U.S. patent application number 10/904417 was filed with the patent office on 2005-06-09 for method for producing a well-exfoliated and dispersed polymer silicate nanocomposite by ultrasonication.
This patent application is currently assigned to FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to Lee, Ellen Cheng-chi, Mielewski, Deborah Frances.
Application Number | 20050122834 10/904417 |
Document ID | / |
Family ID | 26854887 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050122834 |
Kind Code |
A1 |
Lee, Ellen Cheng-chi ; et
al. |
June 9, 2005 |
METHOD FOR PRODUCING A WELL-EXFOLIATED AND DISPERSED POLYMER
SILICATE NANOCOMPOSITE BY ULTRASONICATION
Abstract
The present invention discloses a method for dispersing and
exfoliating fillers in a thermoplastic polymer by sonicating a
mixture of the thermoplastic polymer and the filler. The method of
the present invention is particularly useful in dispersing layered
silicate clays in thermoplastic polymers. A reinforced composite
comprising a filler dispersed in a thermoplastic polymer is also
disclosed. In another variation, the method of the invention is
incorporated into conventional plastic extruder and injection
molding equipment.
Inventors: |
Lee, Ellen Cheng-chi; (Ann
Arbor, MI) ; Mielewski, Deborah Frances; (Ann Arbor,
MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C./FGTL
1000 TOWN CENTER
22ND FLOOR
SOUTHFIELD
MI
48075-1238
US
|
Assignee: |
FORD GLOBAL TECHNOLOGIES,
LLC
One Parklane Blvd Suite 600 Parklane Towers East
Dearborn
MI
|
Family ID: |
26854887 |
Appl. No.: |
10/904417 |
Filed: |
November 9, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10904417 |
Nov 9, 2004 |
|
|
|
10158270 |
May 30, 2002 |
|
|
|
6828371 |
|
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60347536 |
Jan 11, 2002 |
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Current U.S.
Class: |
366/79 |
Current CPC
Class: |
C08J 3/201 20130101 |
Class at
Publication: |
366/079 |
International
Class: |
B28C 001/16 |
Claims
What is claimed is:
1. A sonic mixing apparatus comprising: a chamber for holding
plastic material; a stirrer; a heater in communication with the
chamber for heating the chamber and plastic material within the
chamber; and at least one sonicator in communication with the
chamber and the plastic material for transferring sonic energy to
plastic material within the chamber.
2. The sonic mixing apparatus of claim 1 wherein the at least one
screw feeder can be translated through the chamber.
3. The sonic mixing apparatus of claim 1 wherein the at least one
sonicator comprises a sonic horn and a sonic processor.
4. The sonic mixing apparatus of claim 1 further comprising: a
motor; a feeder in communication with the chamber for introducing
the plastic material into the chamber; and an exit port on the
chamber for providing an exit path for the plastic material from
the chamber; wherein the stirrer is at least one screw feeder
within the chamber for mixing and moving material through the
chamber and the motor is in communication with the screw feeder for
turning the screw feeder.
5. The sonic mixing apparatus of claim 4 wherein the feeder
comprises a hopper.
6. The sonic mixing apparatus of claim 4 further comprising a
nozzle in communication with the port, wherein the nozzle provides
a conduit out of the chamber for the plastic material.
7. The sonic mixing apparatus of claim 6 wherein the nozzle is
attachable to a mold used in injection molding.
8. The sonic mixing apparatus of claim 6 wherein the nozzle is
adapted such that the sonic mixing apparatus functions as an
extruder.
9. The sonic mixing apparatus of claim 1 wherein: the sonicator
operates at a frequency from 5 kHz to 10.sup.10 kHz and provides
sonic energy at a level is from about 5 kJ/g to about 100 kJ/g.
10. The sonic mixing apparatus of claim 1 wherein: the sonicator
operates at a frequency from 15 kHz to 200 MHZ and provides sonic
energy at a level from about 10 kJ/g to about 40 kJ/g.
11. The sonic mixing apparatus of claim 1 wherein: the sonicator
operates at a frequency from 15 kHz to 40 kHz and provides sonic
energy at a level from about 10 kJ/g to about 40 kJ/g.
12. A sonic mixing apparatus comprising: a chamber for holding
plastic material; a stirrer; a heater in communication with the
chamber for heating the chamber and plastic material within the
chamber; and at least one sonicator in communication with the
chamber and the plastic material for transferring sonic energy to
plastic material within the chamber, the at least one sonicator
operatable at a frequency from 15 kHz to 200 MHZ and provides sonic
energy at a level from about 10 kJ/g to about 40 kJ/g.
13. The sonic mixing apparatus of claim 12 wherein the at least one
screw feeder can be translated through the chamber.
