Abstract: Intercalates, exfoliates thereof, and nanocomposite compositions are formed by intercalating a layered silicate material, e.g., a phyllosilicate, with an oligomer or polymer intercalant that is a reaction product of at least one diamine with at least one dicarboxylic acid, to form a polyamide oligomer containing a xylylenediamine component. The oligomer or polymer may be formed in-situ by contacting the layered phyllosilicate with polymerizable monomer reactants using conditions to cause reaction and polymerization in the intercalating composition and intercalation of the resulting oligomer and/or polymer, between platelet layers of the phyllosilicate. An amine functionality of the oligomer or polymer is protonated for ion-exchange with interlayer cations of the phyllosilicate to bond the intercalant to the phyllosilicate platelet, at the protonated amine, at a negative charge site previously occupied by the interlayer cations.

Abstract: A resin composition comprising melt blending a polyamide resin such as nylon MXD6 with a polyphenoxy resin. The polyamide resin and the polyphenoxy resin may be combined prior to or after melting and can be sandwiched between two PET layers in a perform mold to form an article capable of blow molding to form a container with improved delamination resistance. Also, intercalated layered materials are prepared by co-intercalation of an onium ion, an aromatic polyamide oligomer or polymer, e.g., nylon MXD6, and a polyphenoxy oligomer or polymer between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The co-intercalated layered materials are combined with the aromatic polyamide and polyphenoxy resin to form a nanocomposite composition for sandwiching between PET layers to form containers having improved delamination resistance.

Abstract: A method of manufacturing a nanocomposite composition comprising forming an intercalating composition comprising 1% to about 90% by weight of a purified sodium smectite clay that contains at least 75% Na+ ions based on the total interlayer exchangeable cations, that has been intercalated and thereby swollen sufficiently for polyamide monomer or oligomer intercalation, with a protonated organic, non-carboxylic acid moiety-containing onium ion swelling agent; and about 10% to about 99% of a lactam ring-containing monomer or oligomer, and heating the intercalating composition to a temperature above the melting point of the lactam to open the lactam ring and polymerize the lactam to form the polyamide while in contact with the smectite clay.

Abstract: A resin composition comprising melt blending a polyamide resin such as nylon MXD6 with a polyphenoxy resin. The polyamide resin and the polyphenoxy resin may be combined prior to or after melting and can be sandwiched between two PET layers in a perform mold to form an article capable of blow molding to form a container with improved delamination resistance. Also, intercalated layered materials are prepared by co-intercalation of an onium ion, an aromatic polyamide oligomer or polymer, e.g., nylon MXD6, and a polyphenoxy oligomer or polymer between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The co-intercalated layered materials are combined with the aromatic polyamide and polyphenoxy resin to form a nanocomposite composition for sandwiching between PET layers to form containers having improved delamination resistance.

Abstract: A composite of nanoclay and thermoplastic matrix polymer is disclosed, optionally containing a polyolefin elastomer and also optionally containing a dispersion agent for the nanoclay. The nanocomposite is prepared for use with thermoplastic polyolefins (TPO's). The polyolefin elastomer, preferably an ethylene-octene copolymer, is added into a mixing extruder downstream of the other ingredients. The nanoconcentrate contributes increased stiffness and toughness to a TPO, which can be used form molded articles such as automotive parts.

Abstract: A method of manufacturing a nanocomposite composition comprising forming an intercalating composition comprising 1% to about 90% by weight of a purified sodium smectite clay that contains at least 75% Na+ ions based on the total interlayer exchangeable cations, that has been intercalated and thereby swollen sufficiently for polyamide monomer or oligomer intercalation, with a protonated organic, non-carboxylic acid moiety-containing onium ion swelling agent; and about 10% to about 99% of a lactam ring-containing monomer or oligomer, and heating the intercalating composition to a temperature above the melting point of the lactam to open the lactam ring and polymerize the lactam to form the polyamide while in contact with the smectite clay.

Abstract: Intercalates, exfoliates thereof, and nanocomposite compositions are formed by intercalating a layered silicate material, e.g., a phyllosilicate, with an oligomer or polymer intercalant that is a reaction product of at least one diamine with at least one dicarboxylic acid, to form a polyamide oligomer containing a xylylenediamine component. The oligomer or polymer may be formed in-situ by contacting the layered phyllosilicate with polymerizable monomer reactants using conditions to cause reaction and polymerization in the intercalating composition and intercalation of the resulting oligomer and/or polymer, between platelet layers of the phyllosilicate. An amine functionality of the oligomer or polymer is protonated for ion-exchange with interlayer cations of the phyllosilicate to bond the intercalant to the phyllosilicate platelet, at the protonated amine, at a negative charge site previously occupied by the interlayer cations.

