Mica Particles

Abstract

The mica particles are (a) about 4.5 m 2 / g or greater; and (b) a lamellarity index of about 2.5 or greater. A method of preparing mica particles includes classifying a ground mica material, such as a wet-ground mica material.

Description

[Technical field]

[0001] The present disclosure relates to mica particles, methods of preparing the mica particles, polymer compositions including the mica particles, methods of making polymer compositions including the mica particles, articles formed from polymer compositions including the mica particles, and related uses of the mica particles in polymer compositions and methods of using the mica particles in polymer compositions. [Background technology]

[0002] Polymer compositions are generally reinforced with filler materials. Mica and talc are examples of filler materials used to reinforce polymer compositions, such as thermoplastic polymer compositions containing polyolefins and / or polyamides. Such filler materials are used to improve properties such as impact strength of the polymer composition. However, further improvement of impact strength would be desirable. Improvement of other mechanical properties (such as flexural modulus) of filled polymer compositions would also be desirable. Summary of the Invention

[0003] According to a first embodiment, the mica particles are about 4.5 m 2 / g or greater BET specific surface area; and (b) a lamellarity index of about 2.5 or greater. According to a second aspect, a method of preparing mica particles according to the first aspect includes classifying ground mica material, such as wet-ground mica material. According to a third aspect, a polymer composition comprises mica particles according to the first aspect. According to a fourth aspect, a method of making a polymer composition according to the third aspect comprises combining a polymer or a polymer precursor with mica particles according to the first aspect. According to a fifth aspect, there is provided an article formed from a polymer composition according to the third aspect. According to a sixth aspect, there is provided the use of mica particles according to the first aspect in a polymer composition to increase the impact strength of the polymer composition. According to a seventh aspect, there is provided a method of increasing the impact strength of a polymer composition, the method comprising adding mica particles according to the first aspect to the polymer composition. Those skilled in the art will recognize that, unless mutually exclusive, a feature described in connection with any one of the above embodiments may also be applied mutatis mutandis to any other embodiment. Furthermore, unless mutually exclusive, any feature described herein may be applied to any embodiment and / or may be combined with any other feature described herein. Embodiments will now be described, by way of example only, with reference to the drawings, in which: [Brief description of the drawings]

[0004] [Figure 1] FIG. 1 shows plots of flexural modulus and Charpy impact strength for four different polypropylene compositions, each filled with different mica particles, as a function of the classifier speed used to prepare the respective mica particles. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] It has surprisingly been found that mica particles that combine a relatively high BET specific surface area with a relatively high lamellarity index are particularly effective at increasing the impact strength of polymer compositions, such as thermoplastic polymer compositions. Mica Particles As used herein, the term "mica" refers to the mica group of hydrous phyllosilicate minerals. The mica group includes: Biotite (i.e., K(Mg,Fe)3(AlSi3)O 10 (OH)2); Chromite (i.e., K(Al,Cr)2(AlSi3)O 10 (OH)2); Muscovite (i.e., KAl2(AlSi3)O 10 (OH)2); Phlogopite (i.e., KMg3(AlSi3)O 10 (OH)2); Lepidolite (i.e., K(Li,Al) 2~3 (AlSi3)O 10 (OH)2); Pearlite (i.e., CaAl2(Al2Si2)O 10 (OH)2); and Glauconite (i.e., (K,Na)(Al,Mg,Fe)2(Si,Al)4O 10 (OH)2). The mica particles may include a single mica group mineral or a mixture of different mica group minerals. For example, the mica particles may include one (i.e., only one) of biotite, chromite, muscovite, phlogopite, lepidolite, nacreous mica, and glauconite. Alternatively, the mica particles may include two or more of biotite, chromite, muscovite, phlogopite, lepidolite, nacreous mica, and glauconite. The mica particles may consist essentially of or consist of mica group minerals, or the mica particles may further include one or more non-mica group minerals.

[0006] The one or more non-mica group minerals may include (e.g., may be) non-mica group phyllosilicate minerals, such as serpentine group or clay group phyllosilicate minerals. The one or more non-mica group phyllosilicate minerals may be talc (i.e., magnesium silicate minerals (Mg3SiO4O5, 10 (OH)2), chlorite (i.e., (Mg,Fe)3(Si,Al)4O 10 (e.g., may be) (OH)2·(Mg,Fe)3(OH)6) and / or kaolinite (i.e., Al2Si2O5(OH)4). Additionally or alternatively, the one or more non-mica group minerals may include (e.g., may be) a non-phyllosilicate mineral such as dolomite, magnesite, feldspar, or quartz. The total amount of non-mica group minerals can be less than about 25% by weight, for example, less than about 20% by weight, or less than about 15% by weight, or less than about 10% by weight, or less than about 5% by weight, or less than about 1% by weight, or less than about 0.5% by weight, or less than about 0.1% by weight, based on the total weight of the mica particles.

[0007] The mica particles may comprise about 75% by weight or more mica (i.e., mica group minerals), for example, about 80% by weight or more, or about 90% by weight or more, or about 95% by weight or more, or about 99% by weight or more, or about 99.9% by weight or more mica (i.e., mica group minerals), based on the total weight of the mica particles. The mica particles may consist essentially of, or consist of, mica (i.e., mica group minerals). The majority of the mica (i.e., mica group minerals) present in the mica particles may be muscovite. The mica (i.e., mica group minerals) present in the mica particles may comprise about 50% by weight or more, e.g., about 60% by weight or more, or about 70% by weight or more, or about 80% by weight or more, or about 90% by weight or more, or about 95% by weight or more, or about 99% by weight or more, e.g., about 100% by weight muscovite, based on the total weight of the mica (i.e., mica group minerals) present in the mica particles. The mica (i.e., mica group minerals) in the mica particles may consist essentially of or consist of muscovite.

[0008] The majority of the mica particles may be muscovite. The mica particles may comprise about 50% by weight or more, e.g., about 60% by weight or more, or about 70% by weight or more, or about 80% by weight or more, or about 90% by weight or more, or about 95% by weight or more, or about 99% by weight or more, e.g., about 100% by weight muscovite, based on the total weight of the mica particles. The mica particles may consist essentially of or consist of muscovite. The mica particles may be muscovite particles. The composition of the mica particles can be determined using semi-quantitative powder X-ray diffraction (XRD). For example, the intensity of the kaolinite peak at about 2θ=12.1° can be compared to the intensity of the main mica peak at about 2θ=9.0° to determine the relative amounts of kaolinite and mica present in the sample. XRD measurements can be obtained by the following method: A sample of mica particles is ground to a particle size of less than 10 μm (by sedigraph). Insert into the XRD sample holder by backfilling using a method suitable to produce a lump-free powder and ensure that preferential orientation is avoided. The sample is scanned in the XRD (Malvern Panalytical X'Pert PRO or D8 Advance A25 Bruker with Bragg-Brentano Geometry and K430 X-ray generator) at 40 mA and 40 eV between 2θ=5° and 2θ=60° using a step size of 0.02° and 10 seconds per step. Scans are displayed in XRD analysis software HighScore Plus (available from Malvern Panalytical) or DIFFRAC.EVA (available from Bruker) and XRD peaks are assigned according to the PDF-2 mineral database (available from the International Centre for Diffraction Data). XRD peak information is also available from public databases (such as the mineralogy database at http: / / webmineral.com). The amount of each mineral in the sample is determined from the corresponding XRD peak height by the Reference Intensity Ratio (RIR) method.

[0009] BET specific surface area refers to the area of ​​the surface of a mica particle relative to unit mass, and is determined by the amount of nitrogen adsorbed on the surface of the particle to form a monolayer that completely covers the surface of the particle according to the BET method (measured according to BET method, AFNOR standards X11-621 and 622 or ISO 9277). Details of the BET specific surface area measurement method used in the preparation of this application are shown in the examples.

[0010] The mica particles are approximately 4.5m 2 / g or more, for example, about 4.6m2 / g or more, or about 4.7m 2 / g or more, or about 4.8m 2 / g or more, or about 4.9m 2 / g or more, or about 5.0m 2 / g or more, or about 5.1m 2 / g or more, or about 5.2m 2 / g or more, or about 6.0m 2 / g or more, or about 7.0m 2 / g or more, or about 8.0m 2 / g or more, or about 9.0m 2 / g or more, or about 10m 2 / g or more (e.g., 10.0m 2 / g), or about 11m 2 / g or more (e.g., 11.0m 2 The mica particles may have a BET specific surface area of ​​about 50 m 2 / g or less (e.g., 50.0m 2 / g), for example, about 40m 2 / g or less (e.g., 40.0m 2 / g), or about 30m 2 / g or less (e.g., 30.0m 2 / g), or about 20m 2 / g or less (e.g., 20.0m 2 / g), or about 15m 2 / g or less (e.g., 15.0m 2 / g), or about 12m 2 / g or less (e.g., 12.0m 2 / g), or about 11m 2 / g or less (e.g., 11.0m 2 / g), or about 10m 2 / g or less (e.g., 10.0m 2 / g), or about 8.0 m 2 / g or less, or about 7.0m 2 / g or less, or about 6.0m 2 The mica particles may have a BET specific surface area of ​​about 4.6 m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), for example, about 4.6m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 4.6 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 4.6 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 4.6 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 4.6 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 4.6 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 4.6 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 4.6 m 2 / g~approx.8.0m 2 / g, or about 4.6m 2 / g ~ approx. 7.0m 2 / g, or about 4.6m 2 / g~approx.6.0m 2 / g, or about 4.7m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 4.7m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 4.7m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 4.7m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 4.7m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 4.7m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 4.7m2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 4.7m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 4.7m 2 / g~approx.8.0m 2 / g, or about 4.7m 2 / g ~ approx. 7.0m 2 / g, or about 4.7m 2 / g~approx.6.0m 2 / g, or about 4.8m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 4.8m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 4.8m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 4.8m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 4.8m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 4.8m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 4.8m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 4.8m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 4.8m 2 / g~approx.8.0m 2 / g, or about 4.8m 2 / g ~ approx. 7.0m 2 / g, or about 4.8m 2 / g~approx.6.0m 2 / g, or about 4.9m 2 / g~about 50m 2 / g (e.g., 50.0 m2 / g), or about 4.9m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 4.9m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 4.9m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 4.9m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 4.9m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 4.9m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 4.9m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 4.9m 2 / g~approx.8.0m 2 / g, or about 4.9m 2 / g ~ approx. 7.0m 2 / g, or about 4.9m 2 / g~approx.6.0m 2 / g, or about 5.0m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 5.0 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 5.0 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 5.0 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 5.0 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 5.0 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 5.0 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 5.0 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 5.0 m 2 / g~approx.8.0m 2 / g, or about 5.0m 2 / g ~ approx. 7.0m 2 / g, or about 5.0m 2 / g~approx.6.0m 2 / g, or about 5.1m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 5.1 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 5.1 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 5.1 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 5.1 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 5.1 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 5.1 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 5.1 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 5.1 m 2 / g~approx.8.0m 2 / g, or about 5.1m 2 / g ~ approx. 7.0m 2 / g, or about 5.1m 2 / g~approx.6.0m 2 / g, or about 5.2m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 5.2 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 5.2 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 5.2 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 5.2 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 5.2 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 5.2 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 5.2 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 5.2 m 2 / g~approx.8.0m 2 / g, or about 5.2m 2 / g ~ approx. 7.0m 2 / g, or about 5.2m 2 / g~approx.6.0m 2 / g, or about 6.0m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 6.0 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 6.0 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 6.0 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 6.0 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 6.0 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 6.0 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 6.0 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 6.0 m 2 / g~approx.8.0m 2 / g, or about 6.0m 2 / g ~ approx. 7.0m 2 / g, or about 7.0m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 7.0 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 7.0 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 7.0 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 7.0 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 7.0 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 7.0 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 7.0 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 7.0 m 2 / g~approx.8.0m 2 / g, or about 8.0m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 8.0 m2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 8.0 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 8.0 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 8.0 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 8.0 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 8.0 m 2 / g ~ approx. 11m 2 / g (e.g., 11.0m 2 / g), or about 8.0 m 2 / g~about 10m 2 / g (e.g., 10.0m 2 / g), or about 9.0 m 2 / g~about 50m 2 / g (e.g., 50.0 m 2 / g), or about 9.0 m 2 / g~about 40m 2 / g (e.g., 40.0 m 2 / g), or about 9.0 m 2 / g ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 9.0 m 2 / g~about 20m 2 / g (e.g., 20.0 m 2 / g), or about 9.0 m 2 / g ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 9.0 m 2 / g ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 10m 2 / g (e.g., 10.0m 2 / g) ~ approx. 50m 2 / g (e.g., 50.0 m 2 / g), or about 10m2 / g (e.g., 10.0m 2 / g) ~ approx. 40m 2 / g (e.g., 40.0 m 2 / g), or about 10m 2 / g (e.g., 10.0m 2 / g) ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 10m 2 / g (e.g., 10.0m 2 / g) ~ approx. 20m 2 / g (e.g., 20.0 m 2 / g), or about 10m 2 / g (e.g., 10.0m 2 / g) ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 10m 2 / g (e.g., 10.0m 2 / g) ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 50m 2 / g (e.g., 50.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 40m 2 / g (e.g., 40.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 30m 2 / g (e.g., 30.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 20m 2 / g (e.g., 20.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 15m 2 / g (e.g., 15.0 m 2 / g), or about 11m 2 / g (e.g., 11.0m 2 / g) ~ approx. 12m 2 / g (e.g., 12.0 m 2 / g).

[0011] High BET specific surface area (e.g., about 4.5 m 2 / g or more, or preferably about 5.0 m 2 / g or more, or more preferably about 10.0 m 2 / g or more) tends to increase the impact strength of the polymer composition in which it is incorporated.

[0012] Approximately 4.5m 2 / g ~ approx. 15m 2 / g, or preferably about 4.5m 2 / g~about 10m 2 / g, or more preferably about 5.0 m 2 / g~about 10m 2 / g, for example, about 5.0m 2 It has been found that a mica having a BET specific surface area of ​​100 / g achieves a good balance between high impact strength and high flexural modulus of the polymer composition into which it is incorporated.