14. The sonic mixing apparatus of claim 12 wherein the at least one
sonicator comprises a sonic horn and a sonic processor.
15. The sonic mixing apparatus of claim 12 further comprising: a
motor; a feeder in communication with the chamber for introducing
the plastic material into the chamber; and an exit port on the
chamber for providing an exit path for the plastic material from
the chamber; wherein the stirrer is at least one screw feeder
within the chamber for mixing and moving material through the
chamber and the motor is in communication with the screw feeder for
turning the screw feeder.
16. The sonic mixing apparatus of claim 15 wherein the feeder
comprises a hopper.
17. The sonic mixing apparatus of claim 15 further comprising a
nozzle in communication with the port, wherein the nozzle provides
a conduit out of the chamber for the plastic material.
18. The sonic mixing apparatus of claim 17 wherein the nozzle is
attachable to a mold used in injection molding.
19. The sonic mixing apparatus of claim 6 wherein the nozzle is
adapted such that the sonic mixing apparatus functions as an
extruder.
20. The sonic mixing apparatus of claim 12 wherein: the sonicator
operates at a frequency from 15 kHz to 40 kHz and provides sonic
energy at a level from about 10 kJ/g to about 40 kJ/g.
21. A sonic mixing apparatus comprising: a chamber for holding
plastic material; a stirrer; a heater in communication with the
chamber for heating the chamber and plastic material within the
chamber; at least one sonicator in communication with the chamber
and the plastic material for transferring sonic energy to plastic
material within the chamber; a feeder in communication with the
chamber for introducing the plastic material into the chamber; and
an exit port on the chamber for providing an exit path for the
plastic material from the chamber.
22. The sonic mixing apparatus of claim 21 further comprising a
nozzle in communication with the port, wherein the nozzle provides
a conduit out of the chamber for the plastic material.
23. The sonic mixing apparatus of claim 22 wherein the nozzle is
attachable to a mold used in injection molding.
24. The sonic mixing apparatus of claim 22 wherein the nozzle is
adapted such that the sonic mixing apparatus functions as an
extruder.
25. The sonic mixing apparatus of claim 21 wherein: the sonicator
operates at a frequency from 5 kHz to 10.sup.10 kHz and provides
sonic energy at a level is from about 5 kJ/g to about 10 kJ/g.
26. The sonic mixing apparatus of claim 21 wherein: the sonicator
operates at a frequency from 15 kHz to 200 MHZ and provides sonic
energy at a level from about 10 kJ/g to about 40 kJ/g.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. application Ser. No.
10/158,270 filed May 30, 2002, which, in turn, claims the benefit
of U.S. provisional application Ser. No. 60/347,536, filed Jan. 11,
2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to methods of forming plastic
composites comprising a filler and a thermoplastic polymer. More
specifically, the present invention relates to methods of
dispersing and exfoliating fillers in thermoplastic polymers.
[0004] 2. Background Art
[0005] Nanocomposites are a class of materials that can address
many of the challenges currently presented by automotive plastics
and composites needs. These materials offer a variety of desirable
properties including: low coefficient of thermal expansion, high
heat deflection temperatures, lightweight, improved scratch
resistance, and potential application in automotive Class A
surfaces. Nanocomposites are polymers reinforced with nanometer
sized particles, i.e., particles with a dimension on the order of 1
to several hundred nanometers. These materials can be used in
structural, semi-structural, high heat underhood, and Class A
automotive components, among others. Polyolefin based
nanocomposites, in particular, have long been sought after due to
polyolefin's wide usage and low resin cost. The major difficulty
lies in generating a well-dispersed, well-exfoliated sample due to
differences in polarity and compatibility between the clay and
polymer phases.
[0006] Reinforced plastic materials are continually finding new
uses in automotive components. These materials have certain
advantages over metals which include higher impact loads before
deformation, lighter weight, increased design flexibility, and
corrosion resistance. Automotive structural applications have
traditionally been made from continuous glass mat composites and
highly filled plastic materials such as sheet molding compound
("SMC") where the polymeric component can be as little as 15% by
weight. Both SMC and glass mat composite materials ("GMT"),
however, are still relatively high in density.
[0007] Automobile trim and semi-structural components, on the other
hand, are commonly fabricated from injection moldable
thermoplastics and thermosets. These lighter weight composites,
such as short fiber and mineral filled thermoplastics, could be
substituted for metals or SMC and GMT composites in the same
applications if their mechanical properties could meet the more
stringent requirements. Virtually all bumper fascias and air intake
manifolds have transitioned from metallic materials to plastics. As
new plastic-based materials are developed, the transition will also
encompass both more structural components, as well as Class A body
panels and high heat underhood applications.
