Amcol International Corporation

Hannah T Cruz

Tie Lan

Gary W Beall

Anthony S Tomlin

Fernando Serrano

Intercalated layered materials prepared by co-intercalation of an onium ion and MXD6 nylon between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The spacing of adjacent layers of the layered materials is expanded at least about 3 &angst;, preferably at least about 5 &angst;, usually preferably to a d-spacing of about 15-20 &angst;, e.g., 18 &angst; with the onium ion spacing/coupling agent. The intercalation of the MXD6 nylon polymer then increases the spacing of adjacent layers an additional at least 3 &angst;, e.g., to at least about 20 &angst;, preferably about 25 &angst; to about 30 &angst;, generally about 28 &angst;.

Intercalates formed by co-intercalation of onium ion spacing/coupling agents and monomer, oligomer or polymer MXD6 nylon intercalants and nanocomposites prepared with the intercalates

A phyllosilicate material is exfoliated by admixture of the phyllosilicate with water, and a solvent for a water-insoluble oligomer or polymer that is sorbed or electrostatically bonded to the inner surfaces of the phyllosilicate platelets after exfoliation of the phyllosilicate. Intercalation and exfoliation can be achieved via contact of the phyllosilicate with an organic solvent and water to electrostatically bond one or more polar moieties from the organic solvent to a metal cation on the platelet inner surfaces, so that after evaporation of the water used for intercalation of the organic solvent between phyllosilicate platelets, the platelets do not then collapse together, but remain exfoliated. After exfoliation of the phyllosilicate, the exfoliated platelets are contacted with a polymer/carrier composition that includes a water-insoluble polymer or water-insoluble oligomer, and a solvent for the water-insoluble polymer or oligomer. After exfoliating the phyllosilicate and prior to polymer contact, the individual phyllosilicate platelets are contacted with the polymer/carrier composition to sorb the water-insoluble polymer or water-insoluble oligomer onto one or both surfaces of the exfoliated phyllosilicate platelets and drive off the adhered solvent.

Exfoliated layered materials and nanocomposites comprising said exfoliated layered materials having water-insoluble oligomers or polymers adhered thereto

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Elk Grove Village, IL, United States of America

Hannah T Cruz