Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/04—Ingredients treated with organic substances
  • C08K9/06—Ingredients treated with organic substances with silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/04—Ingredients treated with organic substances
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/346—Clay
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/54—Silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L101/00—Compositions of unspecified macromolecular compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L21/00—Compositions of unspecified rubbers

Definitions

• the present invention relates to a composite comprising a polymer and an inorganic additive, more specifically, layers of a swellable material, and to a method for preparing the polymer composite.
• Polymer composites comprising a polymer matrix having one or more additives such as a particulate or fiber material dispersed throughout the continuous polymer matrix are well known.
• the additive is often added to enhance one or more properties of the polymer.
• Useful additives include inorganic layered materials such as talc, clays and mica of micron size.
• the intercalated silicate is described as having a layer thickness of 7 to 12A and an interlayer distance of 3 ⁇ A or above.
• WO 93/1 1190 an alternative method for forming a composite is described in which an intercalated layered, particulate material having reactive organosilane compounds is dispersed in a thermoplastic polymer or vulcanizabie rubber
• the present invention is a composite comprising a polymer matrix having, dispersed therein, delaminated or exfoliated particles derived from a multilayered inorganic material intercalated with an inorganic intercalant
• an organic intercalant can also be employed. If employed, the optionally employed organic intercalant can be calcined or at least partially removed from the multilayered inorganic material
• the present invention is a composite comprising a polymer matrix having dispersed therein delaminated or exfoliated particles derived from a multilayered material which has been intercalated with an organic intercalant only which is subsequently calcined or otherwise at least partially removed from the layered, reinforcing material
• the present invention is a method for forming a composite which method comprises contacting a polymer or a precursor to the polymer with a multilayered inorganic particulate material intercalated with an inorganic polymeric intercalant and, optionally, an organic intercalant If the optionally employed organic intercalant is used, it can be calcined or at least partially removed from the multilayered inorganic material prior to mixing the material with the polymer.
• the polymer is a melt processible, thermoplastic polymer and the method comprises mixing the polymer and intercalated material at conditions to disperse the intercalated material into the polymer.
• the polymeric compositions of this invention can exhibit an excellent balance of properties and can exhibit one or more superior properties such as improved heat or chemical resistance, ignition resistance, superior resistance to diffusion of polar liquids and of gases, yield strength in the presence of polar solvents such as water, methanol, or ethanol, or enhanced stiffness and dimensional stability, as compared to composites which contain the same multilayered material which has not previously been intercalated or where no intercalated material is employed.
• superior properties such as improved heat or chemical resistance, ignition resistance, superior resistance to diffusion of polar liquids and of gases, yield strength in the presence of polar solvents such as water, methanol, or ethanol, or enhanced stiffness and dimensional stability, as compared to composites which contain the same multilayered material which has not previously been intercalated or where no intercalated material is employed.
• the composites of the present invention are useful in a wide variety of applications including transportation (for example, automotive and aircraft) parts, electronics, business equipment such as computer housings, building and construction materials, and packaging materials.
• the polymer matrix of the composite can be essentially any normally solid polymer, including both thermoset and thermoplastic polymers and vulcanizable and thermoplastic rubbers.
• thermoplastic polyurethane such as derived from the reaction of a diisocyanate such as
• thermoplastic polymer is a polycarbonate such as prepared by the reaction of an aromatic polyol (for example, resorcinol, catechol, hydroqumone, a dihydroxynaphthalene, a dihydroxyanthracene, a b ⁇ s(hydroxyaryl) fluorene, a dihydroxyphenanthrene, a dihydroxybiphenyl; and a bis(hydroxyphenyl) propane), more preferably an aromatic diol, with a carbonate precursor (for example, carbonic acid derivative, phosgene, haloformate, or carbonate ester such as dimethyl carbonate or diphenyl carbonate, poly(methane bis(4-phenyl) carbonate), or poly(1 ,1 -ether bis(4-phenyl)carbonate).