[0013] Particle size characteristics can be measured in a known manner by sedimenting particulate fillers or materials in fully dispersed conditions in an aqueous medium using a Sedigraph 5100 instrument supplied by Micromeritics Instruments Corporation, Norcross, Georgia, USA (website: www.micromeritics.com), referred to herein as a "Micromeritics Sedigraph 5100 unit." Such an instrument provides a measurement and plot of the cumulative mass percentage of particles having a diameter, referred to in the art as the "equivalent sphere diameter" (esd), less than a given equivalent sphere diameter (esd) value. The mean particle size d 50 That d 50 The particle ESD determined in this manner is the value at which 50% by mass of particles have an equivalent spherical diameter less than this value. 98 , d 95 , d 90 , d 75 , d25 and d 10 That d 98 , d 95 , d 90 , d 75 , d 25 Or d 10 These are the values ​​thus determined of particle esd at which 98%, 95%, 90%, 75%, 25% and 10% by weight of the particles are present having equivalent sphere diameters less than this value.

[0014] Particle size characteristics can also be measured by wet Malvern laser scattering (standard ISO 13320-1). In this technique, the size of particles in powders, suspensions and emulsions can be measured using the diffraction of a laser beam, based on the application of Mie theory. Such instruments, for example the Malvern Mastersizer S or Malvern Mastersizer 2000 (supplied by Malvern instruments), provide measurements and plots of the cumulative volume percentage of particles having a diameter less than a given equivalent spherical diameter (esd) value, referred to in the art as the "equivalent spherical diameter" (esd). Mean particle size d 50 That d 50 The particle ESD value thus determined is the value at which 50% by volume of particles have an equivalent spherical diameter less than this value. 98 , d 95 , d 90 , d 75 , d 25 and d 10 That d 98 , d 95 , d 90 , d 75 , d 25 Or d 10 These are the values ​​thus determined of particle esd at which 98%, 95%, 90%, 75%, 25% and 10% by volume of particles have equivalent spherical diameters less than this value, respectively. For the avoidance of doubt, measurement of particle size using laser light scattering is not an equivalent method to the sedimentation method referred to above. Details of the sedigraph and laser particle size measurement techniques used in the preparation of this application are given in the Examples.

[0015] The Lamellarity Index (LI) is a measure of the overall particle shape. It is defined by the ratio of:

number

[0016]

number

[0017]

number

[0018] It has been found that mica having a high lamellarity index (eg, about 3.5 or greater, or preferably about 4.0 or greater) tends to increase the flexural modulus of the polymer composition into which it is incorporated.

[0019] The mica particles can be laser-deposited to a size of about 150 μm or less, e.g., about 140 μm or less, or about 130 μm or less, or about 120 μm or less, or about 110 μm or less, or about 100 μm or less, or about 90 μm or less, or about 80 μm or less, or about 70 μm or less, or about 60 μm or less, or about 50 μm or less, or about 25 μm or less, or about 10 μm or less. 95 The mica particles may have a laser d of 5 μm or more, for example, about 8 μm or more, or about 25 μm or more, or about 40 μm or more, or about 50 μm or more, or about 60 μm or more, or about 70 μm or more, or about 80 μm or more, or about 90 μm or more, or about 100 μm or more. 95The mica particles may have a diameter of about 5 μm to about 150 μm, for example, about 5 μm to about 140 μm, or about 5 μm to about 130 μm, or about 5 μm to about 120 μm, or about 5 μm to about 110 μm, or about 5 μm to about 100 μm, or about 5 μm to about 90 μm, or about 5 μm to about 80 μm, or about 5 μm to about 70 μm, or about 5 μm to about 60 μm, or about 5 μm to about 50 μm, or about 5 μm to about 25 μm, or about 5 μm to about 10 μm, or about 8 μm to about 150 μm, or about 8 μm to about 140 μm, or about 8 μm to about 130 μm, or about 8 μm to about 120 μm, or about 8 μm to about 110 μm, or about 8 μm to about 100 μm, or about 8 μm to about 90 μm, or about 8 μm to about 80 μm, or about 8 μm to about 70 μm, or about 8 μm to about 60 μm, or about 8 μm to about 50 μm, or about 8 μm to about 25 μm, or about 8 μm to about 10 μm, or about 25 μm to about 150 μm, or about 25 μm to about 140 μm, or about 25 μm to about 130 μm, or about 25 μm to about 120 μm, or about 25 μm to about 110 μm, or about 25 μm to about 100 μm, or about 25 μm to about 90 μm, or about 25 μm to about 80 μm, or about 25 μm to about 70 μm, or about 25 μm to about 60 μm, or about 25 μm to about 50 μm, or about 40 μm to about 150 μm, or about 40 μm to about 140 μm, or about 40 μm to about 130 μm, or about 40 μm to about 120 μm, or about 40 μm to about 110 μm, or about 40 μm to about 100 μm, or about 40 μm to about 90 μm, or about 40 μm to about 80 μm, or about 40 μm to about 70 μm, or about 40 μm to about 60 μm, or about 40 μm to about 50 μm, or about 50 μm to about 150 μm, or about 50 μm to about 140 μm, or about 50 μm to about 130 μm, or about 50 μm to about 120 μm, or is about 50 μm to about 110 μm, or about 50 μm to about 100 μm, or about 50 μm to about 90 μm, or about 50 μm to about 80 μm, or about 50 μm to about 70 μm, or about 50 μm to about 60 μm, or about 60 μm to about 150 μm, or about 60 μm to about 140 μm, or about 60 μm to about 130 μm, or about 60 μm to about 120 μm, or about 60 μm to about 110 μm, or about 60 μm to about 100 μm, or about 60 μm to about 90 μm, or about 60 μm to about 80 μm, or about 60 μm to about 70 μm, or about 70 μm to about 150 μm, or about 70 μm to about 140 μm,or about 70 μm to about 130 μm, or about 70 μm to about 120 μm, or about 70 μm to about 110 μm, or about 70 μm to about 100 μm, or about 70 μm to about 90 μm, or about 70 μm to about 80 μm, or about 80 μm to about 150 μm, or about 80 μm to about 140 μm, or about 80 μm to about 130 μm, or about 80 μm to about 120 μm, or about 80 μm to about 110 μm, or about 80 μm to about 100 μm, or about 80 μm to about about 90 μm, or about 90 μm to about 150 μm, or about 90 μm to about 140 μm, or about 90 μm to about 130 μm, or about 90 μm to about 120 μm, or about 90 μm to about 110 μm, or about 90 μm to about 100 μm, or about 100 μm to about 150 μm, or about 100 μm to about 140 μm, or about 100 μm to about 130 μm, or about 100 μm to about 120 μm, or about 100 μm to about 110 μm, 95 may have:

[0020] The mica particles have a diameter of about 30 μm or less, e.g., about 25 μm or less, or about 20 μm or less, or about 15 μm or less, or about 12 μm or less, or about 11 μm or less, or about 10 μm or less, or about 5 μm or less, as measured by sedigraph. 95 The mica particles may have a sedigraph d of about 2 μm or more, e.g., about 5 μm or more, or about 10 μm or more, or about 11 μm or more, or about 15 μm or more, or about 20 μm or more. 95The mica particles may have a diameter of about 2 μm to about 30 μm, for example, about 2 μm to about 25 μm, or about 2 μm to about 20 μm, or about 2 μm to about 15 μm, or about 2 μm to about 12 μm, or about 2 μm to about 11 μm, or about 2 μm to about 10 μm, or about 2 μm to about 5 μm, or about 5 μm to about 30 μm, or about 5 μm to about 25 μm, or about 5 μm to about 20 μm, or about 5 μm to about 15 μm, or about 5 μm to about 12 μm, or about 5 μm to about 11 μm, or about 5 μm to about 10 μm, or about 10 μm to about 30 μm, or about 0 μm to about 25 μm, or about 10 μm to about 20 μm, or about 10 μm to about 15 μm, or about 10 μm to about 12 μm, or about 10 μm to about 11 μm, or about 11 μm to about 30 μm, or about 11 μm to about 25 μm, or about 11 μm to about 20 μm, or about 11 μm to about 15 μm, or about 11 μm to about 12 μm, or about 15 μm to about 30 μm, or about 15 μm to about 25 μm, or about 15 μm to about 20 μm, or about 20 μm to about 30 μm, or about 20 μm to about 25 μm, as measured by a sedigraph. 95 may have:

[0021] Low top cut, i.e. low d 95 It has been found that mica having a diameter of about 150 μm or less, or preferably about 130 μm or less, or more preferably about 100 μm or less, or even more preferably about 60 μm or less (e.g., by laser: about 150 μm or less, or preferably about 130 μm or less, or more preferably about 100 μm or less, or even more preferably about 60 μm or less; or by sedigraph: about 30 μm or less, or preferably about 20 μm or less, or more preferably about 15 μm or less) tends to increase the impact strength of polymer compositions into which the mica is incorporated.

[0022] The mica particles are preferably laser deformed to a size of about 40 μm or less, e.g., about 35 μm or less, or about 25 μm or less, or about 20 μm or less, or about 10 μm or less, or about 5 μm or less. 50 The mica particles may have a laser d of about 3 μm or more, e.g., about 10 μm or more, or about 15 μm or more, or about 20 μm or more, or about 30 μm or more. 50The mica particles may have a diameter of about 3 μm to about 40 μm, for example, about 3 μm to about 35 μm, or about 3 μm to about 25 μm, or about 3 μm to about 20 μm, or about 3 μm to about 10 μm, or about 3 μm to about 5 μm, or about 10 μm to about 40 μm, or about 10 μm to about 35 μm, or about 10 μm to about 25 μm, or about 10 μm to about 20 μm. μm, or about 15 μm to about 40 μm, or about 15 μm to about 35 μm, or about 15 μm to about 25 μm, or about 15 μm to about 20 μm, or about 20 μm to about 40 μm, or about 20 μm to about 35 μm, or about 20 μm to about 25 μm, or about 30 μm to about 40 μm, or about 30 μm to about 35 μm 50 may have:

[0023] The mica particles have a sedigraph diameter of about 6 μm or less (e.g., about 6.0 μm or less), for example, about 5 μm or less (e.g., about 5.0 μm or less), or about 4 μm or less (e.g., about 4.0 μm or less), or about 3 μm or less (e.g., about 3.0 μm or less), or about 2 μm or less (e.g., about 2.0 μm or less), or about 1 μm or less (e.g., about 1.0 μm or less). 50 The mica particles may have a sedigraph diameter of about 0.5 μm or more, e.g., about 1 μm or more (e.g., about 1.0 μm or more), or about 2 μm or more (e.g., about 2.0 μm or more), or about 3 μm or more (e.g., about 3.0 μm or more), or about 3.5 μm or more, or about 4 μm or more (e.g., about 4.0 μm or more), or about 5 μm or more (e.g., about 5.0 μm or more). 50The mica particles may have a diameter of about 0.5 μm to about 6 μm (e.g., about 6.0 μm), for example, about 0.5 μm to about 5 μm (e.g., about 5.0 μm), or about 0.5 μm to about 4 μm (e.g., about 4.0 μm), or about 0.5 μm to about 3 μm (e.g., about 3.0 μm), or about 0.5 μm to about 2 μm (e.g., about 2.0 μm), or about 0.5 μm to about 1 μm (e.g., about 1.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 6 μm (e.g., about 6.0 μm). , or about 1 μm (e.g., about 1.0 μm) to about 5 μm (e.g., about 5.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 4 μm (e.g., about 4.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 3 μm (e.g., about 3.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 2 μm (e.g., about 2.0 μm), or about 2 μm (e.g., about 2.0 μm) to about 6 μm (e.g., about 6.0 μm), or about 2 μm (e.g., about 2.0 μm) to about 5 μm (e.g., about 5.0 μm), or about 2 μm (e.g., about 2.0 μm) to about 4 μm (e.g., about 4.0 μm), or about 2 μm (e.g., about 2.0 μm) to about 3 μm (e.g., about 3.0 μm), or about 3 μm (e.g., about 3.0 μm) to about 6 μm (e.g., about 6.0 μm), or about 3 μm (e.g., about 3.0 μm) to about 5 μm (e.g., about 5.0 μm), or about 3 μm (e.g., about 3.0 μm) to about 4 μm (e.g., about 4.0 μm), or is about 3.5 μm to about 6 μm (e.g., about 6.0 μm), or about 3.5 μm to about 5 μm (e.g., about 5.0 μm), or about 3.5 μm to about 4 μm (e.g., about 4.0 μm), or about 4 μm (e.g., about 4.0 μm) to about 6 μm (e.g., about 6.0 μm), or about 4 μm (e.g., about 4.0 μm) to about 5 μm (e.g., about 5.0 μm), or about 5 μm (e.g., about 5.0 μm) to about 6 μm (e.g., about 6.0 μm) by sedigraph 50 may have:

[0024] The mica particles are preferably laser-depleted to about 25 μm or less, e.g., about 20 μm or less, or about 15 μm or less, or about 10 μm or less, or about 5 μm or less. 25The mica particles may have a laser d of about 0.5 μm or more, e.g., about 1 μm or more (e.g., about 1.0 μm or more), or about 5 μm or more, or about 10 μm or more. 25 The mica particles may have a diameter of about 0.5 μm to about 25 μm, for example, about 0.5 μm to about 20 μm, or about 0.5 μm to about 15 μm, or about 0.5 μm to about 10 μm, or about 0.5 μm to about 5 μm, or about 1 μm (for example, about 1.0 μm) to about 25 μm, or about 1 μm (for example, about 1.0 μm) to about 20 μm, or about 1 μm (for example, about 1.0 μm) to about 15 μm. m, or about 1 μm (e.g., about 1.0 μm) to about 10 μm, or about 1 μm (e.g., about 1.0 μm) to about 5 μm, or about 5 μm to about 25 μm, or about 5 μm to about 20 μm, or about 5 μm to about 15 μm, or about 5 μm to about 10 μm, or about 10 μm to about 25 μm, or about 10 μm to about 20 μm, or about 10 μm to about 15 μm 25 may have:

[0025] The mica particles have a diameter by sedigraph of about 4 μm or less (e.g., about 4.0 μm or less), for example, about 3 μm or less (e.g., about 3.0 μm or less), or about 2 μm or less (e.g., about 2.0 μm or less), or about 1 μm or less (e.g., about 1.0 μm or less). 25 The mica particles may have a sedigraph d of about 0.1 μm or more, e.g., about 0.5 μm or more, or about 1 μm or more (e.g., about 1.0 μm or more), or about 1.5 μm or more. 25The mica particles may have a diameter of about 0.1 μm to about 4 μm (e.g., about 4.0 μm), for example, about 0.1 μm to about 3 μm (e.g., about 3.0 μm), or about 0.1 μm to about 2 μm (e.g., about 2.0 μm), or about 0.1 μm to about 1 μm (e.g., about 1.0 μm), or about 0.5 μm to about 4 μm (e.g., about 4.0 μm), or about 0.5 μm to about 3 μm (e.g., about 3.0 μm), or about 0.5 μm to about 2 μm (e.g., about 2.0 μm), or about 0.5 μm to about 1 μm (e.g., , about 1.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 4 μm (e.g., about 4.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 3 μm (e.g., about 3.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 2 μm (e.g., about 2.0 μm), or about 1.5 μm to about 4 μm (e.g., about 4.0 μm), or about 1.5 μm to about 3 μm (e.g., about 3.0 μm), or about 1.5 μm to about 2 μm (e.g., about 2.0 μm), as measured by a sedigraph. 25 may have:

[0026] The mica particles are preferably laser-depleted to a size of about 60 μm or less, e.g., about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 15 μm or less, or about 10 μm or less. 75 The mica particles may have a laser d of about 3 μm or more, e.g., about 10 μm or more, or about 15 μm or more, or about 20 μm or more, or about 25 μm or more, or about 30 μm or more. 75The mica particles may have a diameter of about 3 μm to about 60 μm, for example, about 3 μm to about 50 μm, or about 3 μm to about 40 μm, or about 3 μm to about 35 μm, or about 3 μm to about 30 μm, or about 3 μm to about 15 μm, or about 3 μm to about 10 μm, or about 10 μm to about 60 μm, or about 10 μm to about 50 μm, or about 10 μm to about 40 μm, or about 10 μm to about 35 μm, or about 10 μm to about 30 μm, or about 10 μm to about 15 μm, or about 15 μm to about 60 μm, or about 15 μm to about 50 μm, or about 15 μm to about 40 μm, or about 5 μm to about 35 μm, or about 15 μm to about 30 μm, or about 20 μm to about 60 μm, or about 20 μm to about 50 μm, or about 20 μm to about 40 μm, or about 20 μm to about 35 μm, or about 20 μm to about 30 μm, or about 25 μm to about 60 μm, or about 25 μm to about 50 μm, or about 25 μm to about 40 μm, or about 25 μm to about 35 μm, or about 25 μm to about 30 μm, or about 30 μm to about 60 μm, or about 30 μm to about 50 μm, or about 30 μm to about 40 μm, or about 30 μm to about 35 μm 75 may have:

[0027] The mica particles have a sedigraph diameter of about 15 μm or less, e.g., about 10 μm or less, or about 7 μm or less (e.g., about 7.0 μm or less), or about 6 μm or less (e.g., about 6.0 μm or less), or about 5 μm or less (e.g., about 5.0 μm or less), or about 3 μm or less (e.g., about 3.0 μm or less), or about 2 μm or less (e.g., about 2.0 μm or less). 75 The mica particles may have a sedigraph d of about 0.5 μm or more, e.g., about 1 μm or more (e.g., about 1.0 μm or more), or about 5 μm or more (e.g., about 5.0 μm or more), or about 6 μm or more (e.g., about 6.0 μm or more). 75The mica particles may have a diameter of about 0.5 μm to about 15 μm, for example, about 0.5 μm to about 10 μm, or about 0.5 μm to about 7 μm (for example, about 7.0 μm), or about 0.5 μm to about 6 μm (for example, about 6.0 μm), or about 0.5 μm to about 5 μm (for example, about 5.0 μm), or about 0.5 μm to about 3 μm (for example, about 3.0 μm), or about 0.5 μm to about 2 μm. (e.g., about 2.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 15 μm, or about 1 μm (e.g., about 1.0 μm) to about 10 μm, or about 1 μm (e.g., about 1.0 μm) to about 7 μm (e.g., about 7.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 6 μm (e.g., about 6.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 5 μm (e.g., about 5.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 3 μm (e.g., about 3.0 μm), or about 1 μm (e.g., about 1.0 μm) to about 2 μm (e.g., about 2.0 μm), or about 5 μm (e.g., about 5.0 μm) to about 15 μm, or about 5 μm (e.g., about 5.0 μm) to about 10 μm, or about 5 μm (e.g., about 5.0 μm ) to about 7 μm (e.g., about 7.0 μm), or about 5 μm (e.g., about 5.0 μm) to about 6 μm (e.g., about 6.0 μm), or about 6 μm (e.g., about 6.0 μm) to about 15 μm, or about 6 μm (e.g., about 6.0 μm) to about 10 μm, or about 6 μm (e.g., about 6.0 μm) to about 7 μm (e.g., to about 7.0 μm), as measured by a sedigraph 75 may have:

[0028] The mica particles may have a Minolta Y whiteness of about 70 or more, e.g., about 75 or more, or about 80 or more. The mica particles may have a Minolta Y whiteness of about 88 or less, e.g., about 85 or less. The mica particles may have a Minolta Y whiteness of about 70 to about 88, e.g., about 75 to about 88, or about 80 to about 88, or about 70 to about 85, or about 75 to about 85, or about 80 to about 85. The Minolta Y whiteness may be measured using a spectrophotometer / colorimeter such as a Konica Minolta CM-3700d (available from Konica Minolta Sensing Europe BV) using a D65 illuminant, 10 mm spectral interval, reflectance measurement, d / 8 geometry, and color space CIE LAB 1964 (10°). Before the measurement, check if the sample contains compressed powder granules; if so, pass 10 g of the sample through a coffee mill for 30 seconds. The sample is then pelletized. The annular mount is placed at the bottom end of the mold tube and the assembly is placed on the glass plate. Approximately 5 g of the dry powder to be characterized is placed into the tube. The plunger is gently slid into the tube until it comes into contact with the powder. The lug placed on the lever is placed on the top of the plunger to compress the powder. Pressure is allowed to build for 30 seconds. The lever, plunger and then the tube are removed. The bottom of the mount is placed into the annular mount and while holding the assembly firmly against the glass plate, the back of the frame mount is screwed using a special key. The compacted powder pellet clamped in the annular mount should have a perfect surface finish; if not, the pelleting operation is repeated. Once pelleted, the spectrophotometer / colorimeter is calibrated using a white plate and then the Minolta Y whiteness of the pelleted sample is measured.

[0029] The mica particles can have a PANACEA shape factor of about 100 or more, such as about 120 or more, or about 140 or more, or about 145 or more. The mica particles can have a PANACEA shape factor of about 250 or less, such as about 200 or less, or about 175 or less, or about 165 or less. The mica particles may have a PANACEA shape factor of about 100 to about 250, for example, about 100 to about 200, or about 100 to about 175, or about 100 to about 165, or about 120 to about 250, or about 120 to about 200, or about 120 to about 175, or about 120 to about 165, or about 140 to about 250, or about 140 to about 200, or about 140 to about 175, or about 140 to about 165, or about 145 to about 250, or about 145 to about 200, or about 145 to about 175, or about 145 to about 165.

[0030] PANACEA shape factor refers to a property measured by the PANACEA (Particle Assessment by Natural Alignment and Conductivity Effect Analysis) method. It is an apparatus that allows the shape factor of minerals to be measured. The apparatus described in US Pat. No. 5,576,617 and WO 2013 / 015841, the contents of which are incorporated herein by reference in their entirety, can be used. During the measurement, a mica particle suspension is circulated by a pump through a cell whose conductivity is measured from one end to the other. When the pump is turned on, the non-spherical particles naturally align along the axis of the pipe. In this position, the particles present the least resistance to the flow of charge. Therefore, the conductivity measurement is maximum. When the pump is off, the particles are randomly oriented according to Brownian motion. In this position, the charge has to traverse a long path to progress in the suspension. Therefore, the conductivity value is reduced. The number obtained by the test is obtained from the ratio of these two measurements (maximum to minimum). Thus, a more lamellar product will have a higher ratio between these two measurements (higher shape factor) compared to a product exhibiting less lamellarity (lower shape factor).

[0031] For the shape factor measurement itself, a suspension volume corresponding to 50 g of dry product is taken. 10 mL of a dispersing agent, e.g. sodium polyacrylate, and 80 mL of deionized water are added before homogenizing the suspension to avoid settling when the pump is off. The suspension is then passed through a 53 μm BSS sieve to remove any coarse particles that may interfere with the measurement. Deionized water (approximately 200 mL) is then added to obtain a density between 1.08 and 1.12 (i.e. a mass concentration between 12 and 17% by weight, e.g. approximately 15% by weight). The pH of the suspension is then measured to ensure that it is within 8.5 to 10, and if not, sodium hydroxide is added. The suspension is then left to stand for at least 20 minutes. The sample is then resuspended by vigorous shaking, after which the PANACEA method is carried out. The method is carried out at room temperature, e.g. approximately 23 °C. The shape factor is obtained from the average of at least three measurements.

[0032] Mica is a layered mineral. Its crystal structure is described as TOT-c because it consists of parallel TOT layers weakly bonded to each other by cations (c), such as sodium, potassium, or calcium ions. The TOT layers are AlSiO 10 5- Tetrahedral (“T”) layer and Al(OH) 2+ or M3(OH)2 4+ It consists of octahedral ("O") layers, where M is a divalent ion such as ferrous or magnesium. The number of TOT layers per mica crystallite (N(TOT)) can be determined by X-ray diffraction (XRD) and by applying the Scherrer equation to the (002) and (006) peaks of the pattern.

[0033] For example, XRD patterns can be acquired using a PAnalytical X'PRO X-ray diffractometer using CuKα radiation with a wavelength of λ=1.5406 Å. Samples are acquired by packing an aluminum holder to obtain a quasi-random orientation. Example acquisition parameters can be 2θ range=8-80° with a step size of 0.01° and step duration of 2 seconds. The Scherrer equation is then applied to the (002) and (006) peaks of the mica pattern, which are located approximately at 2θ=8.7-9.1° and 2θ=17.5-17.9° on the XRD pattern. This equation gives c * The width of the peak at half height relative to the background line is used to calculate the coherent scattering domain of the mica crystallite along the axis. The number of TOT layers in a single mica crystallite can then be estimated. This method is implemented in a paper on synthetic talc (Dumas et al., Angewandte Chemie International Edition 2016, 55, 9868-9871), the contents of which are incorporated herein by reference. The Scherrer formula is expressed as follows:

[0034]

number

[0035]

number

[0036]

number

[0037]

number

[0038] The mica particles are (a) about 4.5 m 2 (b) a BET specific surface area of ​​about 2.5 or more; (c) a laser-induced d 95 and (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 For example, the mica particles may have a diameter of about (a) about 4.5 m 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 (b) a BET specific surface area of ​​about 2.5 to about 6.5, e.g., about 4.0 to about 5.7; (c) a laser d 95 and (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 may have:

[0039] The mica particles are (a) about 4.5 m 2 (b) a BET specific surface area of ​​about 2.5 or more; (c) a laser-induced d 95 (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm; 95 and (e)(i) a laser-induced d 50(ii) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (iii) a Minolta Y Whiteness of about 70 or greater, e.g., from about 70 to about 88; and / or (iv) a PANACEA Shape Factor of about 100 to about 250, e.g., from about 140 to about 180. For example, a mica particle has a diameter of about 4.5 m. 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 (b) a BET specific surface area of ​​about 2.5 to about 6.5, e.g., about 4.0 to about 5.7; (c) a laser d 95 (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm; 95 and (e)(i) a laser-induced d 50 (ii) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (iii) a Minolta Y Whiteness of about 70 or greater, e.g., from about 70 to about 88; and / or (iv) a PANACEA Shape Factor of about 100 to about 250, e.g., from about 140 to about 180.

[0040] For example, a mica particle has a diameter of about 4.5 m. 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 (b) a BET specific surface area of ​​about 2.5 to about 6.5, e.g., about 4.0 to about 5.7; (c) a laser d 95 (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm;95 (e) a laser d of about 40 μm or less, e.g., about 3 μm to about 40 μm, or about 20 μm to about 40 μm; 50 (f) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (g) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 88; and (h) a PANACEA shape factor of about 100 to about 250, e.g., from about 140 to about 180.

[0041] The mica particles contain about 90% by mass or more of muscovite, and (a) about 4.5 m 2 (b) a BET specific surface area of ​​about 2.5 or more; (c) a laser-induced d 95 (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm; 95 and (e)(i) a laser-induced d 50 (ii) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (iii) a Minolta Y Whiteness of about 70 or greater, e.g., from about 70 to about 88; and / or (iv) a PANACEA Shape Factor of about 100 to about 250, e.g., from about 140 to about 180.

[0042] For example, the mica particles contain about 90% by mass or more of muscovite, and (a) have a particle size of about 4.5 m 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 (b) a BET specific surface area of ​​about 2.5 to about 6.5, e.g., about 4.0 to about 5.7; (c) a laser d 95(d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm; 95 and (e)(i) a laser-induced d 50 (ii) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (iii) a Minolta Y Whiteness of about 70 or greater, e.g., from about 70 to about 88; and / or (iv) a PANACEA Shape Factor of about 100 to about 250, e.g., from about 140 to about 180.

[0043] For example, the mica particles contain about 90% by mass or more of muscovite, and (a) have a particle size of about 4.5 m 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 (b) a BET specific surface area of ​​about 2.5 to about 6.5, e.g., about 4.0 to about 5.7; (c) a laser d 95 (d) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm; 95 (e) a laser d of about 40 μm or less, e.g., about 3 μm to about 40 μm, or about 20 μm to about 40 μm; 50 (f) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (g) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 88; and (h) a PANACEA shape factor of about 100 to about 250, e.g., from about 140 to about 180.

[0044] In some examples, the mica particles are (a) about 4.5 m 2 / g ~ approx. 12.0m 2 / g, for example, about 5.0m 2 / g ~ approx. 10.0m 2 / g BET specific surface area; and (b) a lamellarity index of about 2.5 or greater, e.g., from about 2.5 to about 6.5, or from about 4.0 to about 5.7. In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 / g BET specific surface area; and (b) a lamellarity index of from about 2.5 to about 5.9, e.g., from about 4.0 to about 5.7. In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) (i) a laser dTc of about 150 μm or less, e.g., about 5 μm to about 150 μm, or about 40 μm to about 130 μm. 95 and (ii) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 It has one or both of the following.

