolin according to the first aspect of the invention is a hydrous kaolin which may be obtained from a primary or secondary (sedimentary) source and may be processed using known procedures to have the specified properties.
  • the processing procedures may for example involve comminution, e.g. grinding or milling, and particle size classification, e.g using screens, centrifuges, cyclones, air classifiers and the like.
  • the particulate kaolin according to the first aspect of the invention may be subjected to further refinement or beneficiation treatments to remove impurities and to improve properties, e.g. optical properties such as brightness.
  • Such treatments may be known per se and may be selected for example from magnetic impurity separation, froth flotation, selective flocculation, impurity leaching and bleaching.
  • the particulate kaolin according to first aspect of the present invention may consist of at least 95% by weight kaolinite, preferably at least 98% by weight kaolinite.
  • the particulate kaolin according to the first aspect may be blended with other particulate filler materials for use in paper making compositions.
  • Such other filler materials may be known per se and may be selected for example from other hydrous kaolin, calcined kaolin, talc, calcium sulphate, titanium dioxide and alkaline earth metal carbonate, especially calcium carbonate.
  • a blend or composition of fillers for use in compositions for making uncoated paper comprises (a) particulate kaolin according to the first aspect and (b) a particulate calcium carbonate.
  • the blend according to the second aspect may comprise from 5% to 95%, especially from 20% to 80%, by weight of the kaolin according to the first aspect and from 95% to 5%, especially from 80% to 20%, by weight of the particulate calcium carbonate product.
  • the weight ratio of kaolin: calcium carbonate in the blend may be 50:50 or more, e.g. from 60:40 to 80:20 where the kaolin has a mean particle size greater than 1.2 ⁇ m and not greater than 1.7 ⁇ m.
  • the weight ratio of kaolin: calcium carbonate in the blend may be 50:50 or less, e.g. from 40:60 to 20:80 where the kaolin has a mean particle size less than 1.2 ⁇ m and not less than
  • the blend according to the second aspect of the invention benefits from the enhancement of properties such as brightness provided by the calcium carbonate as well as retaining desirable properties such as gloss and print quality provided by the kaolin.
  • the kaolin according to the first aspect shows a superior combination of properties when used as a filler in paper making compositions, especially when used in the form of a blend with calcium carbonate, compared with prior art kaolin fillers used in a comparable manner.
  • Use of such fillers allows paper especially wood containing paper to be made having an improved combination of porosity, strength, sheet gloss, sheet brightness, print density and print gloss especially when printed upon by a gravure printing process or an offset printing process, especially a heatset offset process.
  • the papermaking composition in which the kaolin according to the first aspect or the blend according to the second aspect is used may be obtained from a groundwood pulp composition of cellulose fibres, i.e. from a pulp containing from 70% to 100% by weight of a so-called mechanical pulp, which is one that has been mechanically refined, e.g.
  • composition obtained from logs and ground, refined and bleached or obtained from wood chips and refined (optionally under pressure and/or at elevated temperature and/or with the use of chemicals) and bleached.
  • the composition may contain a minor percentage, e.g. up to 30% by weight, of a so called chemical pulp, i.e. one which has been chemically treated to remove lignin.
  • the filler blend comprises calcium carbonate having (i) a mean particle size of from 0.4 ⁇ m to 1.5 ⁇ m, especially from 0.7 ⁇ m to 1.3 ⁇ m; and (ii) a steepness factor of at least 40, preferably at least 50, especially at least 60.
  • 'steepness factor' (sometimes referred to as 'narrowness' ) as used herein refers to the steepness of the particle size distribution curve as measured by the SEDIGRAPH 5100 machine in the manner described earlier and is given by the expression lOOx (d 30 ⁇ d 70 ) , where d 30 is the value of the particle size less than which there are 30% by weight of the particles and d 70 is the value of the particle size less than which there are 70% by weight of the particles.
  • the said calcium carbonate may comprise a so called ground carbonate, i.e. a product obtained from natural sources, e.g. marble, chalk or limestone, and processed to have appropriate properties by known treatments involving at least one grinding step.
  • the calcium carbonate may be synthesised, e.g. by chemical precipitation, e.g. by the reaction in an aqueous medium of carbon dioxide and lime (calcium hydroxide) .
  • Carbonate products made in this way may be mixed materials optionally containing other fine solids, e.g. fibres or particulate solids, present in the aqueous medium when the precipitation reaction is carried out. Such other solids become bonded to the calcium carbonate crystals during the precipitation of the calcium carbonate crystals. Examples of composite filler materials produced in this way are described in our EP 892,019.
