Scalable Production of 2D Minerals by Polymer Intercalation and Adhesion for Multifunctional Applications

Natural and sustainable 2D minerals have many unique properties and may reduce reliance on petroleum-based products. However, the large-scale production of 2D minerals remains challenging. Herein, a green, scalable, and universal polymer intercalation and adhesion exfoliation (PIAE) method to produce 2D minerals such as vermiculite, mica, nontronite, and montmorillonite with large lateral sizes and high efficiency, is developed. The exfoliation relies on the dual functions of polymers involving intercalation and adhesion to expand interlayer space and weaken interlayer interactions of minerals, facilitating their exfoliation. Taking vermiculite as an example, the PIAE produces 2D vermiculite with an average lateral size of 1.83 ± 0.48 µm and thickness of 2.40 ± 0.77 nm at a yield of ≈30.8%, surpassing state-of-the-art methods in preparing 2D minerals. Flexible films are directly fabricated by the 2D vermiculite/polymer dispersion, exhibiting outstanding performances including mechanical strength, thermal resistance, ultraviolet shielding, and recyclability. The representative application of colorful multifunctional window coatings in sustainable buildings is demonstrated, indicating the potential of massively produced 2D minerals.