The University of Chicago

Uchicago Argonne, LLC

The United States of America As Represented by the United States

Arch Development Corporation

Argonne National Laboratory

David J Chaiko

R Mensah-Biney

Adam James Ellison

John P Kopasz

Suhas Niyogi

Argentina A Leyva

William A Mego

There are provided novel thermally stable surfactants for use with fillers in the preparation of polymer composites and nanocomposites. Typically, surfactants of the invention are urethanes, ureas or esters of thiocarbamic acid having a hydrocarbyl group of from 10 to 50 carbons and optionally including an ionizable or charged group (e.g., carboxyl group or quaternary amine). Thus, there are provided surfactants having Formula I: wherein the variables are as defined herein. Further provided are methods of making thermally stable surfactants and compositions, including composites and nanocomposites, using fillers coated with the surfactants.

Thermally stable surfactants and compositions and methods of use thereof

The present invention provides barrier films having reduced gas permeability for use in packaging and coating applications. The barrier films comprise an anisotropic liquid crystalline composite layer formed from phyllosilicate-polymer compositions. Phyllosilicate-polymer liquid crystalline compositions of the present invention can contain a high percentage of phyllosilicate while remaining transparent. Because of the ordering of the particles in the liquid crystalline composite, barrier films comprising liquid crystalline composites are particularly useful as barriers to gas transport.

Liquid crystalline composites containing phyllosilicates

The present invention provide methods for producing a low moisture organophyllosilicate composition using monomers, oligomers, or polymers to displace water associated with the organophyllosilicates in an aqueous organophyllosilicate slurry or filter cake. The invention additionally provides methods for producing organophyllosilicate nanocomposites from the concentrated organophyllosilicate compositions by dispersing the compositions in a polymer matrix.

Preparation of a concentrated organophyllosilicate and nanocomposite composition

Polymer-phyllosilicate nanocomposites that exhibit superior properties compared to the polymer alone, and methods-for producing these polymer-phyllosilicate nanocomposites, are provided. Polymeric surfactant compatabilizers are adsorbed onto the surface of hydrophilic or natural phyllosilicates to facilitate the dispersal and exfoliation of the phyllosilicate in a polymer matrix. Utilizing polymeric glycol based surfactants, polymeric dicarboxylic acids, polymeric diammonium surfactants, and polymeric diamine surfactants as compatabilizers facilitates natural phyllosilicate and hydrophilic organoclay dispersal in a polymer matrix to produce nanocomposites.

Polymer-phyllosilicate nanocomposites and their preparation

The present invention relates to methods for the preparation of clay/polymer nanocomposites. The methods include combining an organophilic clay and a polymer to form a nanocomposite, wherein the organophilic clay and the polymer each have a peak recrystallization temperature, and wherein the organophilic clay peak recrystallization temperature sufficiently matches the polymer peak recrystallization temperature such that the nanocomposite formed has less permeability to a gas than the polymer. Such nanocomposites exhibit 2, 5, 10, or even 100 fold or greater reductions in permeability to, e.g., oxygen, carbon dioxide, or both compared to the polymer. The invention also provides a method of preparing a nanocomposite that includes combining an amorphous organophilic clay and an amorphous polymer, each having a glass transition temperature, wherein the organophilic clay glass transition temperature sufficiently matches the polymer glass transition temperature such that the nanocomposite formed has less permeability to a gas than the polymer.

Polyolefin nanocomposites

The invention provides methods for making clay/wax nanocomposites and coatings and films of same with improved chemical resistance and gas barrier properties. The invention further provides methods for making and using emulsions of such clay/wax nanocomposites. Typically, an organophillic clay is combined with a wax or wax/polymer blend such that the cohesion energy of the clay matches that of the wax or wax/polymer blend. Suitable organophilic clays include mica and phyllosilicates that have been surface-treated with edge or edge and surface modifying agents. The resulting nanocomposites have applications as industrial coatings and in protective packaging.

Coatings and films derived from clay/wax nanocomposites

This invention provides phyllosilicates and polyfunctional dispersants which can be manipulated to selectively control the viscosity of phyllosilicate slurries. The polyfunctional dispersants used in the present invention, which include at least three functional groups, increase the dispersion and exfoliation of phyllosilicates in polymers and, when used in conjunction with phyllosilicate slurries, significantly reduce the viscosity of slurries having high concentrations of phyllosilicates. The functional groups of the polyfunctional dispersants are capable of associating with multivalent metal cations and low molecular weight organic polymers, which can be manipulated to substantially increase or decrease the viscosity of the slurry in a concentration dependent manner. The polyfunctional dispersants of the present invention can also impart desirable properties on the phyllosilicate dispersions including corrosion inhibition and enhanced exfoliation of the phyllosilicate platelets.

