# US 2009/0260541 A1 · Powder formed from mineral or rock material with controlled particle size distribution for thermal films > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2009/0260541 A1 - Document ID: US20090260541A1 - Status: Published application - Kind: A1 - Application number: 12/237,628 - Filed: 2008-09-25 - Published: 2009-10-22 - Earliest claimed: 2008-04-17 - Assignees: Unimin Corporation - Inventors: David D. Kragten; Christy Karr, JR.; Scott VanRemortel; Robert Ratcliff; Ibezim Anazia; Louis M. Schlesinger - Web page: https://patentgrep.com/patent/US20090260541A1 ## CPC - B02C 23/30: the applied gas acting to effect material separation (B02C23/34 takes precedence) - C09D 5/031: {characterised by particle size or shape} - Y10T 428/2982: Particulate matter [e.g., sphere, flake, etc.] - B02C: CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN ({household tools and machines for pulverising foodstuffs, e.g. coffee and spice mills A47J42/00; pharmaceutical mortars A61J3/02; mechanical processing of refuse and garbage B03B9/06; dressing mould materials by grinding B22C5/04}; obtaining metallic powder by crushing, grinding or milling B22F9/04; {recovery of plastics by disintegrating B29B17/00; crushing raw materials in starch making C08B30/02; beaters for papermaking D21D1/02; crushing devices specially for transport in mines E21F13/002; slag crushing devices F23J1/00; fuel milling devices in combustion apparatus F23K1/00; household devices for crushing coal F24B15/02; ice disintegrating devices F25C5/02}) - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An ultra-fine powder formed from a naturally occurring mineral or rock material and having a controlled or “engineered” particle size distribution (PSD) to match the infrared spectra with a maximum particle size in the range of 14-17 microns measured as either D99, or preferably D95, and a minimum particle size D5 in the range of 4-7 microns. Preferably the maximum particle size is about 15 microns, the minimum particle size is about 5 microns and the D50 particle size is about 8-10 microns with the moisture content of the particle size “engineered” powder being less than about 0.20 percent by weight and preferably about 0.05 to 0.08 percent by weight of the powder. This specially “engineered” ultra-fine powder is used to reduce the thermicity of thermal film to a value less than about 20%. ## Claims ### Claim 1 An ultra-fine nepheline syenite powder produced from a feedstock constituting pre-processed nepheline syenite powder with a maximum grain size D99 greater than 20 microns, said ultra-fine nepheline syenite powder produced from said feedstock has a moisture content of less than 1.0% by weight, a controlled minimum grain size D5 in the range of 4-7 microns and a control maximum grain size D95 of about 15 microns and a mean grain size D50 in the range of about 8-10 microns and wherein the maximum node of the PSD curve for the powder being between 7 and 14 microns. ### Claim 2 (depends on 1) An ultra-fine nepheline syenite powder as defined in claim 1 wherein said D5 grain size is about 5 microns. ### Claim 3 (depends on 1) An ultra-fine nepheline syenite powder as defined in claim 1 wherein the range of particle sizes between D5 and D95 is about 10-12 microns. ### Claim 4 (depends on 1) An ultra-fine nepheline syenite powder as defined in claim 1 wherein the feedstock has a D99 particle size of less than about 100-150 microns. ### Claim 5 (depends on 4) An ultra-fine nepheline syenite powder as defined in claim 4 produced by using a dry mill and air classifier operated in series in a continuous process wherein said classifier controls said minimum grain size. ### Claim 6 (depends on 2) An ultra-fine nepheline syenite powder as defined in claim 2 produced by using a dry mill and air classifier operated in series in a continuous process wherein said classifier controls said minimum grain size. ### Claim 7 (depends on 1) An ultra-fine nepheline syenite powder as defined in claim 1 produced by using a dry mill and air classifier operated in series in a continuous process wherein said classifier controls said minimum grain size. ### Claim 8 (depends on 4) An ultra-fine nepheline syenite powder as defined in claim 4 produced by using a dry mill and first and second classifier stages wherein said first classifier stage controls said maximum grain size and said second classifier stage controls said minimum grain size. ### Claim 9 (depends on 2) An ultra-fine nepheline syenite powder as defined