Nanocomposite material

0001The invention relates to a nanocomposite material, and to a process for the preparation thereof.

0002In the past decades, it has already often been proposed to improve the properties of polymeric materials by including in these materials a specific amount of a clay. The presence of a clay in a polymeric material particularly contributes to properties such as the mechanical strength and the heat resistance of the polymeric material.

0003A greet difficulty when including a clay in a polymeric matrix resides in the mutually rather different nature of the materials. The polymeric material of the matrix is a usually non-polar organic material, whereas the clay is a much more polar inorganic material. Because of this difference the materials are poorly intermixable; they are intrinsically not mixable.

0004To circumvent this difficulty, it has been proposed to carry out the synthesis of the polymer that forms the matrix, a polymerization reaction, in the presence of the inorganic material. The idea was that the clay is perhaps more easily intermixable with a monomeric material than with a polymeric material. This method, however, proved to result in an inhomogeneous product which does not have the desired properties. The clay has a layered or fibrous structure which cannot be broken easily, so that a homogeneous mixing is hard to obtain.

0005<patcit id="pcit0001" dnum="US4889885A"><text>U.S. patents 4,889,885</text></patcit> and <patcit id="pcit0002" dnum="US4810734A"><text>4,810,734</text></patcit> propose to first swell the clay before adding monomeric material and carrying out a polymerization. To this end, the clay is modified with a swelling agent which increases the mutual distance between the layers of the clay structure to such an extent that monomers fit there between. After polymerization of the monomers polymeric material is then automatically located between the clay layers.

0006The swelling agent described in the above patents is so-called onium ions. Within this context an onium ion is a surfactant with a head group formed by an ammonium, pyridinium, sulfonium or phosphonium group, and one or more non-polar tails. The cationic head group of an onium ion is exchanged for cations between the crystalline layers of the clay. The tails must have a functional group capable of entering into a bonding interaction with the monomeric material, so that the polymers are formed between the layers of the clay.

0007Nevertheless, swelling with an onium ion also often proved ineffective in obtaining a proper mixing of the clay with a polymeric matrix. European patent application <patcit id="pcit0003" dnum="EP0747322A"><text>0 747 322</text></patcit> describes that even when an onium ion with two non-polar tails is used, additional measures are necessary to homogeneously disperse a clay in a polymeric matrix which particularly consists of rubbery materials. Accordingly, the above European patent application proposes to introduce, in addition to an onium ion with two non-polar tails, one or more host molecules, also surfactant-like molecules, between the clay layers. A drawback of this method is that it is very complicated and does not in all polymeric materials enable a homogeneous dispersion of clay in the polymeric matrix.

0008Another approach is described in <patcit id="pcit0004" dnum="US6578672B"><text>U.S. patent 6,578,672</text></patcit>. This approach comprises two steps. In the first step, an aqueous layered clay is swollen with monomers, oligomers or polymers that are compatible with water. This leads to a partly hydrophilic material. This first step is often referred to as the so-called intercalation. The distance between the clay layers is thereby increased. The second step comprises the mixing of the intercalated clay with a second polymer. This step is referred to as the so-called exfoliation and must lead to loose individual clay plates. The resulting product is finally included in the desired polymeric matrix through extrusion. In this procedure it is essential that the clay contains a specific minimum content (usually at least 5%) of water. The method described in this U.S. patent is rather laborious and complicated. Moreover, this method is not applicable to many polymeric matrices, so that a clay cannot be included in every polymeric material.

0009The international patent application <patcit id="pcit0005" dnum="WO9304118A"><text>WO-A-93/04118</text></patcit> describes a composite material on the basis of a polymeric matrix and a clay, which clay is modified with a specific compound. This specific compound consists of a silane or an onium group and a group compatible with the polymeric matrix. It has turned out that with this specific compound a substantial dispersion of a clay in a polymeric matrix is only obtainable with nylon as polymeric matrix.

0010<patcit id="pcit0006" dnum="EP1167430A"><text>EP-A-1167 430</text></patcit> describes a reinforced filter material in which a nanocomposite is used that comprises a polymeric matrix into which a clay and a block copolymer or a graft copolymer have been incorporated. Fibrous clays are not mentioned.

0011<patcit id="pcit0007" dnum="WO0078540A"><text>WO-A-00/78540</text></patcit> describes nanocomposites that include at least one type of inorganic layered silicate and at least one type of organophilic agent. These nanocomposites are said to have high thermal stability.

