Biocarbon and nylon based hybrid carbonaceous biocomposites and methods of making those and using thereof

Patent metadata

Field	Value
Publication number	US-2018022921-A1
Application number	US-201715654366-A
Country	US
Kind code	A1
Filing date	Jul 19, 2017
Priority date	Jul 19, 2016
Publication date	Jan 25, 2018
Grant date	—

Abstract

A polymer blend comprising polyamide, polypropylene (PP) and at least one of poly (lactic acid) (PLA) and a multi-phase compatibilizer comprising PA11-co-PP-maleic anhydride (MA). The polymer blend can be reinforced with hybrid fillers including biocarbon, glass fiber, carbon fiber and nano-clay to create composites useful in the creation of products of manufacture such as auto parts.

First claim

What is claimed is:

1 . A polymer blend comprising polyamide (PA), polypropylene (PP) and at least one of poly (lactic acid) (PLA) and a multi-phase compatibilizer comprising PA11-co-PP-maleic anhydride (MA).

2 . The polymer blend of claim 1 , wherein the PA is PA 6, PA 6,6 or PA 6,10.

3 . The polymer blend of claim 1 , wherein the polymer blend includes from about 60 to about 85% by weight of the PA, up to about 20 wt. % of the PLA and up to about 20 wt. % of the PP.

4 . The polymer blend of claim 1 , wherein the polymer blend comprises PA, PP, PLA and an additive selected from a compatibilizing agent, a chain extender, or both a compatibilizing agent and a chain extender.

5 . The polymer blend of claim 1 , wherein the polymer blend comprises PA, PP, PLA and about 7.5% wt. or less of a compatibilizing agent.

6 . The polymer blend of claim 1 , wherein the polymer blend comprises PA, PP and the multi-phase compatibilizer comprising PA11-co-PP-maleic anhydride (MA).

7 . The polymer blend of claim 6 , wherein the polymer blend further comprises no more than 10% wt. of the PLA.

8 . The polymer blend of claim 5 , wherein the compatibilizing agent is a maleated polyolefin or epoxidized natural rubber.

9 . The polymer blend of claim 8 , wherein the maleated polyolefin is maleated polypropylene (MAPP), maleated polyethylene (MAPE), or a mixture of MAPP and MAPE.

10 . The polymer blend of claim 1 , wherein the polymer blend further includes about 7.5% wt. or less of a chain extender.

11 . The polymer blend of claim 1 , wherein the blend has a greater flexural strength, flexural modulus and impact strength than pure nylon.

12 . A composite comprising a polymeric blend of polyamide (PA) and polypropylene (PP) and biocarbon.

13 . The composite of claim 12 , wherein the composite further comprises epoxidized natural rubber (ENR).

14 . The composite of claim 12 , wherein the composite further comprises a filler selected from carbon fiber, glass fiber, mineral fiber such as, talc and nanoclay, or any combinations thereof.

15 . The composite of claim 12 , wherein the composite further comprises a melt flow enhancer.

16 . The composite of claim 15 , wherein the melt flow enhancer is poly (lactic acid) (PLA), and the PLA is 10% wt. or less of the composite.

17 . The composite of claim 12 , wherein the polymeric blend comprises PA 6, PLA, PP and MAPP, and wherein the composite further comprises carbon fiber, epoxidized natural rubber and zinc stearate.

18 . The composite of claim 12 , wherein the polymeric blend comprises PA 6, PLA, PP, MAPP and MAPE, and wherein the composite further comprises glass fiber and zinc stearate.

19 . The composite of claim 12 , wherein the biocarbon has a particle size of about 63 μm or less.

20 . The composite of claim 12 , wherein the composite has similar or enhanced impact strength relative to pure PA.

21 . The composite of claim 12 , wherein the composite further includes a copper salt thermal stabilizer.

22 . An article of manufacture that is made from the composite of claim 12 .

23 . A polyamide (PA)-based composite having similar or enhanced impact strength relative to pure PA, the composite comprising PA and biocarbon, wherein the biocarbon has a particle size of about 63 μm or less.

24 . The composite of claim 23 , wherein the PA is PA 6,10 or PA6.

25 . The composite of claim 23 , wherein the PA is PA 6.

26 . The composite of claim 23 , wherein the composite comprises about 80 wt. % nylon and about 20 wt. % biocarbon.

27 . The composite of claim 25 , wherein the biocarbon has a mean particle size between about 2 μm and about 3.8 μm.

28 . The composite of claim 23 , wherein the composite comprises about 90 wt. % PA 6 and about 10 wt. % biocarbon.

29 . A method of enhancing thermal stability of a binary or ternary hybrid system, the method comprising adding a copper salt thermal stabilizer to the binary or ternary hybrid system, wherein the binary system includes a polyamide and polypropylene, and the ternary hybrid system includes a polyamide, polypropylene and poly (lactic acid).

30 . A multi-phase compatibilizer for a binary system of PA and PP, the multi-phase compatibilizer comprising PA11-co-PP-maleic anhydride.

Assignees

• Univ Guelph

Inventors

• Mohanty Amar
• Misra Manjusri
• Ogunsona Emmanuel Olusegun
• Anstey Andrew James
• Torres Galvez Simonet Evelyn
• CODOU Amandine Marie Floriane Magali-Sophie
• Jubinville Dylan Fernand

Classifications

• C08L77/02 Primary

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08L77/10 takes precedence) · CPC title

• C08L2205/035

  containing four or more polymers in a blend · CPC title

• C08L77/06

  Polyamides derived from polyamines and polycarboxylic acids (C08L77/10 takes precedence) · CPC title

• C08K3/04

  Carbon · CPC title

• C08L2205/03

  containing three or more polymers in a blend · CPC title