[0045] In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) a laser dTc of about 35 μm or less, e.g., about 10 μm to about 35 μm, or about 15 μm to about 35 μm, or about 15 μm to about 25 μm. 50 has. In some examples, the mica particles include about 90% by weight or more of muscovite, and (a) about 4.5 m2 / g or greater BET specific surface area; and (b) a lamellarity index of about 2.5 or greater. In some examples, the mica particles include about 90% by weight or more of muscovite, and (a) about 4.5 m 2 / g ~ approx. 12.0m 2 / g, for example, about 5.0m 2 / g ~ approx. 10.0m 2 / g BET specific surface area; and (b) a lamellarity index of about 2.5 or greater, e.g., from about 2.5 to about 6.5, or from about 4.0 to about 5.7. In some examples, the mica particles include about 90% by weight or more of muscovite, and (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 / g BET specific surface area; and (b) a lamellarity index of from about 2.5 to about 5.9, e.g., from about 4.0 to about 5.7.

[0046] In some examples, the mica particles include about 90% by weight or more of muscovite, and (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) (i) a laser dTc of about 150 μm or less, e.g., about 5 μm to about 150 μm, or about 40 μm to about 130 μm. 95 and (ii) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 It has one or both of the following. In some examples, the mica particles include about 90% by weight or more of muscovite, and (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) a laser dTc of about 35 μm or less, e.g., about 10 μm to about 35 μm, or about 15 μm to about 35 μm, or about 15 μm to about 25 μm. 50 has.

[0047] In some examples, the mica particles are (a) about 4.5 m 2 / g or greater BET specific surface area; and (b) muscovite particles having a lamellarity index of about 2.5 or greater. In some examples, the mica particles are (a) about 4.5 m 2 / g ~ approx. 12.0m 2 / g, for example, about 5.0m 2 / g ~ approx. 10.0m 2 / g BET specific surface area; and (b) a lamellarity index of about 2.5 or greater, e.g., from about 2.5 to about 6.5, or from about 4.0 to about 5.7. In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 / g BET specific surface area; and (b) muscovite particles having a lamellarity index of about 2.5 to about 5.9, e.g., about 4.0 to about 5.7.

[0048] In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) (i) a laser dTc of about 150 μm or less, e.g., about 5 μm to about 150 μm, or about 40 μm to about 130 μm. 95and (ii) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 The muscovite particles have one or both of the above.

[0049] In some examples, the mica particles are (a) about 4.5 m 2 / g or more, for example, about 4.5m 2 / g ~ approx. 50.0m 2 / g, or about 5.0m 2 / g ~ approx. 12.0m 2 (b) a BET specific surface area of ​​about 2.5 or more, e.g., about 2.5 to about 6.5, or about 2.5 to about 5.9, or about 4.0 to about 5.7; and (c) a laser dTc of about 35 μm or less, e.g., about 10 μm to about 35 μm, or about 15 μm to about 35 μm, or about 15 μm to about 25 μm. 50 The particles are muscovite particles having the following structure:

[0050] Optional surface treatment In certain embodiments, the mica particles are treated with a surface treatment. Surface-treated mica may be referred to, for example, as coated mica. Surface treatment of the mica may help reduce or eliminate agglomeration of the mica particles and / or enhance incorporation of the mica particles into polymer compositions.

[0051] In certain embodiments, the mica particles are not treated with a surface treatment (uncoated mica). Suitable surface treatment agents include compounds having hydrophobic carbon chains bearing polar groups, such as the families of amines, silanes, siloxanes, alcohols or acids and their metal salts.

[0052] In one particular embodiment, the surface treatment is a polyether or a derivative thereof, such as a polyether-modified polysiloxane. In certain embodiments, the polyether is a polyoxyalkylene (POA), such as a polyalkylene glycol (PAG) or a polyalkylene oxide (PAO). As used herein, the term "polyalkylene glycol" refers to a POA having a number average molecular mass less than 20,000 g / mol, and the term "polyalkylene oxide" refers to a POA having a number average molecular mass above 20,000 g / mol. In a specific embodiment, the surface treatment agent comprises or is a polyalkylene glycol having a number average molecular mass of about 100 to about 15,000 g / mol, e.g., about 200 to about 10,000 g / mol, or about 500 to about 9000 g / mol, or about 1000 to about 9000 g / mol, or about 2000 to about 900 g / mol, or about 4000 to about 9000 g / mol, or about 6000 to about 9000 g / mol, or about 6000 to about 8500 g / mol. In certain embodiments, the polyether is a polyalkylene oxide selected from one or more of paraformaldehyde (polymethylene oxide), polytetramethylene glycol, polytetramethylene ether glycol, polyethylene oxide, polypropylene oxide, polybutylene oxide, and combinations thereof. In certain embodiments, the surface treatment comprises or is a polyethylene glycol. In certain embodiments, the surface treatment comprises or is a mixture of polyethylene glycol and polypropylene glycol (PPG). In certain embodiments, the surface treatment is a polyethylene glycol having a number average molecular mass of about 200 to about 10,000 g / mol, e.g., about 500 to about 9000 g / mol, or about 1000 to about 9000 g / mol, or about 2000 to about 900 g / mol, or about 4000 to about 9000 g / mol, or about 6000 to about 9000 g / mol, or about 6000 to about 8500 g / mol. Exemplary PEGs include the Puriol™ suite of polyglycols from BASF, e.g., Puriol™ 8005.

[0053] In certain embodiments, the surface treatment comprises or is a fatty acid and / or a metal salt thereof, such as stearic acid or a metal stearate, such as magnesium stearate, calcium stearate, or zinc stearate, including fatty acids with carbon chain lengths of C8 to C24 and mixtures of fatty acids with carbon chain lengths of C8 to C24. Suitable silane-based agents include aminosilanes, such as trimethoxysilylethylamine, triethoxysilylethylamine, tripropoxysilylethylamine, tributoxysilylethylamine, trimethoxysilylpropylamine, triethoxysilylpropylamine, tripropoxysilylpropylamine, triisopropoxysilylpropylamine, tributoxysilylpropylamine, trimethoxysilylbutylamine, triethoxysilylbutylamine, tripropoxysilylbutylamine, tributoxysilylbutylamine, trimethoxysilylpentylamine, triethylenesilylpropylamine, triethylenesilylpropylamine, triethylenesilylpropylamine, tripropylene ... Examples of suitable agents having hydrocarbyl and polar groups include hydrocarbyl amines such as triethanolamine (TEA) and amino alcohol agents such as 2-amino-2-methyl-1-propanol. AMP-95® is a commercially available formulation of 2-amino-2-methyl-1-propanol that contains 5% water.

[0054] The surface treatment agent may be added in an amount effective to achieve the desired result, in certain embodiments, the amount of the surface treatment agent is about 0.1% to 5% by weight relative to the weight of the mica, for example, about 0.1% to 2% by weight relative to the weight of the mica. The surface treatment may be applied by adding to the mica particles and mixing using conventional methods. The surface treatment may be applied during the preparation of the mica particles from the relatively coarse mica starting material and prior to adding the mica particles to the polymer composition.

[0055] Method for making mica particles Mica particles can be made by classifying ground mica material, which typically involves separating a fine fraction from a coarse fraction (e.g., removing the coarse fraction from the ground mica material and retaining the fine fraction). The ground mica material can be a wet-milled mica material (i.e., ground mica material prepared by a wet-milling process). Because wet-milling typically preserves particle shape, the wet-milled mica material can have a higher lamellarity index than a dry-milled mica material.

[0056] Classification refers to a process in which particles of a ground mica material (e.g., wet-ground mica material) are separated by size. Classification can be done by any suitable method, including, for example, air classification, sieve analysis, and sedimentation. Classification can be, for example, dry classification. Preferably, the ground mica material (e.g., wet-ground mica material) is classified using air classification or by sieve analysis. A suitable air classifier is the NETZSCH Ecutec BORA 50 Turbo Air Classifier (available from NETZSCH-Feinmahltechnik GmbH, Germany). The NETZSCH Ecutec BORA 50 Turbo Air Classifier has a maximum air flow rate of 1800 m 3 / h, maximum rotor speed 8700 rpm, installed power 10 kW, feed rate maximum 1800 kg / h and main fan installed power 30 kW. A suitable screening device is an electromagnetic vibratory sieve shaker D0407.2 (available from Controlab, France).

[0057] In the methods described herein, the largest particles (i.e., the coarse fraction) and a portion of the ground mica material (e.g., wet-milled mica material) are removed by classification (e.g., by air classification or by sieving). Thus, the ground mica material (e.g., wet-milled mica material) of the present invention comprises (e.g., consists essentially of, or consists of) the fine mica particles remaining after the larger particles have been removed. In other words, the ground mica material (e.g., wet ground mica material) can be classified to separate the material into two fractions. The fine fraction is the mica particles of the present invention. The coarse fraction can be considered a by-product.

[0058] The percentage of larger particles to be removed can be selected depending on the target particle size distribution of the mica particles, for example, about 10% to about 99.5% by weight of the largest particles, such as about 10% to about 99% by weight, or about 10% to about 95% by weight, or about 20% to about 99.5% by weight, or about 20% to about 99% by weight, or about 20% to about 95% by weight, or about 30% to about 99.5% by weight, or about 30% to about 99% by weight, or about 30% to about 95% by weight, or about 40% to about 99.5% by weight, or about 40% to about 99% by weight, or about 40% to about 95% by weight, or about 50% to about 99.5% by weight, or about 50% to about 9 ... % to about 95% by mass, or about 60% to about 99.5% by mass, or about 60% to about 99% by mass, or about 60% to about 95% by mass, or about 70% to about 99.5% by mass, or about 70% to about 99% by mass, or about 70% to about 95% by mass, or about 80% to about 99.5% by mass, or about 80% to about 99% by mass, or about 80% to about 95% by mass, or about 80% to about 90% by mass, or about 90% to about 99.5% by mass, or about 90% to about 99% by mass, or about 90% to about 95% by mass can be removed to produce mica particles.

[0059] When classified by air classification, the amount of fine fraction produced can be directly correlated to the speed of the classification turbine. The faster the classifier speed, the lower the yield (%) of fine product. The faster the classifier speed, the lower the top cut (e.g., d 95 Or d 98 ) is lower. Thus, the speed of the classification turbine can be adjusted depending on the desired particle size and product yield.

[0060] The classification turbine may be operated at a peripheral speed of about 25 m / s or more, such as about 50 m / s or more. The classification turbine may be operated at a peripheral speed of about 100 m / s or less, such as about 75 m / s or less. The classification turbine may be operated at a peripheral speed of about 25 m / s to about 100 m / s, such as about 25 m / s to about 75 m / s, or about 50 m / s to about 100 m / s, or about 50 m / s to about 75 m / s. The classification turbine may be operated at a speed of about 1000 rpm or more, e.g., about 2000 rpm or more, or about 3000 rpm or more, or about 4000 rpm or more, or about 5000 rpm or more, or about 6000 rpm or more, or about 7000 rpm or more, or about 8000 rpm or more. The classification turbine may be operated at a speed of about 15000 rpm or less, e.g., about 14000 rpm or less, or about 13000 rpm or less, or about 12000 rpm or less, or about 11000 rpm or less, or about 10000 rpm or less, or about 9000 rpm or less, or about 8000 rpm or less, or about 7000 rpm or less, or about 6000 rpm or less, or about 5000 rpm or less, or about 4000 rpm or less. The classification turbine may be operated at a speed of about 1000 rpm to about 15000 rpm, for example, about 2000 rpm to about 14000 rpm, or about 3000 rpm to about 13000 rpm, or about 4000 rpm to about 12000 rpm, or about 4000 rpm to about 11000 rpm, or about 4000 rpm to about 10000 rpm, or about 4000 rpm to about 9000 rpm, or about 5000 rpm to about 10000 rpm, or about 5000 rpm to about 9000 rpm, or about 6000 rpm to about 10000 rpm, or about 6000 rpm to about 9000 rpm, or about 1000 rpm to about 5000 rpm, or about 2000 rpm to about 4000 rpm, or about 3000 rpm to about 4000 rpm.

[0061] The classification turbine may be operated with a fines yield of about 3% or more, e.g., about 4% or more, or about 5% or more, or about 6% or more, or about 7% or more, or about 8% or more, or about 9% or more, or about 10% or more. The classification turbine may be operated with a fines yield of about 20% or less, e.g., about 15% or less, or about 12% or less, or about 11% or less. The classification turbine may be operated with a fines yield of about 3% to about 20%, e.g., about 4% to about 15%, or about 5% to about 12%, or about 6% to about 12%, or about 7% to about 11%. When classified by sieving, the amount of fine fraction produced may depend on the (i.e., maximum) sieve opening (i.e., diameter) of the sieve used. The method may include sieving the ground mica material (e.g., wet-ground mica material) using a sieve having a maximum sieve opening (i.e., diameter) of about 500 μm or less, e.g., about 200 μm or less, or about 150 μm or less, or about 125 μm or less, or about 100 μm or less, or about 75 μm or less, or about 50 μm or less.

[0062] Classification typically involves the determination of the top cut of a ground mica material (e.g., a wet-ground mica material), e.g. 95 Classification also typically involves reducing the density of the ground mica material (e.g., wet-ground mica material). 75 , d 50 and / or d 25 Classification can also aid in removing impurities from the ground mica material (e.g., wet-milled mica material). Removal of impurities can increase the whiteness, such as Minolta Y whiteness, of the ground mica material (e.g., wet-milled mica material). The method may include preparing a ground mica material (e.g., wet-milled mica material) prior to classification. Thus, the method may include (e.g., wet-milling) a mica feed material to produce a ground mica material (e.g., wet-milled mica material); and classifying the ground mica material (e.g., wet-milled mica material) to remove a coarse fraction.

