Stable aluminosilicate aquasols having uniform size particles and their preparation

Claim 1

A stable aluminosilicate aquasol having uniform size particles ranging from 3 to 90 nanometers in diameter with a molar ratio of Si:Al of 1:1 to 19:1, said uniformity defined by particles having a maximum standard deviation of 0.37d where d is the weight average particle size diameter.

Claim 6

A method for the preparation of a stable amorphous aluminosilicate sol having uniform, spheroidal, discrete, colloidal particles in the range of 3 to 90 nanometers comprising (a) preparing a heel sol of discrete colloidal particles selected from the group consisting of sodium, potassium or ammonium aluminosilicate, silica and one or more refractory oxides selected from the group consisting of alumina, zirconia, lanthana, thoria, titania and rare earth oxides, said particles having a substantially uniform diameter within the range of 2 to about 85 nanometers, said aluminosilicate having a molar ratio of Si:Al of from 1:1 to 19:1, the initial concentration in the heel sol of sodium, potassium, ammonium aluminosilicate or refractory metal oxide being at least 0.2% by weight, with the particles stabilized against aggregation in the pH range 9 to 12; (b) adding to said heel, separately but simultaneously, two feed solutions, one being a solution of sodium or potassium silicate having from one to 36 grams of silica per 100 cc, or a sol of silicic acid containing from 1 to 12% silica, the other being a solution of sodium or potassium aluminate containing from 1 to 15% alumina, said feed solutions being added in relative rates and proportions to maintain a constant molar ratio of Si:Al in the feed streams of from 1:1 to 19:1 with the rate of addition of silica not to exceed 10 grams of SiO 2 per 1000 square meters of total surface area of particles in the heel sol per hour; (c) maintaining the pH of the heel sol at a constant value between 9 and 12 by adding cation exchange resin in the hydrogen or ammonium form, maintaining the temperature of the heel sol at from 50° to 100° C. until the particles in the heel sol have attained an increase in diameter of at least 1 nanometer and a maximum size of 90 nanometers; and (d) filtering the sol from (c) to remove cation exchange resin and optionally concentrating the sol to a solids content of up to 60% by weight.

Claim 7

A method for the preparation of a stable amorphous aluminosilicate sol having uniform, spheroidal, discrete, colloidal particles in the range of 3 to 90 nanometers comprising (a) preparing a heel sol of discrete colloidal particles selected from the group consisting of sodium, potassium or ammonium aluminosilicate, silica and one or more refractory oxides selected from the group consisting of alumina, zirconia, lanthana, thoria, titania and rare earth oxides, said particles having a substantially uniform diameter within the range of 2 to about 85 nanometers, said aluminosilicate having a molar ratio of Si:Al of from 1:1 to 19:1, the initial concentration in the heel sol of sodium, potassium, ammonium aluminosilicate or refractory metal oxide being at least 0.2% by weight, with the particles stabilized against aggregation in the pH range 9 to 12; (b) adding to said heel, separately but simultaneously, two feed solutions, one being a solution of sodium or potassium silicate having from one to 36 grams of silica per 100 cc, or a sol of silicic acid containing from 1 to 12% silica, the other being a solution of sodium or potassium aluminate containing from 1 to 15% alumina, said feed solutions being added in relative rates and proportions to maintain a constant molar ratio of Si:Al in the feed streams of from 1:1 to 19:1 with the rate of addition of silica not to exceed 10 grams of SiO 2 per 1000 square meters of total surface area of particles in the heel sol per hour; (c) maintaining the pH of the heel sol at a constant value between 9 and 12 by adding cation exchange resin in the hydrogen or ammonium form, maintaining the temperature of the heel sol at from 50° to 100° C. until the particles in the heel sol have attained an increase in diameter of at least 1 nanometer and a maximum size of 90 nanometers; and (d) filtering the sol from (c) to remove cation exchange resin and optionally concentrating the sol to a solids content of up to 60% by weight.