0012<patcit id="pcit0008" dnum="WO9941299A"><text>WO-A-99/41299</text></patcit> describes nanocomposite compositions of a polyamide and a treated silicate. The polyamides are homo- or copolymers, but not graft- or block copolymers.

0013It is an object of the invention to provide a nanocomposite material in which a clay is very homogeneously dispersed in a polymeric matrix, which nanocomposite material is easy to prepare. The invention therefore relates to a nanocomposite material as defined in claim 1.

0014It has been found that by using a block copolymer or graft copolymer as defined in claim 1 a clay can be very homogeneously mixed with a polymeric matrix. Moreover, by suitably selecting the structural units of the block copolymer or the graft copolymer a clay can be included in a polymeric matrix selected from the group consisting of polyolefins, vinyl polymers, polyesters, polyethers, polysiloxanes and acrylic polymers . A nanocomposite material according to the invention has very favorable properties, such as a great heat resistance, a great mechanical strength, in particular a great tensile strength and a good impact resistance, a low electric conductivity, a high glass transition temperature and a very low permeability to gases, such as oxygen or water vapor, and liquids, such as water or solvents.

0015A nanocomposite material according to the invention ie, as stated before, based on a clay having a fibrous structure. When compared to other clays, typically of a layered structure, it has been found that with a fibrous clay it is easier to prepare a nanocomposite material of a highly homogeneous composition. In addition, a nanocomposite material based on a fibrous clay has highly advantageous mechanical properties.

0016The clay may be of a natural or synthetic nature. Preferably, the clay has a large contact surface. Very suitable are fibrous clays such as sepioloite, attapulgite and palygorskite. These materials impart very favorable mechanical properties and a great heat resistance to a nanocomposite material

0017The clay has a cation exchange capacity of from 5 to 250 milliequivelents per 100 gram. In a preferred embodiment, the clay is a fibrous clay having a cation exchange capacity is in the range of from 6 to 30 milliequivalents per 100 gram. When this capacity exceeds the upper limit of 260 milliequivaleats per 100 gram, it proves difficult to finely disperse the clay on a molecular level because of the strong mutual interaction of the clay fibers. When the cation exchange capacity is lower than the above lower limit, it turns out that the clay is hard to modify, owing to the fact that the interaction with the block copolymer or graft copolymer is small. There is preferably used a clay having a cation exchange capacity of from 25 to 200 milliequivalents per 100 gram.

0018The polymeric matrix present in a nanocomposite material according to the invention can be formed by the polymeric material defined in claim 1. Both homopolymers and copolymers may serve as polymeric matrix. It is one of the advantages of the invention that by selecting the block copolymer or the graft copolymer the polymeric matrix can be modified with a clay of the above-deecribed nature. Accordingly, by providing the right constituents, e.g. in the form of a kit, the skilled worker is afforded an opportunity to prepare for any desired use a combination of a specific clay and a specific polymeric material, and thus a desired nanocomposite material.

0019Polymeric materials suitable as polymeric matrix in a nanocomposite material according to the invention are both polyadducts and polycondensates.

0020The polymeric matrix is selected from the group consisting of polyolefins, vinyl polymers, polyesters, polyethers, polysiloxanes and acrylic polymers. The properties of these materials show a substantial improvement due to the presence of a clay.

0021Besides on the clay described before and the polymeric matrix, a nanocomposite material according to the invention is based on a block copolymer or a graft copolymer. This block copolymer or graft copolymer is a polymer comprising first structural units (A), which are compatible with the clay, and one or more second structural unite (B), which are compatible with the polymeric matrix. When the structural units occur in a straight polymeric chain, reference is made to a block copolymer. When the structural units (A) occur in a chain which is a branch of the chain in which the structural units (B) occur, or vice versa, reference is made to a graft copolymer.