[0063] The mica feed material can be (e.g., wet) milled using a (e.g., wet) pan mill. Wet milling can be used because it typically maintains particle shape and can produce mica particles with a higher lamellarity index. The method can include increasing the BET surface area of ​​the ground mica material. For example, the method can include increasing the BET surface area of ​​the ground mica material by about 0.5 m (compared to the BET surface area of ​​the ground mica material before classification). 2 / g or more, for example, about 1.0m 2 / g or more, or about 5.0m 2 / g or more. The method may include increasing the BET surface area of ​​the ground mica material by about 10% or more (compared to the BET surface area of ​​the ground mica material before classification), such as by about 20% or more, or by about 50% or more, or by about 100% or more.

[0064] The method is the sedigraph of crushed mica material. 95 For example, the method may include reducing the d by sedigraph of the ground mica material. 95 The method may include reducing the BET specific surface area of ​​the ground mica material by about 5 μm or more, e.g., about 7 μm or more, or about 10 μm or more (compared to the BET specific surface area of ​​the ground mica material before classification). 95 by about 10% or more, such as about 20% or more, or about 30% or more, or about 40% or more. The method involves the laser delamination of crushed mica material. 95 For example, the method may include reducing the d of the milled mica material by laser. 95 The method may include reducing the BET specific surface area of ​​the milled mica material by about 10 μm or more, e.g., about 20 μm or more, or about 30 μm or more, or about 40 μm or more (compared to the BET specific surface area of ​​the milled mica material before classification). 95 by about 10% or more, such as about 20% or more, or about 30% or more, or about 40% or more.

[0065] The method is the sedigraph of crushed mica material. 50 For example, the method may include reducing the d by sedigraph of the ground mica material.50 The method may include reducing the specific surface area of ​​the ground mica material by about 0.5 μm or more, e.g., by about 1.0 μm or more, or by about 2.0 μm or more, or by about 3.0 μm or more (compared to the BET specific surface area of ​​the ground mica material before classification). 50 by about 5% or more, such as about 10% or more, or about 20% or more, or about 30% or more.

[0066] The method involves the laser delamination of crushed mica material. 50 For example, the method may include reducing the d of the milled mica material by laser. 50 The method may include reducing the BET specific surface area of ​​the ground mica material by about 5 μm or more, e.g., about 10 μm or more, or about 15 μm or more, or about 20 μm or more (compared to the BET specific surface area of ​​the ground mica material before classification). 50 by about 10% or more, such as about 15% or more, or about 20% or more, or about 30% or more, or about 40% or more.

[0067] Crushed mica material before classification The crushed mica material (e.g., wet-ground mica material) is approximately 5.0 m 2 / g, e.g., about 4.9m 2 / g or less, or about 4.5m 2 / g or less, or about 4.3m 2 / g or less, or about 4.2m 2 The ground mica material (e.g., wet ground mica material) may have a BET specific surface area of ​​about 1.0 m 2 / g or more, for example, about 2.0m 2 / g or more, or about 3.0m 2 / g or more, or about 4.0m 2 The ground mica material (e.g., wet ground mica material) may have a BET specific surface area of ​​about 1.0 m 2 / g~approx.5.0m 2 / g, e.g., about 1.0 m 2 / g ~ approx. 4.9m 2 / g, or about 1.0m 2 / g ~ approx. 4.5m 2 / g, or about 1.0m 2 / g ~ approx. 4.3m 2 / g, or about 1.0m 2 / g ~ approx. 4.2m 2 / g, or about 2.0m 2 / g~approx.5.0m 2 / g or less than about 2.0m 2 / g~approx. 4.9m 2 / g, or about 2.0m 2 / g ~ approx. 4.5m 2 / g, or about 2.0m 2 / g ~ approx. 4.3m 2 / g, or about 2.0m 2 / g ~ approx. 4.2m 2 / g, or about 3.0m 2 / g~approx.5.0m 2 / g or less than about 3.0m 2 / g~approx. 4.9m 2 / g, or about 3.0m 2 / g ~ approx. 4.5m 2 / g, or about 3.0m 2 / g ~ approx. 4.3m 2 / g, or about 3.0m 2 / g ~ approx. 4.2m 2 / g, or about 4.0m 2 / g~approx.5.0m 2 / g or less than about 4.0m 2 / g~approx. 4.9m 2 / g, or about 4.0m 2 / g ~ approx. 4.5m 2 / g, or about 4.0m 2 / g ~ approx. 4.3m 2 / g, or about 4.0m 2 / g ~ approx. 4.2m 2 / g.

[0068] The ground mica material (e.g., wet ground mica material) can have a Lamellarity Index of about 2.5 or more, e.g., about 3.5 or more, or about 4.0 or more, or about 4.5 or more. The ground mica material (e.g., wet ground mica material) can have a Lamellarity Index of about 7.0 or less, e.g., about 6.5 or less, or about 6.0 or less, or about 5.5 or less. The ground mica material (e.g., wet ground mica material) can have a Lamellarity Index of from about 2.5 to about 7.0, e.g., from about 2.5 to about 6.5, or from about 2.5 to about 6.0, or from about 2.5 to about 5.5, or from about 3.5 to about 7.0, or from about 3.5 to about 6.5, or from about 3.5 to about 6.0, or from about 3.5 to about 5.5, or from about 4.0 to about 7.0, or from about 4.0 to about 6.5, or from about 4.0 to about 6.0, or from about 4.0 to about 5.5, or from about 4.5 to about 7.0, or from about 4.5 to about 6.5, or from about 4.5 to about 6.0, or from about 4.5 to about 5.5.

[0069] The ground mica material (e.g., wet ground mica material) may have a sedigraph diameter of about 10 μm to about 100 μm, e.g., about 15 μm to about 50 μm, or about 15 μm to about 30 μm, or about 15 μm to about 20 μm. 95 The ground mica material (e.g., wet ground mica material) may have a sedigraph diameter of about 5 μm to about 50 μm, e.g., about 5 μm to about 25 μm, or about 5 μm to about 20 μm, or about 5 μm to about 15 μm, or about 8 μm to about 12 μm. 75 The ground mica material (e.g., wet ground mica material) may have a sedigraph diameter of about 1 μm to about 20 μm, e.g., about 1 μm to about 15 μm, or about 1 μm to about 10 μm, or about 2 μm to about 7 μm, or about 5 μm to about 6 μm. 50 The ground mica material (e.g., wet ground mica material) may have a sedigraph diameter of about 1 μm to about 10 μm, e.g., about 1 μm to about 6 μm, or about 1 μm to about 4 μm, or about 2 μm to about 3 μm. 25 may have:

[0070] The milled mica material (e.g., wet milled mica material) may be laser-depleted to a diameter of about 30 μm to about 300 μm, e.g., about 30 μm to about 150 μm, or about 70 μm to about 100 μm, or about 80 μm to about 90 μm. 95 The milled mica material (e.g., wet milled mica material) may have a laser d of about 20 μm to about 100 μm, e.g., about 30 μm to about 90 μm, or about 40 μm to about 70 μm, or about 40 μm to about 60 μm, or about 45 μm to about 55 μm. 75 The ground mica material (e.g., wet ground mica material) may have a laser d of about 10 μm to about 60 μm, e.g., about 10 μm to about 50 μm, or about 20 μm to about 40 μm, or about 30 μm to about 35 μm. 50 The milled mica material (e.g., wet milled mica material) may have a laser d of about 5 μm to about 50 μm, e.g., about 10 μm to about 40 μm, or about 10 μm to about 30 μm, or about 15 μm to about 25 μm, or about 18 μm to about 21 μm. 25 may have:

[0071] The ground mica material (eg, wet ground mica material) can have a Minolta Y brightness of about 70 or greater, such as about 80 or greater, or from about 70 to about 85, or from about 70 to about 83, or from about 80 to about 83. The ground mica material (eg, wet ground mica material) can have a shape factor of about 100 or greater.

[0072] The ground mica material (e.g., wet ground mica material) may be (a) approximately 5.0 m 2 / g, e.g., about 1.0 m 2 / g~approx. 4.9m 2 (b) a BET specific surface area of ​​about 10 μm to about 100 μm, for example, about 15 μm to about 50 μm, or about 15 μm to about 30 μm, measured by sedigraph 95 (c) a sedigraph d of about 5 μm to about 50 μm, e.g., about 5 μm to about 25 μm, or about 5 μm to about 20 μm; 75(d) a d by sedigraph of about 1 μm to about 20 μm, for example, about 1 μm to about 15 μm, or about 1 μm to about 10 μm; 50 (e) a sedigraph d of about 1 μm to about 10 μm, for example, about 1 μm to about 6 μm, or about 1 μm to about 4 μm; 25 (f) a laser d of about 30 μm to about 300 μm, for example, about 30 μm to about 150 μm, or about 70 μm to about 100 μm; 95 (g) a laser d of about 20 μm to about 100 μm, for example, about 30 μm to about 90 μm, or about 40 μm to about 70 μm; 75 (h) a laser d of about 10 μm to about 60 μm, for example, about 10 μm to about 50 μm, or about 20 μm to about 40 μm; 50 (i) a laser d of about 5 μm to about 50 μm, for example, about 10 μm to about 40 μm, or about 10 μm to about 30 μm; 25 (j) a lamellarity index of from about 2.5 to about 7.0, e.g., from about 3.5 to about 6.5; (k) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 85; and / or (l) a shape factor of about 100 or greater.

[0073] The ground mica material (e.g., wet ground mica material) may be (a) approximately 5.0 m 2 / g, e.g., about 1.0 m 2 / g ~ approx. 4.9m 2 (b) a BET specific surface area of ​​about 10 μm to about 100 μm, e.g., about 15 μm to about 50 μm, or about 15 μm to about 30 μm, measured by sedigraph 95 (c) a sedigraph d of about 5 μm to about 50 μm, e.g., about 5 μm to about 25 μm, or about 5 μm to about 20 μm; 75 (d) a d by sedigraph of about 1 μm to about 20 μm, e.g., about 1 μm to about 15 μm, or about 1 μm to about 10 μm; 50 (e) a sedigraph d of about 1 μm to about 10 μm, e.g., about 1 μm to about 6 μm, or about 1 μm to about 4 μm; 25(f) a laser d of about 30 μm to about 300 μm, e.g., about 30 μm to about 150 μm, or about 70 μm to about 100 μm; 95 (g) a laser d of about 20 μm to about 100 μm, e.g., about 30 μm to about 90 μm, or about 40 μm to about 70 μm; 75 (h) a laser d of about 10 μm to about 60 μm, for example, about 10 μm to about 50 μm, or about 20 μm to about 40 μm; 50 (i) a laser d of about 5 μm to about 50 μm, e.g., about 10 μm to about 40 μm, or about 10 μm to about 30 μm; 25 (j) a Lamellarity Index of from about 2.5 to about 7.0, e.g., from about 3.5 to about 6.5; (k) a Minolta Y Whiteness of from about 70 or greater, e.g., from about 70 to about 85; and (l) a Shape Factor of from about 100 or greater.

[0074] The ground mica material (e.g., wet milled mica material) may be comprised mostly of muscovite. The ground mica material (e.g., wet milled mica material) may comprise about 50% by weight or more, e.g., about 60% by weight or more, or about 70% by weight or more, or about 80% by weight or more, or about 90% by weight or more, or about 95% by weight or more, or about 99% by weight or more, e.g., about 100% by weight muscovite, based on the total weight of the ground mica material (e.g., wet milled mica material). The ground mica material (e.g., wet milled mica material) may consist essentially of, or consist of, muscovite. The ground mica material (e.g., wet milled mica material) may be ground muscovite (e.g., wet milled muscovite).

[0075] Polymer Composition The mica particles described herein can be used as a filler in a polymer composition. The mica particles can be used as an extender filler or a functional filler. As used herein, the term "functional filler" is understood to mean an additive incorporated into a polymer composition for the purpose of enhancing one or more of its physical (e.g., mechanical) properties. "Extender fillers" typically do not significantly change the properties of the polymer composition and essentially serve to reduce costs. Thus, a polymer composition comprising the mica particles described herein is also provided herein.

[0076] In certain embodiments, mica particles may be used as a functional filler in a polymer composition, for example, to modify or enhance one or more mechanical properties of the polymer composition. In certain embodiments, mica particles are used as an extender filler, for example to supplement or replace other filler materials that may be more expensive or more difficult to incorporate into polymer compositions. In one particular embodiment, the mica particles function as both an extender filler and a functional filler.

[0077] The polymer composition may comprise about 5% by weight or more, e.g., about 10% by weight or more, or about 15% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more of the mica particles (based on the total weight of the polymer composition). The polymer composition may comprise about 50% by weight or less, e.g., about 40% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less of the mica particles (based on the total weight of the polymer composition). The polymer composition may be present in an amount of from about 5% to about 50% by weight (based on the total weight of the polymer composition), e.g., from about 5% to about 40% by weight, or from about 5% to about 30% by weight, or from about 5% to about 25% by weight, or from about 5% to about 20% by weight, from about 10% to about 50% by weight, or from about 10% to about 40% by weight, or from about 10% to about 30% by weight, or from about 10% to about 25% by weight, or from about 10% to about 20% by weight, or from about 15% to about 50% by weight. The composition may contain 0% by weight, or about 15% to about 40% by weight, or about 15% to about 30% by weight, or about 15% to about 25% by weight, or about 15% to about 20% by weight, or about 20% to about 50% by weight, or about 20% to about 40% by weight, or about 20% to about 30% by weight, or about 20% to about 25% by weight, or about 30% to about 50% by weight, or about 30% to about 40% by weight, or about 40% to about 50% by weight.

[0078] The polymer composition may include fillers other than mica particles.For example, the polymer composition may include one or more minerals other than mica particles.For example, the polymer composition may include talc, chlorite, synthetic silica or silicate (e.g., precipitated silica or silicate), natural silica or silicate, clay minerals (e.g., hydrous kandite clays such as kaolin, halloysite or ball clay), carbon black, alkaline earth metal carbonates or sulfates, such as calcium carbonate, magnesium carbonate, dolomite, gypsum, anhydrous (calcined) kandite clays, such as metakaolin or fully calcined kaolin, perlite, feldspar, nepheline syenite, wollastonite, diatomaceous earth, barite and / or glass. Filler compounds other than the mica particles can be included during the preparation of the polymer composition or, alternatively, during the preparation of the mica particles, for example, the mica particles can be mixed and blended with other filler compounds and combined with a surface treatment agent. In certain embodiments, the amount of other filler compounds is present in an amount less than about 10% by weight, such as less than about 5% by weight, or less than about 1% by weight, or less than about 0.5% by weight, or less than about 0.1% by weight.