Polyfunctional dispersants for controlling viscosity of phyllosilicates

A method for preparing organoclays for use as rheological control agents and in the preparation of nanocomposites. Typically, the clay is dispersed in water, and a specific amount of polymeric hydrotrope, ranging from 0.1 to 15 weight percent relative to the weight of the clay, is adsorbed onto the clay surface. Quaternary amine exchange is also performed on the clay to modify the surface hydrophilic/lipophilic balance (HLB) of the clay.

Process for the preparation of organoclays

The present invention provides phyllosilicates edge modified with anionic surfactants, composite materials made from the edge modified phyllosilicates, and methods for making the same. In various embodiments the phyllosilicates are also surface-modified with hydrophilic lipophilic balance (HLB) modifying agents, polymeric hydrotropes, and antioxidants. The invention also provides blends of edge modified phyllosilicates and semicrystalline waxes. The composite materials are made by dispersing the edge modified phyllosilicates with polymers, particularly polyolefins and elastomers.

Composite materials with improved phyllosilicate dispersion

The present invention provides phyllosilicate-polymer compositions which are useful as liquid crystalline composites. Phyllosilicate-polymer liquid crystalline compositions of the present invention can contain a high percentage of phyllosilicate while at the same time be transparent. Because of the ordering of the particles liquid crystalline composite, liquid crystalline composites are particularly useful as barriers to gas transport.

A method for preparing organoclays from smectites for use as rheological control agents and in the preparation of nanocomposites. Typically, the clay is dispersed in water, and a substantially monomolecular layer of a water soluble polymer is applied to the surfaces of the clay. A surfactant is also applied to the clay to modify the surface hydrophilic/hydrophobic balance of the clay, and the organoclay is separated out for subsequent use.

An improved aqueous-based extraction method for the separation and recovery of ultra-fine mineral particles. The process operates within the pseudophase region of the conventional aqueous biphasic extraction system where a low-molecular-weight, water soluble polymer alone is used in combination with a salt and operates within the pseudo-biphase regime of the conventional aqueous biphasic extraction system. A combination of low molecular weight, mutually immiscible polymers are used with or without a salt. This method is especially suited for the purification of clays that are useful as rheological control agents and for the preparation of nanocomposites.

Pseudophasic extraction method for the separation of ultra-fine minerals

A process for preparing organoclays as thixotropic agents to control the rheology of water-based paints and other aqueous and polar-organic systems. The process relates to treating low-grade clay ores to achieve highly purified organoclays and/or to incorporate surface modifying agents onto the clay by adsorption and/or to produce highly dispersed organoclays without excessive grinding or high shear dispersion. The process involves the treatment of impure, or run-of-mine, clay using an aqueous biphasic extraction system to produce a highly dispersed clay, free of mineral impurities and with modified surface properties brought about by adsorption of the water-soluble polymers used in generating the aqueous biphasic extraction system. This invention purifies the clay to greater than 95%.

Process for preparing organoclays for aqueous and polar-organic systems

A method of separating ultra-fine particulates from an aqueous suspension such as a process stream or a waste stream. The method involves the addition of alkali silicate and an organic gelling agent to a volume of liquid, from the respective process or waste stream, to form a gel. The gel then undergoes syneresis to remove water and soluble salts from the gel containing the particulates, thus, forming a silica monolith. The silica monolith is then sintered to form a hard, nonporous waste form.

Method for the removal of ultrafine particulates from an aqueous

A method for separating water-miscible organic species from a process stream by aqueous biphasic extraction is provided. An aqueous biphase system is generated by contacting a process stream comprised of water, salt, and organic species with an aqueous polymer solution. The organic species transfer from the salt-rich phase to the polymer-rich phase, and the phases are separated. Next, the polymer is recovered from the loaded polymer phase by selectively extracting the polymer into an organic phase at an elevated temperature, while the organic species remain in a substantially salt-free aqueous solution. Alternatively, the polymer is recovered from the loaded polymer by a temperature induced phase separation (cloud point extraction), whereby the polymer and the organic species separate into two distinct solutions. The method for separating water-miscible organic species is applicable to the treatment of industrial wastewater streams, including the extraction and recovery of complexed metal ions from salt solutions, organic contaminants from mineral processing streams, and colorants from spent dye baths.

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Naperville, IL, United States of America

David J Chaiko