US4775586A — Paper, paper products, films composites and other…

Claim 1

Independent Claim 91 words

A process for a water resistant floc of polymer and a 2:1 layered silicate comprising: (1) preparing a co-dispersion of (a) a 2:1 layered silicate having an average charge per structural unit of from -0.4 to about -1.0 which is selected from mica and vermiculite, said silicate having interstitial cations that promote swelling, (b) a polymer having a molecular weight of at least 50,000, and (c) a polar liquid; and (2) contacting the co-dispersion with a cationic flocculant thereby destabilizing the co-dispersion and forming a silicate floc also containing the polymer.

Claim 2

Dependent Claim 91 words

A process for a water resistant floc of polymer and a 2:1 layered silicate comprising: (1) preparing a co-dispersion of (a) a 2:1 layered silicate having an average charge per structural unit of from -0.4 to about -1.0 which is selected from mica and vermiculite, said silicate having interstitial cations that promote swelling, (b) a polymer having a molecular weight of at least 50,000, and (c) a polar liquid; and (2) contacting the co-dispersion with a cationic flocculant thereby destabilizing the co-dispersion and forming a silicate floc also containing the polymer.

Claim 3

Dependent Claim 36 words

A process described in claim 1, wherein the polymer is characterized in that it is not dispersible in the polar liquid, but the said polymer can be dispersed in the silicate dispersed in the polar liquid.

Claim 4

Dependent Claim 14 words

A process as described in claim 2 wherein the polar liquid is substantially aqueous.

Claim 5

Dependent Claim 27 words

A process as described in claim 2 wherein the polar liquid is selected from the group consisting of glycol, water, acetone, methanol, ethanol, propanol, isopropanol, and butanol.

Claim 6

Dependent Claim 12 words

A process as described in claim 3 wherein the polymer is polyimide.

Claim 7

Dependent Claim 15 words

A process as described in claim 2 wherein the cationic flocculant is a diammonium compound.

Claim 8

Dependent Claim 70 words

A process as described in claim 6 wherein the diammonium compound has the formula: ##STR2## wherein (1) each R2 is independently selected from hydrogen, and a C1-C8 saturated or unsaturated, striaght or branched chain alkyl group; and wherein (2) R3 is selected from, a saturated or unsaturated, branched or linear alkyl group, having from 1 to 18 carbon atoms or an aryl group having from 1 to 18 carbon atoms.

Claim 9

Dependent Claim 13 words

A process as described in claim 7 wherein each R 2 is hydrogen.

Claim 10

Dependent Claim 31 words

A process as described in claim 2 wherein after step (1) a film is prepared with the co-dispersion and then, the film is contacted with the cationic flocculant in step (2).

Claim 11

Dependent Claim 18 words

A process as described in claim 9 wherein after step (2) the film is dried and hot pressed.

Claim 12

Dependent Claim 15 words

A process as described in claim 2 wherein the cationic flocculant is an aminomethyleneimine cation.

Claim 13

Dependent Claim 115 words

A process as described in claim 2 wherein the cationic flocculant is a compound having the formula: [(R.sup.1).sub.3 N--(CX.sub.2)n--N(R.sup.1).sub.3 ].sup.+2 wherein (1) each R 1 is independently selected from hydrogen, a C 1 -C 8 straight or branched chain alkyl group, a C 3 -C 6 ayclic alkyl group, or an aryl group, with the proviso that there be no more than one aryl group on each nitrogen, (2) each X is independently selected from hydrogen, an alkyl group or an aryl group and (3) n represents an integer from 2 to 15, with the option that, when n is 3 or more, the CX 2 groups may form ringed moieties which may be aromatic.

Claim 14

Dependent Claim 13 words

A process as described in claim 2 wherein the polymer is also flocculated.

Claim 15

Dependent Claim 31 words

A process as described in claim 1, wherein after Step (1), a film is prepared with the co-dispersion and then the film is contacted with the cationic flocculant in Step (2).

Claim 16

Dependent Claim 19 words

A process as described in claim 14 wherein, after Step (2), the film is dried and then hot pressed.

Claim 17

Dependent Claim 15 words

A process as described in claim 14 wherein the cationic flocculant is an aminomethyleneimine cation.