in claim 2 produced by using a dry mill and first and second classifier stages wherein said first classifier stage controls said maximum grain size and said second classifier stage controls said minimum grain size. ### Claim 10 (depends on 1) An ultra-fine nepheline syenite powder as defined in claim 1 produced by using a dry mill and first and second classifier stages wherein said first classifier stage controls said maximum grain size and said second classifier stage controls said minimum grain size. ### Claim 11 (depends on 2) An ultra-fine powder as defined in claim 2 wherein the D99 particle size is in the range of about 15 to 17 microns. ### Claim 12 (depends on 1) An ultra-fine powder as defined in claim 1 wherein the D99 particle size is in the range of about 15 to 17 microns. ### Claim 13 An ultra-fine powder substantially free of silica and formed from a naturally occurring mined substance with a controlled maximum grain size D95 of about 15 microns, a controlled minimum grain size D5 of about 4-7 microns and a D50 grain size in the range of about 8-10 microns where said powder has a moisture content of less than 1.0% by weight and wherein the maximum node of the PSD curve for the powder being between 7 and 14 microns. ### Claim 14 (depends on 13) An ultra-fine powder as defined in claim 13 wherein said substance is syenitic. ### Claim 15 (depends on 14) An ultra-fine powder as defined in claim 14 wherein said substance is nepheline syenite. ### Claim 16 (depends on 13) An ultra-fin e powder as defined in claim 13 wherein said moisture content is less than about 0.4% by weight. ### Claim 17 (depends on 15) An ultra-fine powder as defined in claim 15 wherein said powder is produced by removing particles less than said D5 grain size from a nepheline syenite powder to control said minimum grain size. ### Claim 18 (depends on 11) An ultra-fine powder as defined in claim 11 wherein said powder is produced by removing particles less than said D5 grain size from a nepheline syenite powder to control said minimum grain size. ### Claim 19 (depends on 15) An ultra-fine powder as defined in claim 15 wherein said powder is produced by removing particles less than said D5 grain size from a nepheline syenite powder and controlling said maximum grain size by removing particles greater than said D95 grain size from said nepheline syenite powder. ### Claim 20 (depends on 15) An ultra-fine powder as defined in claim 15 wherein said D5 grain size is about 5 microns. ### Claim 21 (depends on 13) An ultra-fine powder as defined in claim 13 wherein said D5 grain size is about 5 microns. ### Claim 22 (depends on 15) An ultra-fine powder as defined in claim 15 wherein the range of particle sizes between D5 and D95 is about 10-12 microns. ### Claim 23 (depends on 13) An ultra-fine powder as defined in claim 13 wherein the range of particle sizes between D5 and D95 is about 10-12 microns. ### Claim 24 (depends on 15) An ultra-fine nepheline syenite powder as defined in claim 15 produced by using a dry mill and air classifier operated in series in a continuous process wherein said classifier controls said minimum grain size. ### Claim 25 (depends on 15) An ultra-fine powder as defined in claim 15 produced by using a dry mill and first and second classifier stages wherein said first classifier stage controls said maximum grain size and said second classifier stage controls said minimum grain size. ### Claim 26 (depends on 20) A thermal film using said ultra-fine powder as defined in claim 20 as a filler. ### Claim 27 (depends on 21) A thermal film using said ultra-fine powder as defined in claim 21 as a filler. ### Claim 28 (depends on 27) A thermal film as defined in claim 27 wherein said powder filler is at least 5% by weight of said film. ### Claim 29 (depends on 15) A thermal film using said ultra-fine powder as defined in claim 15 as a filler. ### Claim 30 (depends on 29) A thermal film as defined in claim 29 wherein said powder filler is at least 5% by weight of said film. ### Claim 31 (depends on 13) A thermal film using said ultra-fine powder as defined in claim 13 as a filler. ### Claim 32 (depends on 31) A thermal film as defined in claim 31 wherein said powder filler is at least 5% by weight of said film. ### Claim 33 (depends on 4) A thermal film using said ultra-fine nepheline syenite powder as defined in claim 4 as a filler. ### Claim 34 (depends on 33) A thermal film as defined in claim 33 wherein said powder filler is at least 5% by weight of said film. ### Claim 35 (depends on 2) A thermal film using said ultra-fine nepheline syenite powder as defined in claim 2 as a filler. ### Claim 36 (depends on 35) A thermal film as defined in claim 35 wherein said powder filler is at least 5% by weight of said film. ### Claim 37 (depends on 1) A thermal film using said ultra-fine nepheline syenite powder as defined in claim 1 as a filler. ### Claim 38 (depends on 37) A thermal film as defined in claim 37 wherein said powder filler is at least 5% by weight of said film. ### Claim 39 An ultra-fine nepheline syenite powder with a controlled minimum grain size in the range of 4-7 microns and a controlled maximum grain size of about 15 microns. ### Claim 40 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 produced from a nepheline syenite powder feedstock by using a dry mill and an air classifier operated in series in a continuous process. ### Claim 41 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 wherein said powder has a particle size distribution generally matching infrared light wave lengths in the spectra of about 7-14 microns. ### Claim 42 (depends on 39) The method of producing the ultra-fine nepheline syenite powder as defined in claim 39. ### Claim 43 (depends on 39) A film with the ultra-fine nepheline syenite powder as defined in claim 39 used as a filler. ### Claim 44 (depends on 43) A film as defined in claim 43 wherein said powder is loaded in said film at a level greater than about 5% by weight. ### Claim 45 (depends on 44) A film as defined in claim 44 wherein said level is in said loading range of 5-20% by weight. ### Claim 46 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 wherein said maximum grain size is the D95 particle size. ### Claim 47 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 wherein said maximum grain size is the D99 particle size. ### Claim 48 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 wherein said minimum grain size is the D5 particle size. ### Claim 49 (depends on 39) An ultra-fine nepheline syenite powder as defined in claim 39 wherein said minimum grain size is the D1 particle size. ### Claim 50 An ultra-fine powder having substantially no free silica and formed from a naturally occurring mined substance with a controlled maximum grain size D95 of about 15 microns, a controlled minimum grain size D5 of about 4-7 microns and a D50 grain size in the range of about 8-10 microns where said powder has a moisture content of less than 1.0% by weight and wherein the maximum node of the PSD curve for the powder being between 7 and 14 microns and the thermicity of a film using said powder is less than 20%. ### Claim 51 (depends on 50) An ultra-fine powder as defined in claim 50 wherein said substance is syenitic. ### Claim 52 (depends on 50) An ultra-fine powder as defined in claim 50 wherein said substance is nepheline syenite. ### Claim 53 (depends on 50) An ultra-fine powder as defined in claim 50 wherein said powder is produced by removing particles less than said D5 grain size from a nepheline syenite powder to control said minimum grain size. ### Claim 54 (depends on 52) An ultra-fine nepheline syenite powder, as defined in claim 52, wherein said nepheline syenite powder is made from a nepheline syenite feedstock having a D50 particle size of about 15 microns and a D99 particle size of about 100 microns. ### Claim 55 (depends on 54) An ultra-fine nepheline syenite powder as defined in claim 54 produced by using a dry mill and air classifier operated in series in a continuous process wherein said classifier controls said minimum grain size. ### Claim 56 (depends on 54) An ultra-fine nepheline syenite powder as defined in claim 54 produced by using a dry mill and first and second classifier stages wherein said first classifier stage controls said maximum grain size and said second classifier stage controls said minimum grain size. ### Claim 57 (depends on 52) An ultra-fine nepheline syenite powder as defined in claim 52, wherein said nepheline syenite powder is made from a commercial nepheline syenite feedstock having a maximum particle size D99 of less than about 100 microns. ### Claim 58 A powder filler for thermal film, said powder having substantially no free silica and being formed from a naturally occurring mined substance with the particle size controlled whereby said powder is ultra-fine and has a particle size spread between D5 and D95 of less than about 12 microns. ### Claim 59 (depends on 58) A filler as defined in claim 58 wherein the D95 particle size is about 15 