0022The structural units (A) are compatible with the clay. By this is meant that these units in themselves, i.e. not in the copolymeric form with the structural units (B), are excellently mixable with the clay. The structural units (A) are preferably of a hydrophilic nature. The material for the one or more structural units (A) is chosen from the group consisting of polyvinyl pyrrolidone, polyvinyl alcohol, polyethylene oxide, liner or dendritic polyethylenimine, polyoxymethylene, polytetrahydrofuran, polyacrylic acid, polymethacrylic acid, polydimethylacrylamide, polymethylacrylamide, copolymers of acrylic acid or methacrylic acid and acrylamide, polyisopropylamide, starch, polysaccharides and cellulose derivatives. It is preferred that at least one of the structural units (A) is derived from monomeric units selected from the group of vinylpyrrolidone, vinyl alcohol, ethylene oxide, ethylenimine, vinylpyridine, acrylic acid and acrylamide. These preferred units (A) are excellently compatible with a clay.

0023Very suitable materials for use as structural units (A) have a molecular weight of from 100 to 6,000, preferably from 1,000 to 3,000. The material of the structural units (A) contains from 5 to 20 monomeric units.

0024The structural units (B) are compatible with the polymeric matrix. By this is meant that these units in themselves, i.e. not in the copolymeric form with the structural units (A), are excellently mixable with the material of the polymeric matrix. It is also possible that the nature of the structural units (B) is the same as the nature of the polymeric matrix. An example is a polymeric matrix of polyethylene having a molecular weight of 6,000 and structural units (B) of polyethylene having a molecular weight of 2,500. It is even possible that the material of the polymeric matrix is exactly equal to that of the structural units (B). In the above example, the structural units (B) could then be of polyethylene having a molecular weight of 5,000.

0025The nature of the structural units (B) will depend on the nature of the polymeric matrix. The material for the one or more structural units (B) is chosen from the group consisting of polyolefins, such as polyethylene or polypropylene, vinyl polymers, such as polystyrene or polymethyl methacrylate, polyesters, such as polyethylene terephthalate or polycaprolactone, polycarbonates, polyaryl ethers, polysulfones, polysulfides, polyamides, polyetherimides, polyether esters, polyether ketones, polyether eater ketones, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, polysiloxanes, polyurethanes and polyepoxides. There are preferably used polyolefins, vinyl polymere, polyesters, polyethers, polysiloxanes or acrylic polymers.

0026According to a preferred embodiment, a block copolymer or a graft copolymer is used in which the structural unite (A) contain from 5 to 20 monomeric units and the structural units (B) contain the same or a larger amount of monomeric units as/than the structural unite (A). It has been found that with such a block copolymer or graft copolymer a very finely divided homogeneous dispersion of the clay is obtained in the polymeric matrix.

0027In a nanocomposite material according to the invention, the weight ratio of the amount of block copolymer or graft copolymer to the amount of clay is between 0.01:1 and 100:1, with a special preference between 0.05:1 and 6:1. The weight ratio of the amount of clay to the amount of polymeric matrix is between 1:200 and 2: 1, with a special preference between 1:50 and 1.2: 1.

0028The invention further relates to a process for preparing a nanocomposite material as described above. It should be noted that it is possible in this connection to first bring together the clay and the block copolymer or graft copolymer or first bring together the polymeric matrix and the block copolymer or graft copolymer and only then add the required third constituent. It is further possible to simultaneously bring together all the three required constituents, namely clay, polymeric matrix and block copolymer or graft copolymer.

0029It is preferred, however, to first modify the clay with a block copolymer or graft copolymer of the above-described nature. The invention therefore also discloses a modified clay suitable for preparing a nanocomposite material as described above, based on a clay having a fibrous structure and a cation exchange capacity of from 5 to 250 milliequivalents per 100 gram, which clay is modified with a block copolymer or a graft copolymer, which block copolymer or graft copolymer comprises one or more first structural units (A), which are compatible with the clay, and one or more second structural units (B). This modified clay can then be suitably mixed with a polymeric matrix. By suitably selecting the structural unite (B), a skilled worker is capable of including a clay in a polymeric matrix of any desired nature.

0030When preparing a nanocomposite material according to the invention, in any of the above-mentioned sequences of bringing together, it is preferred to grind or pulverize the clay previously. Such a pretreatment of the clay results in an easier and better mixability of the different constituents.

0031The constituents of a nanocomposite material according to the invention may be brought together in any suitable manner, provided this manner gives a good mixture. Examples of methods of bringing together the constituents comprise agitation for a longer period of time at elevated temperature and extrusion. Suitable mixing conditions depend on the nature of the selected constituents and can be easily determined by a skilled worker. The agitation may be carried out, e.g., at a temperature between 40 and 80°C and the extrusion, e.g., between 40 and 150°C in a twin-screw extruder.