  • the calcium carbonate product used to form the blend according to the second aspect of the invention may include a chemical additive employed to provide resistance to acidic conditions which are present in some papermaking systems.
  • a chemical additive employed to provide resistance to acidic conditions which are present in some papermaking systems. Such an additive is described for example in US 5,593,489.
  • the kaolin according to the first aspect and the blend according to the second aspect of the invention may be employed in a paper making composition and paper sheets, especially paper sheets to be calendered and printed upon by a gravure or offset printing process, may be made using such a composition all in a known manner.
  • EXAMPLE 1 (Comparative) A paper pulp composition was prepared using an 80:20 (by weight) blend of mechanical and chemical pulps. The composition was formed into a dilute aqueous suspension (containing less than 1% by weight solids) by addition of water.
  • the filler consisted of a 70:30 (by weight) kaolin-rich blend of kaolin and precipitated calcium carbonate (pec) .
  • the kaolin, Kaolin 1 had the following properties: (i) percentage by weight of particles smaller than 2 ⁇ m: 50%; (ii) mean particle size: l. ⁇ m; (iii) shape factor 45.
  • the pec, PCC1 had the following properties: (i) percentage by weight of particles smaller than
  • the conditioned handsheets were calendered using a laboratory soft nip calender.
  • the calendering conditions were as follows : (i) roll temperature: 100 °C; (ii) nip pressure: 300kN.rrf 2 ; (iii) speed: 30m.minA
  • EXAMPLE 2 (Invention embodiment) The procedure used in Example 1 was repeated to prepare and measure the properties of handsheets except that the kaolin used in the filler composition was a different kaolin, Kaolin 2, having the following properties: (i) percentage by weight of particles smaller than 2urn: 50%; (ii) mean particle size: 1. ⁇ ; (iii) shape factor: 70.
  • the resulting calendered handsheets had the properties which are shown in Tables 1 to 3 later.
  • Example 1 The procedure used in Example 1 to prepare and measure the properties of handsheets was repeated ' except that the percentage by weight of Kaolin 1 used in the filler composition was 30%, the percentage by weight of PCC 1 being 70%.
  • the resulting calendered handsheets had the properties which are also shown in Tables 1 to 3 later.
  • Example 1 The procedure used in Example 1 to prepare and measure the properties of handsheets was repeated except that (i) the percentages by weight of kaolin and pec (PCC 1) were respectively 30% and 70% by weight and (ii) the kaolin used in the filler composition was a further different kaolin, Kaolin 3, having the following properties: (ii) percentage by weight of particles smaller than
  • the resulting calendered handsheets had the properties which are shown in Tables 1 to 3 later.
  • Tables 1 to 3 illustrate the improved combination of properties obtained by using kaolins embodying the invention (Kaolins 2 and 3) in blends with particulate calcium carbonate.

Abstract

A particulate kaolin suitable for use as a filler material in compositions for making uncoated paper, the kaolin having a mean particle size of between 0.7 νm and 3 νm and a shape factor of at least 60.

Description

KAOLIN PRODUCTS AND THEIR USE
The present invention relates to kaolin products and blends or compositions containing them. In particular, it relates to particulate kaolin products and blends containing them for use as fillers in making uncoated, e.g. supercalendered (SC) papers and their production.
Mineral fillers are used in the production of most papers for printing or writing applications. The incorporation of such fillers together with cellulose fibres in a paper making composition reduces the overall cost of the raw materials and can improve optical and printing properties of the paper. However, adding fillers causes reduction in the strength of the paper, so there is a practical limit ""'- . to the amount of fillers normally used in the paper making composition.
Highly filled uncoated papers can compete with some coated paper grades .
Suitable smoothness, gloss, density per unit area and printing ink porosity can be achieved by multiple calendering of the filled paper sheets. The well known process of calendering involves passing the sheets of paper between rollers to compress the sheets .
Highly filled uncoated, calendered papers having properties approaching those of coated papers are generally known as supercalendered (SC) papers. Such papers can be used for various applications, particularly involving printing upon the paper by rotogravure or offset processes .
Kaolin materials have been widely used in the prior art as fillers for making papers, especially SC papers. One purpose of the present invention is to provide hydrous kaolin materials suitable for use as improved fillers in the production of uncoated writing and printing grade papers, especially SC papers . According to the present invention in a first aspect there is provided a particulate kaolin suitable for use as a filler material in compositions for making uncoated paper, the kaolin having a mean particle size of between 0.7μm and 3μm and a shape factor of at least 60.
In this specification, mean particle size and all other particle size properties are as determined for a fully dispensed dilute aqueous suspension of the particulate material in question by sedimentation using a SEDIGRAPH™ 5100 machine, (supplied by the Micromeritics Corporation) in a well-known manner.
