Nanocomposites containing layered nanoparticles and dispersant, composites, articles, and methods of making same

Abstract

A nanocomposite is provided including layered nanoparticles and a dispersant dispersed in a curable resin, where the nanocomposite contains less than 2% by weight solvent. A composite is also provided including from about 1 to 70 weight percent of layered nanoparticles, and a dispersant, dispersed in a cured resin, and a filler embedded in the cured resin. Further, a method of preparing a nanoparticle-containing curable resin system is provided including mixing from 1 to 70 weight percent of aggregated layered nanoparticles with a curable resin and a dispersant to form a mixture. The mixture contains less than 2% by weight solvent. The method also includes milling the mixture in an immersion mill containing milling media to form a milled resin system including layered nanoparticles dispersed in the curable resin.

What is claimed is: 
     
         1 . A method of preparing a nanoparticle-containing curable resin system comprising:
 mixing from 10 to 70 weight percent of aggregated layered nanoparticles with a curable resin, a first dispersant, and optionally a catalyst, a surface treatment agent, and/or a diluent, to form a first mixture, wherein the mixture comprises less than 2% by weight solvent; and   milling the first mixture in a first immersion mill comprising milling media to form a milled resin system comprising layered nanoparticles and the first dispersant dispersed in the curable resin.   
     
     
         2 . The method of  claim 1  wherein the layered nanoparticles include a platelet shape, an acicular shape, an irregular shape, or combinations thereof. 
     
     
         3 . The method of  claim 1  wherein the platelet shaped nanoparticles include talc, halloysite, hydrotalcite, montmorillonite, kaolin, mica, or combinations thereof. 
     
     
         4 . The method of  claim 1 , wherein the aggregated nanoparticles include an average size in the range from about 2 micrometers (μm) to about 20 μm. 
     
     
         5 . The method of  claim 1 , wherein the milling media comprises zirconia particles. 
     
     
         6 . The method of  claim 1 , wherein the milling is performed until the aggregated nanoparticles are dispersed to form layered nanoparticles including an average particle size in the range from about 1 nanometer to about 1000 nanometers. 
     
     
         7 . The method of  claim 6 , wherein the layered nanoparticles include an average particle size in the range from about 1 nanometer to about 500 nanometers. 
     
     
         8 . The method of  claim 1 , wherein the optional catalyst is present in the mixture for reacting hydroxyl groups on the surface of the nanoparticles with the curable resin system. 
     
     
         9 . The method of  claim 1 , wherein the optional surface treatment agent is present, wherein the surface treatment agent includes an organosilane, a monohydric alcohol, a polyol, or a combination thereof. 
     
     
         10 . The method of  claim 1 , wherein the optional diluent is present, wherein the at least one diluent comprises a mono- or poly-functional glycidyl ether, styrene, or a combination thereof. 
     
     
         11 . The method of  claim 1 , wherein the curable resin comprises an epoxy resin, a curable imide resin, a vinyl ester resin, an acrylic resin, a bisbenzocyclobutane resin, a polycyanate ester resin, or a mixture thereof. 
     
     
         12 . The method of  claim 1 , wherein the milled resin system comprises from about 15 to about 50 weight percent of the layered nanoparticles. 
     
     
         13 . The method of  claim 1 , wherein the milled resin system comprises from about 20 to about 70 weight percent of the layered nanoparticles. 
     
     
         14 . The method of  claim 1 , further comprising including a filler in the milled resin system comprising at least one of reinforcing continuous fibers, reinforcing discontinuous fibers, and hollow glass bubbles. 
     
     
         15 . The method of  claim 1 , further comprising including a curing agent in the mixture, the curing agent comprising an amine curing agent, an anhydride curing agent, a dicyandiamide curing agent, a diaminodiphenyl sulfone curing agent, or a combination thereof.