[0008] Injection moldable thermoplastics have long been
mechanically reinforced by the addition of particulate and fiber
fillers in order to improve mechanical properties such as
stiffness, dimensional stability, and temperature resistance.
Typical fillers include chopped glass fiber and talc, which are
added at filler loadings of 20-40% in order to obtain significant
mechanical reinforcement. At these loading levels, however, low
temperature impact performance and material toughness are
sacrificed. Polymer-silicate nanocomposite materials can address
these issues.
[0009] Polymer-layered silicate nanocomposites incorporate a clay
filler in a polymer matrix. Two groups of clay are currently
recognized--the kaolin group and the montmorillonite group. The
molecules of the kaolin are arranged in two sheets or plates, one
of silica and one of alumina. Similarly, montmorillonite clays are
arranged in two silica sheets and one alumina sheet. The molecules
of the montmorillonite clays are less firmly linked together than
those of the kaolin group and are thus further apart. Composites
incorporating either of these clays are potential candidates for
structural, semi-structural, and Class A vertical and horizontal
body applications. Nanocomposites have enjoyed increased interest
since the initial development of nylon based material by Usuki et
al in 1993. (Usuki, A., et al., Journal of Materials Research,
1993.8(5): p.1179-1184.) Typically, polymer nanocomposites combine
an organic polymer with an inorganic layered silicate (in the work
of Usuki et al., the thermoplastic material Nylon 6 and a
montmorillonite clay). Layered silicates are made up of several
hundred thin platelet layers stacked into an orderly packet known
as a tactoid. Each of these platelets is characterized by large
aspect ratio (diameter/thickness on the order of 100-1000).
Accordingly, when the clay is dispersed homogeneously and
exfoliated as individual platelets throughout the polymer matrix,
dramatic increases in strength, flexural and Young's modulus, and
heat distortion temperature are observed at very low filler
loadings (<10% by weight) due to the large surface area contact
between polymer and filler. The Nylon 6 nanocomposites generated by
Usuki were produced by intercalation of caprolactam monomers into
the silicate galleries and then in situ polymerization of the
monomers. While melt compounding of Nylons with organically
modified clays (nanoclays) has also been attempted, the mechanical
properties and degree of clay dispersion and exfoliation are
slightly short of those of the in situ polymerized type. Efforts to
generate similar nanocomposites using other types of thermoplastics
and thermosets have enjoyed varying degrees of success.
[0010] Due to the polar nature of layered silicates, attempts to
generate nanocomposites in a non-polar polyolefin matrix have been
only marginally successful. Many research groups have attempted
melt compounding of polypropylene and polyethylene based
nanocomposites by adding maleic anhydride grafted polypropylene
oligomers (PP-MA) to aid in compatibilization and dispersion. While
this strategy is somewhat effective in improving nanoclay
exfoliation, it requires almost 25% PP-MA, which has the
deleterious effect of softening the matrix. To circumvent this
issue, a few groups have attempted intercalation of olefin monomers
and in situ polymerization to generate polyolefin-silicate
nanocomposites. In 1996, Tudor attempted in situ polypropylene
polymerization with a Ziegler-Natta catalyst, which produced
oligomers, but did not succeed in producing an intercalated or
exfoliated structure due to catalyst instability. (Tudor et al.,
J., et al., Chemical Communications, 1996. v. 17, p. 2031-32.) In
1999, Bergman was able to generate an exfoliated polyethylene by in
situ polymerization with a new class of catalyst. (Bergman, J. S.,
et al., Chemical Communications, 1999.21: p. 2179-2180.)
Polypropylene nanocomposites, however, have yet to be generated by
in situ polymerization.
[0011] For the reasons set forth above, there exists a need for an
improved process for dispersing and exfoliating filler material in
a polymer matrix.
SUMMARY OF THE INVENTION
[0012] The present invention overcomes the problems encountered in
the prior art by providing a method of dispersing and exfoliating a
filler in a polymer matrix by sonicating a mixture of the filler
and polymer. The method of the present invention comprises:
[0013] a) sonicating a polymer mixture comprising a thermoplastic
polymer and a filler at a sonic energy level sufficient to disperse
the filler within the thermoplastic polymer;
[0014] wherein the thermoplastic polymer is in a melted state
during the sonication. This method is particularly useful for
dispersing and exfoliating a layered silicate in a polymer
matrix.
[0015] In another embodiment of the present invention, a
polymer-filler composite is provided. The polymer-filler composite
of the present invention is characterized as having a filler
dispersed within a thermoplastic polymer by the method set forth
above. The polymer-filler composite of the present invention is
preferably used to form a molded part by method such as injection
molding, compression molding, blow molding, and the like.
