Abstract: A method for preparing a polymer-organoclay composite composition comprises combining a solvent and an unexfoliated organoclay to provide a first mixture, wherein the unexfoliated organoclay comprises alternating inorganic silicate layers and organic layers, and has an initial spacing between the silicate layers; exposing the first mixture to an energized condition of a sufficient intensity and duration to increase the initial spacing of the inorganic silicate layers, to provide a second mixture; contacting the second mixture with a polymer composition so that the polymer composition fills at least one region located between at least one pair of silicate layers, wherein the polymer composition is at least partially soluble in the solvent; and removing at least a portion of the solvent from the second mixture, wherein the inorganic silicate layers remain separated by the polymer after removal of the solvent.

Abstract: This invention relates to organic salt compositions useful in the preparation of organoclay compositions, polymer-organoclay composite compositions, and methods for the preparation of polymer nanocomposites. In one embodiment, the present invention provides a polymer-organoclay composite composition comprising (a) a polymeric resin; and (b) an organoclay composition comprising alternating inorganic silicate layers and organic layers, said organic layers comprising a quaternary phosphonium cation having structure XXXIII wherein Ar12, Ar13, Ar14 and Ar15 are independently C2-C50 aromatic radicals; and Ar16 is a C2-C200 aromatic radical, or a polymer chain comprising at least one aromatic group.

Abstract: A slot armor component for use in a rotor of a dynamo-electric machine comprises a plurality of profile co-extruded polymer layers. The composite cross-section of the profile co-extruded layers may include a first leg portion and a second leg portion disposed at an angle to the first leg portion. The plurality of co-extruded polymer layers may include a glass-filled polymer layer arranged between two unfilled polymer layers such as a glass-filled Ultem layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled Ultem layers or a glass-filled polyetheretherketone (PEEK) layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled PEEK layers.