Inorganic material composite

Patent metadata

Field	Value
Publication number	US-10508187-B2
Application number	US-201615162787-A
Country	US
Kind code	B2
Filing date	May 24, 2016
Priority date	Apr 29, 2009
Publication date	Dec 17, 2019
Grant date	Dec 17, 2019

Abstract

The invention relates to a ceramic particulate and polymer composite having enhanced viscoelastic and rheological properties.

First claim

We claim:

1. A method of making an inorganic material particulate and polymer composite comprising:
(a) coating about 40 to 90 vol. % of an inorganic material particulate having a particle size greater than about 5 microns with an interfacial modifier, the percentage based on the composite, to form an interfacial modifier coated particle;
(b) combining the coated particle with a polymer phase under melt processing conditions to make the composite, and;
(c) forming a pellet by melt processing the composite.

2. The method of claim 1 wherein the composite has a tensile strength of about 0.1 to 30 times that of the base polymer.

3. The method of claim 1 wherein the composite has a tensile elongation of about 5% to 100% of the base polymer.

4. The method of claim 3 wherein the composite has a thermoplastic shear of at least 5 sec −1 .

5. The method of claim 1 wherein the composite comprises greater than 30 vol-% of a glass microsphere, a ceramic particulate or an inorganic mineral particulate.

6. The method of claim 1 wherein the coated particle is combined with the polymer phase to make the composite in an extruder.

7. The method of claim 1 wherein the particulate has a P s of about 10 to 1000 microns.

8. The method of claim 1 wherein the particulate has a particle size P s of about 10 to 500 microns and the composite additionally comprises a second particulate with a second particle size P s 1 that differs from P s by at least 5 microns.

9. The method of claim 8 wherein the second particulate comprises a metal particulate, a second solid inorganic particulate, a glass particulate, or a ceramic particulate.

10. The method of claim 8 wherein the second particulate comprises a hollow glass sphere having a particle size (P s ) of about 10 to 500 microns.

11. The method of claim 8 wherein the second particulate comprises a silica having a particle size (P s ) of about 75 to 500 microns.

12. The method of claim 1 wherein the polymer is selected from the group of thermoplastic polymers consisting of a polyamide, a nylon, a poly (ethylene-co-vinyl acetate), a synthetic rubber, a polyvinyl chloride, a fluoropolymer, a polyolefin, a thermoset polymer, a fluoroelastomer, and a high-density polyolefin.

13. The method of claim 1 wherein the particulate comprises a coating comprising about 0.01 to 4 wt. % of an interfacial modifier the percentage based on the composite.

14. The method of claim 1 wherein the particle has an excluded volume of about 13 vol.-% to about 70 vol.-%.

15. A particulate polymer composite comprising an inorganic material particle in a polymer phase, the composite comprising:
(a) about 90 to 40 volume-% of the inorganic material particle, having a density greater than 0.10 gm-cm −3 and less than 10 gm-cm −3 , a particle size greater than 5 microns, a circularity greater than 12.5; and
(b) about 10 to 70 volume-% of a polymer phase;

wherein the particle has a coating comprising about 0.005 to 8 wt.-% of an interfacial modifier, the percentage based on the composite; and a composite density of about 0.4 to 5 gm-cm −3 .

16. The composite of claim 15 wherein the inorganic material particle is an inorganic mineral particle.

17. The composite of claim 15 further comprising fiber with the coating of the interfacial modifier.

18. A method of making an inorganic material particulate, fiber, and polymer composite comprising:
(a) coating about 40 to 90 vol. % of an inorganic material particulate having a particle size greater than about 5 microns and fiber with an aspect ratio greater than 10, with an interfacial modifier, the percentage based on the composite, to form coated particle and fiber;
(b) combining the coated particle and the fiber with a polymer phase to make the composite, and;
(c) forming a pellet by melt processing the composite.

Assignees

• Tundra Composites Llc

Inventors

• Heikkila Kurt E
• Williams Rodney K
• Kroll John S

Classifications

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title

• Y10T428/249974

  Metal- or silicon-containing element · CPC title

• C08K7/28

  Glass · CPC title

• B60C1/00

  Tyres characterised by the chemical composition or the physical arrangement or mixture of the composition · CPC title

• C08K2003/2227

  of aluminium · CPC title