Amcol International Corporation

Amcol Internatioanl Corporation

Semeon J Tsipursky

Gary W Beall

Anatoliy Sorokin

Anatoliy Goldman

Tie Lan

Don D Eisenhour

Gary W Beal

Ying Liang

Mark William Clarey

Katherine R Turk

James Edwards

Vasiliki Psihogios

Charles R Landis

Marek R Mosiewicz

Fernando Serrano

Steven J Engman

Robert Matthew Ferraro

Vladimir Dolinko

Elena I Vinokour

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 surface modifier selected from the group consisting of a compound having an alkyl radical containing at least 6 carbon atoms, a compound containing an aromatic ring, and mixtures thereof, said surface modifier including a matrix material-reactive functional group, to sorb or intercalate the intercalant surface modifier between adjacent platelets of the layered material. Sufficient intercalant surface modifier is sorbed between adjacent platelets to expand the adjacent platelets to at least about 10 &angst;, up to about 100 &angst;. 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.

Intercalates and exfoliates formed with long chain (C6&plus;) or aromatic matrix polymer-compatible monomeric, oligomeric or polymeric intercalant compounds, and composite materials containing same

Method of determining the composition of clay deposit

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 surface modifier selected from the group consisting of a compound having an alkyl radical containing at least 6 carbon atoms, a compound containing an aromatic ring, and mixtures thereof, said surface modifier including a matrix material-reactive functional group, to sorb or intercalate the intercalant surface modifier between adjacent platelets of the layered material. Sufficient intercalant surface modifier is sorbed between adjacent platelets to expand the adjacent platelets to at least about 10 .ANG., up to about 100 .ANG.. 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.

Intercalates and exfoliates formed with long chain (C6+) or aromatic

A hydrothermal reaction which dissolves the amorphous silica and the crystalline silica impurities contained in a recovered, naturally occurring montmorillonite clay, and subsequently converts the dissolved silicas into a dioctahedral and/or trioctahedil smectite clay. The dissolution of silica is accomplished by adjusting the pH of an aqueous slurry of the recovered clay to a value of about 8.5 to about 10.0, preferably about 9.0 to about 9.5, at a temperature of at least about 150.degree. C., preferably about 180.degree. C. to about 250.degree. C., more preferably about 190.degree. C. to about 235.degree. C. Dissolved silica reacts with stoichiometric amounts of aluminum and/or magnesium and/or sodium added to the slurry, while at a temperature of at least about 150.degree. C., preferably about 185.degree. C. to about 250.degree. C., and at a pressure of at least about 200 bars, to synthesize a dioctahedral smectite clay from the dissolved silica; or the dissolved silica reacts with stoichiometric amounts of lithium and/or magnesium and/or sodium added to the slurry, at the same conditions, to form a trioctahedral smectite clay.

Process for purifying clay by the hydrothermal conversion of silica

The present invention discloses intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer surface modifier including an alkyl radical having at least 6 carbon atoms and a polymerizable monomer, oligomer or polymer. The intercalant monomer surface modifier converts the interlayer region of the layered materials from hydrophilic to hydrophobic, therefore, polymerizable monomers, oligomers or polymers can be easily intercalated into the interlayer spacing. The co-presence of the intercalant monomer surface modifier and polymerizable monomer, oligomer or polymer provide an environment for more polymerizable monomers, oligomers or polymers to be intercalated into the interlayer spacing and the intercalates are readily exfoliated into polymer matrices to form nanocomposites. The nanocomposites (e.g., epoxy-clay) prepared from the intercalates demonstrated enhanced mechanical, thermal and chemical resistance compared with pristine polymer matrices.

Intercalates formed by co-intercalation of monomer, oligomer or polymer

A clay purification process, for removing impurities recovered with the clay, particularly a montmorillonite clay, includes the steps of separating the clay from rocks and other large non-clay impurities; dispersing the clay and smaller impurities in water, preferably at a concentration of at least about 4% by weight clay, based on the total weight of clay and water, more preferably about 6-10% by weight clay in water, to provide a clay slurry; passing the clay slurry through a series of hydrocyclones to remove the larger particles (impurities) while retaining clay particles having a size of about 100 microns or less, particularly about 80 microns or less; ion exchanging the clay to remove at least about 95% of the interlayer, multivalent (e.g., divalent and trivalent) cations in an ion exchange column, wherein the multivalent ions are replaced by monovalent cations, such as sodium, lithium and/or hydrogen; and then centrifuging the clay to remove a majority of the particles having a size in the range of about 0.5 .mu.m to about 100 .mu.m.

Method of manufacturing polymer-grade clay for use in nanocomposites

Intercalates formed by contacting the layer material, e.g., a phyllosilicate, with an intercalant to sorb or intercalate the between adjacent platelets of the layered material. Sufficient intercalant polymer is sorbed between adjacent platelets to expand the adjacent platelets at least about 5 .ANG. (as measured after water removal to 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. A monovalent, divalent and/or trivalent cation is added to the intercalating composition, or after intercalation for surprising increases in viscosity. 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 grade 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

Intercalates formed by contacting an activated layered material, e.g., an activated phyllosilicate, with an intercalant pesticide to intercalate an intercalant pesticide between adjacent platelets of the layered material is disclosed. Sufficient intercalant pesticide 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 to about 45 .ANG., so that, if desired, the intercalate can be exfoliated into individual platelets. The intercalate can be combined with an organic liquid to form a viscous composition for delivery of a pesticide compound. Alternatively, the intercalate can be exfoliated prior to combination with the organic liquid. The intercalated complex also can be admixed with solid particles to provide a granular, dust, or wettable powder pesticide composition.

Intercalates and exfoliates formed with organic pesticides compounds and

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer including an alkyl radical having at least 10 carbon atoms and having a dipole moment greater than the dipole moment of water, 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.

Intercalates and exfoliates formed with long chain (C.sub.10 +)

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.

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Lincolnwood, IL, United States of America

Semeon J Tsipursky