• aromatic polyol for example, resorcinol, catechol, hydroqumone, a dihydroxynaphthalene, a dihydroxyanthracene, a b ⁇ s(hydroxyaryl
• thermoplastic polymers and copolymers derived from esters of ethylenically unsaturated methacrylic or acrylic acid such as poly(methyl or ethyl)acrylate, poly(methyl or ethyl)methacrylate, including copolymers of methyl methacrylate and a monovinylidene aromatic such as styrene, copolymers of ethylene and ethyl acrylate, methacrylated and butadiene-styrene copolymers; polymers derived from ethylenically unsaturated monomers such as polyolefins (for example, polypropylene and polyethylene including high density polyethylene, linear low density polyethylene, ultra low linear density polyethylene, homogeneously branched, linear ethylene/ ⁇ -olefin copolymers, homogeneously branched, substantially linear ethylene/ ⁇ -olefin polymers, and high pressure, free radical polymerized ethylene copolymers such as ethylene-
• thermoplastic polymers include polyesters such as poly(ethylene-1 ,5-naphthalate), poly(1 ,4-cyclohexane dimethylene terephthalate), poly(ethylene oxybenzoate), poly(para-hydroxy benzoate), polyethylene terephthalate, or polybutylene terephthalate; polysulfones such as the reaction product of the sodium salt of 2,2-bis(4-hydroxyphenyl) propane and 4,4'-dichlorodiphenyl sulfone; polyetherimides; and polymers of ethylenically unsaturated nitriles such as polyacrylonitrile; poly(epichlorohydrin); polyoxyalkylenes such as poly(ethylene oxide); poly(furan); cellulose- based plastics such as cellulose acetate, cellulose acetate butyrate; silicone based plastics such as poly(dimethyl siloxane) and poly(dimethyl siloxane co-phenylmethyl siloxane); poly
• thermoplastic polymers include the polymers and copolymers of ethylene and/or propylene, polymers and copolymers of a monovinylidene aromatic compound, more preferably styrene, polycarbonates, and thermoplastic polyurethanes or mixtures thereof.
• Preferred ethylene polymers and copolymers include linear low density polyethylenes, low density polyethylenes and the homogeneously branched linear and substantially linear ethylene copolymers with a density (ASTM D-792) of 0.85 to 0.92 g/cm 3 , more preferably of 0.85 to 0.90 0.92 g/cm 3 , and a measured melt index (ASTM D-1238 (190/2.16)) of 0.1 to 10 g/minutes; substantially linear, functionalized, ethylene copolymers, particularly a copolymer of ethylene with vinyl acetate containing from 0.5 to 50 weight percent units derived from vinyl acetate, are especially preferred, especially copolymers of ethylene with vinyl acetate having a melt index of 0.1 to 10 g/10 minutes; and copolymers of ethylene with acrylic acid containing from 0.5 to 25 weight percent units derived from acrylic acid.
• a density ASTM D-792
• ASTM D-1238 190/2.16
• vulcanizable and thermoplastic rubbers which may be useful in the practice of the present invention include rubbers such as brominated butyl rubber, chlorinated butyl rubber, polyurethane elastomers, fluoroelatomers, polyester elastomers, butadiene/acrylonitrile elastomers, silicone elastomers, rubbers derived from conjugated dienes such as poly(butadiene), poly(2,3-dimethylbutadiene), poly(butadiene-pentadiene), and poly(isobutylene), ethylene-propylene-diene terpolymer (EPDM) rubbers and sulfonated EPDM rubbers, poly(chloroprene), chlorosulphonated or chlorinated poly(ethylenes), and poly(sulfide) elastomers.
• rubbers such as brominated butyl rubber, chlorinated butyl rubber, polyurethane elastomers, fluoroelatomers, polyester
• block copolymers made up of segments of glassy or crystalline blocks such as poly(styrene), poly(vinyl-toluene), poly(t-butyl styrene), or polyester and elastomeric blocks such as poly(butadiene), poly(isoprene), ethylene-propylene copolymers, ethylene-butylene copolymers, or polyether ester, for example, poly(styrene)- poly(butadiene)-poly(styrene) block copolymers.
• Thermoset resins differ from thermoplastic polymers in that they become substantially infusible or insoluble irreversibly since they are cured (cross-linked) as opposed to the thermoplastics which are typically not cross-linkable and soften when exposed to heat and are capable of returning to original conditions when cooled.
• thermoplastic polymers are polycarbonates, homo- and copolymers of styrene, nylons, polyesters, thermoplastic polyurethanes, and homo- and copolymers of ethylene and propylene; and the preferred thermoset polymers include the epoxy and urethane resins.