Claim 18

Dependent Claim 15 words

A process as described in claim 14 wherein the cationic flocculant is a diammonium cation.

Claim 19

Dependent Claim 21 words

A process as described in claim 1, wherein the polymer is characterized in that it is dispersible in the polar liquid.

Claim 20

Dependent Claim 15 words

A process as described in claim 18 wherein the cationic flocculant is a diammonium compound.

Claim 21

Dependent Claim 115 words

A process as described in claim 18 wherein the cationic flocculant is a cation having the formula: [(R.sup.1).sub.3 N--(CX.sub.2)n--N(R.sup.1).sub.3 ].sup.+2 wherein (1) each R 1 is independently selected from hydrogen, a C 1 -C 8 straight or branched chain alkyl group, a C 3 -C 6 ayclic alkyl group, or an aryl group, with the proviso that there be no more than one aryl group on each nitrogen, (2) each X is independently selected from hydrogen, an alkyl group or an aryl group and (3) n represents an integer from 2 to 15, with the option that, when n is 3 or more, the CX 2 groups may form ringed moieties which may be aromatic.

Claim 22

Dependent Claim 13 words

A process as described in claim 18 wherein the polymer is also flocculated.

Claim 23

Dependent Claim 15 words

A process as described in claim 18 wherein the cationic flocculant is an aminomethyleneimine cation.

Claim 24

Dependent Claim 31 words

A process as described in claim 1 wherein the co-dispersion of Step (1) is applied to a woven fibrous substrate and then is contacted with the cationic flocculant in Step (2).

Claim 25

Dependent Claim 16 words

A process as described in claim 1 wherein the co-dispersion in Step (1) also contains fibers.

Claim 26

Dependent Claim 25 words

A process as described in claim 1 wherein the co-dispersion of Step (1) is molded and then contacted with the cationic flocculant in Step (2).

Claim 27

Dependent Claim 60 words

A water-resistant silicate and polymer material comprising a polymer having a molecular weight of at least 50,000 which is intermixed homogeneously in a flocculated, swelled 2:1 layered silicate having an average charge per structural unit that ranges from about -0.4 to about -1, wherein said silicate is selected from mica and vermiculite, and contains at least some diamine interstitial cations.

Claim 28

Dependent Claim 60 words

A water-resistant silicate and polymer material comprising a polymer having a molecular weight of at least 50,000 which is intermixed homogeneously in a flocculated, swelled 2:1 layered silicate having an average charge per structural unit that ranges from about -0.4 to about -1, wherein said silicate is selected from mica and vermiculite, and contains at least some diamine interstitial cations.

Claim 29

Dependent Claim 9 words

The material of claim 26 also containing non-woven fiber.

Claim 30

Dependent Claim 11 words

The material of claim 26 further comprising a woven fibrous substrate.

Claim 31

Dependent Claim 60 words

A material as described in claim 26 which was prepared by contacting a co-dispersion of the polymer and a swelled 2:1 layered silicate having interstitial cations that promote swelling, and which was selected from mica and vermiculite, with a diamine cationic flocculant thereby causing an ion exchange and destabilizing the co-dispersion to form a silicate floc also containing the polymer.

Claim 32

Dependent Claim 20 words

A material as described in claim 29 wherein the diamine cationic flocculant simultaneously flocculates the polymer, and the silicate floc.

Claim 33

Dependent Claim 18 words

The material of claim 29 also containing a non-woven fiber which was added before contacting the cationic flocculant.

Claim 34

Dependent Claim 21 words

The material of claim 29 wherein the co-dispersion was drawn into a film and then contacted with the diamine cationic flocculant.

Claim 35

Dependent Claim 12 words

The material of claim 32 which was dried and then hot pressed.

Claim 36

Dependent Claim 21 words

The material of claim 29 which also contains polybenzimidazole fibers which were added before contacting the co-dispersion with the cationic flocculant.

Claim 37

Dependent Claim 12 words

The material of claim 29 which has been formed into a laminate.

Claim 38

Dependent Claim 22 words

The material of claim 29 wherein the co-dispersion is applied to a woven fibrous substrate and then contacted with the cationic flocculant.