The mean particle size of the kaolin product may be from 0.9μm to 2.5μm, especially from 0.9μm to 1.2μm, or from 1.2μm to 1.7μm. The powder brightness of the particulate kaolin according to the first aspect may be at least 80 ISO units, preferably at least 83 ISO units measured in a well-known manner according industry (TAPPI) standard procedures . The shape factor of the particles of the particulate kaolin according to the invention is at least 60, preferably at least 65, in some cases at least 70 or more. The expression Λshape factor' as used herein means the average value (on a weight average basis) of the ratio of mean particle diameter to particle thickness for a population of particles of varying size and shape (i.e. in this case the particulate kaolin) as measured using the electrical conductivity method and apparatus described in GB-A- 2240398, US-A-5128606 and EP-A-528078 and using the equations derived in those patent specifications. 'Mean particle diameter' is here defined as the diameter of a circle, which has the same area as the largest face of the particle. In the electrical conductivity measurement method described in the said specifications, the electrical conductivity of a fully dispersed aqueous suspension of the particles under test is caused to flow through an elongated tube. Measurements of the electrical conductivity are taken between (a) a pair of electrodes separated longitudinally along the axis of the tube and (b) a pair of electrodes separated transversely across the tube. The shape factor of the particles under test is calculated from the two conductivity measurements. The particulate kaolin according to the first aspect of the invention is a hydrous kaolin which may be obtained from a primary or secondary (sedimentary) source and may be processed using known procedures to have the specified properties. The processing procedures may for example involve comminution, e.g. grinding or milling, and particle size classification, e.g using screens, centrifuges, cyclones, air classifiers and the like.
The particulate kaolin according to the first aspect of the invention may be subjected to further refinement or beneficiation treatments to remove impurities and to improve properties, e.g. optical properties such as brightness. Such treatments may be known per se and may be selected for example from magnetic impurity separation, froth flotation, selective flocculation, impurity leaching and bleaching.
The particulate kaolin according to first aspect of the present invention may consist of at least 95% by weight kaolinite, preferably at least 98% by weight kaolinite.
The particulate kaolin according to the first aspect may be blended with other particulate filler materials for use in paper making compositions. Such other filler materials may be known per se and may be selected for example from other hydrous kaolin, calcined kaolin, talc, calcium sulphate, titanium dioxide and alkaline earth metal carbonate, especially calcium carbonate.
According to the present invention in a second aspect there is provided a blend or composition of fillers for use in compositions for making uncoated paper, especially so called wood containing or groundwood paper, comprises (a) particulate kaolin according to the first aspect and (b) a particulate calcium carbonate. The blend according to the second aspect may comprise from 5% to 95%, especially from 20% to 80%, by weight of the kaolin according to the first aspect and from 95% to 5%, especially from 80% to 20%, by weight of the particulate calcium carbonate product.
For blends according to the second aspect where the kaolin according to the first aspect has a mean particle size of 1.2μm or more the weight ratio of kaolin: calcium carbonate in the blend may be 50:50 or more, e.g. from 60:40 to 80:20 where the kaolin has a mean particle size greater than 1.2μm and not greater than 1.7μm.
For blends according to the second aspect where the kaolin according to the first aspect has a mean particle size of 1.2μm or less the weight ratio of kaolin: calcium carbonate in the blend may be 50:50 or less, e.g. from 40:60 to 20:80 where the kaolin has a mean particle size less than 1.2μm and not less than
0.9μm. The blend according to the second aspect of the invention benefits from the enhancement of properties such as brightness provided by the calcium carbonate as well as retaining desirable properties such as gloss and print quality provided by the kaolin. We have found, unexpectedly, that the kaolin according to the first aspect shows a superior combination of properties when used as a filler in paper making compositions, especially when used in the form of a blend with calcium carbonate, compared with prior art kaolin fillers used in a comparable manner. Use of such fillers allows paper especially wood containing paper to be made having an improved combination of porosity, strength, sheet gloss, sheet brightness, print density and print gloss especially when printed upon by a gravure printing process or an offset printing process, especially a heatset offset process. Such an improved combination of properties is obtained especially when the paper sheet made using the said filler is heavily compressed by calendering, e.g. is supercalendered. The combination of properties may have a particularly good brightness when the composition is calcium carbonate rich and particularly good gloss and print quality properties when the composition is kaolin rich. The papermaking composition in which the kaolin according to the first aspect or the blend according to the second aspect is used may be obtained from a groundwood pulp composition of cellulose fibres, i.e. from a pulp containing from 70% to 100% by weight of a so-called mechanical pulp, which is one that has been mechanically refined, e.g. obtained from logs and ground, refined and bleached or obtained from wood chips and refined (optionally under pressure and/or at elevated temperature and/or with the use of chemicals) and bleached. The composition may contain a minor percentage, e.g. up to 30% by weight, of a so called chemical pulp, i.e. one which has been chemically treated to remove lignin.