[0079] The polymer composition may include any natural or synthetic polymer or mixtures thereof. The polymer may be, for example, thermoplastic or thermoset. As used herein, the term "polymer" includes homopolymers and / or copolymers, as well as crosslinked and / or entangled polymers. The term "precursor" as it may be applied to a polymer component will be readily understood by those skilled in the art. For example, a suitable precursor may include one or more of a monomer, a crosslinker, a curing system including a crosslinker and a promoter, or any combination thereof. When mica particles are mixed with a precursor of a polymer, a polymer composition is then formed by curing and / or polymerizing the precursor components to form the desired polymer.

[0080] The polymers, including homopolymers and / or copolymers, included in the polymer composition of the present invention may be crosslinked dimers, trimers, or tetramers of one or more of the following monomers: acrylic acid, methacrylic acid, methyl methacrylate, and alkyl acrylates having 1 to 18 carbon atoms in the alkyl group, styrene, substituted styrenes, divinylbenzene, diallyl phthalate, butadiene, vinyl acetate, acrylonitrile, methacrylonitrile, maleic anhydride, esters of maleic or fumaric acid, tetrahydrophthalic acid or anhydride, itaconic acid or anhydride, and esters of itaconic acid. It may be prepared with or without crotonic acid, neopentyl glycol, propylene glycol, butanediol, ethylene glycol, diethylene glycol, dipropylene glycol, glycerol, cyclohexanedimethanol, 1,6 hexanediol, trimethyolpropane, pentaerythritol, phthalic anhydride, isophthalic acid, terephthalic acid, hexahydrophthalic anhydride, adipic or succinic acid, azelaic acid and dimer fatty acid, toluene diisocyanate and diphenylmethane diisocyanate.

[0081] The polymer may be selected from one or more of polymethylmethacrylate (PMMA), polyacetal, polycarbonate, polyvinyl, polyacrylonitrile, polybutadiene, polystyrene, polyacrylate, polyethylene, polypropylene, epoxy polymers, unsaturated polyesters, polyurethanes, polycyclopentadiene, and copolymers thereof. Suitable polymers also include liquid rubbers such as silicones. In certain embodiments, the polymer composition comprises an elastomer, such as a synthetic or natural rubber, e.g., styrene-butadiene rubber (e.g., the polymer content of the polymer composition is an elastomer, such as a synthetic or natural rubber, e.g., styrene-butadiene rubber).

[0082] The polymers that may be used according to the invention are advantageously thermoplastic polymers. Thermoplastic polymers are those that soften under the action of heat and harden again on cooling to their original properties, i.e. the heating-cooling cycle is fully reversible. According to the conventional definition, thermoplastics are linear and branched linear chain organic polymers with molecular bonds. Examples of polymers that may be used according to the invention include, but are not limited to, polyethylene, such as linear low density polyethylene (LLDPE) and its medium density grades, high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), polyethylene terephthalate (PET), vinyl / polyvinyl chloride (PVC), polystyrene, polyamide polymers (e.g. nylon), polycarbonate, and mixtures thereof.

[0083] In certain embodiments, the polymer is a polyolefin (i.e., polyalkylene or polyalkene) polymer, such as polyethylene, polypropylene, polybutylene, or a copolymer of two or more of ethylene, propylene, and butylene monomers, such as an ethylene-propylene copolymer. In certain embodiments, the polymer is a mixture of two or more of polypropylene, polyethylene, and an ethylene-propylene copolymer, such as a mixture of polypropylene and polyethylene. In certain embodiments, the polymer comprises, consists essentially of, or consists of polypropylene or polyethylene or a mixture of polypropylene and polyethylene, hi certain embodiments, the polymer is polypropylene. In certain embodiments, the polymer is a polyamide polymer, for example an aliphatic polyamide polymer such as nylon. In certain embodiments, the polymer composition comprises a thermoplastic polyolefin polymer (such as polyethylene and / or polypropylene) and / or a thermoplastic polyamide polymer.

[0084] The polymer composition may further comprise one or more additives. The one or more additives may be selected from thickeners, emulsifiers, viscosity modifiers, softeners, plasticizers (such as polyethylene glycol), antioxidants (such as phenolic antioxidants), heat stabilizers, activators (such as zinc oxide), accelerators (such as 2-mercaptobenzothiazole (MBT), mercaptobenzothiazole disulfide (MBTS) or tetramethylthiuram disulfide (DTMT)), rubber processing oils (such as naphthenic oils), flame retardants (such as aluminum hydroxide), antibacterial agents, fungicides (such as propionic acid), hydrophobic agents (such as silicone oils), stearic acid or its salts (such as calcium stearate), sulfur, and / or thermal conductivity modifiers (such as graphite), or any combination thereof. The polymer composition may contain a total of about 5% by weight or less of such additives, e.g., about 4% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less. The presence of mica particles in the polymer composition may increase the impact strength of the polymer composition. The presence of mica particles in the polymer composition may increase, maintain or decrease the flexural modulus of the polymer composition. The exact impact strength and flexural modulus of the polymer composition may vary depending on the exact polymer used and any other components in the polymer composition.

[0085] The polymer composition may have an impact strength that is at least about 1.0% higher, e.g., at least about 5.0% higher, or at least about 10% higher, or at least about 11% higher, or at least about 14% higher, or at least about 20% higher, or at least about 30% higher, than the impact strength of an identical polymer composition except that it does not include the mica particles of the present invention. The polymer composition may have an impact strength that is up to about 100% higher, e.g., up to about 50% higher, or up to about 40% higher, or up to about 30% higher, or up to about 20% higher, or up to about 15% higher, than the impact strength of an identical polymer composition except that it does not include the mica particles of the present invention. The polymer composition may have an impact strength that is about 1.0% to about 100% higher, for example, about 1.0% to about 50% higher, or about 5% to about 50% higher, or about 5% to about 40% higher, or about 5% to about 15% higher, or about 10% to about 15% higher, or about 11% to about 15% higher, or about 14% to about 20% higher, or about 14% to about 15% higher, or about 30% to about 50% higher, or about 30% to about 40% higher, than the impact strength of an identical polymer composition except that it does not contain the mica particles of the present invention.

[0086] Impact strength may refer to Charpy impact strength or drop weight impact strength as described herein. Charpy impact strength (kJ / m 2 ) (unnotched flatwise and normal impact) can be measured on an 80 mm x 10 mm x 4 mm bar according to ISO 179-1 at -20°C. The drop weight index (J) at -21°C is 60 according to EN ISO 6603:2. * 60 * Measurements can be made on 3 mm plaques.

[0087] Flexural modulus may be measured on 80 mm x 10 mm x 4 mm bars according to ISO 178 (total length between specimen stages = 64 mm, test speed = 1 mm / sec, bending strain = maximum 0.3%, measured on at least 7 specimens).

[0088] The polymer composition has a capacitance of about 10 kJ / m 2 More than, for example, about 15 kJ / m 2 or more, or about 18 kJ / m2 or more, or about 20 kJ / m 2 or more, or about 21 kJ / m 2 or more, or about 25 kJ / m 2 The polymer composition may have a Charpy impact strength of about 50 kJ / m or more. 2 For example, about 40 kJ / m 2 Less than or about 30kJ / m 2 Less than or about 26kJ / m 2 or less than 22 kJ / m 2 The polymer composition may have a Charpy impact strength of about 10 kJ / m 2 ~about 50kJ / m 2 , for example, about 10 kJ / m 2 ~about 40kJ / m 2 , or about 10 kJ / m 2 ~about 30kJ / m 2 , or about 10 kJ / m 2 ~about 26kJ / m 2 , or about 10 kJ / m 2 ~Approx. 22kJ / m 2 , or about 15 kJ / m 2 ~about 50kJ / m 2 , or about 15 kJ / m 2 ~about 40kJ / m 2 , or about 15 kJ / m 2 ~about 30kJ / m 2 , or about 15 kJ / m 2 ~about 26kJ / m 2 , or about 15 kJ / m 2 ~Approx. 22kJ / m 2 , or about 18 kJ / m 2 ~about 50kJ / m 2 , or about 18 kJ / m 2 ~about 40kJ / m 2 , or about 18 kJ / m 2 ~about 30kJ / m 2 , or about 18 kJ / m 2 ~about 26kJ / m 2 , or about 18 kJ / m 2 ~Approx. 22kJ / m 2 , or about 20 kJ / m 2 ~about 50kJ / m 2 , or about 20 kJ / m 2 ~about 40kJ / m2 , or about 20 kJ / m 2 ~about 30kJ / m 2 , or about 20 kJ / m 2 ~about 26kJ / m 2 , or about 20 kJ / m 2 ~Approx. 22kJ / m 2 , or about 21 kJ / m 2 ~about 50kJ / m 2 , or about 21 kJ / m 2 ~about 40kJ / m 2 , or about 21 kJ / m 2 ~about 30kJ / m 2 , or about 21 kJ / m 2 ~about 26kJ / m 2 , or about 21 kJ / m 2 ~Approx. 22kJ / m 2 , or about 25 kJ / m 2 ~about 50kJ / m 2 , or about 25 kJ / m 2 ~about 40kJ / m 2 , or about 25 kJ / m 2 ~about 30kJ / m 2 The Charpy impact strength may be

[0089] Additionally or alternatively, the polymeric composition may have a flexural modulus of about 2000 MPa or more, e.g., about 2500 MPa or more, or about 2700 MPa or more, or about 3000 MPa or more, or about 3200 MPa or more. The polymeric composition may have a flexural modulus of about 7000 MPa or less, e.g., about 5000 MPa or less, or about 4000 MPa or less, or about 3500 MPa or less, or about 3300 MPa or less, or about 3250 MPa or less, or about 3100 MPa or less. The polymer composition may have a pressure of about 2000 MPa to about 7000 MPa, for example, about 2000 MPa to about 5000 MPa, or about 2000 MPa to about 4000 MPa, or about 2000 MPa to about 3500 MPa, or about 2000 MPa to about 3300 MPa, or about 2000 MPa to about 3250 MPa, or about 2500 MPa to about 7000 MPa, or about 2500 MPa to about 5000 MPa, or about 2500 MPa to about 4000 MPa, or about 2500 MPa to about 3500 MPa, or about 2500 MPa to about 3300 MPa, or about 2500 MPa to about 3250 MPa, about 2700 MPa to about 7000 MPa, or about 2700 MPa to about 5000 MPa, or about 2700 MPa to about 4000 MPa, or about 2700 MPa to about The flexural modulus may be 3500 MPa, or about 2700 MPa to about 3300 MPa, or about 2700 MPa to about 3250 MPa, or about 3000 MPa to about 7000 MPa, or about 3000 MPa to about 5000 MPa, or about 3000 MPa to about 4000 MPa, or about 3000 MPa to about 3500 MPa, or about 3000 MPa to about 3300 MPa, or about 3000 MPa to about 3250 MPa, or about 3200 MPa to about 7000 MPa, or about 3200 MPa to about 5000 MPa, or about 3200 MPa to about 4000 MPa, or about 3200 MPa to about 3500 MPa, or about 3200 MPa to about 3300 MPa, or about 3200 MPa to about 3250 MPa, or about 3000 MPa to about 3100 MPa.

[0090] An "identical polymer composition except that it does not contain the mica particles of the invention" can be, for example, a polymer composition in which the mica particles of the invention have been removed and not replaced by different mica particles. Alternatively, the mica particles of the invention may be removed and replaced (e.g., in the same amount) with mica particles not within the scope of the invention, e.g., commercially available mica particles such as WG333 mica. WG333 mica is a polymer composition that is similar to the one described in Sedigraph d 95 Approximately 18.4 μm; d by sedigraph 50 Approximately 5.5 μm; laser d 95 Approximately 87.8 μm; laser d 50 Approximately 32.9μm; BET specific surface area approximately 4.1m 2 3. / g; and a lamellarity of about 5.0.

[0091] Method for making a polymer composition A polymer composition can be prepared by combining a polymer or polymer precursor with the mica particles of the present invention and any other optional ingredients. When the mica particles (and any other optional ingredients) are combined with the polymer precursor, the resulting combination of the polymer precursor, the mica particles (and any other optional ingredients) can be cured. The polymer composition can be prepared by intimately mixing together its components (except the mica particles), in which case the mica particles can be suitably blended, e.g., dry blended, with the mixture of components and any desired additional components prior to processing to form the final polymer composite or article.

[0092] The polymer composition can be, for example, according to any embodiment disclosed herein. The preparation of the polymer composition of the present invention can be accomplished by any suitable mixing method known in the art, as will be readily apparent to those skilled in the art. Such methods include, for example, dry blending of the individual components or their precursors, and subsequent processing in a conventional manner. Certain of the components can be premixed, if desired, before being added to the compounded mixture.

[0093] In the case of thermoplastic polymer compositions, such processing may include melt mixing directly in an extruder to make articles from the composition, or premixing in a separate mixing device, or a dry blend of the individual components may be directly injection molded without premelt mixing. The polymer composition can be prepared by intimately mixing the components together, in which case the mica particles can be suitably dry blended with the polymer and any desired additional components before being treated as described above. Other filler compounds may be added and blended in during the mixing stage. To prepare the crosslinked or cured polymer composition, the blend of uncured components or their precursors, and, if desired, mica particles and any desired non-mica components, are contacted under suitable conditions of heat, pressure and / or light with an effective amount of any suitable crosslinker or curing system, according to the nature and amount of polymer used, to crosslink and / or cure the polymer. To prepare a polymeric composition in which the mica particles and any other desired ingredients are present in situ upon polymerization, a blend of monomers and any other desired polymer precursors, mica particles and any other ingredients are contacted under appropriate conditions of heat, pressure and / or light, according to the nature and amount of monomer used, to polymerize the monomers in situ with the mica particles and any other ingredients.

