Intercalates; exfoliates; process for manufacturing intercalates and exfoliates and composite materials containing same

A method of manufacturing an intercalated phyllosilicate, capable of being exfoliated into individual phyllosilicate platelets, said phyllosilicate having a polymer intercalated between adjacent phyllosilicate platelets comprising:

• extruding a mixture of a phyllosilicate;
• an intercalant polymer having a functionality selected from the group consisting of an aromatic ring;
• carbonyl;
• carboxyl;
• hydroxyl;
• amine;
• amide;
• ether and ester structures;
• and an aqueous liquid carrier through a die-opening, water being included in the mixture in an amount of at least about 20% by weight, based on the dry weight of the phyllosilicate, and said polymer present in the mixture in an amount of 16% to about 80% by weight, based on the dry weight of phyllosilicate to achieve intercalation of said polymer between said adjacent phyllosilicate platelets in an amount sufficient to space said adjacent phyllosilicate platelets to a distance of at least about 10 .ANG. without first reacting the phyllosilicate with a silane compound or onium ion compound.

A composite material comprising a matrix polymer 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 extruding a mixture of a phyllosilicate, an intercalant polymer having a functionality selected from the group consisting of an aromatic ring;

• carbonyl;
• carboxyl;
• hydroxyl;
• amine;
• amide;
• ether and ester structures, and an aqueous carrier, said aqueous carrier present in the mixture in an amount in the range of about 20% by weight to about 50% by weight, based on the dry weight of the phyllosilicate in the mixture and containing water in an amount of at least about 10% by weight, based on the dry weight of the phyllosilicate, said polymer present in an amount of at least about 16% by weight, based on the dry weight of phyllosilicate in the mixture, when the mixture is extruded, to achieve sorption of the intercalant polymer between adjacent spaced layers 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 water-soluble polymer without first reacting the phyllosilicate with a silane compound or onium ion compound.

A method of manufacturing a composite material containing about 40% to about 99.95% by weight of a thermoplastic or thermosetting matrix polymer, and about 0.05% to about 60% by weight of exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalated phyllosilicate having a polymer intercalated between adjacent phyllosilicate platelets comprising:

• mixing a phyllosilicate with an intercalant polymer having a functionality selected from the group consisting of an aromatic ring;
• carbonyl;
• carboxyl;
• hydroxyl;
• amine;
• amide;
• ether and ester structures and water, comprising at least about 20% by weight water and at least about 16% by weight intercalant polymer, based on the dry weight of the phyllosilicate, and extruding the mixture, to achieve intercalation of said polymer between said adjacent phyllosilicate platelets in an amount sufficient to space said adjacent phyllosilicate platelets to a distance of at least about 10 .ANG. without first reacting the phyllosilicate with a silane compound or onium ion compound;
• combining the intercalated platelets with said matrix polymer, and heating the matrix polymer sufficiently to provide for flow of said matrix polymer and exfoliation of said intercalated platelets;
• and
• dispersing said exfoliated platelets throughout said matrix polymer.