We have found that particularly beneficial results are obtained in use of the filler blend according to the second aspect of the invention when the filler blend comprises calcium carbonate having (i) a mean particle size of from 0.4μm to 1.5μm, especially from 0.7μm to 1.3μm; and (ii) a steepness factor of at least 40, preferably at least 50, especially at least 60.
The expression 'steepness factor' , (sometimes referred to as 'narrowness' ) as used herein refers to the steepness of the particle size distribution curve as measured by the SEDIGRAPH 5100 machine in the manner described earlier and is given by the expression lOOx (d30÷d70) , where d30 is the value of the particle size less than which there are 30% by weight of the particles and d70 is the value of the particle size less than which there are 70% by weight of the particles.
The said calcium carbonate may comprise a so called ground carbonate, i.e. a product obtained from natural sources, e.g. marble, chalk or limestone, and processed to have appropriate properties by known treatments involving at least one grinding step. Alternatively, the calcium carbonate may be synthesised, e.g. by chemical precipitation, e.g. by the reaction in an aqueous medium of carbon dioxide and lime (calcium hydroxide) . Carbonate products made in this way may be mixed materials optionally containing other fine solids, e.g. fibres or particulate solids, present in the aqueous medium when the precipitation reaction is carried out. Such other solids become bonded to the calcium carbonate crystals during the precipitation of the calcium carbonate crystals. Examples of composite filler materials produced in this way are described in our EP 892,019.
The calcium carbonate product used to form the blend according to the second aspect of the invention may include a chemical additive employed to provide resistance to acidic conditions which are present in some papermaking systems. Such an additive is described for example in US 5,593,489.
The kaolin according to the first aspect and the blend according to the second aspect of the invention may be employed in a paper making composition and paper sheets, especially paper sheets to be calendered and printed upon by a gravure or offset printing process, may be made using such a composition all in a known manner.
Embodiments of the present invention will now be described by way of example with reference to the following Examples. EXAMPLE 1 (Comparative) A paper pulp composition was prepared using an 80:20 (by weight) blend of mechanical and chemical pulps. The composition was formed into a dilute aqueous suspension (containing less than 1% by weight solids) by addition of water. The filler consisted of a 70:30 (by weight) kaolin-rich blend of kaolin and precipitated calcium carbonate (pec) . The kaolin, Kaolin 1, had the following properties: (i) percentage by weight of particles smaller than 2μm: 50%; (ii) mean particle size: l.βμm; (iii) shape factor 45. The pec, PCC1, had the following properties: (i) percentage by weight of particles smaller than
2μm: 95%; (ii) mean particle size: 0.9μm; (iii) additive: 5% by weight (active based on the dry weight of calcium carbonate) of a neutrally buffering chemical comprising a solution of an aluminium compound and phosphoric acid. Retention aid chemical commercially available under the trade name Percol 292 was added in an amount of 0.02% by weight (active based on the dry weight of solids present) to the filler containing pulp suspension. Handsheets of grammage 57g.m"2 were made from the suspension using a standard semi-automatic handsheet former according to TAPPI standard procedures. The handsheets were conditioned for 24 hours in a room at a temperature of 23 °C and a relative humidity of 50%. The conditioned handsheets were calendered using a laboratory soft nip calender. The calendering conditions were as follows : (i) roll temperature: 100 °C; (ii) nip pressure: 300kN.rrf2; (iii) speed: 30m.minA
(iv) number of nips: 4 per side.
The properties specified in Tables 1 to 3 later of the handsheets produced were measured according to industry standard (TAPPI) procedures well known to those skilled in the art. The results which were obtained for these measurements are also shown in Tables 1 to 3 later.
EXAMPLE 2 (Invention embodiment) The procedure used in Example 1 was repeated to prepare and measure the properties of handsheets except that the kaolin used in the filler composition was a different kaolin, Kaolin 2, having the following properties: (i) percentage by weight of particles smaller than 2urn: 50%; (ii) mean particle size: 1. βμ ; (iii) shape factor: 70.
The resulting calendered handsheets had the properties which are shown in Tables 1 to 3 later.
EXAMPLE 3 (Comparative)
The procedure used in Example 1 to prepare and measure the properties of handsheets was repeated ' except that the percentage by weight of Kaolin 1 used in the filler composition was 30%, the percentage by weight of PCC 1 being 70%.
