Reinforced polyolefin composite

Patent metadata

Field	Value
Publication number	US-12104048-B2
Application number	US-201917043179-A
Country	US
Kind code	B2
Filing date	Mar 29, 2019
Priority date	Mar 29, 2018
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

A reinforced polyolefin composite is provided. The reinforced polyolefin composite comprises a polyolefin such as polyethylene or polypropylene, a rigid fibre micro filler such as glass fiber, carbon or cellulosic fibers, and at least one nano filler such as clay. The reinforced polyolefin composite may also comprise a modified polyolefin, which has a polar functional group such as maleate monoester, an acid anhydride or an acrylate grafted thereon. The clay nano filler may also be modified with an organosilane. The reinforced polyolefin composite may also comprise a stabilizer or other additives. A method of producing the reinforced polyolefin composite is also provided, comprising mixing a polyolefin, a rigid micro filler and at least one nano filler to form a mixture, melting the mixture and kneading the melted mixture. The obtained reinforced polyolefin composite is used in transportation, infrastructure, consumer goods and construction.

First claim

The invention claimed is:

1. A reinforced polyolefin composite comprising
a polyolefin and fillers dispersed in the polyolefin, wherein the fillers comprise a rigid micro filler, and at least one nano filler, wherein the rigid micro filler is rigid in that it has a Young's modulus that is higher than that of the at least one nano filler, and wherein the at least one nano filler comprises positive charged clay particles having a layer of silica disposed thereon, wherein the positive charged clay particles having a layer of silica disposed thereon are obtained by surface treating clay particles with an acrylate, and treating thereafter with an organo silane and an organo silicate in the presence of a basic liquid catalyst.

2. The reinforced polyolefin composite of claim 1 , wherein the polyolefin is polyethylene, polypropylene, or polypropylene in a combination with an ethylene-α-olefin copolymer.

3. The reinforced polyolefin composite of claim 1 , wherein the polyolefin has a melt flow rate of about 5 g/10 min to 50 g/10 min at a temperature of 230° ° C. at a weight of 2.16 kg.

4. The reinforced polyolefin composite of claim 1 , wherein the polyolefin has a polar functional group grafted thereon, or the reinforced polyolefin composite further comprises a modified polymer having a polar functional group grafted thereon, or the polyolefin has a polar functional group grafted thereon and the reinforced polyolefin composite further comprises a modified polymer having a polar functional group grafted thereon, wherein the polar functional group grafted on the polyolefin is the same as or different from the polar functional group grafted on the modified polymer.

5. The reinforced polyolefin composite of claim 4 , wherein the polar functional group grafted on the polyolefin and the polar functional group grafted on the modified polymer are independently selected from the group consisting of an acid anhydride, an ester, an acrylate and a combination thereof.

6. The reinforced polyolefin composite of claim 4 , wherein the polar functional group grafted on the polyolefin and the polar functional group grafted on the modified polymer are independently an ester selected from the group consisting of a maleate monoester, a maleate diester, and a combination thereof.

7. The reinforced polyolefin composite of claim 4 , wherein the modified polymer is a modified polyolefin.

8. The reinforced polyolefin composite of claim 7 , wherein the modified polyolefin is modified polypropylene.

9. The reinforced polyolefin composite of claim 1 , wherein a material of the rigid micro filler is selected from the group consisting of glass, carbon, cellulose, and a combination thereof.

10. The reinforced polyolefin composite of claim 1 , wherein the clay comprises calcium silicate.

11. The reinforced polyolefin composite of claim 1 , wherein the clay comprises layered and/or pellet-like metal oxide.

12. The reinforced polyolefin composite of claim 11 , wherein the layered and/or pellet-like metal oxide is selected from the group consisting of SiO 2 , TiO 2 , ZnO, CaO, Al 2 O 3 , Fe 2 O 3 , and a combination thereof.

13. The reinforced polyolefin composite of claim 1 , further comprising a styrene-based polymer.

14. The reinforced polyolefin composite of claim 1 , wherein the organo silane (a) comprises an active functional group selected from the group consisting of octyl, amine, vinyl, hydroxyl, and thiol, or (b) is trimethoxy aminoalkyl silane or triethoxy alkyl silane.

15. A method of providing a reinforced polyolefin composite, comprising a polyolefin and fillers dispersed in the polyolefin, wherein the fillers comprise a rigid micro filler, and at least one nano filler, wherein the rigid micro filler is rigid in that it has a Young's modulus that is higher than that of the at least one nano filler, and wherein the at least one nano filler comprises positive charged clay particles having a layer of silica disposed thereon, the method comprising
(i) providing at least one nano filler comprising positive charged clay particles having a layer of silica disposed thereon, wherein the providing comprises dispersing a nano filler material comprising clay particles in an aqueous solvent with acrylate to form positively charged ions on the clay particles; dispersing the positive charged clay particles in an organic solvent; and contacting the dispersion of the positive charged clay particles with an organo silicate and an organo silane in the presence of a basic liquid catalyst to form a layer of silica on the positive charged clay particles;
(ii) mixing a polyolefin, a rigid micro filler and the at least one nano filler to form a mixture;
(iii) melting the mixture to form a melted mixture; and
(iv) kneading the melted mixture.

16. The method of claim 15 , wherein the organo silane (a) comprises an active functional group selected from the group consisting of octyl, amine, vinyl, hydroxyl, and thiol, or (b) is trimethoxy aminoalkyl silane or triethoxy alkyl silane.

Assignees

• Agency Science Tech & Res
• Scg Chemicals Co Ltd

Inventors

• Thitsartarn Warintorn
• He Chaobin
• Yeo Chee Chuan Jayven
• Phonthammachai Nopphawan
• Treethammakul Supakitt
• Sukachonmakul Tanapon

Classifications

• C08K3/346

  Clay · CPC title

• C08K9/06

  with silicon-containing compounds · CPC title

• C08K9/04

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

• C08L2310/00

  Masterbatches · CPC title

• C08J2451/06

  grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond · CPC title