Processes for utilizing various emulsion polymerization procedures for
preparing aqueous nanocomposite dispersions are disclosed. The disclosed
processes include both in-situ polymerizations in the presence of at
least partially exfoliated unmodified clays as well as admixtures of
polymer dispersions with at least partially exfoliated unmodified clay
dispersions. The disclosed nanocomposite dispersions are useful for
preparing a variety of materials, such as coatings, adhesives, caulks,
sealants, plastics additives, and thermoplastic resins. Processes for
preparing polymer clay nanocomposite powders and use of these powders as
plastic resin and plastics additives are also disclosed.