microns. ### Claim 60 (depends on 58) A filler as defined in claim 58 wherein said D5 particle size is in the range of 4-7 microns. ### Claim 61 (depends on 58) A filler as defined in claim 58 wherein the particle size spread between D5 and D99 is less than about 12 microns. ### Claim 62 (depends on 58) A filler as defined in claim 58 wherein the particle size spread between D1 and D99 is less than about 12 microns. ### Claim 63 (depends on 58) A filler as defined in claim 58 wherein said substance is syenitic. ### Claim 64 (depends on 58) A filler as defined in claim 58 wherein said substance is nepheline syenite. ### Claim 65 An ultra-fine powder formed from a naturally occurring mineral or rock material having a Mohs hardness of at least 5, said powder having a controlled or “engineered” particle size distribution with a maximum particle size in the range of 14-17 microns and a minimum particle size D5 in the range of 4-7 microns. ### Claim 66 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said maximum particle size is the D95 size and the minimum particle size is the D5 size. ### Claim 67 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said maximum particle size is the D99 size and the minimum particle size is the D5 size. ### Claim 68 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said material is selected from the class comprising nepheline syenite, feldspar, silica, quartz, cristobalite and tridymite. ### Claim 69 (depends on 68) An ultra-fine powder as defined in claim 68 wherein maximum particle size is about 15 microns and said minimum particle size is about 5 microns. ### Claim 70 (depends on 65) An ultra-fine powder as defined in claim 65 wherein maximum particle size is about 15 microns and said minimum particle size is about 5 microns. ### Claim 71 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said material is syenitic. ### Claim 72 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said material is nepheline syenite. ### Claim 73 (depends on 72) An ultra-fine powder as defined in claim 72 wherein the D50 particle size is in the range of about 8-10 microns. ### Claim 74 (depends on 70) An ultra-fine powder as defined in claim 70 wherein the D50 particle size is in the range of about 8-10 microns. ### Claim 75 (depends on 65) An ultra-fine powder as defined in claim 65 wherein the D50 particle size is in the range of about 8-10 microns. ### Claim 76 (depends on 75) An ultra-fine powder as defined in claim 75 wherein the moisture content of said powder is less than about 0.20% by weight of said powder. ### Claim 77 (depends on 75) An ultra-fine powder as defined in claim 75 wherein said moisture content is less than about 0.10% by weight of said powder. ### Claim 78 (depends on 75) An ultra-fine powder as defined in claim 75 wherein the moisture content of said powder is in the range of 0.04 to 0.10 by weight of said powder. ### Claim 79 (depends on 78) An ultra-fine powder as defined in claim 78 wherein said moisture content is less than about 1.0%. ### Claim 80 (depends on 65) An ultra-fine powder as defined in claim 65 wherein the moisture content of said powder is less than about 0.20% by weight. ### Claim 81 (depends on 65) An ultra-fine powder as defined in claim 65 wherein the moisture content is in the range of 0.04 to 0.10 percent by weight of said powder ### Claim 82 (depends on 65) An ultra-fine powder as defined in claim 65 wherein said moisture content is less than about 0.10%. ### Claim 83 (depends on 65) A film or coating using the ultra-fine powder as defined in claim 65. ### Claim 84 (depends on 66) A film or coating using the ultra-fine powder as defined in claim 66. ### Claim 85 (depends on 67) A film or coating using the ultra-fine powder as defined in claim 67. ### Claim 86 An ultra-fine powder formed from a naturally occurring mineral or rock material having a refractive index of about 1.4 to 1.6, said powder having a controlled or “engineered” particle size distribution with a maximum particle size in the range of 14-17 microns and a minimum particle size D5 in the range of 4-7 microns. ### Claim 87 (depends on 86) An ultra-fine powder as defined in claim 86 wherein said maximum particle size is the D95 size and the minimum particle size is the D5 size. ### Claim 88 (depends on 86) An ultra-fine powder as defined in claim 86 wherein said maximum particle size is the D99 size and the minimum particle size is the D5 size. ### Claim 89 (depends on 86) An ultra-fine powder as defined in claim 86 wherein said