• the inorganic layered material which may be used as the reinforcing agent can be any swellable material which can be intercalated with an inorganic and an organic intercalant.
• Representative examples of inorganic layered materials which may be used in the practice of the present invention include phyllosilicates such as montm ⁇ rillonite, nontronite, beidellite, volkonskoite, hectorite, saponite, sauconite, magadiite, and kenyaite; or vermiculite.
• Other representative examples include illite minerals such as ledikite; the layered double hydroxides or mixed metal hydroxides such as Mg 6 AI 3 4(OH) 18 8(CO 3 )1 7H 2 O (see W.T.
• Preferred layered materials are those having charges on the layers and exchangeable ions such as sodium, potassium, and calcium cations, which can be exchanged, preferably by ion exchange, with ions, preferably cations such as ammonium cations, or reactive organosilane compounds, that cause the multi-lamellar or layered particles to delaminate or swell.
• the negative charge on the surface of the layered materials is at least 20 milliequivalents, preferably at least 50 milliequivalents, and more preferably from 50 to 120 milliequivalents, per 100 grams of the multilayered material.
• smectite clay minerals such as montmorillonite, nontronite, beidellite, volkonskoite, hectorite, saponite, sauconite, magadiite, and kenyaite, with hectorite and montmorilonite having from 20 milliequivalents to 150 milliequivalents per 100 grams material being more preferred.
• Most preferred layered materials are phyllosilicates.
• the multilayered material may be intercalated with an inorganic intercalant and an organic intercalant.
• the inorganic intercalant can be an inorganic polymeric substance or an inorganic solid having a colloidalparticle size.
• Representative polymeric substances are substances obtained by hydrolyzing a polymerizable metallic alcoholate such as Si(OR) 4 , AI(OR) 3 , Ge(OR) 4 , Si(OC) 2 H 5 ) 4 , Si(OCH 3 ) 4 , Ge(OC 3 H 7 ), or Ge(OC 2 H 5 ) 4 , either alone or in combination.
• colloidal sized particles of an inorganic compound which can be used include the colloidal sized particles of the hydrolyzed form of SiO 2 (for example, Si(OH) or silica sol), Sb 2 O 3 , Fe 2 O 3 , AI 2 O 3 , TiO 2 , ZrO 2 and SnO 2 alone or in any combination.
• the grain size of the colloidal inorganic should preferably be in a range of from 5, more preferably from 10, most preferably from 20, to 250, more preferably 12 ⁇ A. While it may be possible to intercalate the unmodified form of the inorganic material between the layers of the multilayered particulate material, the inorganic intercalant is preferably modified at its surface by a cationic inorganic compound or a metallic alcoholate different than the polymerizable metallic alcoholate.
• Representative cationic inorganic compounds which may be used to surface treat the inorganic intercalant are titanium compounds, zirconium compounds, hafnium compounds, iron compounds, copper compounds, chromium compounds, nickel compounds, zinc compounds, aluminum compounds, manganese compounds, phosphorus compounds, and boron compounds.
• Metallic chlorides such as TiCI 4 , metallic oxychlorides such as ZrCOCI 2 , and nitrate chloride are preferred.
• Representative metallic alcoholates which can be used to the treat the surface of the inorganic intercalant are Ti(OR) 4 , Zr(OR) 4 , PO(OR) 3 , or B(OR) 3 alone or combination, with Ti(OC 3 H 7 ) 4 , Zr(OC 3 H 7 ) 4 , PO(OCH 3 ) 3 , PO(OC 2 H 5 ) 3 , B(OCH 3 ) 3 , B(OC 2 H5) 3 being preferred.
• the organic intercalant can be any organic material which displaces, totally or in part, the ions originally on the surface of the multilayered material.
• the intercalant contains a functional group which interacts with the negative charges on the surface of that material.
• the intercalant preferably also contains a functional group reactive with the matrix polymer or possesses some property such as cohesive energy, a capacity for dispersive, polar, or hydrogen-bonding interactions or other specific interactions, such as acid/base or Lewis-acid/Lewis-base interactions, to promote the intermingling ("compatibility") of the matrix polymer and multilayered material.
• the organic intercalant can be a water soluble polymer, a reactive organosilane compound, an onium compound such as an ammonium, phosphonium or sulfonium salt, an amphoteric surface active agent, or a choline compound.