[0016] In yet another embodiment of the present invention a sonic
mixing apparatus is provided. The sonic mixing apparatus is
preferably combined with a number of plastic mixing or molding
equipment. Examples of such equipment include, but are not limited
to extruders, injection molding equipment, compression molding
equipment, blow molding equipment, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a cross-section of a plastic extruder
incorporating the sonic mixing apparatus of the present invention;
and
[0018] FIG. 2 is a cross-section of an injection molding apparatus
utilizing the sonic mixing apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0019] Reference will now be made in detail to presently preferred
compositions or embodiments and methods of the invention, which
constitute the best modes of practicing the invention presently
known to the inventors.
[0020] In an embodiment of the present invention a method for
dispersing a filler in a thermoplastic polymer is provided. The
method of the present invention comprises:
[0021] a) sonicating a polymer mixture comprising a thermoplastic
polymer and a filler at a sonic energy level sufficient to disperse
the filler within the thermoplastic polymer;
[0022] wherein the thermoplastic polymer is in a melted state
during the sonication. Sonication may be performed with any device
capable of delivering sonic energy in the frequency ranges and
energy described below. Such devices will at times be referred to
as sonicators, ultrasonicators, sonic probes or ultrasonic probes.
For example, a suitable 60 Watt ultrasonic processor with a 1/2"
diameter horn, operating at 20 kHz. is commercially available from
Sonics and Materials, Inc. Typically, the sound frequency utilized
in the present invention will be in the ultrasonic frequency range.
However, frequencies near the upper limit of the audible range are
also useful in the present invention. Preferably, the step of
sonicating is performed at a sound frequency of 5 kHz to 10.sup.10
kHz. More preferably, the sonicating is performed at a sound
frequency range 15 kHz to 200 MHZ, and most preferably, the
sonication is performed at a frequency 15 kHz to 40 kHz.
[0023] The sonication step of the present invention is further
characterized by the sonic energy applied to the polymer mixture.
This energy is best described by an energy density defined as the
amount of energy per gram of polymer mixture. Preferably, the
energy density is from about 5 kJ/g to about 100 kJ/g. More
preferably, the energy density is from about 10 kJ/g to about 40
kJ/g, and most preferably the energy density is about 20 kJ/g. The
amount of time that a given amount of polymer mixture is sonicated
will depend on the amount of energy deployed. For energy densities
in the range of about 5 kJ/g to about 100 kJ/g the polymer mixture
is preferably sonicated from about 10 seconds to about 10 minutes.
For large polymer mixture samples the sonication may be
accomplished by using additional sonicators or ultrasonicators. As
used herein, the term "sonicator" refers to any source of sonic
energy and "ultrasonicator" refers to any source of ultrasonic
energy.
[0024] A number of fillers can be dispersed in a polymer by the
method of the present invention. Preferably, such fillers are
present in an amount of about 0.1% to about 30% of the total weight
of the polymer mixture. Suitable examples of fillers include, but
are not limited to, montmorillonite clay, kaolin clay, calcium
carbonate, titanium dioxide, talc, zirconium dioxide, zinc oxide,
calcium silicate, aluminum silicate, calcium sulfate, alumina
trihydrate, glass fibers, carbon fibers, and mixtures thereof. The
preferred fillers will be materials having particles with a size of
about 5 nm. to about 1000 nm. with aspect ratios from about 100 to
about 1000. More preferably, the filler used in the method of the
present invention is a layered silicate clay, and most preferably
the filler is an aluminum silicate clay. Suitable fillers include
montmorillonite clays such as Cloisite 20A commercially available
from Southern Clay Products, Inc, and I.30E commercially available
from Nanocor, Inc. These alkyl ammonium cation exchanged
montmorillonite clays are referred to as nanoclays. The Southern
Clay Products nanoclay is cation exchanged with excess amine, while
the Nanocor nanoclays are rinsed of excess salts and purified. In a
variation of the present invention, the filler is a mixture of a
nanoclay and one or more traditional fillers. Such traditional
fillers include, but are not limited to calcium carbonate, titanium
dioxide, talc, zirconium dioxide, zinc oxide, calcium silicate,
aluminum silicate, calcium sulfate, alumina trihydrate, glass
fibers, carbon fibers, and mixtures thereof.
[0025] The thermoplastic polymer used in the method of the present
invention is preferably a polyolefin-based polymer, a
polystyrene-based polymer, a polycabonate polymer, a polyamide
polymer, or mixture thereof. More preferably, the thermoplastic
polymer used in the method of the present invention is a
polyethylene homopolymer, a polyethylene copolymer, a polypropylene
homopolymer, or a polypropylene copolymer. Most preferably the
thermoplastic polymer is a polypropylene homopolymer.
