Halogenated Elastomer Clay Nanocomposite Air Barrier Process
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Solution Overview
Problem
Current methods for producing polymer/clay nanocomposites face challenges such as limited thermal stability, poor mechanical properties, and increased hysteresis due to the use of organically modified clays, and require expensive modification processes, while also struggling with inefficient exfoliation and high costs.
Innovation Solution
A process involving an organic aqueous emulsion where the polymer is in the organic phase and the clay is in the aqueous phase, without organic modification, allowing for efficient and economical production of nanocomposites with improved exfoliation by mixing an aqueous slurry of clay with a polymer solution, using emulsifiers or surfactants to enhance dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If organically modified clays are used to produce nanocomposites, then exfoliation is improved, but thermal stability is limited and mechanical properties deteriorate
Solution Approach 1:
The patent removes the organic modification step entirely, using raw unmodified clays instead. This extracts the problematic organic components that limited thermal stability while maintaining the desired exfoliation and barrier properties through the aqueous emulsion process.
Solution Approach 2:
The patent introduces an aqueous emulsion as an intermediary medium to facilitate the interaction between polymer and clay. The emulsion allows unmodified clay to be effectively incorporated into the polymer matrix without requiring organic modifiers, achieving exfoliation through the emulsion process rather than chemical modification.
2Stability of the object's composition
If organically modified clays are used to produce nanocomposites, then exfoliation is improved, but mechanical properties and hysteresis worsen
Solution Approach 1:
The patent eliminates the organic modification step that caused poor mechanical properties and increased hysteresis. By using raw unmodified clays in an aqueous emulsion process, the invention achieves effective exfoliation without the detrimental effects of organic modifiers on mechanical performance.
3Stability of the object's composition
If organically modified clays are used to produce nanocomposites, then exfoliation is improved, but production cost increases
Solution Approach 1:
The patent removes the expensive organic modification step from the production process. By using raw unmodified clays directly in the aqueous emulsion process, the invention achieves effective exfoliation and nanocomposite formation without the additional cost of purchasing and applying organic modifiers.
4Stability of the object's composition
If conventional methods are used to produce nanocomposites, then some exfoliation is achieved, but barrier properties are insufficient
Solution Approach 1:
The patent changes the fundamental parameters of the process by using an aqueous emulsion system instead of conventional organic-based methods. This parameter change enables superior exfoliation and dispersion of clay platelets, creating a more effective barrier structure that significantly reduces air and moisture permeability.
Solution Approach 2:
The patent creates a novel composite structure through the aqueous emulsion process, where unmodified clay platelets are uniformly dispersed and exfoliated within the polymer matrix. This composite structure achieves superior barrier properties by creating a tortuous path for gas and moisture transmission that is more effective than conventional nanocomposites.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method results in nanocomposites with enhanced barrier properties and improved mechanical properties, reducing production costs and overcoming limitations of existing methods by achieving higher exfoliation and better interaction between polymer and clay.
Implementation Method 1
mixing an aqueous slurry of clay with a polymer solution in an organic solvent to form an emulsion
Implementation Method 2
using emulsifiers or surfactants to enhance dispersion
Implementation Method 3
mixing an aqueous slurry of clay with a polymer solution
Data Source
AI summary
A nanocomposite of a halogenated elastomer and an inorganic, exfoliated clay, suitable for use as an air barrier, is disclosed. The halogenated elastomer can be a polymer comprising C4 to C7 isoolefin derived units, para-methylstyrene derived units, and para(halomethylstyrene) derived units, or can be a butyl-type rubber. The nanocomposite can be formed by contacting an aqueous slurry of inorganic clay with a polymer cement while agitating vigorously to form emulsions or micro-emulsions to intimately mix the inorganic clay and the elastomer. The nanocomposite so formed has improved air barrier properties and is suitable for use as an innerliner or innertube.