Abstract: Nanocomposite layered materials prepared by co-intercalation of an onium ion, preferably an alkoxylated onium ion and an ethylene vinyl alcohol oligomer or polymer between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The spacing of adjacent layers of the layered materials is expanded at least about 3 Å, preferably at least about 5 Å, usually preferably to a d-spacing of about 15-20 Å, e.g., 18 Å with the alkoxylated onium ion spacing/coupling agent. The intercalation of the ethylene vinyl alcohol polymer then increases the spacing of adjacent layers an additional at least 2 Å, e.g., to at least about 20 Å, preferably about 25 Å to about 30 Å, generally about 28 Å. Improved O2 barrier properties are observed over a broad range of humidity conditions when intercalation is accomplished by both the solvent route and the direct compounding route.

Abstract: 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.

Abstract: Provided are acidified aqueous stable dispersions of an exfoliated silicate derived from a silicate having a layer lattice structure in which the silicate layer units have a thickness of 5 to 25 Angstroms, wherein the exchange capacity ranges from 30 to 200 millequivalents per gram of silicate having a layer lattice structure, and wherein the silicate materials have been exfoliated with a cationic group-containing polymer or polymer having functional groups which can be post-reacted to form cationic groups. These silicate dispersions are useful in coating compositions, particularly in electrodepositable coating compositions, where they impart improved crater control.

Abstract: The present invention relates to particulate concentrate compositions formed by intercalation of a polymer polymerizing component into the galleries of a layered inorganic cation exchange composition initially in proton exchanged form and to the use of the particulate concentrates for the preparation of cured polymer-inorganic nanolayer hybrid composite compositions. The polymer polymerizing component comprising the particulate concentrate contains a basic group for reaction with the protons of the inorganic cation exchanger. Also, the polymer polymerizing component contains a functional group for polymerization reaction with a polymer precursor, a mixture of polymer precursors, or a polymer melt which is introduced into the galleries of the inorganic cation exchanger and reacts with the polymer polymerizing component to form a cured polymer-inorganic nanolayer hybrid composite.

Abstract: Provided are cationic electrodepositable compositions comprised of an acidified aqueous dispersion of (a) an ungelled cationic resin, (b) a curing agent having at least two functional groups which are reactive with (a), and (c) an exfoliated silicate derived from a layered silicate. These compositions exhibit improved crater control. Also provided is a method of electrocoating conductive substrates using such compositions.

Abstract: 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.

Abstract: The present invention relates to particulate concentrate compositions formed by intercalation of a polymer polymerizing component into the galleries of a layered inorganic cation exchange composition initially in proton exchanged form and to the use of the particulate concentrates for the preparation of cured polymer-inorganic nanolayer hybrid composite compositions. The polymer polymerizing component comprising the particulate concentrate contains a basic group for reaction with the protons of the inorganic cation exchanger. Also, the polymer polymerizing component contains a functional group for polymerization reaction with a polymer precursor, a mixture of polymer precursors, or a polymer melt which is introduced into the galleries of the inorganic cation exchanger and reacts with the polymer polymerizing component to form a cured polymer-inorganic nanolayer hybrid composite.

Abstract: Homostructured, cation exchanged, layered compositions containing mixed onium and alkali metal, alkaline earth metal, protonated hydronium ions and mixtures thereof are described. Particulate concentrates formed by intercalation of a polymer component into the galleries of the layered inorganic and organic homostructured layered cation exchange composition and to the use of the particulate concentrates for the preparation of cured polymer-inorganic nanolayer hybrid composite compositions are described. In the most preferred embodiment of the invention the layered inorganic composition is selected from the family of 2:1 layered silicate clays.

Abstract: Homostructured, cation exchanged, layered compositions containing mixed onium and alkali metal, alkaline earth metal, protonated hydronium ions and mixtures thereof are described. Particulate concentrates formed by intercalation of a polymer component into the galleries of the layered inorganic and organic homostructured layered cation exchange composition and to the use of the particulate concentrates for the preparation of cured polymer-inorganic nanolayer hybrid composite compositions are described. In the most preferred embodiment of the invention the layered inorganic composition is selected from the family of 2:1 layered silicate clays.

Abstract: The present invention relates to particulate concentrate compositions formed by intercalation of a polymer polymerizing component into the galleries of a layered inorganic cation exchange composition initially in proton exchanged form and to the use of the particulate concentrates for the preparation of cured polymer-inorganic nanolayer hybrid composite compositions. The polymer polymerizing component comprising the particulate concentrate contains a basic group for reaction with the protons of the inorganic cation exchanger. Also, the polymer polymerizing component contains a functional group for polymerization reaction with a polymer precursor, a mixture of polymer precursors, or a polymer melt which is introduced into the galleries of the inorganic cation exchanger and reacts with the polymer polymerizing component to form a cured polymer-inorganic nanolayer hybrid composite.

Abstract: A clay-resin composition of a cured epoxy resin and a layered clay with the cured epoxy resin in the galleries of the clay by intercalation or exfoliation. The preferred epoxy resins are flexible and usually elastic because of the epoxy resin and/or curing agent which is used. The result is a composite which can have superior tensile strength and/or solvent resistance as compared to the cured epoxy resin without the clay or with the clay but without the intercalation or exfoliation. The flexible composites are particularly useful for seals and other thin layer applications.

Abstract: A clay-resin composition of a cured epoxy resin and a layered clay with the cured epoxy resin in the galleries of the clay by intercalation or exfoliation. The preferred epoxy resins are flexible and usually elastic because of the epoxy resin and/or curing agent which is used. The result is a composite which can have superior tensile strength and/or solvent resistance as compared to the cured epoxy resin without the clay or with the clay but without the intercalation or exfoliation. The flexible composites are particularly useful for seals and other thin layer applications.