• water-soluble polymers which can be employed as the organic intercalant in the practice of this invention are water soluble polymers of vinyl alcohol (for example, poly(vinyl alcohol); polyalkylene glycols such as polyethylene glycol; water soluble cellulosics polymers such methyl cellulose and carboxymethyl cellulose, the polymers of ethylenically unsaturated carboxylic acids such as poly(acrylic acid), and their salts, or polyvinyl pyrrolidone.
• vinyl alcohol for example, poly(vinyl alcohol); polyalkylene glycols such as polyethylene glycol; water soluble cellulosics polymers such methyl cellulose and carboxymethyl cellulose, the polymers of ethylenically unsaturated carboxylic acids such as poly(acrylic acid), and their salts, or polyvinyl pyrrolidone.
• onium compounds include quaternary ammonium salts (cationic surface active agents) having octadecyl, hexadecyl, tetradecyl, dodecyl or like moieties; with preferred quaternary ammonium salts including octadecyl trimethyl ammonium salt, dioctadecyl dimethyl ammonium salt, hexadecyl trimethyl ammonium salt, dihexadecyl dimethyl ammonium salt, tetradecyl trimethyl ammonium salt, or ditetradecyl dimethyl ammonium salt .
• quaternary ammonium salts cationic surface active agents having octadecyl, hexadecyl, tetradecyl, dodecyl or like moieties
• preferred quaternary ammonium salts including octadecyl trimethyl ammonium salt, dioctadecy
• amphoteric surface-active agent which can be employed in this invention include surfactants having an aliphatic amine cationic moiety and a carboxyl, sulfate, sulfone or phosphate as the anionic moiety.
• Representative examples of choline compounds include [HOCH 2 CH 2 N(CH 3 ) 3 ]+OH-, C 5 H l4 CINO, C 5 H 14 NOC 4 H 5 O 6 , C 6 H, 4 NOC 6 H 7 O 7 - and C 5 H t4 NOC ⁇ H, 2 O 7 .
• organosilane compounds include silane agents of the formula: ( v-) ' providingnSiR ( ( 4 n n m ⁇ m )R 1 m m
• (-) is a covalent bond to the surface of the layered material, m is 0, 1 or 2; n is 1 , 2 or 3 with the proviso that the sum of m and n is equal to 3;
• R 1 is a nonhydrolyzable organic radical (including alkyl, alkoxyalkyl, alkylaryl, arylalkyl, alkoxyaryl) and is not displaceable during the formation of the composite;
• R is the same or different at each occurrence and is an organic radical which is not hydrolyzable and displaceable during the formation of the composite which is reactive with the polymer matrix or at least one monomeric component of the polymer.
• R groups include amino, carboxy, acylhalide, acyloxy, hydroxy, isocyanato ureido, halo, epoxy, or epichlorohydryl.
• Preferred organosilane intercalants include long chain branched quaternary ammonium salts and/or suitably functionalized organosilane compounds, as disclosed in WO 93/1 1190, pages 9-21.
• Organic materials other than those described can also be employed as the organic intercalants provided they can be intercalated between the layers of the multilayered particulate material and subsequently degraded such as by calcination to at least partially remove the intercalant and leave gaps between the layers.
• the multilayered particulate material is intercalated with the inorganic, if employed, and organic intercalants. While the method of intercalation is not particularly critical, in one embodiment of the present invention, prior to intercalating the multilayered material, it is swollen in an aqueous or organic liquid Any aqueous or organic liquid capable of swelling the multilayered material being intercalated can be employed By aqueous liquid it is meant water, including acids and bases as well as some salt solutions.
• solutions of water and one or more water-miscible organic liquids such as the lower alkyl alcohols, for example, methanol and butanol
• organic liquids which can be employed include dimethylformamide, dimethylsulfone, halogenated hydrocarbons, for example, methylene chloride, or a liquid hydrocarbon, preferably having from 4 to 15 carbon atoms, including aromatic and aliphatic hydrocarbons or mixtures thereof such as heptane, benzene, xylene, cyclohexane, toluene, mineral oils and liquid paraffins, for example, kerosene and naphtha
• the polymerizable inorganic intercalant is formed as a solution in a suitable solvent such as ethyl alcohol, or isopropyl alcohol and subsequently hydrolyzed, preferably in the presence of the multilayered material For example, a mixture of the multilayered material, swollen in an appropriate swelling material, and the polymerizable in
• the hydrolyzation is conducted at a temperature above 70°C.
