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AssigneeAMCOL International Corporation
InventorsSemeon Tsipursky, Gary W. Beall, Elena I. Vinokour
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Nanocomposites are manufactured by combining a host material, such as an organic solvent or a matrix polymer and exfoliated intercalates formed by contacting a phyllosilicate with an intercalant selected from the group consisting of (1) an N-alkenyl amide monomer and an allylic monomer; (2) an oligomer formed by copolymerizing an N-alkenyl amide monomer and an allylic monomer; (3) a polymer formed by copolymerizing an N-alkenyl amide monomer and an allylic monomer; and (4) mixtures thereof to adsorb or the intercalant between adjacent phyllosilicate platelets. Sufficient polymer is adsorbed between adjacent phyllosilicate platelets to expand the adjacent platelets to increase the spacing at least about 10 .ANG., preferably at least about 20 .ANG. (as measured after water removal), up to about 100 .ANG. and preferably in the range of about 30-40 .ANG., so that the intercalate easily can be exfoliated, e.g., when mixed with an organic solvent or a polymer melt, to provide a carrier material for drugs and the like, or to provide a matrix polymer/platelet composite (nanocomposite) material--the platelets being exfoliated from the intercalate.
A composite material comprising a host material 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 with an intercalant-containing composition, said composition having a concentration of said intercalant of at least about 2% by weight intercalant, to achieve sorption of the intercalant between adjacent spaced layers of the phyllosilicate to expand the spacing between a predominance of the adjacent phyllosilicate platelets a distance of at least about 10 .ANG., when measured after sorption of the intercalant, said intercalant selected from the group consisting of (1) an N-alkenyl amide monomer and an allylic monomer;
A method of manufacturing a composite material containing about 40% to about 99.95% by weight of a matrix thermoplastic or thermosetting 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 an intercalant intercalated between adjacent phyllosilicate platelets 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 a water content of at least about 4% by weight, with an intercalant to form an intercalating composition, thereby achieving sorption of the intercalant between adjacent spaced layers of the phyllosilicate to expand the spacing between a predominance of the adjacent phyllosilicate platelets at least about 10 .ANG., when measured after sorption of the polymer, and thereafter exfoliating the intercalate into a predominance of single platelets;
A composition comprising an intercalate, together with an organic solvent, said intercalate formed by contacting a layered material, having a moisture content of at least about 4% by weight, with an intercalant polymer to form an intercalating composition, said intercalate having a weight ratio of polymer to layered material of at least 1:20, to achieve sorption and complexing of the polymer between adjacent spaced layers 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 intercalant polymer and drying to a maximum of 5% by weight water;
A composition comprising an organic liquid selected from the group consisting of monohydric alcohols, polyhydric alcohols and mixtures thereof, in an amount of about 40% to about 99.95% by weight of the composition and about 0.05% to about 60% by weight of the composition of an intercalate, or exfoliate thereof, of a phyllosilicate material, said intercalate formed by contacting a phyllosilicate, having a water content of at least about 4% by weight, with an intercalant to form said intercalate having said intercalant sorbed between adjacent spaced layers of the phyllosilicate and complexed on platelet surfaces of said phyllosilicate to expand the spacing between a predominance of the adjacent phyllosilicate platelets at least about 10 .ANG., when measured after sorption of the polymer and drying of the intercalate to a maximum water content of 5% by weight, wherein said intercalant is selected from the group consisting of (1) an N-alkenyl amide monomer and an allylic monomer;
Dependencies are inferred from the claim text.