[0026] In accordance with the method of the present invention, the
polymer mixture which is sonicated is a combination of a
thermoplastic polymer and a filler and may be formed by methods
well known to one skilled in the art of polymer science and plastic
molding. For example, the polymer mixture may be formed by
physically combining a thermoplastic polymer and a filler together
to form a polymer premix followed by heating the polymer premix at
a sufficient temperature to melt the thermoplastic polymer.
Optionally, the heated, melted premix may be mechanically stirred
during sonicating. Furthermore, a portion of the polymer is
optionally replaced by a compatibilizer such as maleic anhydride
grafted polypropylene.
[0027] Patent application Ser. No. 09/748,669, filed Dec. 22, 2000,
and patent application Ser. No. 09/748,670, filed Dec. 22, 2000,
disclose methods of dispersing and exfoliating layered silicates.
Both these applications are hereby incorporated by reference. The
methods of these applications may be used to form a polymer mixture
in which the filler is dispersed or exfoliated to some degree prior
to further dispersion and exfoliation by the method of the present
invention. Accordingly, the polymer mixture utilized in the method
of the present invention may be formed by the process
comprising:
[0028] a) mixing the layered silicate with the thermoplastic
polymer to form a treatable silicate-polymer mixture;
[0029] b) contacting the treatable mixture with a supercritical
fluid to form a contacted mixture; and
[0030] c) depressurizing the contacted mixture to form the
dispersed/exfoliated polymer composite.
[0031] A preferred supercritical fluid is carbon dioxide.
[0032] The method of the present invention is advantageously
combined with any plastic mixing or molding process in which a
thermoplastic polymer and a filler are combined together. Such
processes include, but are not limited to, extrusion, injection
molding, compression molding, and blow molding. Similarly, the
method of the present invention may be utilized during batch
processing in a batch mixer such as a banbury mixer. For example, a
thermoplastic polymer and a filler are introduced into a plastics
extruder and the step of sonicating the mixture is performed while
the mixture is within the extruder. Similarly, a mixture of a
thermoplastic polymer and a filler is introduced into an injection
molding apparatus and the step of sonicating the mixture is
performed while the mixture is within the barrel of the injection
molding machine.
[0033] In another embodiment of the present invention, a
polymer-filler composite is provided. The polymer-filler composite
of the present invention is characterized as having a filler
dispersed within a thermoplastic polymer by the method set forth
above. The polymer-filler composite of the present invention is
preferably used to form a molded part by method such as injection
molding, compression molding, blow molding, and the like.
[0034] In yet another embodiment of the present invention a sonic
mixing apparatus is provided. The sonic mixing apparatus is
preferably combined with a number of plastic mixing or molding
equipment. Examples of such equipment include, but are not limited
to extruders, injection molding equipment, compression molding
equipment, blow molding equipment, and the like. The sonic mixing
apparatus of the present invention comprises:
[0035] a chamber for holding plastic material;
[0036] a stirrer;
[0037] a heater in communication with the chamber for heating the
chamber and plastic material within the chamber; and
[0038] at least one sonicator in communication with the chamber and
the plastic material for transferring sonic energy to plastic
material within the chamber.
[0039] In a variation of the present invention the sonic mixing
equipment further comprises:
[0040] a motor;
[0041] a feeder in communication with the chamber for introducing
the plastic material into the chamber; and
[0042] an exit port on the chamber for providing an exit path for
the plastic material from the chamber;
[0043] wherein the stirrer is at least one screw feeder within the
chamber for mixing and moving material through the chamber and the
motor is in communication with the screw feeder for turning the
screw feeder. The sonic mixing apparatus of this variation
optionally further comprises a nozzle in communication with the
exit port. The nozzle provides a conduit out of the chamber for the
plastic material. In a variation of the sonic mixing apparatus the
nozzle is adapted such that the apparatus functions as an extruder.
In such an application, the plastic will emerge from the nozzle and
be processed by methods known to one skilled in the art of plastic
molding. These post-extrusion processes include cooling the plastic
and cutting the plastic into pellets. In another refinement of the
sonic mixing apparatus, the nozzle is adapted to attach to a mold
used for injection molding.
[0044] The incorporation of the sonic mixing apparatus with a
plastic extruder is best appreciated by reference to FIG. 1.
Plastic mixer 2 comprises feeder 4 which is attached to barrel 6.
Feeder 4 will is typically a hopper which is capable of introducing
one or more materials into barrel 6. Screw feeder 8 is positioned
within barrel 6. Screwfeeder 8 turned in a circular motion by motor
10 which is attached to screwfeeder 8 by shaft 12. Heater elements
14, 16, 18, 20 surround barrel 6. Housing 22 surrounds the barrel
as indicated in FIG. 1. Sonic horn 24 is positioned with barrel 6.
