University of California

Brian Peoples

Susannah L Scott

Cathleen M Yung

Rene' Rojas

Fumihiko Shimizu

Akio Tanna

Rene Rojas

A method for forming a nanocomposite by olefin polymerization in which at least one cation-exchanging layered load material, selected from the group consisting of cation-exchanging, layered inorganic silicates and cation-exchanging, layered compounds other than silicates, is treated with acid to disrupt its layered structure and is combined with a catalyst that becomes activated for olefin polymerization when in contact with the acid-treated filler. An olefin is contacted by the activated catalyst&#x2014;filler combination either (a) in the absence of an alkylaluminum co-catalyst or (b) with an alkylaluminum co-catalyst when the activatable catalyst is a polyalkylmetal compound, to form a nanocomposite containing polyolefin and the acid-treated filler. In a particular embodiment, sufficient filler is used to constitute at least 30 weight % of the nanocomposite to prepare a highly loaded nanocomposite masterbatch. A predetermined amount of one or more olefinic polymers can then be blended with the masterbatch to obtain a nanocomposite having a desired amount of loading. The filler is preferably clay, exemplified by montmorillonite. The catalyst is preferably a non-metallocene catalyst, most preferably a nickel complex bearing an &#x3b1;-iminocarboxamidato ligand.

Method for forming exfoliated clay-polyolefin nanocomposites

A method for forming polyolefin/clay composites by olefin polymerization which can be used as flame retardants in which at least one filler is combined with an early or late transition metal first catalyst component that becomes activated for olefin polymerization when in contact with the treated filler. An olefin is contacted by the activated catalyst-filler combination either (a) in the absence of an alkylaluminum second catalyst component or (b) in the presence an alkylaluminum second catalyst component when the first catalyst component is an early transition metal catalyst, whereby to form an clay-polyolefin composite incorporating platelets of said filler. The filler is preferably clay, exemplified by montmorillonite and chlorite. The first catalyst component is preferably a non-metallocene catalyst. A predetermined amount of one or more olefinic polymers can also be blended with a masterbatch to obtain a composite having a desired amount of loading.

Method for forming flame-retardant clay-polyolefin composites

Growing community of inventors

Goleta, CA, United States of America

Brian Peoples