Claim 39

Dependent Claim 61 words

A water resistant silicate and polymer material comprising: a co-flocculated, homogeneously intermixed material of a flocculated polymer with a molecular weight of at least 50,000 and a flocculated swelled 2:1 layered silicate having an average charge per structural unit of from about -0.4 to about -1.0 wherein said flocculated swelled 2:1 layered silicate is a silicate selected from mica and vermiculite.

Claim 40

Dependent Claim 61 words

A water resistant silicate and polymer material comprising: a co-flocculated, homogeneously intermixed material of a flocculated polymer with a molecular weight of at least 50,000 and a flocculated swelled 2:1 layered silicate having an average charge per structural unit of from about -0.4 to about -1.0 wherein said flocculated swelled 2:1 layered silicate is a silicate selected from mica and vermiculite.

Claim 41

Dependent Claim 9 words

The material of claim 37 containing a diamine cation.

Claim 42

Dependent Claim 70 words

A material as described in claim 38 wherein the diamine cation has the formula: ##STR3## wherein (1) each R2 is independently selected from hydrogen, and a C1-C8 saturated or unsaturated, striaght or branched chain alkyl group; and wherein (2) R3 is selected from a saturated or unsaturated, branched or linear alkyl group, having from 1 to 18 carbon atoms or an aryl group having from 1 to 18 carbon atoms.

Claim 43

Dependent Claim 12 words

A material as described in claim 39 wherein each R2 is hydrogen.

Claim 44

Dependent Claim 26 words

A material as described in claim 40 wherein R3 is the saturated or unsaturated, branched or linear alkyl group, having from 1 to 18 carbon atoms.

Claim 45

Dependent Claim 11 words

The material of claim 41 wherein the polymer is a latex.

Claim 46

Dependent Claim 11 words

The material of claim 38 wherein the polymer is a latex.

Claim 47

Dependent Claim 12 words

The material of claim 37 containing a cation with an aminomethyleneimine moiety.

Claim 48

Dependent Claim 11 words

The material of claim 44 wherein the polymer is a latex.

Claim 49

Dependent Claim 11 words

The material of claim 37 which also contains a non-woven fiber.

Claim 50

Dependent Claim 10 words

The material of claim 46 wherein the fiber is polybenzimidazole.

Claim 51

Dependent Claim 12 words

The material of claim 46 wherein the fiber is polybenzimidazole and fiberglass.

Claim 52

Dependent Claim 10 words

The material of claim 37 with a woven fiberous substrate.

Claim 53

Dependent Claim 12 words

The material of claim 37 which has been drawn into a film.

Claim 54

Dependent Claim 11 words

The material of claim 50 wherein the film has been hot-pressed.

Claim 55

Dependent Claim 9 words

The material of claim 37 which is a laminate.

Claim 56

Dependent Claim 11 words

The material of claim 37 wherein the polymer is a latex.

Claim 57

Dependent Claim 63 words

A water-resistant silicate and polymer material comprising a polymer having a molecular weight of at least 50,000 which is intermixed homogeneously in a flocculated, swelled 2:1 layered silicate having an average charge per structural unit that ranges from about -0.4 to about -1, wherein said silicate is selected from mica and vermiculite, and contains at least some interstitial cations with an aminomethyleneimine moiety.

Claim 58

Dependent Claim 63 words

A water-resistant silicate and polymer material comprising a polymer having a molecular weight of at least 50,000 which is intermixed homogeneously in a flocculated, swelled 2:1 layered silicate having an average charge per structural unit that ranges from about -0.4 to about -1, wherein said silicate is selected from mica and vermiculite, and contains at least some interstitial cations with an aminomethyleneimine moiety.

Claim 59

Dependent Claim 59 words

A material as described in claim 54 which was prepared by contacting a co-dispersion of the polymer and a swelled 2:1 layered silicate which had interstitial cations that promote swelling, and was selected from mica and vermiculite, with a cationic flocculant having an aminomethyleneimine moiety to thereby destabilize the co-dispersion and form a silicate floc also containing the polymer.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-10-04	1992-04-04	1992-10-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-10-04	1996-04-04	1996-10-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-10-04	2000-04-04	2000-10-04	$7700.00	Window Closed / Lapsed

Paper, paper products, films composites and other silicate-polymer, construction materials

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