Exit port 26 is located an end of barrel 6 and provides a conduit
for plastic to exit barrel 6. During operation, materials which
include at least one polymer are introduced into barrel 6 through
feeder 4. The at least one polymer is melted by heaters 16, 18, 20,
22 and pushed towards exit port 26 by the rotating motion of
screwfeeder 8. The rotating motion of screwfeeder 8 acts to mix the
materials. Sonic horn 24 provides sonic energy produced by sonic
processor 27 to the materials and thereby assists in dispersing and
exfoliating the filler within the polymer. The mixed plastic then
emerges from barrel 6 through exit port 26 and then nozzle 28. When
the plastic exits nozzle 28, it has typically cooled and started to
resolidify. At this point the plastic may be cooled further with a
water bath and then chopped into pellets.
[0045] Similarly, the incorporation of the sonic mixing apparatus
with an injection molding apparatus is best appreciated by
reference to FIG. 2. Sonicating injection molding apparatus 32
comprises feeder 34 which is attached to barrel 36. Feeder 34 will
is typically a hopper which is capable of introducing one or more
materials into barrel 36. Screw feeder 38 is positioned within
barrel 36. Screwfeeder 38 turned in a circular motion by motor 40
which is attached to screwfeeder 38 by shaft 42. Shaft 42 is
surrounded by bearings 46, 48. Bearings 46, 48 are enclosed with
chamber 50 which is attached to housing 52. Housing 52 surrounds
barrel 36 as indicated in FIG. 2. Heater elements 54, 56, 58, 60,
62 surround barrel 36. Sonic horn 64 is positioned with barrel 36.
Exit port 66 is located an end of barrel 36 and provides a conduit
for plastic to exit barrel 36. During operation materials which
include at least one polymer are introduced into barrel 36 through
feeder 34. The at least one polymer is melted by heaters 54, 56,
58, 60, 62 and pushed towards exit port 66 by the rotating motion
of screwfeeder 38. The rotating motion of screwfeeder 38 acts to
mix the materials. Sonic horn 64 delivers sonic energy produced by
sonic processor 68 to the materials and thereby assist in
dispersing and exfoliating the filler within the polymer. The mixed
plastic then emerges from exit port 66 and then nozzle 70. The
melted plastic is then introduced into mold 72 through conduit 74.
Mold 72 is formed from mold halves 76, 78. In this configuration,
screwfeeder 38 is typically moveable along the direction defined by
the longitudinal axis of shaft 42. This motion will allow melted
plastic to be pushed (injected) into mold 70.
Preparation of the Filler-Polymer Composites
[0046] The filler-polymer composites of the present invention are
prepared by sonicating a mixture of a filler and a thermoplastic
polymer. Suitable examples of fillers include, but are not limited
to, montmorillonite clay, kaolin clay, calcium carbonate, titanium
dioxide, talc, zirconium dioxide, zinc oxide, calcium silicate,
aluminum silicate, calcium sulfate, alumina trihydrate, glass
fibers, carbon fibers, and mixtures thereof. Preferably, the filler
will be a nanoclay such as Cloisite 20A (Southern Clay Products).
Suitable examples of thermoplastic polymers include, but are not
limited to, polyolefin-based polymers, polystyrene-based polymers,
polycabonate polymers, polyamide polymers, or mixtures thereof. A
preferred thermoplastic is polypropylene (Ph020, commercially
available from Basell Polyolefins). The nanoclay and thermoplastic
polymer are preferably brought together at a nanoclay to polymer
ratio of between 1:100 and 2:3. A portion of the polymer is
optionally replaced by a compatibilizer such as maleic anhydride
grafted polypropylene. The mixture is heated to between
150-210.degree. C. and sonicated. Sonication may be achieved by any
source of sonic energy. A preferred method of applying such sonic
energy is by placing an ultrasonic horn in contact with the
material. For example, an ultrasonic processor (Sonics &
Materials, Inc., Model VC60) vibrating at a frequency of 20 kHz to
50 kHz at 100% amplitude with a 1/2" horn is found to deliver
sufficient energy for the examples provided below. The sonic energy
delivered should be enough to achieve the desired improved
mechanical properties or until a uniform dispersion of the nanoclay
is achieved. It will be readily recognized by one skilled in the
art of plastic molding and processing that the method of the
present invention can be applied to any plastic forming or
compounding process in which a plastic and filler can be combined
together.
[0047] The following examples illustrate the various embodiments of
the present invention. Those skilled in the art will recognize many
variations that are within the spirit of the present invention and
scope of the claims.
EXAMPLE 1
[0048] Approximately 1 g of conventionally compounded polymer
nanocomposite pellets with composition 5% I.30E (Nanocor, Inc.)+95%
Ph020 polypropylene ("PP") are placed in a vessel and heated to
160.degree. C. A 1/2" ultrasonic horn is applied to the material
and sonicated in a similar manner as in the previous example.
Sonication at 20 kHz is performed for several minutes until the
energy delivered to the sample reaches 40 kJ.
EXAMPLE 2
[0049] Approximately 1 g of conventionally compounded polymer
nanocomposite pellets with composition 5% I.30E+95% 6523
polypropylene (Basell Polyolefins) are placed in a vessel and
heated to 160.degree. C. A 1/2" ultrasonic horn is applied to the
material and sonicated in a similar manner as in the previous
example. Sonication at 20 kHz is performed for several minutes
until the energy delivered to the sample reaches 40 kJ.
EXAMPLE 3
[0050] Approximately 1 g of conventionally compounded polymer
nanocomposite pellets with composition 5% I.30E+95% 6823
polypropylene (Basell Polyolefins) are placed in a vessel and
heated to 160.degree. C. A 1/2" ultrasonic horn is applied to the
material and sonicated in a similar manner as in the previous
example. Sonication at 20 kHz is performed for several minutes
until the energy delivered to the sample reaches 40 kJ.
EXAMPLE 4
[0051] Approximately 1 g of conventionally compounded polymer
nanocomposite pellets (Nanocor, Inc.) are placed in a vessel and
heated to 160.degree. C. The nanocomposite pellets have a
composition of 5% I.30E nanoclay+5% Polybond 3200 (Uniroyal
Chemical)+90% 6523 PP. A 1/2" ultrasonic horn is applied to the
material and sonicated in a similar manner as in the previous
example. Sonication at 20 kHz is performed for several minutes
until the energy delivered to the sample reaches 40 kJ.
EXAMPLE 5
[0052] Approximately 1 g of conventionally compounded polymer
nanocomposite pellets with composition 5% supercritical fluid
treated nanoclay+95% 6523 polypropylene are placed in a vessel and
heated to 160.degree. C. A 1/2" ultrasonic horn is applied to the
material and sonicated in a similar manner as in the previous
example. Sonication at 20 kHz is performed for several minutes
until the energy delivered to the sample reaches 40 kJ.
EXAMPLE 6
[0053] Approximately 4.5 g of polypropylene is dry mixed with 0.25
g of maleic anhydride grafted polypropylene and 0.25 g of nanoclay
in a vessel. The vessel is heated to 165.degree. C. An ultrasonic
horn is brought into contact with the mixture. The melt is
sonicated at 20 kHz for 5 minutes.
EXAMPLE 7
[0054] Approximately 4.75 g of nylon 6 is dry mixed with 0.25 g of
nanoclay in a vessel. The vessel is heated to 240.degree. C. An
ultrasonic horn is brought into contact with the mixture. The melt
is sonicated at 30 kHz for 1 minute.
EXAMPLE 8
[0055] Approximately 4.7 g of polypropylene is dry mixed with 0.3 g
of nanoclay in a vessel. The vessel is heated to 150.degree. C. An
ultrasonic horn is brought into contact with the mixture to impart
sonic energy. The combination of heat and sonic energy is
sufficient to cause the mixture to melt. The melt is sonicated for
several minutes at 40 kHz until the energy delivered to the sample
reaches 20 kJ.
EXAMPLE 9
[0056] Approximately 5 g of polymer nanocomposite masterbatch
(nanoclay concentrate, Nanocor, Inc. C.30P) pellets are placed in a
vessel and heated to 175.degree. C. The masterbatch has a
composition of 40% I.30E nanoclay+30% Polybond 3200+30% 6523 PP. An
ultrasonic horn is applied to the material and sonicated at 20 kHz
for 5 minutes. The sonicated masterbatch is let down with 28.3 g
polypropylene and compounded.
EXAMPLE 10
[0057] Approximately 80 g of conventionally compounded polymer
nanocomposite pellets are placed in a batch mixer (Haake Model
600). The mixer is heated to 170.degree. C. and sheared at 60 rpm.
An ultrasonic horn is placed in the melt and sonic energy at 20 kHz
is imparted into the sample for 5 minutes.
EXAMPLE 11
[0058] Approximately 80 g of polymer nanocomposite masterbatch
pellets are placed in a heated banbury mixer and mixed at 75 rpm.
An ultrasonic horn is placed into the melt and ultrasonicated at 20
kHz for 30 minutes. The ultrasonicated masterbatch is let down with
533.3 g polypropylene and compounded.
EXAMPLE 12
[0059] Polypropylene and nanoclay are fed into a twin screw
extruder (ThermoHaake Rheomex Model PTW25) at a ratio of 19:1. The
extruder is heated to 185.degree. C. As the material is compounded,
the melt contacts an ultrasonic horn vibrating at 20 kHz. The
compounded strand is cooled through a water bath and
pelletized.
