US4739007A
Expired / Lapsed
US
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Composite material and process for manufacturing same
Assignee: Toyota Central R&D Labs Inc
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Filing: 1986-09-19
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Granted: 1988-04-19
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Expires: 2006-09-19
Abstract
Abstract Composite material with high mechanical strength and excellent high-temperature characteristics comprising a polymer matrix containing polyamide and layers of a silicate uniformly dispersed in the order of molecules in the polymer matrix, each of said silicate layers being 7 to 12 ANGSTROM thick and the interlayer distance being at least 20 ANGSTROM ; and a process for manufacturing such composite material.
Inventors
- 👤 Akane Okada
- 👤 Yoshiaki Fukushima
- 👤 Masaya Kawasumi
- 👤 Shinji Inagaki
- 👤 Arimitsu Usuki
- 👤 Shigetoshi Sugiyama
- 👤 Toshio Kurauchi
- 👤 Osami Kamigaito
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 03:09
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/005; B; B82; B82Y; B82Y30/00; C08K; C08K3/00; C08K3/34; C08K3/346; C08L; C08L77/00; C08L77/02; C08J2377/00
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
78 words
Composite material with high mechanical strength and excellent high-temperature characteristics comprising a polymer matrix containing polyamide and a phyllosilicate uniformly dispersed in said polymer matrix, the phyllosilicate layers of said dispersed phyllosilicate being 7 to 12 Å thick and the interlayer distances of said phyllosilicate layers in the dispersed phyllosilicate being at least 20 Å, and the amount of said phyllosilicate layers being 0.5 to 150 parts by weight per 100 parts by weight of said polymer matrix.
Claim 2
Dependent Claim
78 words
Composite material with high mechanical strength and excellent high-temperature characteristics comprising a polymer matrix containing polyamide and a phyllosilicate uniformly dispersed in said polymer matrix, the phyllosilicate layers of said dispersed phyllosilicate being 7 to 12 Å thick and the interlayer distances of said phyllosilicate layers in the dispersed phyllosilicate being at least 20 Å, and the amount of said phyllosilicate layers being 0.5 to 150 parts by weight per 100 parts by weight of said polymer matrix.
Claim 3
Dependent Claim
15 words
Composite material as defined in claim 1, wherein said phyllosilicate is aluminum or magnesium phyllosilicate.
Claim 4
Dependent Claim
36 words
Composite material as defined in claim 1, wherein the interlayer distances of said phyllosilicate layers are at least 30 Å and said phyllosilicate layers are combined with part of chains of said polyamide through ionic bonding.
Claim 5
Dependent Claim
56 words
Composite material as defined in claim 3, wherein said phyllosilicate layers are negatively charged and form ionic bonds with positively charged groups arranged on part of said polyamide in said polymer matrix, the area occupied by each of the negative charges on said phyllosilicate layers being in the range from 25 to 200 Å 2 .
Claim 6
Dependent Claim
56 words
Composite material as defined in claim 3, wherein part of said polyamide in said polymer matrix carries ammonium ion (--NH 3 + ), trimethylammonium ion (--N + (CH 3 ) 3 ), or cations expressed by --NX + , in which X is at least one member selected from hydrogen (H), copper (Cu) and aluminum (Al).
Claim 7
Dependent Claim
41 words
Composite material as defined in claim 1, wherein the molecular weight distribution of said polyamide expressed by the ratio of its weight average molecular weight (M w ) to its number average molecular weight (M n ) is 6 or smaller.
Claim 8
Dependent Claim
35 words
Composite material as defined in claim 6, wherein said phyllosilicate layers are negatively charged and the area occupied by each of the negative charges is in the range from 25 to 200 Å 2 .
Claim 9
Dependent Claim
90 words
A process for manufacturing composite material with high mechanical strength and excellent high-temperature characteristics comprising the steps of bringing a swelling agent into contact with a clay mineral having a cation-exchange capacity of 50 to 200 milliequivalent per 100 g of said clay mineral to form a complex capable of being swollen by a polyamide monomer at a temperature higher than the melting point of said monomer, mixing said complex with said polyamide monomer, and heating the mixture obtained in said mixing step to a prescribed temperature to effect polymerization.
