Amcol International Corporation

Steven J Engman

Gary W Beall

Fernando Serrano

Semeon J Tsipursky

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 +)

Nanocomposites are manufactured by combining an EVOH matrix polymer and exfoliated intercalates formed by contacting a phyllosilicate with a non-EVOH intercalant to adsorb or intercalate the intercalant between adjacent phyllosilicate platelets. Sufficient intercalant 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 the EVOH matrix polymer melt, to provide an EVOH matrix polymer/platelet composite (nanocomposite) material that does not degrade the EVOH matrix polymer.

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Skokie, IL, United States of America

Steven J Engman