EXAMPLE 13
[0060] Polyproplyene, maleic anhydride grafted polypropylene, and
nanoclay are fed into a twin screw extruder at a ratio of 18:1:1.
The extruder is heated to 200.degree. C. As the material is
compounded, the melt contacts an ultrasonic horn vibrating at 20
kHz. The material acquires sonic energy during the melt residence
time in the extruder barrel. The compounded strand is cooled in a
water bath and pelletized.
EXAMPLE 14
[0061] Polypropylene, maleic anhydride grafted polypropylene, and
nanoclay are fed into a twin screw extruder at a ratio of 3:3:4 to
produce a polymer nanocomposite masterbatch. The extruder is heated
to 190.degree. C. As the material is compounded, the melt contacts
several ultrasonic horns in series along the barrel of the
extruder, each vibrating at 20 kHz. The material strand is cooled
in a water bath and pelletized. The masterbatch is let down with
polypropylene at a ratio of 1:7 (MB:PP) in an extruder or injection
molding process.
EXAMPLE 15
[0062] Polymer nanocomposite pellets are fed into an injection
molding machine (Boy Machines Model 80M). The barrel of the
injection molding machine is equipped with an ultrasonic horn such
that the horn contacts the plasticized material. As the material is
plasticized and injected into the mold, sonic energy is imparted
into the material from the horn during the injection molding cycle
time. The barrel zones are heated between 175.degree. C. and
200.degree. C. The mold temperature is maintained at 25.degree.
C.
Determination of Filler Dispersion and Exfoliation
[0063] The effectiveness of the methods of the present invention is
quantified by a combination of wide angle X-ray diffraction
("WAXS") and transmission electron microscopy ("TEM"). WAXS allows
the determination of the interlayer spacing of the platelets in a
layered silicate clay dispersed in a polymer matrix. Typically the
peak(s) corresponding to 2.theta. for the silicate clay will be
less than 5.degree.. Application of the Bragg equation allows the
2.theta. value to be converted to an interlayer spacing. WAXS was
performed on a conventionally processed nanoclay/ polypropylene
mixture and a mixture processed by the method of the present
invention. The conventionally processed silicate clay (I.30E)
polypropylene mixture has an interlayer spacing of about 25.6 .ANG.
while the sonically processed clay/polypropylene mixture has an
interlayer spacing of about 31.7 .ANG.. Table I provides the
interlayer spacing determined by WAXS for several polypropylene
clay mixture before and after sonication.
1TABLE I % interlayer interlayer change spacing spacing in before
after inter- Mixture Polypropylene sonication sonication layer
number matrix nanoclay (.ANG.) (.ANG.) spacing 1 Ph020 (low mol.
I.30E 23.6 36 53% wt.) 2 PP6523 I.30E 25.6 31.7 24% (medium mol.
wt.) 3 PP6823 (high I.30E 35 37 6% mol. wt.) 4 PP6523/PP-MA I.30E
27.5 35.5 29% 5 PP6523/PP-MA SCF I.30E 29 36.5 26%
[0064] Examples 1 through 3 show an increase in interlayer spacing
after sonication for combinations of a nonoclay with low, medium,
and high molecular weight polypropylene polymers. The effect is
most significant for the low molecular weight polypropylene. In
Example 4, a medium molecular weight polypropylene is processed
with the maleic anhydride grafted polypropylene oligomer. This
compatibilizer is known to assist in the dispersion of nanoclay. As
demonstrated in Example 4, the method of the present invention
enhances the clay dispersion in this combination. Finally, Example
5 provides the dispersion of a nanoclay that has been processed
with a supercritical fluid. Again the method of the present
invention shows an enhancement in clay dispersion and exfoliation
for this pre-dispersed combination. Preferably, the method of the
present invention disperses the nanoclay such that the layer
distances are increased by at least 5%. More preferably, the layer
distances are increased by at least 15%, and most preferably the
layer distances are increased by at least 25%.
[0065] Although the WAXS analysis indicates significant dispersion
by the method of the present invention, it is must be understood
that WAXS cannot provide a complete picture of filler exfoliation
and dispersion in the polymer matrix. For layered silicates in
which the platelets have completely exfoliated and dispersed, there
will be no corresponding signal in the WAXS because the order has
been destroyed. Accordingly, TEM analysis is an important
supplement to understand the nature and degree of filler
dispersion. TEM micrographs of Examples 1-3 in Table 1 revealed
separation of the platelets forming the nanoclays.
[0066] While the best mode for carrying out the invention has been
described in detail, those familiar with the art to which this
invention relates will recognize various alternative designs and
embodiments for practicing the invention as defined by the
following claims.
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