[0094] In one particular embodiment, the mica particles are dispersed by stirring in a mixture that includes a polymer (e.g., polypropylene) and, optionally, a hardener. The mixture may further include a release agent. The resulting dispersion can be degassed to remove entrapped air. The resulting dispersion can then be poured into a suitable mold and cured. Suitable curing temperatures range from 20 to 200°C, such as from 20 to 120°C, or such as from 60 to 90°C. The starting polymer mixture can further include a prepolymer (e.g., a propylene monomer). The prepolymer may or may not correspond to the starting polymer. The viscosity of the starting polymer or polymer / monomer solution, the amount of curing agent, release agent and mica particles can be varied according to the requirements of the final cured product. In general, the more mica particles added, the higher the viscosity of the dispersion. A dispersant can be added to reduce the viscosity of the dispersion. Alternatively, the amount of polymer in the starting solution can be reduced.

[0095] Suitable curing agents will be readily apparent to those skilled in the art and include organic peroxides, hydroperoxides and azo compounds. Examples of peroxide and hydroperoxide curing agents include dimethyldibutylperoxyhexane, benzyl peroxide, dicumyl peroxide, methyl ethyl ketone peroxide, lauryl peroxide, cyclohexanone peroxide, t-butyl perbenzoate, t-butyl hydroperoxide, t-butyl benzene hydroperoxide, cumene hydroperoxide and t-butyl peroctoate. The compounded composition may further include additional ingredients such as slip aids (eg, erucamide), processing aids (eg, Polybatch® AMF-705), mold release agents, and antioxidants.

[0096] Suitable release agents will be readily apparent to those skilled in the art and include fatty acids, as well as zinc, calcium, magnesium and lithium salts of fatty acids and organic phosphate esters. Specific examples are stearic acid, zinc stearate, calcium stearate, magnesium stearate, lithium stearate, calcium oleate, zinc palmitate. Typically, slip and processing aids and release agents are added in amounts less than about 5% by weight based on the weight of the masterbatch. The polymeric article can then be extruded, compression molded, or injection molded using conventional techniques known in the art, as will be readily apparent to those skilled in the art. Thus, as described below, the present invention also relates to articles formed from the polymeric compositions of the present invention. In certain embodiments, the polymer composition includes a colorant, if present, that is added during compounding of the polymer composition. The colorant may be added in the form of a masterbatch. Suitable colors are widely varied. In one particular embodiment, the mica particles are added to a twin screw extruder into which the unfilled polymer is fed and melted. The mica particles are fed into the extruder through a hopper, for example, via gravity feed, and are homogeneously blended with the polymer. The mixture exits the extruder and can be cooled. The mixture can then be further compression molded or injection molded into a useful shape, for example.

[0097] The above method may include compounding and extrusion. Compounding may be performed using a twin screw compounder, such as a Clextral BC21 double screw extruder or a Leistritz ZSE 18 twin screw extruder or a Baker Perkins 25mm twin screw compounder. The polymer, mica particles and any additional ingredients may be premixed and fed from a single hopper. The resulting melt may be cooled, for example in a water bath, and then pelletized. Test specimens, such as Charpy bars or tensile dumbbells, may be injection molded or compression molded or cast or blown into a film. The screw temperature can be between about 100°C and about 300°C, for example, between about 150°C and about 280°C, for example, between about 180°C and about 250°C, or between about 210 and 250°C.

[0098] The screw speed can be between about 100 and 1200 rpm, for example, between about 100 and 1000 rpm, for example, between about 200 and 800 rpm, for example, between about 250 and 650 rpm, for example, between about 200 and 400 rpm, or between about 300 and 600 rpm, or between about 400 and 600 rpm, or between about 500 and 700 rpm. In certain embodiments, the screw speed is about 300 rpm. In other embodiments, the screw speed is about 400 rpm. In other embodiments, the screw speed is about 500 rpm. In other embodiments, the screw speed is about 600 rpm. Suitable injection molding equipment includes, for example, a Billion 50T Proxima press. The polymer composition may be dried prior to molding. Drying may be performed at any suitable temperature, for example, about 60°C, for a suitable period of time, for example, about 1 hour to 20 hours, for example, about 2 to 18 hours, or about 1 to 3 hours, or about 4 to 8 hours, or about 12 to 18 hours. The temperature during drying may be kept constant or may be varied. In certain embodiments, the temperature during drying is between about 70 and 120°C, for example, between about 80 and 100°C, for example, about 90°C. Molding is generally carried out at a temperature at which the polymer composition is fluid. For example, the molding temperature can be between about 100 and 300° C., for example, between about 200 and 300° C., or between about 240 and about 280° C. After molding, the molded piece is cooled and hardened.

[0099] Other suitable processing techniques include gas-assisted injection molding, calendaring, vacuum forming, thermoforming, blow molding, drawing, spinning, film casting, lamination, or any combination thereof. Any suitable equipment may be used, as will be apparent to one skilled in the art. The polymer composition can be processed in any suitable manner as described herein to form or incorporate into an article (e.g., an article of manufacture). There are a wide variety of articles that can be formed from the polymer composition. Examples include automobile body parts and panels, such as hoods, fender parts, side mirror casings, doors (front and / or rear), tailgates, and bumpers (front and / or rear). In some examples, the polymer composition is not provided in the form of a film. For example, the article is not a film and / or the article may not incorporate the polymer composition as a film or film-like coating. In some examples, the article is not a coated paper.

[0100] Use of mica particles The mica particles can be used in a polymer composition. For example, the mica particles can be used to increase the impact strength (e.g., the Charpy impact strength or drop impact strength as described above) of a polymer composition into which the mica particles are incorporated. The polymer composition can be according to any embodiment described herein. The mica particles may increase the impact strength of the polymer composition compared to the same polymer composition in the absence of the mica particles of the present invention. The mica particles may increase the impact strength of the polymer composition compared to the same polymer composition without any mica particles. Alternatively, the mica particles may increase the impact strength of the polymer composition compared to a polymer composition that includes an equivalent amount of alternative mica particles not according to the present invention.

[0101] The polymer composition can be processed in any suitable manner as described herein to form or incorporate into an article of manufacture. There are a wide variety of articles of manufacture that can be formed from the polymer composition. Examples include automobile body parts and panels, such as hoods, fender parts, side mirror casings, doors (front and / or rear), tailgates, and bumpers (front and / or rear). In some examples, the polymer composition is not provided in the form of a film. For example, the article is not a film, and / or the article may not incorporate the polymer composition as a film or film-like coating. In some examples, the article is not a coated paper.

[0102] It will be understood that the present invention is not limited to the above-described embodiments, and various modifications and improvements can be made without departing from the concepts described herein. Any of the features may be employed separately or in combination with any other feature, except where mutually exclusive, and the present disclosure extends to and includes all combinations and subcombinations of one or more features described herein.

[0103] For the avoidance of doubt, this application is directed to the subject matter described in the following numbered paragraphs: 1.(a) Approx. 4.5m 2 / g or greater BET specific surface area; and (b) mica particles having a lamellarity index of about 2.5 or greater. 2. (a) A laser cut of about 150 μm or less, for example, about 5 μm to about 150 μm, or about 40 μm to about 130 μm. 95 and (b) a sedigraph d of about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm. 95 2. The mica particles of paragraph 1, having one or both of the following: 3. (A) (a) BET specific surface area is approximately 4.5 m 2 / g~about 50m 2 / g, for example, about 5.0m 2 / g ~ approx. 12m 2 / g; and / or (b) a lamellarity index of from about 2.5 to about 6.5, e.g., from about 4.0 to about 5.7; or (B) (a) BET specific surface area is approximately 5.0 m 2 / g~about 50m 2 / g, for example, about 5.1m 2 / g~about 50m 2 / g; and / or (b) a lamellarity index of about 3.0 or more, for example, about 3.1 or more; 3. Mica particles according to paragraph 1 or 2. 4. (a) Laser d of about 40 μm or less, for example, about 3 μm to about 40 μm, or about 20 μm to about 40 μm 50 (b) a sedigraph d of about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm; 50 (c) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 88; and / or (d) a PANACEA shape factor of about 100 to about 250, e.g., from about 140 to about 180.

[0104] 5. The mica particles of any of paragraphs 1 to 4, comprising about 90% by weight or more of muscovite. 6. A method of preparing mica particles according to any of paragraphs 1-5, comprising classifying a ground mica material, such as a wet-ground mica material. 7. The method of paragraph 6, comprising: (a) classifying the ground mica material using an air classifier operated at a peripheral speed of about 25 m / sec or greater, e.g., from about 25 m / sec to about 100 m / sec; or (b) classifying the ground mica material by sieving. 8. The method of paragraph 6 or paragraph 7, further comprising grinding the mica feed material to produce a ground mica material prior to classification, the grinding optionally being wet grinding.

[0105] 9. Crushed mica material is (a) approximately 5.0 m 2 / g, e.g., about 1.0 m 2 / g~approx. 4.9m 2 (b) a BET specific surface area of ​​about 10 μm to about 100 μm, for example, about 15 μm to about 50 μm, or about 15 μm to about 30 μm, measured by sedigraph 95 (c) a sedigraph d of about 5 μm to about 50 μm, e.g., about 5 μm to about 25 μm, or about 5 μm to about 20 μm; 75 (d) a d by sedigraph of about 1 μm to about 20 μm, for example, about 1 μm to about 15 μm, or about 1 μm to about 10 μm; 50 (e) a sedigraph d of about 1 μm to about 10 μm, for example, about 1 μm to about 6 μm, or about 1 μm to about 4 μm; 25 (f) a laser d of about 30 μm to about 300 μm, for example, about 30 μm to about 150 μm, or about 70 μm to about 100 μm; 95 (g) a laser d of about 20 μm to about 100 μm, for example, about 30 μm to about 90 μm, or about 40 μm to about 70 μm; 75 (h) a laser d of about 10 μm to about 60 μm, for example, about 10 μm to about 50 μm, or about 20 μm to about 40 μm; 50 (i) a laser d of about 5 μm to about 50 μm, for example, about 10 μm to about 40 μm, or about 10 μm to about 30 μm; 25 (j) a lamellarity index of from about 2.5 to about 7.0, e.g., from about 3.5 to about 6.5; (k) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 85; and / or (l) a shape factor of about 100 or greater.

[0106] 10. (a) may contain about 5% by weight or more, e.g., about 5% by weight to about 50% by weight, or about 10% by weight to about 40% by weight, of mica particles; (b) may contain a thermoplastic polymer, e.g., a thermoplastic polyalkylene polymer such as polypropylene; (c) may have a flexural modulus of about 2000 MPa to about 7000 MPa, e.g., about 2500 MPa to about 3400 MPa, or about 2700 MPa to about 3250 MPa; and / or (d) may have a flexural modulus of about 10 kJ / m 2 More than, for example, about 20 kJ / m 2 or more, or about 25 kJ / m 2 6. A polymer composition comprising mica particles according to any one of paragraphs 1 to 5, which may have an impact strength of at least 11. A method of making a polymer composition according to paragraph 10, comprising combining a polymer or a polymer precursor with mica particles according to any of paragraphs 1-5. 12. An article formed from the polymer composition of paragraph 10. 13. Use of mica particles according to any of paragraphs 1 to 5 in a polymer composition to increase the impact strength of the polymer composition compared to a polymer composition containing an equivalent amount of mica particles not according to paragraph 1. 14. A method for increasing the impact strength of a polymer composition compared to a reference polymer composition containing a reference amount of mica particles not described in paragraph 1, the method comprising the step of adding to the polymer composition the mica particles described in any of paragraphs 1 to 5 in the reference amount.

[0107] 15. The use according to paragraph 13 or the method according to paragraph 14, wherein the polymer composition is (a) a thermoplastic polymer composition comprising a thermoplastic polymer, e.g. a thermoplastic polyolefin polymer such as polyethylene or polypropylene, or a thermoplastic polyamide polymer; and / or (b) about 5% by weight or more, e.g., about 5% by weight to about 50% by weight, or about 10% by weight to about 40% by weight, of mica particles. EXAMPLES

[0108] Example 1 Four different inventive mica particles (A, B, C and D) were prepared by classifying two different wet-milled mica materials, Mica 1 and Mica 2. Mica 1 is a commercially available wet-milled mica (WG333, available from Imerys Performance Minerals) with the properties summarized in Table 1. Mica 2 is a wet-milled mica prepared using a pan mill and with the properties summarized in Table 1. Both Mica 1 and Mica 2 contain 93% muscovite by mass as determined by X-ray diffraction using a Bruker D8 Advance A25 by the method described above.

[0109] [Table 1]

[0110] Mica 1 was used to prepare inventive mica particles A to C; mica 2 was used to prepare inventive mica particle D. To prepare the inventive mica particles A, B and C, the wet-milled mica 1 was classified into a coarse fraction and a fine fraction (the fine fraction being the mica particles of the present invention) using a NETZSCH Ecutec BORA 50 turbo air classifier (available from NETZSCH-Feinmahltechnik GmbH, Germany). The NETZSCH Ecutec BORA 50 turbo air classifier has a maximum air flow rate of 1800 m 3 The system operating conditions used to prepare each of the mica particles A to C of the present invention are shown in Table 2.

[0111] [Table 2]

[0112] To prepare the inventive mica particles D, the wet-milled mica 2 was top-cut (d 95 ) to about 105 μm. The D0407.2 sieve shaker ensures elliptical sieving in a horizontal plane by adjustable vibrations generated by electromagnets. The shaker includes a controller for switching on the device, programming the sieving time, programming the amplitude of the mechanical vibration, selecting the continuous mode of sieving or the discontinuous mode of sieving, and adjusting the duration of the vibration cycle between two different pause times (in the case of the discontinuous mode of sieving). The inventive mica particles D were prepared by sieving the wet-milled mica 2 using a sieve with a sieve opening (i.e. diameter) of 125 μm.

[0113] Particle size distribution (by both sedigraph and Malvern laser scattering), lamellarity index, BET specific surface area and Minolta Y whiteness were analyzed for each of the mica particles A to D of the present invention. Methods for obtaining particle size distribution and BET specific surface area are shown in more detail in Examples 2, 3 and 4. Minolta Y whiteness was measured using a Konica Minolta CM-3700d spectrophotometer / colorimeter by the methods described above. The results are shown in Table 3.