0032The nanocomposite materials according to the invention may be very suitably used for a great diversity of applications. The materials are excellently processable and can be molded in conventional molding steps, such as injection molding and extrusion processes. Molded articles of different nature can be prepared from the present nanocomposite material. Examples comprise any application for which the material of the polymeric matrix is suitable. As preferred applications, packaging and construction materials may be mentioned.

0033The invention will now be explained in more detail with reference to the following examples.

<u>Examples</u>

Materials

0034Nanocomposites based on semicrystalline as well as on amorphous polymer matrices have been prepared. Polyethylene nanocomposites were produced using HDPE8621, a commercial grade from DSM. Isotactic polypropylene DM55 (IPP) was supplied by Borealis, Ausria. The PMMA VO55 was obtained from Atofina, France. Caprolactam was used to synthesize PA6. The organic cations used in ion exchange reactions are dioctadecyldimethylammonium bromide (DODAB) or dihexylamine (DHA), both purchased from Sigma-Aldrich Co. Polyethylene grafted with 1.6% maleic anhydrite (PE-g-MA) was also supplied from Sigma-Aldric Co.

0035The block-copolymers EBE 55, which has molecular weight Mw of 8000 g/mol and consists of 4.3 kg/mol PEO and 3.7 kg/mol PBh and ME1010 with molecular weight Mw=2000 that consists from PMMA and PEO block in composition1000:1000 were supplied from Goldschmid AG, Germany.

0036The clays used are sepiolite B20 supplied by Tolsa SA, Spain and attapulgite from Milwhite Corporation, USA. These are natural clays that belong to the mineral class of pseudo-layer silicates. The ideal general chemical formula of sepiolite is Si₁₂Mgs₈O₃₀₂(OH)₂(H₂O)₄ .8H₂O. This mineral has specific gravity of 2 g/cm³ and cation exchange capacity (CEC) of 25 meqv / 100 g. The diameter of the fibrils is approximately 30 nm, their length can range reach up to few microns. The fibrils consist of mosaic arrangement of trioctahedral layers and open channels, both extended in the fibril direction. The general chemical formula of attapulgite is (Mg,Al)₂Si₄O₁₀(OH) 4 H₂O. Its structure is very similar to the structure of sepiolite. The differences are that the unit cell of the octahedral layers is smaller and the open channels a narrower. Attapulgite has specific gravity of 2.2 kg/m and ion exchange capacity of 15meqv/100g.

Materials preparation: clay surface modification

0037The procedure for surface modification of fibrous clays is as follows: Ion exchange reaction was performed with the non-reactive surfactants DODAB or DHA. The clay (5 g) and the surfactant (10 g) were added to 2000 ml warm water and stirred until a homogeneous mixture is obtained. Then the clay was filtrated and washed several times with warm water. After the final filtration the resulting precipitate was freeze-dried. Additional treatment was applied when the clay was prepared for producing PA6 nanocomposites using reactive disaggregation method.

0038Aqueous suspension (200 ml) of the clay (5 g) and α,ω-aminoundecanoic acid (0.5 g) was stirred for three hours at 80 °C. The precipitate was washed with warm water and freeze-dried.

Materials preparation: nanocomposites preparation

a. reactive disaggregation

0039This method was applied for preparation of PA6 nanocomposites. The whitish powder of the with α,ω-aminoundecanoic acid modified attapulgite was mixed with 90 g caprolactam and 10 ml water and heated slowly under stirring in dry nitrogen atmosphere to 260 °C. After 6 hours polycondensation time a transparent melt of PA6 nanocmposites was formed.

b. incorporation trough extrusion melt mixing

0040Typical procedure for incorporation of fibrous minerals by melt extrusion is as follows: The materials were prepared using a 15 cm³ co-rotational twin-screw extruder Xplore (DSM). The materials were mixed for 10 min with rotational speed of the screws 245 rpm. Nanocomposites based on HDPE matrix have been prepared using PB-graft-MA as coupling agent. A range of samples containing different amount of clay were prepared.

