NANOCOMPOSITE INCLUDING HEAT-TREATED CLAY AND POLYMER
Disclosed are systems and methods for producing, and a composite including, a roasted aluminosilicate (e.g., halloysite). A uniform dispersion of an aluminosilicate can be obtained using roasted halloysite clay and subsequently combining it with a polymer in a melt mixing system to produce a composite.
1 . A polymeric composite, comprising:
a roasted aluminosilicate clay; and
a polymer.
2 . The composite according to claim 1 , wherein said polymer is selected from the group consisting of: polyester, aliphatic polyesters and copolyesters; blends containing aliphatic polyesters and copolyesters; nylons; polypropylenes; polyolefins; and polyamids.
3 . The composite of claim 1 , wherein said roasted aluminosilicate clay is halloysite.
4 . The composite of claim 3 , wherein said halloysite is roasted at a temperature less than about 800° C.
5 . The composite of claim 1 , wherein said roasted aluminosilicate clay is kaolinite.
6 . The composite of claim 5 , wherein said kaolinite is roasted at a temperature less than about 800° C.
7 . The composite of claim 3 , wherein said aluminosilicate clay is roasted at a temperature less than about 600° C.
8 . The composite of claim 3 , wherein at least some of said halloysite retains a tubular morphology and includes an agent therein.
9 . The composite of claim 3 , wherein at least some of said halloysite retains a tubular morphology.
10 . The composite of claim 1 , wherein said polymer includes those polymers suitable for wet applications selected from the group consisting of latexes; coatings; and paints.
11 . The composite of claim 1 , where said aluminosilicate clay is roasted at temperatures of at least about 400° C. for at least about 4 hours.
12 . The composite of claim 1 , where said aluminosilicate clay is roasted at temperatures of at least about 600° C. for at least about 2 hours.
13 . The composite of claim 1 , wherein said polymer is selected from the group consisting of: polytrimethylene terephthalate; polybutylene terephthalate; polyethylene napthalate; polyethylene terephthalate; polybutylene succinate; polycaprolactone; polylactic acid; and copolymers of the above, including polyethylene-co-ethyleneoxyethylene terephthalate, butylene glycol polymerized with succinic and adipic acids, and lactide polymerized with glucoside.
14 . A method for producing a polymeric composite, comprising:
exposing an aluminosilicate clay to a thermal treatment to remove at least some structural water therefrom; and
combining the thermally treated aluminosilicate clay with a polymer material to produce a composite.
15 . The method according to claim 14 , wherein said thermal treatment removes substantially all of the structural water.
16 . The method according to claim 15 , wherein said thermal treatment reduces the weight of residual water in the aluminosilicate clay to less than about 14%.
17 . The method according to claim 15 , wherein said thermal treatment reduces the weight of residual water in the aluminosilicate clay to less than about 10%.
18 . The method according to claim 15 , wherein said thermal treatment maintains structure of the aluminosilicate clay after removal of substantially all of the structural water.
19 . The method according to claim 14 , wherein said thermal treatment includes heating to a temperature of at least 212° C. and less than about 800° C.
20 . A polymeric composite produced in accordance with the method of claim 14 .
21 . The composite of claim 20 , wherein said aluminosilicate clay is halloysite.
22 . The composite of claim 21 , wherein said halloysite is roasted at a temperature less than about 800° C.
23 . The composite of claim 20 , wherein said aluminosilicate clay is kaolinite.
24 . The composite of claim 23 , wherein said kaolinite is roasted at a temperature less than about 800° C.
25 . The composite of claim 21 , wherein said aluminosilicate clay is roasted at a temperature up to about 600° C.
26 . The composite of claim 21 , wherein at least some of said halloysite retains a tubular morphology and is suitable for being loaded with an agent.
27 . A method for treating an aluminosilicate clay for use in a polymer composite, comprising:
roasting the aluminosilicate clay at a temperature greater than about 350° C. and less than about 800° C. for at least about 3 hours; and
combining the roasted aluminosilicate clay with a polymer in a melt mixing system to produce a composite.
28 . The method according to claim 27 , wherein said roasted aluminosilicate clay is halloysite.
29 . The method according to claim 27 , wherein said roasted aluminosilicate clay is kaolinite.
30 . The method according to claim 28 , wherein at least some of said halloysite is in a tubular form.
31 . The method according to claim 27 , wherein said polymer is a polyester.
32 . The method according to claim 27 , wherein said polymer is a copolymer.
33 . The method according to claim 32 , wherein said copolymer exhibits a sensitivity toward the presence of water during extrusion.
34 . The method according to claim 27 , wherein said polymer is selected from the group consisting of: polytrimethylene terephthalate (PTT); polybutylene terephthalate (PBT); polyethylene napthalate (PEN); polyethylene terephthalate (PET); polybutylene succinate (PBS), polycaprolactone (PCL); polylactic acid (PLA); and copolymers of the above (for example polyethylene-co-ethyleneoxyethylene terephthalate, butylene glycol polymerized with succinic and adipic acids (PBSA), lactide polymerized with glucoside, etc.).
35 . The method according to claim 27 , wherein said polymer includes those polymers suitable for wet applications including latexes, coatings and paints.
36 . The method according to claim 30 , wherein at least some of said halloysite in tubular form is loaded with an agent.