• the organic intercalant can be added The organic intercalant reacts upon the hydrolyzed surfaces of the layered material.
• the organic intercalant can be added to a dispersion of the colloidal inorganic intercalant.
• the reaction product of the organic intercalant with the inorganic intercalant is mixed with the swollen multilayered material. While the conditions of such intercalation may vary, in general, it is advantageously conducted at a temperature of from 30°C to 100°C, more advantageously from 60°C to 70°C.
• the intercalated multilayered filler can be dehydrated by conventional means such as centrifugal separation and then dried. While drying conditions most advantageously employed will be dependent on the specific intercalant and multilayered particulate material employed, in general, drying is conducted at temperatures of at least 40°C to 100°C and more advantageously at a temperature of 50°C to 80°C by any conventional means such as a hot air oven.
• the organic intercalant can then optionally be calcined such as by heating to 300°C to 600°C, preferably from 450°C to 550°C.
• the organic intercalant can be employed to intercalate the multilayered particulate material but the inorganic intercalant is not employed. In this embodiment, the organic intercalant is calcined such as by heating to 300°C to 600°C, preferably from 450°C to 550°C.
• the intercalant in the multilayered material forms a layer of charge opposite to the charge on the surface of the layers of the multilayered particles with the interlayer spacing being dependent on the intercalants employed and whether the organic intercalant has been calcined or otherwise partially or totally removed.
• the inter-layer spacing (that is, distance between the faces of the layers as they are assembled in the intercalated material) is from 5 to 60 ⁇ A (as determined by X-ray diffraction) whereas prior to intercalation the interlayer spacing is usually equal to or less than 4A.
• the interlayer spacing of the intercalated filler is at least ⁇ A, more preferably at least 12A and less than 10 ⁇ A, more preferably less than 3 ⁇ A.
• the intercalated, multilayered material and matrix polymer are combined to form the desired composite.
• the amount of the intercalated multilayered material most advantageously incorporated into the polymer matrix is dependent on a variety of factors including the specific intercalated material and polymer used to form the composite as well as its desired properties. Typical amounts can range from 0.001 to 90 weight percent of the intercalated, layered material based on the weight of the total composite. Generally, the composite comprises at least 0.1 , preferably 1 , more preferably 2, and most preferably 4 weight percent and less than 60, preferably 50, more preferably 45 and most preferably 40 weight percent of the intercalated, layered material based on the total weight of the composite.
• the intercalated, layered material can be dispersed in the monomer(s) which form the polymer matrix and the monomer(s) polymerized in situ or alternatively, can be dispersed in the polymer, in melted or liquid form.
• Melt blending is one method for preparing the composites of the present invention, particularly when forming the composite from a thermoplastic polymer. Techniques for melt blending of a polymer with additives of all types are known in the art and can typically be used in the practice of this invention.
• the polymer is heated to a temperature sufficient to form a polymer melt and combined with the desired amount of the intercalated, multilayered material in a suitable mixer, such as an extruder, a Banbury Mixer, a Brabender mixer, or a continuous mixer.
• a suitable mixer such as an extruder, a Banbury Mixer, a Brabender mixer, or a continuous mixer.
• the melt blending is preferably carried out in the absence of air, such as in the presence of an inert gas, such as argon, neon, or nitrogen.
• the melt blending operation can be conducted in a batch or discontinuous fashion but is more preferably conducted in a continuous fashion in one or more processing zones such as in an extruder from which air is largely or completely excluded.
• the extrusion can be conducted in one zone or step or in a plurality of reaction zones in series or parallel.
• the matrix polymer may be granulated and dry mixed with the intercalated, multilayered material, and thereafter, the composition heated in a mixer until the polymer is melted to form a flowable mixture.
• This flowable mixture can then be subjected to a shear in a mixer sufficient to form the desired composite.
• This type of mixing and composite preparation is advantageously employed to prepare composites from both thermoplastic and thermoset polymers.
• a polymer melt containing the intercalated, multilayered particulate material may also be formed by reactive melt processing in which the intercalated, multilayered material is initially dispersed in a liquid or solid monomer or cross-linking agent which will form or be used to form the polymer matrix of the composite.
