Abstract
A novel process is described for making integral multilayered polymers with the layers separated by discontinuous narrow gaps containing air and/or a blowing agent. The two step process involves first introducing a low degree of entanglement among some of the polymer chains and then breaking apart these entanglements using a blowing agent to give the discontinuous gaps that resemble elongated, narrow cells. The layer density can be controlled within a wide range, typically 10 to 2000 layers/mm, while the gap between the layers is < 100 nanometers. These layered materials, called nanolayered polymers or layered foams, are mechanically strong and have excellent thermal and electrical, and, possibly, sound insulation properties. The nanolayering process is complimentary to the process described recently (Handa and Zhang, Cellular Polymers 19, (2000) 1) to make microlayered polymers.
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