Claim 10
Dependent Claim
90 words
A process for manufacturing composite material with high mechanical strength and excellent high-temperature characteristics comprising the steps of bringing a swelling agent into contact with a clay mineral having a cation-exchange capacity of 50 to 200 milliequivalent per 100 g of said clay mineral to form a complex capable of being swollen by a polyamide monomer at a temperature higher than the melting point of said monomer, mixing said complex with said polyamide monomer, and heating the mixture obtained in said mixing step to a prescribed temperature to effect polymerization.
Claim 11
Dependent Claim
20 words
The process for manufacturing composite material as defined in claim 8, wherein said clay mineral is a smectite or vermiculite.
Claim 12
Dependent Claim
23 words
The process for manufacturing composite material as defined in claim 8, wherein said swelling agent is an organic cation having a carboxyl group.
Claim 13
Dependent Claim
35 words
The process for manufacturing composite material as defined in claim 10, wherein said swelling agent is at least one member selected from 12-amino-dodecanoic acid ion, 14-amino-tetradecanoic acid ion, 16-amino-hexadecanoic acid ion and 18-amino-octadecanoic acid ion.
Claim 14
Dependent Claim
36 words
The process for manufacturing composite material as defined in claim 8, wherein said swelling agent is at least one member selected from the group consisting of the aluminum ion, the hydrogen ion and the copper ion.
Claim 15
Dependent Claim
18 words
The process for manufacturing composite material as defined in claim 8, wherein said polyamide monomer is a lactam.
Claim 16
Dependent Claim
16 words
The process for manufacturing composite material as defined in claim 13, wherein said lactam is ε-caprolactam.
Claim 17
Dependent Claim
19 words
The process for manufacturing composite material as defined in claim 8, wherein said polyamide monomer is an amino acid.
Claim 18
Dependent Claim
21 words
The process for manufacturing composite material as defined in claim 15, wherein said amino acid is 6-amino-n-caproic acid or 12-amino-dodecanoic acid.
Claim 19
Dependent Claim
19 words
The process for manufacturing composite material as defined in claim 8, wherein said polyamide monomer is a nylon salt.
Claim 20
Dependent Claim
18 words
The process for manufacturing composite material as defined in claim 17, wherein said nylon salt is hexamethylenediamine adipate.
Claim 21
Dependent Claim
25 words
The process for manufacturing composite material as defined in claim 8, wherein a base catalyst and an activator are further added in said mixing step.
Claim 22
Dependent Claim
38 words
The process for manufacturing composite material as defined in claim 19, wherein said base catalyst is one member selected from the group consisting of sodium hydride, sodium methoxide, sodium hydroxide, sodium amide and potassium salt of a lactam.
Claim 23
Dependent Claim
33 words
The process for manufacturing composite material as defined in claim 19, wherein said activator is one member selected from the group consisting of N-acetylcaprolactam, acetic anhydride, carbon dioxide, phenyl isocyanate and cyanuric chloride.
Claim 24
Dependent Claim
20 words
The process for manufacturing composite material as defined in claim 19, wherein said clay mineral is a smectite or vermiculite.
Claim 25
Dependent Claim
19 words
The process for manufacturing composite material as defined in claim 19, wherein said swelling agent is an organic cation.
Claim 26
Dependent Claim
25 words
The process for manufacturing composite material as defined in claim 23, wherein said organic cation is a compound having an onium ion in the molecule.
Claim 27
Dependent Claim
18 words
The process for manufacturing composite material as defined in claim 19, wherein said polyamide monomer is a lactam.
Claim 28
Dependent Claim
48 words
The process for manufacturing composite material as defined in claim 25, wherein said lactam is a compound represented by the following formula ##STR4## wherein n is an integer of 6 to 12, and R stands for hydrogen, and alkyl of 1 to 8 carbon atoms, or an aralkyl.
Claim 29
Dependent Claim
19 words
The process for manufacturing composite material as defined in claim 26, wherein said lactam is caprolactam, caprylolactam or dodecanolactam.
References Cited (Backward Citations)
US3372137A
Cited
US3883469A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1991-04-19 | 1991-10-19 | 1992-04-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-04-19 | 1995-10-19 | 1996-04-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-04-19 | 1999-10-19 | 2000-04-19 | $7700.00 | Window Closed / Lapsed |