• This dispersion can be injected into a polymer melt containing one or more polymers in an extruder or other mixing device.
• the injected liquid may result in new polymer or in chain extension, grafting or even cross- linking of the polymer initially in the melt.
• the composite is formed by mixing monomers and/or oligomers with the intercalated, multilayered material and subsequently polymerizing the monomer and/or oligomers to form the polymer matrix of the composite.
• the intercalated, multilayered material is advantageously dispersed under s conditions such that at least 80, preferably at least 85, more preferably at least 90, and most preferably at least 95, weight percent of the layers of the intercalated, multilayered, material delaminate to form individual layers dispersed in the polymer matrix.
• These layers may be platelet particles having two relatively flat or slightly curved opposite faces where the distance between the faces is relatively small compared to the size of the faces, or needle-like o particles. It is quite probable that the layers of the filler will not delaminate completely in the polymer, but will form layers in a coplanar aggregate.
• These layers are advantageously sufficiently dispersed or exfoliated in the matrix polymer such that at least 80 percent of the layers are in small multiples of less than 10, preferably less than 5, and more preferably less than 3, of the layers.
• the dimensions of the dispersed delaminated layers may vary greatly, but in the case of particles derived from clay minerals, the particle faces are roughly hexagonal, circular, elliptical, or rectangular and exhibit maximum diameters or length from 50 to 2,OO ⁇ A. As such, the aspect ratio of length/thickness ranges from 10 to 2,000. The aspect ratio which is most advantageously employed will depend on the desired end-use properties.
• the o particle faces may also be needle-like.
• the composites of the present invention may contain various other additives such as nucleating agents, other fillers, lubricants, plasticizers, chain extenders, colorants, mold release agents, antistatic agents, pigments, or fire retardants,.
• additives such as nucleating agents, other fillers, lubricants, plasticizers, chain extenders, colorants, mold release agents, antistatic agents, pigments, or fire retardants.
• the optional 5 additives and their amounts employed are dependent on a variety of factors including the desired end-use properties.
• the composites of this invention exhibit useful properties. For example, they may exhibit enhanced yield strength and tensile modulus, even when exposed to polar media 0 such as water or methanol; enhanced heat resistance and impact strength; improved stiffness, wet-melt strength, dimensional stability, and heat deflection temperature, and decreased moisture absorption, flammability, and permeability as compared to the same polymers which contain the same multilayered material which has not previously been intercalated or where no intercalated material is employed. Improvements in one or more properties can be obtained even though small amounts of intercalated multilayered materials are employed.
• the properties of the composites of the present invention may be further enhanced by post-treatment such as by heat treating or annealing the composite at an elevated temperature, conventionally from 80°C to 230°C.
• the annealing temperatures will be more than 100°C, preferably more than 110°C, and more preferably more than 120°C, to less than 250°C, preferably less than 220°C, and more preferably less than 180°C.
• the composites of the present invention can be molded by conventional shaping processes such as melt spinning, casting, vacuum molding, sheet molding, injection molding and extruding.
• molded articles include components for technical equipment, apparatus castings, household equipment, sports equipment, bottles, containers, components for the electrical and electronics industries, car components, and fibers.
• the composites may also be used for coating articles by means of powder coating processes or as hot-melt adhesives.
• the composite material may be directly molded by injection molding or heat pressure molding, or mixed with other polymers. Alternatively, it is also possible to obtain molded products by performing the in situ polymerization reaction in a mold.
• the molding compositions according to the invention are also suitable for the production of sheets and panels using conventional processes such as vacuum or hot- pressing.
• the sheets and panels can be used to coat materials such as wood, glass, ceramic, metal or other plastics, and outstanding strengths can be achieved using conventional adhesion promoters, for example, those based on vinyl resins.
• the sheets and panels can also be laminated with other plastic films such as by coextrusion, the sheets being bonded in the molten state.
• the surfaces of the sheets and panels can be finished by conventional methods, for example, by lacquering or by the application of protective films.
• the composites of this invention are also useful for fabrication of extruded films and film laminates, as for example, films for use in food packaging.
• Such films can be fabricated using conventional film extrusion techniques.
• the films are preferably from 10 to 100, more preferably from 20 to 100, and most preferably from 25 to 75, microns thick.

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