[0114] [Table 3]

[0115] Four filled polymer compositions A-D were prepared using inventive mica particles A-D by the following procedure: - The compound was extruded in a twin screw extruder with a diameter of 18 mm and L / D 48. - 1 extrusion run - Extruder temperature: 240°C (first of three heating zones), then 220°C - Screw speed: 500 rpm - Output: 10kg / hour - Vacuum pump: 800mbar - 20% by weight of mica particles was introduced into side feeder 2 (150 rpm) - The polymer was polypropylene (56M10 Sabic®) - 0.6% by weight of stabilizer added (1 / 6 Irganox® 1010 + 1 / 6 Irganox® PS802 + 1 / 6 calcium stearate + 1 / 2 Luzenac® A20 talc) Reference polymer compositions 1 and 2 were prepared by the same procedure using Mica 1 and Mica 2, respectively.

[0116] The adjusted flexural modulus and Charpy unnotched impact strength of the polymeric compositions were determined by the methods described herein (flexural modulus according to ISO standard 178 and Charpy unnotched flatwise and normal impact according to ISO standard 179-1). An adjusted value of the flexural modulus was obtained by first checking the actual load by ashing the compound and then, secondly, recalculating the flexural modulus at the same load (here 20% by weight) and taking into account the flexural modulus of the neat polymer. The flexural modulus versus mica load is linear. The results are shown in Table 4.

[0117] [Table 4] The flexural modulus and Charpy impact strength for polymer compositions A to C, and reference polymer composition 1, are plotted as a function of classifier speed in FIG. Surprisingly, it has been found that the inventive mica particles A, B and C improve the impact strength of the polymer composition. Surprisingly, it has also been found that the addition of the inventive mica particles A, B and D does not significantly affect the flexural modulus of the polymer composition.

[0118] Example 2 How to determine particle size distribution (by sedigraph) Particle size distribution (PSD) was determined using a Sedigraph III from Micromeritics Instruments. A dispersion solution was prepared by weighing (using an analytical balance) 250 mg of Calgon (sodium metaphosphate) into a beaker containing 1 liter of demineralized water and dissolving it completely (by mechanical stirring). This step took 45-60 minutes. Then 1 ml of Triton X (polyethylene glycol octylphenyl ether) was added to the solution with stirring for at least 10 minutes. Calgon and Triton X are wetting and dispersing agents.

[0119] A sample of mica particles was prepared for sedigraph analysis by combining 4.8 g of the mica particle sample with 80 ml of the dispersion solution. First, the mica particles were combined with a few drops of the 80 ml dispersion solution in a beaker, and the mixture was mixed using a manual stirrer until a paste consistency was achieved. The remainder of the 80 ml dispersion solution was then added to the beaker. The beaker was placed in an ultrasonic bath for 30 seconds to remove any air bubbles. Sedigraph analysis was then performed on the dispersed samples using Sedigraph III with the following settings: - Dispersion solution viscosity: 0.7523mPa.sec - Dispersion solution density: 0.9948g / cm 3 - Sample density: 2.78g / cm for talc powder 3 - Maximum diameter: 52μm - Minimum diameter: 0.4μm - Mode: Fast - Air bubble detection: coarse Results were considered valid if the following criteria were met: - The Reynolds number was less than 0.3; - Baseline (dispersion solution only) was between 125-130 kcounts / sec; - Full scale (sample suspension) was between 95 and 105 kcounts / sec; and - The difference between base / full scale was less than 35kcounts / sec.

[0120] Example 3 How to determine particle size distribution (by laser diffraction) Particle size distribution (PSD) was determined using a Mastersizer 2000 from Malvern instruments. A sample of mica particles was prepared for laser diffraction analysis. The required amount of mica particles was weighed into a 50 ml beaker. 50 For mica particles with a diameter of less than 10 μm (by sedigraph), amounts of talc particles between 1 g and 2 g were used. 50 For mica particles having a particle size of between 0.2 g and 0.5 g, amounts of mica particles were used.

[0121] Coarse mica particles (10 μm or larger, d by sedigraph 50 For the samples with 0.1% ethanol, the samples were combined with absolute ethanol (99.5%) wetting agent. In particular, the powder samples were well distributed at the bottom of the beaker. A few drops of ethanol were added to the powder and mixed using a manual stirrer until a paste consistency was achieved. Between 2ml and 2.5ml of ethanol was added to the beaker using a 3ml disposable pipette and the suspension was mixed with a manual stirrer. The beaker was placed in an ultrasonic bath for 30 seconds to remove any air bubbles.

[0122] Laser diffraction analysis was then performed on the samples using a Mastersizer 2000 with the following settings: - Sampler: Hydro 2000G - Measurement theory: Mie 1.589-0.01 (i.e., talc refractive index) - Water refractive index: 1.33 - Measurement range: 0.02~2000μm - Result calculation model: Standard analysis - Number of snaps: Measurement duration: 8 seconds Number of snaps per measurement: 8000 snaps Background noise time: 8000 snaps Background Noise Snap: 8 seconds - Obscuration limit: Low: 5% High: 20% - Background noise alarm (value of background noise for detector number 1): less than 150 units - Sampler measurement parameters: Pump: 1800 rpm Mixing: 700 rpm Ultrasonic: 100%

[0123] The analysis was carried out as follows: First, it was confirmed that the lower absorbance limit was set to 5% and the upper absorbance limit was set to 20%. The stirrer speed was set to 700 rpm, the pump to 1800 rpm, and the ultrasound to 100%. The laser intensity was checked. If the laser intensity was less than 77.5%, it was confirmed that the measurement cell was clean; there were no air bubbles; and there was no condensation on the measurement cell window. The background noise was measured and the laser (red and blue) intensities were measured. After adjusting the laser position, the laser intensity and the background noise intensity (which should decrease continuously from detector number 1 to detector number 51) were checked. Using a disposable pipette, a 2 ml sample was taken from the beaker containing the mica particle suspension and added drop by drop to the measurement cell until the required absorbance was obtained: d above 10 μm (by sedigraph). 50 For products with absorbance between 15 and 20%, measurements were used; for products with absorbance between 15 and 20%, measurements with absorbance between 15 and 20% were used; for products ... 50 For products with an absorbance between 5 and 12% a measurement with an absorbance between 5 and 12% was used. The suspension was homogenized in the cell for approximately 60 seconds.

[0124] The software directly tracks the PSD curve, expressed as a percentage of fines. The validity of the curve is controlled by the value of the weighted residual, the signal-to-noise ratio and the distribution of the light intensity of the background noise as a function of the detector. The obtained results are valid as long as the weighted residual is less than 1.5% and there are no anomalies in the curve. The intensity of the measured signal and the background noise of the detectors can be examined using the data report tab. The intensity of the background noise should steadily decrease from detector number 1 to detector number 51. The intensity of the measured signal should be significantly greater than the intensity of the background noise. The intensity of the background noise depends on the cleanliness of the cell. The intensity of the signal depends mainly on the sample concentration (i.e., absorbance). It has been found that if the pressure is too high or the water temperature is too low, some problems may occur in the measuring cell, such as air bubbles or condensation. To avoid such problems, it is recommended to install a filtration system to improve the water cleanliness and reduce the pressure, and to install a mixer tap to adjust the water temperature to between 20-25°C before it is fed into the tank. It is also recommended not to turn off the optical bench (laser).

[0125] Example 4 How to Determine BET Specific Surface Area The BET specific surface area was determined using a method based on standard NF X 11-621 entitled "Determination of the mass area (specific surface) of powders by gas adsorption - BET method - Volumetric measurement by nitrogen adsorption at low temperature" (Determination of the mass area (specific surface) of powders by gas adsorption - BET method - Volumetric measurement by nitrogen adsorption at low temperature). The method used a Micromeritics measurement instrument (available from Micromeritics Instrument Corp., USA) equipped with a vacuum pump, a VacPrep 061 degassing section, a Tristar 3000S measurement section and sample holder, a Mettler AG204 scale with an accuracy of 0.1 mg, a Dewar flask, nitrogen adsorption gas and helium carrier gas.

[0126] The sample was weighed (to an accuracy of 0.1 mg) near the empty sample holder and its mass M0 was recorded in g. The pre-homogenized powder sample was then introduced into the sample holder using a funnel. Sufficient space (dead volume) was left between the sample and the top of the sample holder to allow free circulation of gas. The sample holder was placed in one of the degassing stations and degassed at 250 °C under a primary vacuum of 10 Pa for about 20 min. After degassing, a sufficient amount of nitrogen was added to the sample holder to avoid introducing air during the transfer of the sample holder from the degassing station to the measurement station.

[0127] The sample holder was then attached to the measurement station and a Dewar flask containing liquid nitrogen was placed around the sample holder. The device control software was used to start the BET measurement. The device then automatically performed the following operations: - Vacuum removal of the nitrogen introduced for the transfer of the sample holder; - Leak test; - Addition of helium carrier gas; - Determination of dead volume at ambient temperature; - Determination of cold dead volume using liquid nitrogen; - Helium vacuum removal; - Leak test; - Addition of nitrogen at 950mmHg and measurement of saturation pressure; and - Obtaining analytical values.

[0128] The data acquisition and processing software of the instrument plotted a BET line converted from the five measured adsorption points. The Dewar flask and then the sample holder were removed. The apparatus was returned to ambient temperature, and then the sample was weighed again (to an accuracy of 0.1 mg) adjacent to the sample holder and the mass was recorded as M2 (g). The mass of the test portion of the sample, M, was calculated according to the following (g): M=M2-M0

[0129] The value M was then introduced into a software calculation program to calculate the BET specific surface area (m 2 / g) was calculated automatically.

Claims

1. (a) Approximately 4.5m 2 / g or more BET specific surface area; and (b) a lamellarity index of about 2.5 or greater The mica particles have the following structure:

2. (a) A laser-induced d of about 150 μm or less, for example, from about 5 μm to about 150 μm, or from about 40 μm to about 130 μm. 95 and (b) about 30 μm or less, e.g., about 2 μm to about 30 μm, or about 10 μm to about 30 μm, according to sedigraph 95 2. The mica particles of claim 1, wherein said mica particles have one or both of the following properties:

3. (a) BET specific surface area of ​​about 4.5 m 2 / g ~ approx. 50m 2 / g, for example, about 5.0 m 2 / g ~ approx. 12m 2 / g; and / or (b) the lamellarity index is from about 2.5 to about 6.5, e.g., from about 4.0 to about 5.7; 2. The mica particles according to claim 1.

4. (a) A laser-induced d of about 40 μm or less, for example, about 3 μm to about 40 μm, or about 20 μm to about 40 μm. 50 ; (b) about 6 μm or less, e.g., about 0.5 μm to about 6 μm, or about 3.5 μm to about 6 μm, according to sedigraph 50 ; (c) a Minolta Y brightness of about 70 or greater, e.g., from about 70 to about 88; and / or (d) a PANACEA shape factor of about 100 to about 250, e.g., about 140 to about 180; 2. The mica particles of claim 1, having

5. 10. The mica particles of claim 1 comprising at least about 90% by weight muscovite.

6. 13. A method of preparing the mica particles of claim 1, comprising classifying a ground mica material, such as a wet-ground mica material.

7. 7. The method of claim 6, comprising: (a) classifying the pulverized mica material using an air classifier operated at a peripheral speed of about 25 m / sec or greater, e.g., from about 25 m / sec to about 100 m / sec; or (b) classifying the pulverized mica material by sieving.

8. 7. The method of claim 6, further comprising the step of grinding the mica feed material prior to classification to produce a ground mica material, the grinding optionally being wet grinding.

9. The crushed mica material is (a) Approximately 5.0m 2 / g, for example, about 1.0 m 2 / g to about 4.9 m 2 BET specific surface area in g; (b) a d by sedigraph of about 10 μm to about 100 μm, for example, about 15 μm to about 50 μm, or about 15 μm to about 30 μm 95 ; (c) a d by sedigraph of about 5 μm to about 50 μm, for example, about 5 μm to about 25 μm, or about 5 μm to about 20 μm 75 ; (d) a d by sedigraph of about 1 μm to about 20 μm, for example, about 1 μm to about 15 μm, or about 1 μm to about 10 μm 50 ; (e) a d by sedigraph of about 1 μm to about 10 μm, for example, about 1 μm to about 6 μm, or about 1 μm to about 4 μm 25 ; (f) a laser-induced d 95 ; (g) a laser dT of about 20 μm to about 100 μm, for example, about 30 μm to about 90 μm, or about 40 μm to about 70 μm; 75 ; (h) a laser dT of about 10 μm to about 60 μm, for example, about 10 μm to about 50 μm, or about 20 μm to about 40 μm; 50 ; (i) A laser d of about 5 μm to about 50 μm, e.g., about 10 μm to about 40 μm, or about 10 μm to about 30 μm. 25 ; (j) a Lamellarity Index of from about 2.5 to about 7.0, e.g., from about 3.5 to about 6.5; (k) a Minolta Y whiteness of about 70 or greater, e.g., from about 70 to about 85; and / or (l) a shape factor of about 100 or greater The method according to any one of claims 6 to 8, comprising:

10. (a) may include about 5% or more, e.g., about 5% to about 50%, or about 10% to about 40%, by weight, of mica particles; (b) a thermoplastic polymer, which may include a thermoplastic polyalkylene polymer such as polypropylene; (c) a flexural modulus of about 2000 MPa to about 7000 MPa, e.g., about 2500 MPa to about 3400 MPa, or about 2700 MPa to about 3250 MPa; and / or (d) Approximately 10kJ / m 2 More than, for example, about 20 kJ / m 2 or more, or about 25 kJ / m 2 or more impact strength, A polymer composition comprising the mica particles of claim 1.

11. 11. A method of making the polymer composition of claim 10, comprising combining a polymer or a polymer precursor with the mica particles of claim 1.

12. 11. An article formed from the polymer composition of claim 10.

13. 13. Use of the mica particles according to claim 1 in a polymer composition to increase the impact strength of the polymer composition compared to a polymer composition containing an equivalent amount of mica particles not according to claim 1.

14. 13. A method for increasing the impact strength of a polymer composition compared to a reference polymer composition containing a reference amount of mica particles not described in claim 1, comprising the step of adding the mica particles described in claim 1 in the reference amount to the polymer composition.

15. The polymer composition comprises: (a) a thermoplastic polymer composition comprising a thermoplastic polymer, e.g., a thermoplastic polyolefin polymer such as polyethylene or polypropylene, or a thermoplastic polyamide polymer; and / or (b) about 5% by weight or more, e.g., about 5% by weight to about 50% by weight, or about 10% by weight to about 40% by weight, of mica particles; 15. The use according to claim 13 or the method according to claim 14.

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