refractive index is in the range of 1.46 to 1.57. ### Claim 90 (depends on 89) An ultra-fine powder as defined in claim 89 wherein said material is selected from the class comprising silica (including ground natural, diatomaceous and precipitated), cristobalite, feldspar, quartz, nepheline syenite, kaolin, alumina trihydrate, talc, attapulgite, pyrophyllite, calcium hydroxide, magnesium hydroxide and hydrotalcite. ### Claim 91 (depends on 90) An ultra-fine powder as defined in claim 90 wherein maximum particle size is about 15 microns and said minimum particle size is about 5 microns. ### Claim 92 (depends on 86) An ultra-fine powder as defined in claim 86 wherein maximum particle size is about 15 microns and said minimum particle size is about 5 microns. ### Claim 93 (depends on 90) An ultra-fine powder as defined in claim 90 wherein the moisture content of said powder is in the range of 0.04 to 0.10 by weight of said powder. ### Claim 94 (depends on 86) An ultra-fine powder as defined in claim 86 wherein the moisture content of said powder is in the range of 0.04 to 0.10 by w eight of said powder. ### Claim 95 (depends on 90) A thermal film using as a filler th e powder defined in claim 90. ### Claim 96 (depends on 86) A thermal film using as a filler the powder defined in claim 86. ### Claim 97 A method of producing an ultra-fine powder, comprising: (a) providing ground feedstock formed from a naturally occurring mineral or rock material having a refractive index of about 1.4 to 1.6; (b) grinding said feedstock in an opposed jet mill; (c) classifying said ground feedstock in said mill with a classifier to pass an intermediate powder from said mill, said intermediate powder having a maximum particle size of about 14-17 microns; (d) classifying said intermediate powder through an air classifier to remove particles having a particle size of less than about 4-7 microns. ### Claim 98 (depends on 97) The method as defined in claim 97 wherein said feedstock material is a material selected from the class comprising silica (including g round natural and diatomaceous), cristobalite, feldspar, quartz, nepheline syenite, kaolin, talc, attapulgite and pyrophyllite. ### Claim 99 A method of producing an ultra-fine powder, comprising: (a) providing ground feedstock formed from a naturally occurring mineral or rock material having a Mohs hardness of at least 5; (b) grinding said feedstock in an opposed jet mill; (c) classifying said ground feedstock in said mill with a classifier to pass an intermediate powder from said mill, said intermediate powder having a maximum particle size of about 15 microns; (d) classifying said intermediate powder through an air classifier to remove particles having a particle size of less than about 5 microns. ### Claim 100 (depends on 99) The method as defined in claim 99 wherein said feedstock material is a material selected from the class comprising nepheline syenite, feldspar, silica, quartz, cristobalite and tridymite. ### Claim 101 A method of producing an ultra-fine powder with a controlled particle size distribution, said method comprising: (a) providing a feedstock formed from a naturally occurring mineral or rock material having a refractive index of about 1.4 to 1.6; (b) grinding said feedstock; (c) making an intermediate powder by passing said ground feedstock through a first air classifier to remove particles having a first size greater than a value in the range of 14-17 microns; (d) passing said intermediate powder through a second air classifier to remove particles having a second size less than a value in the range of 4-7 microns. ### Claim 102 (depends on 101) A method as defined in claim 101 wherein said first particle size is about 15 microns. ### Claim 103 (depends on 102) A method as defined in claim 102 wherein said second particle size is about 5 microns. ### Claim 104 (depends on 101) A method as defined in claim 101 wherein said second particle size is about 5 microns. ### Claim 105 (depends on 103) A method as defined in claim 103 wherein said feedstock is a material selected from the class comprising silica (including ground natural and diatomaceous), cristobalite, feldspar, quartz, nepheline syenite, kaolin, talc, attapulgite and pyrophyllite. ### Claim 106 (depends on 101) A method as defined in claim 101 wherein said feedstock is a material selected from the class comprising silica (including ground natural and diatomaceous), cristobalite, feldspar, quartz, nepheline syenite, kaolin, talc, attapulgite and pyrophyllite.