The resulting calendered handsheets had the properties which are also shown in Tables 1 to 3 later.
EXAMPLE 4 (Invention embodiment)
The procedure used in Example 1 to prepare and measure the properties of handsheets was repeated except that (i) the percentages by weight of kaolin and pec (PCC 1) were respectively 30% and 70% by weight and (ii) the kaolin used in the filler composition was a further different kaolin, Kaolin 3, having the following properties: (ii) percentage by weight of particles smaller than
2um: 75%; (ii) mean particle size: l.Oμm; (iii) shape factor: 70.
The resulting calendered handsheets had the properties which are shown in Tables 1 to 3 later.
Results
The results obtained for the measurements on the handsheets made in Examples 1 to 4 are given in Table 1 to 3 as follows .
Table 1
Figure imgf000012_0001
Table 2
Figure imgf000013_0001
Table 3
Figure imgf000013_0002
The results in Tables 1 to 3 illustrate the improved combination of properties obtained by using kaolins embodying the invention (Kaolins 2 and 3) in blends with particulate calcium carbonate.

Claims

1. A particulate kaolin suitable for use as a filler material in compositions for making uncoated paper, the kaolin having a mean particle size of from 0.7μm to 3μm and a shape factor of at least 60.
2. A particulate kaolin according to claim 1 and which has a mean particle size of from 0.9μm to
2.5μm.
3. A particulate kaolin according to claim 1 or claim 2 and which has a shape factor of at least 65.
4. A composition of filler materials for use in compositions for making uncoated paper, the blend comprising the kaolin according to claim 1,2 or 3 and one or more other fillers selected from other hydrous kaolin, calcined kaolin, talc, calcium sulphate and alkaline earth metal carbonate.
5. A composition according to claim 4 and wherein the blend contains at least 50% by weight of the kaolin according to claim 1,2 or 3.
6. A composition according to claim 5 and wherein the blend contains from 60% to 80% by weight of the kaolin according to claim 1,2 or 3.
7. A composition according to claim 5 or claim 6 and wherein the other filler comprises calcium carbonate .
8. A composition according to claim 7 and wherein the calcium carbonate comprises a material obtained from a natural source and processed by grinding.
9. A composition according to claim 7 and wherein the calcium carbonate comprises a material prepared by chemical synthesis and optionally containing other solids bonded to the calcium carbonate.
10. A composition according to claim 7,8 or 9 and wherein the calcium carbonate has a mean particle size of from 0.5μm to 1.5μm.
11. A composition according to claim 10 and wherein the calcium carbonate has a mean particle size of from 0.7μm to 1.3μm.
12. A composition according to any one of claims 7 to 11 and wherein the calcium carbonate has a steepness factor of at least 40.
13. A composition according to claim 12 and wherein the calcium carbonate has a steepness factor of at least 50.
14. A composition according to any one of claims 7 to 13 and wherein the calcium carbonate is in the form of a composition containing up to 15% by weight on an active basis of a chemical additive which provides stability of the carbonate in acidic conditions .
15. A composition according to any one of claims 7 to 14 and wherein the kaolin has a mean particle size of 1.2μm or more and the weight ratio of kaolin : calcium carbonate in the blend is 50:50 or more.
16. A composition according to claim 15 and wherein the kaolin has a mean particle size of 1.2μm or more and not greater than 1.7μm and the weight ratio of kaolin : calcium carbonate in the composition is from 60:40 to 80:20.
17. A composition according to any one of claims 7 to 14 and wherein the kaolin has a mean particle size of less than 1.2μm and the weight ratio of kaolin : calcium carbonate in the composition is 50:50 or less.
18. A composition according to claim 17 and wherein the kaolin has a mean particle size less than 1.2μm and not less than 0.9μm and the weight ratio of kaolin: calcium carbonate is from 40:60 to 20:80.
19. A method of making uncoated paper sheets which includes the steps of preparing an aqueous paper making composition from a pulp and mineral filler particles and forming the composition into paper sheets, wherein the mineral filler particles comprise kaolin according to any one of claims 1 to 3 or a composition according to any one of claims 4 to 18.
20. A method according to claim 19 and wherein the paper sheets are calendered by a supercalender process .
21. A method according to claim 19 or claim 20 and wherein the pulp consists of at least 70% by weight of a mechanical pulp.
22. A method according to claim 19, 20 or 21 and wherein the paper sheets are for printing upon by a gravure or offset printing process .
PCT/GB2001/003707 2000-08-17 2001-08-17 Kaolin products and their use WO2002016509A1 (en)

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