Exfoliated polymer-clay nanocomposite

Abstract

A method of producing a polymer-clay nanocomposite comprises providing a supply of polymer-clay mixture, exfoliating the mixture through solid-state shear pulverization in the presence of cooling sufficient to maintain the extruded mixture in the solid state during the pulverization, and discharging the resulting exfoliated mixture. The invention is also directed to a method of producing a polymer hybrid nanocomposite, wherein a component is dispersed throughout a polymer matrix by solid-state shear pulverization of a polymer mixed with the second component.

1 - 8 . (canceled) 
     
     
         9 . A polymer-clay nanocomposite, comprising:
 a nonpolar polymer material; and   at least about 3% highly exfoliated organoclay.   
     
     
         10 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material is selected from the group consisting of polypropylene, polyethylene, polystyrene, copolymers of propylene, copolymers of ethylene, and blends thereof. 
     
     
         11 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material is a polyolefin. 
     
     
         12 . The nanocomposite of  claim 9 , wherein said organoclay comprises between about 40-50% clay content and between about 50-60% organic content. 
     
     
         13 . The nanocomposite of  claim 12 , wherein said organoclay is a montmorillonite. 
     
     
         14 . The nanocomposite of  claim 13 , wherein said organoclay has:
 40-50% nanoclay content,   a density of 38-48 lbs/ft 3 , and   a maximum of 0.2% moisture content.   
     
     
         15 . The nanocomposite of  claim 9 , including about 10% highly exfoliated organoclay. 
     
     
         16 - 17 . (canceled) 
     
     
         18 . The nanocomposite of  claim 9 , wherein said organoclay is a hectorite. 
     
     
         19 . The nanocomposite of  claim 9 , including about 7% highly exfoliated organoclay. 
     
     
         20 . The nanocomposite of  claim 9 , including about 5% highly exfoliated organoclay. 
     
     
         21 . The nanocomposite of  claim 9 , including less than about 12% clay. 
     
     
         22 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises a polymethacrylate. 
     
     
         23 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises a polyvinylalcohol. 
     
     
         24 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises ply(ethylene-co-vinyl acetate). 
     
     
         25 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises polyhydroxystyrene. 
     
     
         26 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises poly(vinyl pyridine). 
     
     
         27 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises a polyvinylalcohol. 
     
     
         28 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises a polyacrylamide. 
     
     
         29 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises polycaprolactone. 
     
     
         30 . The nanocomposite of  claim 9 , wherein said nonpolar polymer material comprises poly(ethylene terephthalate).