Amcol International Corporation

Anatoliy Goldman

Gary W Beall

Anatoliy Sorokin

Semeon J Tsipursky

Charles R Landis

Semeon Tsipsursky

Robert Matthew Ferraro

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer having a hydroxyl and/or an aromatic ring functionality to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 &angst; (as measured after water removal to a maximum of 5% by weight water), up to about 100 &angst; and preferably in the range of about 10-45 &angst;, so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to or after combination with the organic liquid or the matrix polymer.

Intercalates and exfoliates formed with hydroxyl-functional; polyhydroxyl-functional; and aromatic compounds; composite materials containing same and methods of modifying rheology therewith

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer ether and/or ester to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 &angst; (as measured after water removal to a maximum of 5% by weight water), up to about 100 &angst; and preferably in the range of about 10-45 &angst;, so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to combination with the organic liquid or the matrix polymer.

Intercalates and exfoliates formed with monomeric ethers and esters; composite materials containing same methods of modifying rheology therewith

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer having a hydroxyl and/or an aromatic ring functionality to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 .ANG. (as measured after water removal to a maximum of 5% by weight water), up to about 100 .ANG. and preferably in the range of about 10-45 .ANG., so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to or after combination with the organic liquid or the matrix polymer.

Intercalates and exfoliates formed with hydroxyl-functional;

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer amine and/or amide to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 .ANG. (as measured after water removal to a maximum of 5% by weight water), up to about 100 .ANG. and preferably in the range of about 10-45 .ANG., so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to combination with the organic liquid or the matrix polymer.

Intercalates and exfoliates formed with monomeric amines and amides:

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 a polymer to adsorb or intercalate the polymer between adjacent phyllosilicate platelets. Sufficient polymer is adsorbed between adjacent phyllosilicate platelets to expand the adjacent platelets to a spacing of at least about 5 .ANG., preferably at least about 10 .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.

Intercalates and exfoliates formed with oligomers and polymers and

Compositions and methods that include a wax, in an amount of about 20% to about 99.95% by weight, containing an intercalate, or exfoliate thereof, in an amount of about 0.05% to about 80% by weight of the composition formed by contacting a layered phyllosilicate with an oligomer and/or polymer to sorb or intercalate the intercalant polymer or mixtures of intercalant polymers between adjacent phyllosilicate platelets. Sufficient intercalant polymer is sorbed between adjacent phyllosilicate platelets to expand the spacing between adjacent platelets (interlayer spacing) to a distance of at least about 5 .ANG., preferably to at least about 10 .ANG. (as measured after water removal) and more preferably in the range of about 30-45 .ANG., so that the intercalate easily can be exfoliated, sometimes naturally, without shearing being necessary.

Compositions and methods for manufacturing waxes filled with

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer carbonyl-functional compound and/or a carboxylic acid-functional compound to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 .ANG. (as measured after water removal to a maximum of 5% by weight water), up to about 100 .ANG. and preferably in the range of about 10-45 .ANG., so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to combination with the organic liquid or the matrix polymer.

Intercalates and exfoliates formed with monomeric carbonyl-functional

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 50 .ANG. (as measured after water removal to a maximum of 5% by weight water), up to about 100 .ANG. and preferably in the range of about 10-45 .ANG., so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex is combined with an organic liquid into an unexpectedly viscous carrier material, for delivery of the carrier material, or for delivery of an active compound, e.g., a pharmaceutical, or cosmetic, or lubricant, e.g., food guide lubricants dissolved or dispersed in the carrier material. Alternatively, the intercalated complex can be exfoliated prior to combination with the organic liquid.

Viscous carrier compositions, including gels, formed with an organic

Nanocomposites are manufactured by combining a matrix polymer and exfoliated intercalates formed by contacting a phyllosilicate with a water-insoluble polymer to adsorb or intercalate the polymer between adjacent phyllosilicate platelets. Sufficient water-insoluble polymer is adsorbed between adjacent phyllosilicate 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 30-40 .ANG., so that the intercalate easily can be exfoliated, e.g., when mixed with a polymer melt, to provide a matrix polymer/platelet composite (nanocomposite) material--the platelets being exfoliated from the intercalate.

Exfoliated layered materials and nanocomposites comprising matrix

Intercalates formed by mixing the phyllosilicate with a polymer and a liquid carrier, and extruding the mixture through a die-opening to adsorb or intercalate the polymer between adjacent phyllosilicate platelets. Sufficient polymer is adsorbed between adjacent phyllosilicate platelets to expand the adjacent platelets to a spacing of at least about 10 .ANG. (as measured after water removal), up to about 55 .ANG. and preferably in the range of about 30-40 .ANG., so that the intercalate easily can be exfoliated into individual platelets by heating the polymer to its melting point, to provide a matrix polymer/platelet composite material.

Intercalates; exfoliates; process for manufacturing intercalates and

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.

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Palatine, IL, United States of America

Anatoliy Goldman