Abstract: A method of leaching a copper bearing sulfide mineral slurry containing chalcopyrite is described. The method comprises the steps of providing a slurry having chalcopyrite particles therein, exposing the slurry to an acidic leach solution, and chemically leaching copper from the slurry into the acidic leach solution in the presence of microwave irradiation. The microwave irradiation of the slurry takes place under process conditions whereby crystalline pyrite may be formed in-situ on surfaces of the chalcopyrite particles. Crystalline pyrite may be formed on surfaces of the chalcopyrite particles from amorphous phase pyrite. Leached copper is recovered from said acidic leach solution. A device for more efficiently leaching a copper bearing sulfide mineral slurry containing chalcopyrite is also described herein.

Abstract: Polymer composites and polymer nanocomposites are designed and manufactured by choosing surface-modified fillers having a solid surface energy matching the solid surface energy of the polymer, wherein the advancing contact angle of the polymer on the surface-modified filler is less than about 5 degrees. The fillers are surface-modified by adsorption of amorphous polymeric surfactants, consisting of either mono-modal, bimodal, or multi-modal size distribution. The surface-modified fillers of this invention display a measurable yield stress and a viscosity of about 30.000 Pa·s or less at room temperature, and comprise one or more materials selected from the group consisting of minerals, plant material, animal material, carbon fiber, graphite, amorphous carbon, carbon nanotubes, and glass fiber.

Abstract: 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.

Abstract: Polymer composites and polymer nanocomposites are designed and manufactured by choosing surface-modified fillers having a solid surface energy matching the solid surface energy of the polymer, wherein the advancing contact angle of the polymer on the surface-modified filler is less than about 5 degrees. The fillers are surface-modified by adsorption of amorphous polymeric surfactants, consisting of either mono-modal, bimodal, or multi-modal size distribution. The surface-modified fillers of this invention display a measurable yield stress and a viscosity of about 30.000 Pa·s or less at room temperature, and comprise one or more materials selected from the group consisting of minerals, plant material, animal material, carbon fiber, graphite, amorphous carbon, carbon nanotubes, and glass fiber.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.