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AssigneeAMCOL International Corporation
InventorsGary W. Beall, Semeon Tsipsursky, Anatoliy Sorokin, Anatoliy Goldman
Estimating the term…
Exfoliated layered silicate material derived from intercalates formed by contacting the layer material, e.g., a phyllosilicate, with an intercalant polymer to sorb or intercalate the polymer between adjacent platelets of the layered material. Sufficient intercalant polymer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 10 .ANG. (as measured after water removal), up to about 100 .ANG. and preferably in the range of about 30-45 .ANG., so that the intercalate easily can be exfoliated, e.g., when mixed with a thermoplastic or thermosetting matrix polymer melt, to provide a matrix polymer/platelet nanocomposite material--the platelets being exfoliated from the intercalate.
An intercalate, capable of being exfoliated, formed by contacting a layered silicate material, having adjacent silicate platelets and having a moisture content of at least about 5% by weight, with a water-soluble intercalant polymer and water, without a coupling agent selected from the group consisting of onium ion and silane coupling agents, to form a mixture of said layered material in contact with an intercalate polymer composition, said intercalate polymer composition having a concentration of said polymer of at least about 2% by weight polymer, to achieve sorption of the water-soluble polymer between said adjacent silicate platelets of the layered silicate material to expand the spacing between a predominance of the adjacent platelets of said layered silicate material to at least about 10 .ANG., when measured after sorption of the water-soluble polymer.
A method of exfoliating a phyllosilicate comprising:
A composite material comprising a matrix polymer selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and mixtures thereof, in an amount of about 40% to about 99.95% by weight of the composite material, and about 0.05% to about 60% by weight exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalate formed by contacting a phyllosilicate, having adjacent phyllosilicate platelets and having a water content of at least about 7% by weight, with an intercalant polymer, and without a coupling agent selected from the group consisting of onium ion and silane coupling agents, to form an intercalate composition, thereby achieving sorption of the intercalant polymer between the adjacent platelets of the phyllosilicate to expand the spacing between a predominance of the adjacent phyllosilicate platelets to at least about 10 .ANG., when measured after sorption of the polymer, and thereafter exfoliating the intercalate into a predominance of single platelets.
A method of manufacturing a composite material containing about 10% to about 99.95% by weight of a matrix polymer selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and mixtures thereof, and about 0.05% to about 60% by weight of exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalated phyllosilicate having adjacent phyllosilicate platelets and having a water-soluble polymer intercalated between and electrostatically bonded to a phyllosilicate platelet comprising:
A method of exfoliating a phyllosilicate comprising:
An intercalate, capable of being exfoliated, formed by contacting a layered silicate material, having adjacent silicate platelets and having a moisture content of at least about 5% by weight, with polyvinylimine and water to form a mixture of said layered material in contact with an intercalate polymer composition, said intercalate polymer composition having a concentration of polyvinylimine of at least about 2% by weight polymer, to achieve sorption of the polyvinylimine between said adjacent silicate platelets of the layered silicate material to expand the spacing between a predominance of the adjacent platelets of said layered silicate material to at least about 10 .ANG., when measured after sorption of the polyvinylimine.
A method of exfoliating a phyllosilicate comprising:
A composite material comprising a matrix polymer selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and mixtures thereof, in an amount of about 40% to about 99.95% by weight of the composite material, and about 0.05% to about 60% by weight exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalate formed by contacting a phyllosilicate, having adjacent phyllosilicate platelets and having a water content of at least about 7% by weight, with an intercalant polymer composition comprising an intercalant polymer and water and wherein the concentration of said intercalant polymer in said intercalant composition is at least about 5% by weight, thereby achieving sorption of the intercalant polymer between the adjacent platelets of the phyllosilicate to expand the spacing between a predominance of the adjacent phyllosilicate platelets to at least about 10 .ANG., when measured after sorption of the polymer, and thereafter exfoliating the intercalate into a predominance of single platelets.
A method of manufacturing a composite material containing about 10% to about 99.95% by weight of a matrix polymer selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and mixtures thereof, and about 0.05% to about 60% by weight of exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalated phyllosilicate having adjacent phyllosilicate platelets and having a water-soluble polymer intercalated between and electrostatically bonded to a phyllosilicate platelet comprising:
Dependencies are inferred from the claim text.