0041The weight fraction ratio between the fillet and the coupling agent was kept at constant value 1:2. The HDPE, the compatibilizer and the organically modified sepiolite were fed simultaneously in the extruder and mixed at 180 °C. For polypropylene the block co-polymer EBE δδ was used as a coupling agent. One weight fraction of thin block co-polymer was mixed with three weight fractions of the fibrous clay. An appropriate amount of this mixture, corresponding to desired clay ciontent was mixed with the matrix in the extruder at 170 °C. The same incorporation procedure was applied to manufacture PMMA nanocomposites where ME1010 block copolymer was used as compatibilizer. The complete list of the prepared nanocomposite samples is given in Table 1. <tables id="tabl0001" num="0001"><table frame="topbot"><title>Table 1</title><tgroup cols="8" colsep="0"><colspec colnum="1" colname="col1" colwidth="17mm" /><colspec colnum="2" colname="col2" colwidth="23mm" /><colspec colnum="3" colname="col3" colwidth="22mm" /><colspec colnum="4" colname="col4" colwidth="21mm" /><colspec colnum="5" colname="col5" colwidth="21mm" /><colspec colnum="6" colname="col6" colwidth="22mm" /><colspec colnum="7" colname="col7" colwidth="22mm" /><colspec colnum="8" colname="col8" colwidth="21mm" /><thead><row><entry valign="top" /><entry valign="top">Sepiolite wt.%</entry><entry valign="top">Attapulgite wt.%</entry><entry valign="top">PE-g-MA wt.%</entry><entry valign="top">PMMA-b PEO wt.%</entry><entry valign="top">PEB-b-PEO wt.%</entry><entry valign="top">DODAB wt.%</entry><entry valign="top">DHA wt.%.</entry></row></thead><tbody><row rowsep="0"><entry>HDPE^*</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>1</entry><entry>-</entry><entry>2</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>2.6</entry><entry>-</entry><entry>4</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>5</entry><entry>-</entry><entry>10</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>10</entry><entry>-</entry><entry>20</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>16</entry><entry>-</entry><entry>30</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row rowsep="0"><entry>HDPE^*</entry><entry>20</entry><entry>-</entry><entry>40</entry><entry>-</entry><entry>-</entry><entry>+</entry><entry>-</entry></row><row><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /></row><row rowsep="0"><entry>PMMA^*</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry /></row><row rowsep="0"><entry>PMMA^**</entry><entry>6</entry><entry>-</entry><entry>-</entry><entry>1.7</entry><entry>-</entry><entry>-</entry><entry>-</entry></row><row rowsep="0"><entry>PMMA^**</entry><entry>6</entry><entry>-</entry><entry>-</entry><entry>1.7</entry><entry>-</entry><entry>-</entry><entry>+</entry></row><row rowsep="0"><entry>PMMA^**</entry><entry>-</entry><entry>6</entry><entry>-</entry><entry>1.7</entry><entry /><entry>-</entry><entry>-</entry></row><row rowsep="0"><entry>PMMA^**</entry><entry>-</entry><entry>6</entry><entry>-</entry><entry>1.7</entry><entry>-</entry><entry>-</entry><entry>+</entry></row><row><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /></row><row rowsep="0"><entry>PA6^*</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry></row><row><entry rowsep="0">PA6^*</entry><entry rowsep="0">-</entry><entry rowsep="0">10</entry><entry rowsep="0">-</entry><entry rowsep="0">-</entry><entry rowsep="0">-</entry><entry rowsep="0">+</entry><entry rowsep="0">-</entry></row><row><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /><entry rowsep="0" /></row><row rowsep="0"><entry>IPP^*</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry><entry>-</entry></row><row><entry>IPP^*</entry><entry>-</entry><entry>5</entry><entry>-</entry><entry>-</entry><entry>1.7</entry><entry>-</entry><entry>+</entry></row></tbody></tgroup><tgroup cols="8" rowsep="0"><colspec colnum="1" colname="col1" colwidth="17mm" /><colspec colnum="2" colname="col2" colwidth="23mm" /><colspec colnum="3" colname="col3" colwidth="22mm" /><colspec colnum="4" colname="col4" colwidth="21mm" /><colspec colnum="5" colname="col5" colwidth="21mm" /><colspec colnum="6" colname="col6" colwidth="22mm" /><colspec colnum="7" colname="col7" colwidth="22mm" /><colspec colnum="8" colname="col8" colwidth="21mm" /><tbody><row><entry namest="col1" nameend="col8" align="justify">^* Comparative ^** Inventive</entry></row></tbody></tgroup></table></tables>