Polymer nanocomposites and methods of preparation

Abstract

High-use temperature, lightweight polymer/inorganic nanocomposite materials are described having enhanced thermal stability and performance characteristics. These materials are made possible by new methods for synthesizing composite materials that enhance the thermal stability of the nanocomposite systems from 100-150° C. to over 450° C. These materials and techniques for their formation are enabled at least in part by the use of polar organic phthalonitrile monomers and oligomers that can exfoliate layered phyllosilicates, such as smectite clays, in percentages greater than 10% inorganic by weight. This approach offers a solvent-free direct melt intercalation technique that greatly reduces the cost of processing nanocomposites. Additionally, the use of unmodified phyllosilicates overcomes temperature limitations of prior art, which uses organically-modified layered silicates. The new technology provides hitherto unobtainable thermal stability and performance characteristics, and has numerous applications in the automotive, aerospace, electronic and marine industries.

1 - 31 . (canceled) 
     
     
         32 . A method of preparing a nanocomposite intercalate comprising the step of contacting a phyllosilicate with a monomeric organic compound having an electrostatic functionality selected from the group consisting of esters, ethers, copolymers, and mixtures thereof. 
     
     
         33 . The method of  claim 32  wherein the monomeric compound is present in a final concentration of at least 10% by weight of one or more monomers selected from the group consisting of monomeric ethers, monomeric esters, and combinations thereof. 
     
     
         34 . The method of  claim 32  wherein an intercalating composition is prepared having a monomeric component to layered material ratio of at least 1 to 5. 
     
     
         35 . A method of exfoliating clays for the preparation of nanocomposites comprising replacing an alkyl amine present with the clay with an organic nitrile containing agent. 
     
     
         36 . The method of  claim 35  wherein the organic nitrile containing agent is a phthalonitrile monomer selected from the group consisting of bis(3,4,-dicyanophenoxy)-4,4′-biphenyl, a bis(3,4,-dicyanophenoxy)-4,4′-biphenyl having at least one aliphatic group, a bis(3,4,-dicyanophenoxy(4,4′-biphenyl having at least one amine group, a bis(3,4,-dicyanophenoxy)-4,4′-biphenyl having at least one hydroxyl group, and combinations thereof. 
     
     
         37 . The method of  claim 35  wherein the clay is a hydrophilic silicate selected from the group consisting of a layered mica-type silicate, a phylliosilicate, a sodium montmorillonite clay, a smectite clay, and combinations thereof. 
     
     
         38 . The method of  claim 35  wherein the organic nitrile containing agent is added to a final concentration of at least 10% wgt/wgt. 
     
     
         39 . The method of  claim 35  wherein the organic nitrile containing agent is added to a final concentration of at least 20% wgt/wgt. 
     
     
         40 . The method of  claim 35  wherein the organic nitrile containing agent is added to a final concentration of at least 30% wgt/wgt. 
     
     
         41 . The method of  claim 35  wherein the organic nitrile containing agent is added to a final concentration of at least 50% wgt/wgt. 
     
     
         42 . A nanocomposite intercalate produced by the method of  claim 32 . 
     
     
         43 . A nanocomposite comprising inorganic material and a polymer obtained by polymerizing a phthalonitrile monomer. 
     
     
         44 . The nanocomposite of  claim 43  wherein the inorganic material is a hydrophilic silicate. 
     
     
         45 . The nanocomposite of  claim 43  wherein the hydrophilic silicate is selected from the group consisting of a layered mica-type silicate, a clay, a phyllosilicate, a sodium montmorillonite clay, a smectite clay, and combinations thereof. 
     
     
         46 . The nanocomposite of  claim 43  wherein the polymer comprises at least 2% by weight of the nanocomposite. 
     
     
         47 . The nanocomposite of  claim 43  wherein the phthalonitrile monomer is selected from the group consisting of bis(3,4,-dicyanophenoxy)-4,4′-biphenyl, a bis(3,4,-dicyanophenoxy)-4,4′-biphenyl having at least one aliphatic group, a bis(3,4,-dicyanophenoxy)-4,4′-biphenyl having at least one amine group, a bis(3,4,-dicyanophenoxy)-4,4′-biphenyl having at least one hydroxyl, and combinations thereof. 
     
     
         48 . The nanocomposite of  claim 43  further comprising a ceramic material. 
     
     
         49 . A nanocomposite comprising a hydrophilic silicate and a polymerized chemical that contains nitrole groups. 
     
     
         50 . The nanocomposite of  claim 49  wherein the polymerized chemical comprises polymers of phthalonitrile monomers.