Abstract: Nylon-intercalated (concentrate nylon), layered silicates, in concentrated form, containing at least 6% to about 40% by weight layered silicate, preferably about 8% to about 30% by weight layered silicate, intercalated with a nylon that is polymerized while in contact with the clay, during ring-opening polymerization of the nylon reactants (monomers) and melt processing. The in-situ nylon polymerization reaction to form the concentrate nylon is continued until the number average molecular weight (Mn) of the nylon is about 25,000 or less, preferably 15,000 or less, more preferably about 5,000-10,000, to maintain melt processability of the resulting concentrate.

Abstract: The invetion is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix oplymer and a layered clay material having decreased levels of extractable material, such as extractible salts of organic cations. This invention is also derected to processes for preparing polymer-clay nanocomposites, intercalates, exfoliates, and articles or products produced from nanocomposite materials.

Abstract: The invention is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix polymer and a layered clay material having low quartz content. This invention is also directed to a process for preparing polymer-clay nanocomposites, and articles or products produced from nanocomposite materials.

Abstract: This invention relates to a polymer-clay nanocomposite comprising (i) a melt-processible matrix polymer, and incorporated therein (ii) a mixture of at least two layered clay materials. The invention also relates to articles produced from a nanocomposite and a process for preparing a nanocomposite.

Abstract: Nylon-intercalated (concentrate nylon), layered silicates, in concentrated form, containing at least 6% to about 40% by weight layered silicate, preferably about 8% to about 30% by weight layered silicate, intercalated with a nylon that is polymerized while in contact with the clay, during ring-opening polymerization of the nylon reactants (monomers) and melt processing. The in-situ nylon polymerization reaction to form the concentrate nylon is continued until the number average molecular weight (Mn) of the nylon is about 25,000 or less, preferably 15,000 or less, more preferably about 5,000-10,000, to maintain melt processability of the resulting concentrate.

Abstract: This invention relates to a polymer-clay nanocomposite comprising (i) a melt-processible matrix polymer, and incorporated therein (ii) a mixture of at least two layered clay materials. The invention also relates to articles produced from a nanocomposite and a process for preparing a nanocomposite.

Abstract: A nanocomposite concentrate composition comprising about 10 weight percent to about 90 weight percent of a layered silicate material and about 10 weight percent to about 90 weight percent of a matrix polymer comprising about 90-99.8% by weight of a polyolefin and about 0.2% to about 10%, preferably about 0.2% to about 3%, more preferably about 1% to 3% by weight, of a maleic anhydride-modified polyolefin, based on the total weight of polyolefins, wherein the layered silicate material is dispersed uniformly throughout the matrix polymer. Shearing of the concentrate and later (after shear) addition of an added matrix polymer avoids thermal degradation of the added matrix polymer and optimizes the dispersion of the nanomer throughout the matrix polymer; provides increased tensile strength; and reduces degradation of the polymer by melt formation of a concentrate thereby decreasing heat degradation of added matrix polymer.

Abstract: The invention is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix polymer and a layered clay material having low quartz content. This invention is also directed to a process for preparing a polymer-clay nanocomposites, and articles or products produced from nanocomposite materials.

Abstract: The invention is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix polymer and a layered clay material having decreased levels of extractable material, such as extractable salts of organic cations. This invention is also directed to processes for preparing polymer-clay nanocomposites, and articles or products produced from nanocomposite materials.

Abstract: This invention relates to a process for preparing an amorphous polyamide-clay nanocomposite comprising the steps of: a. melt mixing a layered clay material with an oligomeric polyamide resin to form an oligomeric polyamide resin-clay composite, and b.

Abstract: This invention is directed to a polymer-clay nanocomposite, products produced from the nanocomposite, and a process for preparing a polymer-clay nanocomposite. The polymer-clay nanocomposite comprises (a) a matrix polymer, (b) an amorphous oligomer, and (c) a layered clay material.

Abstract: This invention relates to a composite composition comprising one or more polyamide polymers or copolymers, one or more layered clay materials, and one or more alkoxylated ammonium cations. The invention also relates to a process for preparing a nanocomposite and articles produced from the nanocomposite, including bottles.

Abstract: This invention relates to a process for preparing an amorphous polyamide-clay nanocomposite comprising the steps of: