U.S. patent application number 14/684926 was filed with the patent office on 2015-08-06 for glass bubbles, composites therefrom, and method of making glass bubbles.
This patent application is currently assigned to 3M Innovative Properties Company. The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Stephen E. Amos, Robert W. Hunter, Ronald J. Israelson, Towako Takeishi, Mark J. Williams, Takujiro Yamabe.
Application Number | 20150218349 14/684926 |
Document ID | / |
Family ID | 45810946 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150218349 |
Kind Code |
A1 |
Amos; Stephen E. ; et
al. |
August 6, 2015 |
GLASS BUBBLES, COMPOSITES THEREFROM, AND METHOD OF MAKING GLASS
BUBBLES
Abstract
The present disclosure provides a plurality of glass bubbles
having an average true density of up to about 0.55 grams per cubic
centimeter and a size distribution including a median size in a
range from about 15 micrometers to 40 micrometers. A hydrostatic
pressure at which ten percent by volume of the plurality of glass
bubbles collapses is at least about 100 megapascals. In some
embodiments, the plurality of glass bubbles is a graded fraction
preparable by classifying a second plurality of glass bubbles,
wherein the second plurality of glass bubbles has a higher
percentage of glass bubbles with a size of up to ten micrometers
than the first plurality of glass bubbles. Composites including the
plurality of glass bubbles are also disclosed.
Inventors: |
Amos; Stephen E.;
(Minneapolis, MN) ; Hunter; Robert W.;
(Burnsville, MN) ; Israelson; Ronald J.; (Lake
Elmo, MN) ; Takeishi; Towako; (Kawasakai-shi, JP)
; Williams; Mark J.; (Cottage Grove, MN) ; Yamabe;
Takujiro; (Sagamihara-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
ST. PAUL |
MN |
US |
|
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
45810946 |
Appl. No.: |
14/684926 |
Filed: |
April 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13821167 |
Mar 6, 2013 |
9006302 |
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PCT/US2011/050648 |
Sep 7, 2011 |
|
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14684926 |
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61380770 |
Sep 8, 2010 |
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Current U.S.
Class: |
209/2 ;
209/659 |
Current CPC
Class: |
C08K 2201/005 20130101;
Y10T 428/2982 20150115; Y10T 428/2996 20150115; C08K 7/28
20130101 |
International
Class: |
C08K 7/28 20060101
C08K007/28 |
Claims
1. A method of making a graded fraction of glass bubbles, the
method comprising: providing a second plurality of glass bubbles
having a second size distribution comprising a median size, a
number of glass bubbles up to ten micrometers in size, and a number
of glass bubbles at least 40 micrometers in size; removing at least
a portion of the glass bubbles at least 40 micrometers in size;
removing at least a portion of the glass bubbles up to ten
micrometers in size, wherein after removing at least a portion of
the glass bubbles at least 40 micrometers in size and removing at
least a portion of the glass bubbles up to ten micrometers in size,
a first plurality of glass bubbles remains, wherein the first
plurality of glass bubbles has a number of glass bubbles up to ten
micrometers in size that is lower than the number of glass bubbles
up to ten micrometers in size of the second plurality of glass
bubbles, and wherein one of the following conditions is met: the
first plurality of glass bubbles and the second plurality of glass
bubbles have equivalent densities, but the first plurality of glass
bubbles is higher in strength than the second plurality of glass
bubbles; the first plurality of glass bubbles and the second
plurality of glass bubbles have equivalent strengths, but the first
plurality of glass bubbles is lower in density than the second
plurality of glass bubbles; or the first plurality of glass bubbles
is both lower in density and higher in strength than the second
plurality of glass bubbles.
2. The method of claim 1, wherein the first plurality of particles
has an average true density of up to 0.55 grams per cubic
centimeter, and wherein the first plurality of particles has a
median size by volume in a range from 15 micrometers to 40
micrometers.
3. The method of claim 2, wherein the first plurality of particles
has an average true density of up to 0.54 grams per cubic
centimeter.
4. The method of claim 2, wherein the first plurality of particles
has an average true density of up to 0.53 grams per cubic
centimeter.
5. The method of claim 2, wherein the median size is in a range
from about 15 micrometers to about 25 micrometers, and wherein the
size distribution further comprises up to twenty percent by number
of the glass bubbles having a size of up to ten micrometers.
6. The method of claim 2, wherein the first plurality of particles
has an average true density of up to 0.45 grams per cubic
centimeter, and wherein the first plurality of particles has a
median size by volume in a range from 15 micrometers to 25
micrometers.
7. The method of claim 6, wherein the size distribution further
comprises up to forty percent by number of the glass bubbles having
a size of up to ten micrometers.
8. The method of claim 1, wherein the first plurality of particles
has an average true density of up to 0.35 grams per cubic
centimeter, and wherein a hydrostatic pressure at which ten percent
by volume of the first plurality of glass bubbles collapses is at
least 75 megapascals.
9. The method of claim 1, wherein a hydrostatic pressure at which
ten percent by volume of the first plurality of glass bubbles
collapses is at least 100 megapascals.
10. The method of claim 1, wherein removing at least a portion of
the glass bubbles at least 40 micrometers size comprises collecting
glass bubbles that passed through a 32-micrometer screen.
11. The method of claim 1, wherein removing at least a portion of
the glass bubbles up to ten micrometers in size comprises
collecting glass bubbles that were retained on a 20-micrometer
screen.
12. The method of claim 1, wherein removing at least a portion of
the glass bubbles at least 40 micrometers in size comprises at
least one of screening, air classifying, fabric filter classifying,
settling classifying, centrifugal classifying, electrostatic
classifying, and wet scrubbing classifying.
13. The method of claim 1, wherein removing at least a portion of
the glass bubbles up to ten micrometers in size comprises at least
one of screening, air classifying, fabric filter classifying,
settling classifying, centrifugal classifying, electrostatic
classifying, and wet scrubbing classifying
14. The method of claim 1, wherein the glass bubbles have a glass
composition comprising an alkaline earth metal oxide and an alkali
metal oxide in a weight ratio in a range from 1.2:1 to 3:1.
15. The method of claim 1, wherein the glass bubbles have a glass
composition comprising B.sub.2O.sub.3 in a range from 2 to 6
percent by weight, based on the total weight of the glass
bubbles.
16. The method of claim 1, wherein the glass bubbles have a glass
composition comprising up to 5 percent by weight Al.sub.2O.sub.3,
based on the total weight of the glass bubbles.
17. The method of claim 1, wherein the glass bubbles have a glass
composition comprising SiO.sub.2 in a range from 70 to 80 percent
by weight, alkaline earth metal oxide in a range from 8 to 15
percent by weight, and alkali metal oxide in a range from 3 to 8
percent by weight, each percent by weight based on the total weight
of the glass bubbles.
18. The method of claim 1, wherein the glass bubbles are treated
with a coupling agent.
19. The method of claim 1, wherein the first plurality of glass
bubbles and the second plurality of glass bubbles have equivalent
strengths, but the first plurality of glass bubbles is lower in
density than the second plurality of glass bubbles.
20. The method of claim 1, wherein the first plurality of glass
bubbles is both lower in density and higher in strength than the
second plurality of glass bubbles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 13/821,167, filed Mar. 6, 2013, now U.S. Pat. No. 9,006,302,
which is a national stage filing under 35 U.S.C. 371 of
PCT/US2011/050648, filed Sep. 7, 2011, which claims priority to
U.S. Application No. 61/380,770, filed Sep. 8, 2010, the
disclosures of which are incorporated by reference in their
entireties herein.
BACKGROUND
[0002] Glass bubbles having an average diameter of less than about
500 micrometers, also commonly known as "glass microbubbles",
"hollow glass microspheres", or "hollow glass beads" are widely
used in industry, for example, as additives to polymeric compounds.
In many industries, glass bubbles are useful, for example, for
lowering weight and improving processing, dimensional stability,
and flow properties of a polymeric compound. Generally, it is
desirable that the glass bubbles be strong to avoid being crushed
or broken during processing of the polymeric compound, such as by
high pressure spraying, kneading, extrusion, pultrusion, sintering,
or molding (e.g., compression molding, injection molding, blow
molding, roto-molding, thermoforming, and injection-compression
molding).
[0003] Some processes have been described for achieving high
strength glass bubbles. However, at least due to their great
utility, new high strength glass bubbles continue to be
desirable.
SUMMARY
[0004] The present disclosure provides glass bubbles with
unexpectedly high strength for their density and size. For example,
the plurality of glass bubbles according to the present disclosure
has a higher strength than typically would be expected for its
density. Similarly, the plurality of glass bubbles according to the
present disclosure has a lower density than typically would be
expected given its strength. Since the lowest density glass bubble
that can survive in a particular application is typically selected
for use in that application, the glass bubbles disclosed herein are
useful, for example, for providing cost-effective, relatively
low-density glass-bubble-filled polymer composites while
maintaining the polymer physical properties. The plurality of
particles according to the present disclosure can be prepared, for
example, using a counterintuitive classifying method that removes
the smallest, typically strongest bubbles from a distribution of
glass bubbles.
[0005] In one aspect, the present disclosure provides a first
plurality of glass bubbles having an average true density of up to
about 0.55 grams per cubic centimeter and a size distribution
comprising a median size by volume in a range from about 15
micrometers to about 40 micrometers, wherein a hydrostatic pressure
at which ten percent by volume of the first plurality of glass
bubbles collapses is at least about 100 megapascals. In some
embodiments, the first plurality of glass bubbles is a graded
fraction preparable by classifying a second plurality of glass
bubbles, wherein the second plurality of glass bubbles has a higher
number of glass bubbles with a size of up to ten micrometers than
the first plurality of glass bubbles. In some embodiments, the size
distribution further comprises up to forty percent by number of the
glass bubbles having a size of up to ten micrometers. In some
embodiments, the size distribution further comprises up to twenty
percent by number of the glass bubbles having a size of up to ten
micrometers.
[0006] In another aspect, the present disclosure provides a method
of making a graded fraction of glass bubbles, the method
comprising: [0007] providing a second plurality of glass bubbles
having a second size distribution comprising a median size, a
number of glass bubbles up to ten micrometers in size, and a number
of glass bubbles larger at least 40 micrometers in size; [0008]
removing at least a portion of the glass bubbles at least 40
micrometers in size; [0009] removing at least a portion of the
glass bubbles up to ten micrometers in size,
[0010] wherein after removing at least a portion of the glass
bubbles at least 40 micrometers in size and removing at least a
portion of the glass bubbles up to ten micrometers in size, a first
plurality of glass bubbles remains as the graded fraction of glass
bubbles, wherein the first plurality of glass bubbles has a number
of glass bubbles up to ten micrometers in size that is lower than
the number of glass bubbles up to ten micrometers in size of the
second plurality of glass bubbles, and wherein one of the following
conditions is met:
[0011] the first plurality of glass bubbles and the second
plurality of glass bubbles have equivalent densities, but the first
plurality of glass bubbles is higher in strength than the second
plurality of glass bubbles;
[0012] the first plurality of glass bubbles and the second
plurality of glass bubbles have equivalent strengths, but the first
plurality of glass bubbles is lower in density than the second
plurality of glass bubbles; or
[0013] the first plurality of glass bubbles is both lower in
density and higher in strength than the second plurality of glass
bubbles.
[0014] In another aspect, the present disclosure provides a
composite comprising a polymer and a first plurality of glass
bubbles according to and/or prepared according to the foregoing
aspects.
[0015] In this application, terms such as "a", "an" and "the" are
not intended to refer to only a singular entity, but include the
general class of which a specific example may be used for
illustration. The terms "a", "an", and "the" are used
interchangeably with the term "at least one". The phrases "at least
one of" and "comprises at least one of" followed by a list refers
to any one of the items in the list and any combination of two or
more items in the list. All numerical ranges are inclusive of their
endpoints and non-integral values between the endpoints unless
otherwise stated.
[0016] The terms "first" and "second" are used in this disclosure
merely as a matter of convenience in the description of one or more
of the embodiments. It will be understood that, unless otherwise
noted, those terms are used in their relative sense only.
[0017] The term "plurality" refers to more than one. In some
embodiments, the first plurality of glass bubbles disclosed herein
comprises at least 2, 10, 100, or 1000 of such bubbles.
[0018] The term "average true density" is the quotient obtained by
dividing the mass of a sample of glass bubbles by the true volume
of that mass of glass bubbles as measured by a gas pycnometer. The
"true volume" is the aggregate total volume of the glass bubbles,
not the bulk volume.
[0019] The above summary of the present disclosure is not intended
to describe each disclosed embodiment or every implementation of
the present disclosure. The description that follows more
particularly exemplifies illustrative embodiments. It is to be
understood, therefore, that the following description should not be
read in a manner that would unduly limit the scope of this
disclosure.
DETAILED DESCRIPTION
[0020] The present disclosure provides a first plurality of glass
bubbles having an average true density of up to about 0.55 grams
per cubic centimeter and a size distribution comprising a median
size by volume in a range from about 15 micrometers to about 40
micrometers, wherein a hydrostatic pressure at which ten percent by
volume of the first plurality of glass bubbles collapses is at
least about 100 megapascals. The first plurality of glass bubbles
is generally not to be considered a portion of glass bubbles with
bulk properties outside of these ranges. In some embodiments, the
first plurality of glass bubbles consists essentially of a
plurality of glass bubbles having an average true density of up to
about 0.55 grams per cubic centimeter and a size distribution
comprising a median size by volume in a range from about 15
micrometers to about 40 micrometers, wherein a hydrostatic pressure
at which ten percent by volume of the first plurality of glass
bubbles collapses is at least about 100 megapascals. "Consists
essentially of" can mean, for example, the first plurality of glass
bubbles does not contain other bubbles that change its average true
density, median size, or collapse strength from the indicated
values by more than about one percent, one percent, and five
percent, respectively.
[0021] The first plurality of glass bubbles according to the
present disclosure has an average true density of up to about 0.55
grams per cubic centimeter (g/cc). "About 0.55 g/cc" means 0.55
g/cc.+-.one percent. In some of these embodiments, the average true
density is up to 0.54, 0.53, 0.52, 0.51, 0.50, 0.49, 0.48, 0.47,
0.46, 0.45, 0.44, 0.43, 0.42, 0.40, or 0.40 g/cc. The average true
density of the first plurality of glass bubbles disclosed herein is
generally at least 0.30, 0.35, or 0.38 g/cc. For example, the
average true density of the first plurality of glass bubbles
disclosed herein may be in a range from 0.30 g/cc to 0.55 g/cc,
0.35 g/cc to 0.55 g/cc, 0.38 g/cc to 0.55 g/cc, 0.30 g/cc to 0.50
g/cc, 0.35 g/cc to 0.50 g/cc, 0.38 g/cc to 0.50 g/cc, 0.30 g/cc to
0.45 g/cc, 0.35 g/cc to 0.45 g/cc, or 0.38 g/cc to 0.45 g/cc. For
the purposes of this disclosure, average true density is measured
using a pycnometer according to ASTM D2840-69, "Average True
Particle Density of Hollow Microspheres". The pycnometer may be
obtained, for example, under the trade designation "Accupyc 1330
Pycnometer" from Micromeritics, Norcross, Ga. Average true density
can typically be measured with an accuracy of 0.001 g/cc.
Accordingly, each of the density values provided above can be
.+-.one percent.
[0022] The first plurality of glass bubbles according to the
present disclosure has a size distribution comprising a median size
by volume in a range from about 15 micrometers to about 40
micrometers. In the measurement of size "about" a given size can
include a value .+-.one percent. The median size by volume of the
glass bubbles may be, for example, in a range from 15 to 35
micrometers (in some embodiments from 16 to 40 micrometers, 16 to
30 micrometers, 16 to 25 micrometers, 15 to 30 micrometers, from 15
to 25 micrometers, or even from 20 to 35 micrometers). The median
size is also called the D50 size, where 50 percent by volume of the
glass bubbles in the distribution are smaller than the indicated
size. In some embodiments, up to 45, 40, 35, 30, 25, 20, 15, 10, or
5 percent by number of the first plurality of glass bubbles have a
size up to ten (in some embodiments, up to 11, 12, 13, 14, or 15)
micrometers. In some embodiments, the first plurality of glass
bubbles disclosed herein has a size distributed from 20 to 45, 20
to 38, or 20 to 32 micrometers. As used herein, the term size is
considered to be equivalent with the diameter and height of the
glass bubbles. For the purposes of the present disclosure, the
median size by volume is determined by laser light diffraction by
dispersing the glass bubbles in deaerated deionized water. Laser
light diffraction particle size analyzers are available, for
example, under the trade designation "SATURN DIGISIZER" from
Micromeritics. For the purposes of the present disclosure, the
percentage of glass bubbles by number is determined by image
analysis using a scanning electron microscope according to the test
method described in the Examples, below.
[0023] The size distribution of the first plurality of glass
bubbles and/or second plurality of glass bubbles may be Gaussian,
normal, or non-normal. Non-normal distributions may be unimodal or
multi-modal (e.g., bimodal).
[0024] For the first plurality of glass bubbles according to the
present disclosure, a hydrostatic pressure at which ten percent by
volume of the first plurality of glass bubbles collapses is at
least about 100 (in some embodiments, at least about 110, 120, 130
or 140) Megapascals (MPa). "About 100 MPa" means 100 MPa.+-.five
percent. In some embodiments, a hydrostatic pressure at which
twenty percent by volume of the first plurality of glass bubbles
collapses is at least 100, 110, or 120 MPa. In some embodiments, a
hydrostatic pressure at which ten percent, or twenty percent, by
volume of the first plurality of glass bubbles collapses is up to
210 (in some embodiments, up to 190, 170, or 160) MPa. The
hydrostatic pressure at which ten percent by volume of the first
plurality of glass bubbles collapses may be in a range from 100 to
210 MPa, 100 to 190 MPa, 110 to 210 MPa, or 110 to 190 MPa. The
hydrostatic pressure at which twenty percent by volume of the first
plurality of glass bubbles collapses may be in a range from 100 to
210 MPa, 110 to 210 MPa, 110 to 170 MPa, or 110 to 190 MPa. For the
purposes of the present disclosure, the collapse strength of the
glass bubbles is measured on a dispersion of the glass bubbles in
glycerol using ASTM D3102-72 "Hydrostatic Collapse Strength of
Hollow Glass Microspheres"; with the exception that the sample size
(in grams) is equal to 10 times the density of the glass bubbles.
Further details are provided in the Examples, below. Collapse
strength can typically be measured with an accuracy of .+-.about
five percent. Accordingly, each of the collapse strength values
provided above can be .+-.five percent.
[0025] The first plurality of glass bubbles according to the
present disclosure is typically prepared by classifying a second
plurality of glass bubbles, wherein the second plurality of glass
bubbles has a higher number of glass bubbles with a size of up to
ten micrometers than the first plurality of glass bubbles. In other
words, the classifying of the second plurality of glass bubbles
typically involves removing at least some small bubbles to decrease
the number of bubbles with a size less than a selected threshold
(e.g., 15, 14, 13, 12, 11, or 10 micrometers). In some of these
embodiments, the second plurality of glass bubbles further has a
larger number of glass bubbles at least 40 micrometers in size than
the first plurality of glass bubbles, and the classifying further
involves removing glass bubbles at least 40 micrometers in size
from the second plurality of glass bubbles.
[0026] It is unexpected that a plurality of glass bubbles having an
average true density up to 0.55 g/cc and a median size by volume of
in a range from 15 to 40 micrometers would have a crush strength
wherein a hydrostatic pressure at which ten percent by volume of
the plurality of glass bubbles collapses is at least 100
Megapascals. Furthermore, it is unexpected that a first plurality
of glass bubbles according to the present disclosure can be
obtained, in some embodiments, by classifying a second plurality of
glass bubbles, wherein the second plurality of glass bubbles has a
higher percentage of glass bubbles with a size of up to ten
micrometers than the first plurality of glass bubbles.
[0027] Theoretically, the collapse strength of an individual glass
bubble (or a monodisperse sample of glass bubbles) should be as
given by a formula devised by M. A. Krenzke and R. M. Charles
("Elastic Buckling Strength of Spherical Glass Shells," David
Taylor Model Basin Report No. 1759, September, 1963),
Theoretical Collapse Strength = 0.8 E ( h / r ) 2 1 - V 2
##EQU00001##
where "E" is Young's modulus for the glass of the bubbles, "h" is
the thickness of the wall of the bubbles, "r" is the radius of the
bubble, and "V" is Poisson's ratio for the glass. The equation
suggests that two factors, among others, that influence the
approximate theoretical strength of a spherical glass bubble are
wall thickness, which relates to density, and the average radius.
Typically, with other factors being equal, theoretical collapse
strength of glass bubbles is thought to increase with increasing
density and decreasing size. However, size and density alone are
not predictive of glass bubble collapse strength.
[0028] Certain art has suggested the desirability of smaller
bubbles, for example, for high strength. See, e.g., U.S. Pat. No.
6,531,222 (Tanaka et al.) and U.S. Pat. Appl. Pub. No. 2007/0104943
(D'Souza et al.). Contrary to this suggestion, the plurality of
particles according to the present disclosure have a relatively low
percentage (e.g., up to 45, 40, 35, 30, 25, 20, 15, or 10 percent)
with a relatively small size (up to 10, 11, 12, 13, 14, or 15
micrometers). In embodiments where the first plurality of glass
bubbles is preparable by classifying a second plurality of glass
bubbles, wherein the second plurality of glass bubbles has a higher
number of glass bubbles with a size of up to ten micrometers than
the first plurality of glass bubbles and, in some embodiments, a
higher number of glass bubbles at least 40 micrometers in size than
the first plurality of glass bubbles, any one of the following
effects may generally be obtained. First, the density may remain
the same while the collapse strength is increased. Secondly, the
collapse strength may remain the same while the density is
decreased, or thirdly, the collapse strength may be increased while
the density is decreased. As shown in the Examples, below, when
both large bubbles and small bubbles are removed from a
distribution of glass bubbles, Glass Bubbles Example 1 have an
improved strength to density ratio by moving the particle size
distribution to a region that has lower density but strength
equivalent to the original particle size distribution. On the other
had Glass Bubbles Example 2 also have an improved strength to
density ratio by moving the particle size distribution to a region
that has higher strength but the same density as the original
distribution. It is considered counterintuitive that removing a
portion of the small bubbles from a second plurality of glass
bubbles will maintain or even improve the strength when such small
bubbles are considered to be the strongest in the distribution.
[0029] Furthermore, commercial, thermally formed glass bubbles are
known to achieve an empirical maximum between 20 and 37 percent of
the calculated theoretical strength because of defects in the wall
of the bubbles, for example. For the purposes of the present
discussion, 37 percent is taken as the best case empirical maximum.
Surprisingly, the plurality of particles according to the present
disclosure typically exceeds the best case empirical maximum
without changing the composition or thermal forming process of the
glass bubbles. For example, for a glass bubble with a density of
0.42 g/cc, 37% of the theoretical maximum strength is about 84 MPa.
For a first plurality of glass bubbles according to the present
disclosure, removing small and large glass bubbles from a second
plurality of glass bubbles having a density of 0.42 g/cc and a
measured collapse strength of 79 MPa provided a first plurality of
glass bubbles having a density of 0.42 g/cc and a collapse strength
greater than 100 MPa, exceeding the best case theoretical maximum
(see Glass Bubble Example 2, below). Since the first plurality of
glass bubbles was a fraction of the second plurality of glass
bubbles, the composition and process for forming the glass bubbles
was necessarily the same.
[0030] Glass bubbles according to and/or useful for practicing the
present disclosure can be made by techniques known in the art (see,
e.g., U.S. Pat. No. 2,978,340 (Veatch et al.); U.S. Pat. No.
3,030,215 (Veatch et al.); U.S. Pat. No. 3,129,086 (Veatch et al.);
and U.S. Pat. No. 3,230,064 (Veatch et al.); U.S. Pat. No.
3,365,315 (Beck et al.); U.S. Pat. No. 4,391,646 (Howell); and U.S.
Pat. No. 4,767,726 (Marshall); and U. S. Pat. App. Pub. No.
2006/0122049 (Marshall et. al). Techniques for preparing glass
bubbles typically include heating milled frit, commonly referred to
as "feed", which contains a blowing agent (e.g., sulfur or a
compound of oxygen and sulfur). The resultant product (that is,
"raw product") obtained from the heating step typically contains a
mixture of glass bubbles, broken glass bubbles, and solid glass
beads, the solid glass beads generally resulting from milled frit
particles that failed to form glass bubbles for whatever reason.
The milled frit typically has range of particle sizes that
influences the size distribution of the raw product. During
heating, the larger particles tend to form glass bubbles that are
more fragile than the mean, while the smaller particles tend to
increase the density of the glass bubble distribution. When
preparing glass bubbles by milling frit and heating the resulting
particles, the amount of sulfur in the glass particles (i.e., feed)
and the amount and length of heating to which the particles are
exposed (e.g., the rate at which particles are fed through a flame)
can typically be adjusted to adjust the density of the glass
bubbles. Lower amounts of sulfur in the feed and faster heating
rates lead to higher density bubbles as described in U.S. Pat. No.
4,391,646 (Howell) and U.S. Pat. No. 4,767,726 (Marshall).
Furthermore, milling the frit to smaller sizes can lead to smaller,
higher density glass bubbles.
[0031] Although the frit and/or the feed may have any composition
that is capable of forming a glass, typically, on a total weight
basis, the frit comprises from 50 to 90 percent of SiO.sub.2, from
2 to 20 percent of alkali metal oxide, from 1 to 30 percent of
B.sub.2O.sub.3, from 0.005-0.5 percent of sulfur (for example, as
elemental sulfur, sulfate or sulfite), from 0 to 25 percent
divalent metal oxides (for example, CaO, MgO, BaO, SrO, ZnO, or
PbO), from 0 to 10 percent of tetravalent metal oxides other than
SiO.sub.2 (for example, TiO.sub.2, MnO.sub.2, or ZrO.sub.2), from 0
to 20 percent of trivalent metal oxides (for example,
Al.sub.2O.sub.3, Fe.sub.2O.sub.3, or Sb.sub.2O.sub.3), from 0 to 10
percent of oxides of pentavalent atoms (for example, P.sub.2O.sub.5
or V.sub.2O.sub.5), and from 0 to 5 percent fluorine (as fluoride)
which may act as a fluxing agent to facilitate melting of the glass
composition. Additional ingredients are useful in frit compositions
and can be included in the frit, for example, to contribute
particular properties or characteristics (for example, hardness or
color) to the resultant glass bubbles.
[0032] In some embodiments, the first plurality of glass bubbles
according to the present disclosure has a glass composition
comprising more alkaline earth metal oxide than alkali metal oxide.
In some of these embodiments, the weight ratio of alkaline earth
metal oxide to alkali metal oxide is in a range from 1.2:1 to 3:1.
In some embodiments, the first plurality of glass bubbles according
to the present disclosure has a glass composition comprising
B.sub.2O.sub.3 in a range from 2 percent to 6 percent based on the
total weight of the glass bubbles. In some embodiments, the glass
bubbles have a glass composition comprising up to 5 percent by
weight Al.sub.2O.sub.3, based on the total weight of the glass
bubbles. In some embodiments, the glass composition is essentially
free of Al.sub.2O.sub.3. "Essentially free of Al.sub.2O.sub.3" may
mean up to 5, 4, 3, 2, 1, 0.75, 0.5, 0.25, or 0.1 percent by weight
Al.sub.2O.sub.3. Glass compositions that are "essentially free of
Al.sub.2O.sub.3" also include glass compositions having no
Al.sub.2O.sub.3. Glass bubbles according to the present disclosure
may have, in some embodiments, a chemical composition wherein at
least 90%, 94%, or even at least 97% of the glass comprises at
least 67% SiO.sub.2, (e.g., a range of 70% to 80% SiO.sub.2), a
range of 8% to 15% of an alkaline earth metal oxide (e.g., CaO), a
range of 3% to 8% of an alkali metal oxide (e.g., Na.sub.2O), a
range of 2% to 6% B.sub.2O.sub.3, and a range of 0.125% to 1.5%
SO.sub.3.
[0033] Glass bubbles useful for practicing the present disclosure
(in some embodiments, the second plurality of glass bubbles) can be
obtained commercially and include those prepared by spray-drying
and marketed by Potters Industries, Valley Forge, Pa., (an
affiliate of PQ Corporation) under the trade designations
"SPHERICEL HOLLOW GLASS SPHERES" (e.g., grades 110P8 and 60P18) and
glass bubbles marketed by 3M Company, St. Paul, Minn., under the
trade designation "3M GLASS BUBBLES" (e.g., grades S60, S60HS,
iM30K, S38HS, S38XHS, K42HS, K46, and H50/10000). In some
embodiments, glass bubbles useful for practicing the present
disclosure (e.g., the second plurality of glass bubbles) may be
selected to have crush strengths of at least about 28, 34, 41, 48,
or 55 MPa for 90% survival.
[0034] The first plurality of glass bubbles according to the
present disclosure can be prepared, for example, by classifying a
second plurality of glass bubbles, for example, having a size
distribution comprising higher number of glass bubbles with a size
of up to ten micrometers and, in some embodiments, a higher number
of glass bubbles at least 40 micrometers in size than the first
plurality of glass bubbles. Exemplary suitable apparatus for
classifying the glass bubbles include vibrating screens (e.g.,
sieves), air classifiers, wet classifiers (e.g., wet scrubbing
classifiers), fabric filter classifiers, settling classifiers,
centrifugal classifiers, electrostatic classifiers, and
combinations thereof. Exemplary suitable screens include sieves
having a designation of from 200 mesh (74 micrometers) through at
least 635 mesh (20 micrometers) according to ASTM Designation:
E11-04 entitled "Standard Specification for Wire Cloth and Sieves
for Testing Purposes". Such sieves may be obtained from commercial
suppliers such as, for example, Newark Wire Cloth Company, Newark,
N.J. Exemplary suitable air classifiers include gravitational
classifiers, inertial classifiers, and centrifugal classifiers. Air
classifiers are readily available from commercial sources, for
example, as available from Hosokawa Micron Powder Systems under the
trade designations "MICRON SEPARATOR", "ALPINE MODEL 100 MZR",
"ALPINE TURBOPLEX ATP", "ALPINE STRATOPLEX ASP", or "ALPINE
VENTOPLEX"; or from Sepor, Inc., Wilmington, California under the
trade designation "GAYCO CENTRIFUGAL SEPARATOR".
[0035] The classification method and apparatus may be selected so
that the first plurality of glass bubbles is distributed from 1 to
45, 1 to 38, or 1 to 32 micrometers. In some embodiments of the
methods disclosed herein, removing at least a portion of the second
plurality of glass bubbles at least 40 micrometers in size
comprises collecting glass bubbles that passed through a
32-micrometer screen. In some embodiments, removing at least a
portion of the second plurality of glass bubbles up to ten
micrometers in size comprises collecting glass bubbles that were
retained on a 20-micrometer screen.
[0036] The second plurality of glass bubbles typically comprises a
higher number of bubbles with a size of 10 (in some embodiments,
11, 12, 13, 14, or 15) micrometers and under than the first
plurality of glass bubbles. For example the second plurality of
glass bubbles may comprise at least 5, 10, 15, 20, 25, 30, 35, 40,
45, 50, 55, or 60 percent of bubbles with a size of up to 10, 11,
12, 13, 14, or 15 micrometers. In some embodiments, the second
plurality of glass bubbles also has a size distribution with a
higher number of glass bubbles at least 40 micrometers in size than
the first plurality of glass bubbles. The second plurality of glass
bubbles has a size distribution with a higher or lower median size
by volume than the first plurality of glass bubbles. For example,
the second plurality of glass bubbles can have a median size by
volume in a range from 14 to 45 micrometers (in some embodiments
from 15 to 40 micrometers, 20 to 45 micrometers, or 20 to 40
micrometers).
[0037] In some embodiments, the first plurality of glass bubbles is
a graded fraction of the second plurality of glass bubbles of up to
75, 70, 65, 60, 55, 50, 45, 40, 35, 30, or 25 percent by weight of
the second plurality of glass bubbles. In some embodiments, the
first plurality of glass bubbles is a graded fraction of the second
plurality of glass bubbles of at least 15, 20, 25, 30, or 35
percent by weight of the second plurality of glass bubbles. It may
be desirable, for example, to choose a second plurality of glass
bubbles with a high percentage of bubbles with a median size in a
range from 15 to 40 micrometers.
[0038] The present disclosure provides composites comprising a
polymer and a first plurality of glass bubbles according to and/or
prepared according to the present disclosure. The polymer may be a
thermoplastic or thermoset polymer, and the composite may contain a
mixture of polymers. Suitable polymers for the composite may be
selected by those skilled in the art, depending at least partially
on the desired application.
[0039] In some embodiments, the polymer in the composite disclosed
herein is a thermoplastic. Exemplary thermoplastics include
polyolefins (e.g., polypropylene, polyethylene, and polyolefin
copolymers such as ethylene-butene, ethylene-octene, and ethylene
vinyl alcohol); fluorinated polyolefins (e.g.,
polytetrafluoroethylene, copolymers of tetrafluoroethylene and
hexafluoropropylene (FEP), perfluoroalkoxy polymer resin (PFA),
polychlorotrifluoroethylene (pCTFE), copolymers of ethylene and
chlorotrifluoroethylene (pECTFE), and copolymers of ethylene and
tetrafluoroethylene (PETFE)); polyamide; polyamide-imide;
polyether-imide; polyetherketone resins; polystyrenes; polystyrene
copolymers (e.g., high impact polystyrene, acrylonitrile butadiene
styrene copolymer (ABS)); polyacrylates; polymethacrylates;
polyesters; polyvinylchloride (PVC); liquid crystal polymers (LCP);
polyphenylene sulfides (PPS); polysulfones; polyacetals;
polycarbonates; polyphenylene oxides; and blends of two or more
such resins. In some embodiments, the polymer in the composite is a
thermoplastic comprising at least one of polypropylene or
polyethylene (e.g., high density polyethylene (HDPE), low density
polyethylene (LDPE), linear low density polyethylene (LLDPE),
polypropylene (PP)), and polyolefin copolymers (e.g., copolymers of
propylene and ethylene). In some of these embodiments, the
thermoplastic is polypropylene (e.g., high density polyethylene
(HDPE), low density polyethylene (LDPE), and linear low density
polyethylene (LLDPE)). In some embodiments, the thermoplastic is
elastomeric.
[0040] In some embodiments, the polymer in the composite disclosed
herein is a thermoset. Exemplary thermosets include epoxy,
polyester, polyurethane, polyurea, silicone, polysulfide, and
phenolic. In some embodiments, the polymer in the composite is a
thermoset selected from the group consisting of epoxy,
polyurethane, silicone, and polyester. In some embodiments, the
thermoset is elastomeric.
[0041] In some embodiments, the polymer in the composite disclosed
herein is elastomeric. Exemplary useful elastomeric polymers
include polybutadiene, polyisobutylene, ethylene-propylene
copolymers, ethylene-propylene-diene terpolymers, sulfonated
ethylene-propylene-diene terpolymers, polychloroprene,
poly(2,3-dimethylbutadiene), poly(butadiene-co-pentadiene),
chlorosulfonated polyethylenes, polysulfide elastomers, silicone
elastomers, poly(butadiene-co-nitrile), hydrogenated
nitrile-butadiene copolymers, acrylic elastomers, ethylene-acrylate
copolymers, fluorinated elastomers, fluorochlorinated elastomers,
fluorobrominated elastomers and combinations thereof. The
elastomeric polymer may be a thermoplastic elastomer. Exemplary
useful thermoplastic elastomeric polymer resins include block
copolymers, made up of blocks of glassy or crystalline blocks of,
for example, polystyrene, poly(vinyltoluene), poly(t-butylstyrene),
and polyester, and elastomeric blocks of, for example,
polybutadiene, polyisoprene, ethylene-propylene copolymers,
ethylene-butylene copolymers, polyether ester, and combinations
thereof. Some thermoplastic elastomers are commercially available,
for example, poly(styrene-butadiene-styrene) block copolymers
marketed by Shell Chemical Company, Houston, Tex., under the trade
designation "KRATON".
[0042] Other additives may be incorporated into the composite
according to the present disclosure depending on the application
(e.g., preservatives, curatives, mixing agents, colorants,
dispersants, floating or anti-setting agents, flow or processing
agents, wetting agents, air separation promoters, functional
nanoparticles, and acid/base or water scavengers).
[0043] In some embodiments, the composites according to the present
disclosure comprise an impact modifier (e.g., an elastomeric resin
or elastomeric filler). Exemplary impact modifiers include
polybutadiene, butadiene copolymers, polybutene, ground rubber,
block copolymers, ethylene terpolymers, core-shell particles, and
functionalized elastomers available, for example, from Dow Chemical
Company, Midland, Mich., under the trade designation "AMPLIFY
GR-216".
[0044] In some embodiments, composites disclosed herein may further
comprise other density modifying additives like plastic bubbles
(e.g., those available under the trade designation "EXPANCEL" from
Akzo Nobel, Amsterdam, The Netherlands), blowing agents, or heavy
fillers. In some embodiments, composites disclosed herein may
further comprise at least one of glass fiber, wollastonite, talc,
calcium carbonate, titanium dioxide (including nano-titanium
dioxide), carbon black, wood flour, other natural fillers and
fibers (e.g., walnut shells, hemp, and corn silks), silica
(including nano-silica), and clay (including nano-clay).
[0045] In some embodiments of the composite according to the
present disclosure, the glass bubbles may be treated with a
coupling agent to enhance the interaction between the glass bubbles
and the polymer. It is desirable to select a coupling agent that
matches or provides suitable reactivity with corresponding
functional groups of the chosen polymer formulation. Illustrative
examples of coupling agents include zirconates, silanes, or
titanates. Typical titanate and zirconate coupling agents are known
to those skilled in the art and a detailed overview of the uses and
selection criteria for these materials can be found in Monte, S.
J., Kenrich Petrochemicals, Inc., "Ken-React.RTM. Reference
Manual--Titanate, Zirconate and Aluminate Coupling Agents", Third
Revised Edition, March, 1995. If used, coupling agents are commonly
included in an amount of about 1 to 3% by weight, based on the
total weight of the bubble.
[0046] Suitable silanes are coupled to glass surfaces through
condensation reactions to form siloxane linkages with the siliceous
filler. This treatment renders the filler more wet-able or promotes
the adhesion of materials to the glass bubble surface. This
provides a mechanism to bring about covalent, ionic or dipole
bonding between inorganic fillers and organic matrices. Silane
coupling agents are chosen based on the particular functionality
desired. For example, an aminosilane glass treatment may be
desirable for compounding with a polymer containing an anhydride,
epoxy, amide or isocyanate group. Alternatively, silane treatments
with acidic functionality may require polymer selections to possess
blocks capable of acid-base interactions, ionic or hydrogen bonding
scenarios. Another approach to achieving intimate glass
bubble-polymer interactions is to functionalize the surface of
microsphere with a suitable coupling agent that contains a
polymerizable moiety, thus incorporating the material directly into
the polymer backbone. Examples of polymerizable moieties are
materials that contain olefinic functionality such as styrenic,
acrylic and methacrylic moieties. Suitable silane coupling
strategies are outlined in Silane Coupling Agents: Connecting
Across Boundaries, by Barry Arkles, pg 165-189, Gelest Catalog
3000-A Silanes and Silicones: Gelest Inc. Morrisville, Pa. Other
illustrative examples of coupling agents include maleic
anhydride-modified polypropylene and polyethylene.
[0047] In some embodiments, the first plurality of glass bubbles is
present in the composite at a level of up to 60 volume percent
without voids or up to 90 volume percent with voids, based on the
total volume of the composite. In some embodiments, the first
plurality of glass bubbles is present in the composite at a level
of up to 55, 50, 45, 40, 35, or 30 percent by volume, based on the
total volume of the composite. In some embodiments, the first
plurality of glass bubbles is present in the composite at a level
of up to 40, 35, 30, 25, 20, or 15 percent by weight, based on the
total weight of the composite. For example, the first plurality of
glass bubbles may be present in the composite in a range from 5 to
40, 5 to 35, 5 to 30, 5 to 25, 7.5 to 25, or 8 to 25 percent by
weight, based on the total weight of the composite. The present
disclosure can provide a cost-effective, low-density composite
without compromising its physical properties. For example, the
first plurality of glass bubbles according to the present
disclosure has, in some embodiments, lower density and similar
strength properties compared to commercially available glass
bubbles. Hence, a desired composite density can be achieved when
using a lower weight percent of the glass bubbles of the present
disclosure while maintaining its physical properties. As a result,
overall cost of the composite is reduced. Although glass bubbles
have often been used to successfully reduce density of the final
composites, such resultant composites have often exhibited
undesirable loss of certain physical properties such as impact
strength and tensile strength. A lower weight percentage of glass
bubbles according to the present disclosure can be incorporated
into composites, for example, because of their lower density,
impacting the physical properties of the polymer to a lesser
extent.
[0048] Generally, it is desirable that the glass bubbles be strong
to avoid being crushed or broken during processing of a polymer
composite, such as by high pressure spraying, kneading, extrusion,
pultrusion, sintering, or molding (e.g., compression molding,
injection molding, blow molding, roto-molding, thermoforming, and
injection-compression molding). Typically, a first plurality of
glass bubbles according to the present disclosure demonstrate
improved survivability after processing compared to commercially
available microspheres (e.g., the second plurality of glass bubbles
from which the first plurality of glass bubbles is prepared). Thus,
although the first plurality of glass bubbles according to the
present disclosure may have a lower density than that of
commercially available glass bubbles, they are surprisingly strong
and able to survive high shear processes.
[0049] The survivability of the first plurality of glass bubbles
according to the present disclosure can be seen, for example, in
Tables 6 and 7 in the Examples, below. Ash densities were measured
after extruding, injection molding, and compression molding
composites prepared from a first plurality of glass bubbles
according to the present disclosure and a comparative commercially
available plurality of glass bubbles. As it may be seen from Table
6, ash density results for a composite made from the first
plurality of glass bubbles according to the present disclosure had
less of an increase after extrusion as compared to the as-produced
commercial comparative examples from which the first plurality of
glass bubbles is made; (see, Composite Example 1 vs. Comparative
Composite Example A and Composite Example 2 vs. Comparative
Composite Example B). An even more pronounced difference is seen
after injection molding where the first plurality of glass bubbles
according to the present disclosure has, in some cases, half the
breakage of the current commercial material. Correspondingly the
density of the composites is maintained at a lower specific density
through the two processing techniques with the first plurality of
glass bubbles according to the present disclosure.
[0050] Composites according to the present disclosure may be useful
for making a variety of articles. Illustrative examples include
those from the transportation industry such as instrumental panel
cores, engine covers, side impact panels, interior trim, bumpers,
fascia, o-rings, gaskets, brake pads, and hoses; molded household
parts; composite sheets; thermoformed structural components;
polymer wood composites, and wire and cable cladding. Other
illustrative examples include potting compounds, panel structures,
structural composite resins, plastic containers and pallets.
Selected Embodiments of the Disclosure
[0051] In a first embodiment, the present disclosure provides a
first plurality of glass bubbles having an average true density of
up to 0.55 grams per cubic centimeter and a size distribution
comprising a median size by volume in a range from 15 micrometers
to 40 micrometers, wherein a hydrostatic pressure at which ten
percent by volume of the first plurality of glass bubbles collapses
is at least 100 megapascals.
[0052] In a second embodiment, the present disclosure provides a
first plurality of glass bubbles according to the first embodiment,
wherein the median size by volume is in a range from 15 micrometers
to 25 micrometers, and wherein the size distribution further
comprises up to twenty percent by number of the glass bubbles
having a size of up to ten micrometers.
[0053] In a third embodiment, the present disclosure provides a
first plurality of glass bubbles according to the first embodiment,
wherein the average true density is up to 0.45 grams per cubic
centimeter, and wherein the median size by volume is in a range
from 15 to 25 micrometers.
[0054] In a fourth embodiment, the present disclosure provides a
first plurality of glass bubbles according to the first or third
embodiment, wherein the size distribution further comprises up to
forty percent by number of the glass bubbles having a size of up to
ten micrometers.
[0055] In a fifth embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the first
to fourth embodiments, wherein the glass bubbles have a glass
composition comprising an alkaline earth metal oxide and an alkali
metal oxide in a weight ratio in a range from 1.2:1 to 3:1.
[0056] In a sixth embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the first
to fifth embodiments, wherein the glass bubbles have a glass
composition comprising B.sub.2O.sub.3 in a range from 2 to 6
percent by weight, based on the total weight of the glass
bubbles.
[0057] In a seventh embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the first
to sixth embodiments, wherein the glass bubbles have a glass
composition comprising up to 5 percent by weight Al.sub.2O.sub.3,
based on the total weight of the glass bubbles.
[0058] In an eighth embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the first
to seventh embodiments, wherein the glass bubbles have a glass
composition comprising SiO.sub.2 in a range from 70 to 80 percent
by weight, alkaline earth metal oxide in a range from 8 to 15
percent by weight, and alkali metal oxide in a range from 3 to 8
percent by weight, each percent by weight based on the total weight
of the glass bubbles.
[0059] In a ninth embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the first
to eighth embodiments, wherein the first plurality of glass bubbles
is a graded fraction preparable by classifying a second plurality
of glass bubbles, wherein the second plurality of glass bubbles has
a higher number of glass bubbles with a size of up to ten
micrometers than the first plurality of glass bubbles.
[0060] In a tenth embodiment, the present disclosure provides a
first plurality of glass bubbles according to the ninth embodiment,
wherein the second plurality of glass bubbles has a higher number
of glass bubbles at least 40 micrometers in size than the first
plurality of glass bubbles.
[0061] In a eleventh embodiment, the present disclosure provides a
first plurality of glass bubbles according to the ninth or tenth
embodiment, wherein the graded fraction is obtainable by collecting
glass bubbles that are distributed from 1 micrometer to 32
micrometers.
[0062] In a twelfth embodiment, the present disclosure provides a
first plurality of glass bubbles according to any one of the ninth
to eleventh embodiments, wherein classifying comprises at least one
of screening, air classifying, fabric filter classifying, settling
classifying, centrifugal classifying, electrostatic classifying,
and wet scrubbing classifying.
[0063] In a thirteenth embodiment, the present disclosure provides
a first plurality of glass bubbles according to any one of the
first to twelfth embodiments, wherein the glass bubbles are treated
with a coupling agent.
[0064] In a fourteenth embodiment, the present disclosure provides
a composite comprising a polymer and a first plurality of glass
bubbles according to any one of the first to thirteenth
embodiments.
[0065] In a fifteenth embodiment, the present disclosure provides a
composite according to the fourteenth embodiment, wherein the
polymer comprises at least one of a thermoplastic polymer, a
thermoset polymer, or an elastomer.
[0066] In a sixteenth embodiment, the present disclosure provides a
composite according to the fourteenth embodiment, wherein the
polymer is a thermoplastic polymer.
[0067] In a seventeenth embodiment, the present disclosure provides
a composite according to the fourteenth embodiment, wherein the
polymer is an elastomer.
[0068] In an eighteenth embodiment, the present disclosure provides
a composite according to the fourteenth embodiment, wherein the
polymer is a thermoset polymer.
[0069] In a nineteenth embodiment, the present disclosure provides
a composite according to any one of the fourteenth to eighteenth
embodiments, wherein the first plurality of glass bubbles is
present in the composite at a level of up to 40 percent by weight,
based on the total weight of the composite.
[0070] In a twentieth embodiment, the present disclosure provides a
method of making a first plurality of glass bubbles according to
any one of the first to eighth embodiments, the method
comprising:
[0071] providing a second plurality of glass bubbles having a
second size distribution comprising a median size by volume, a
number of glass bubbles up to ten micrometers in size, and a number
of glass bubbles at least 40 micrometers in size; and
[0072] removing at least a portion of the glass bubbles up to ten
micrometers in size,
[0073] wherein after removing at least a portion of the glass
bubbles up to ten micrometers in size, a first plurality of glass
bubbles remains, and wherein the first plurality of glass bubbles
has a number of glass bubbles up to ten micrometers in size that is
lower than the number of glass bubbles up to ten micrometers in
size of the second plurality of glass bubbles.
[0074] In a twenty-first embodiment, the present disclosure
provides a method according to the twentieth embodiment, further
comprising removing at least a portion of the glass bubbles at
least 40 micrometers in size; wherein after removing at least a
portion of the glass bubbles at least 40 micrometers in size and
removing at least a portion of the glass bubbles up to ten
micrometers in size, the first plurality of glass bubbles is
obtained, wherein the first plurality of glass bubbles has a lower
number of glass bubbles at least 40 micrometers in size than the
second plurality of glass bubbles.
[0075] In a twenty-second embodiment, the present disclosure
provides a method according to the twentieth or twenty-first
embodiment, wherein the graded fraction is obtainable by collecting
glass bubbles that are distributed from 1 micrometer to 32
micrometers.
[0076] In a twenty-third embodiment, the present disclosure
provides a method according to any one of the twentieth to
twenty-second embodiments, wherein classifying comprises at least
one of screening, air classifying, fabric filter classifying,
settling classifying, centrifugal classifying, electrostatic
classifying, and wet scrubbing classifying.
[0077] In a twenty-fourth embodiment, the present disclosure
provides a method of making a graded fraction of glass bubbles, the
method comprising: [0078] providing a second plurality of glass
bubbles having a second size distribution comprising a median size
by volume, a number of glass bubbles up to ten micrometers in size,
and a number of glass bubbles at least 40 micrometers in size;
[0079] removing at least a portion of the glass bubbles at least 40
micrometers in size; [0080] removing at least a portion of the
glass bubbles up to ten micrometers in size,
[0081] wherein after removing at least a portion of the glass
bubbles at least 40 micrometers in size and removing at least a
portion of the glass bubbles up to ten micrometers in size, a first
plurality of glass bubbles remains, wherein the first plurality of
glass bubbles has a number of glass bubbles up to ten micrometers
in size that is lower than the number of glass bubbles up to ten
micrometers in size of the second plurality of glass bubbles, and
wherein one of the following conditions is met:
[0082] the first plurality of glass bubbles and the second
plurality of glass bubbles have equivalent densities, but the first
plurality of glass bubbles is higher in strength than the second
plurality of glass bubbles;
[0083] the first plurality of glass bubbles and the second
plurality of glass bubbles have equivalent strengths, but the first
plurality of glass bubbles is lower in density than the second
plurality of glass bubbles; or
[0084] the first plurality of glass bubbles is both lower in
density and higher in strength than the second plurality of glass
bubbles.
[0085] In a twenty-fifth embodiment, the present disclosure
provides a method according to the twenty-fourth embodiment,
wherein the first plurality of particles has an average true
density of up to 0.55 grams per cubic centimeter, and wherein the
first plurality of particles has a median size by volume in a range
from 15 micrometers to 40 micrometers.
[0086] In a twenty-sixth embodiment, the present disclosure
provides a method according to the twenty-fifth embodiment, wherein
the first plurality of particles has an average true density of up
to 0.45 grams per cubic centimeter, and wherein the first plurality
of particles has a median size by volume in a range from 15
micrometers to 25 micrometers.
[0087] In a twenty-seventh embodiment, the present disclosure
provides a method according to any one of the twenty-fourth to
twenty-sixth embodiments, wherein a hydrostatic pressure at which
ten percent by volume of the first plurality of glass bubbles
collapses is at least 100 megapascals.
[0088] In a twenty-eighth embodiment, the present disclosure
provides a method according to any one of the twenty-fourth to
twenty-seventh embodiments, wherein removing at least a portion of
the glass bubbles at least 40 micrometers size comprises collecting
glass bubbles that passed through a 32-micrometer screen.
[0089] In a twenty-ninth embodiment, the present disclosure
provides a method according to any one of the twenty-fourth to
twenty-eighth embodiments, wherein removing at least a portion of
the glass bubbles up to ten micrometers in size comprises
collecting glass bubbles that were retained on a 20-micrometer
screen.
[0090] In a thirtieth embodiment, the present disclosure provides a
method according to any one of the twenty-fourth to twenty-ninth
embodiments, wherein the first plurality of particles has an
average true density of up to 0.35 grams per cubic centimeter, and
wherein a hydrostatic pressure at which ten percent by volume of
the first plurality of glass bubbles collapses is at least 75
megapascals.
[0091] In order that this disclosure can be more fully understood,
the following examples are set forth. It should be understood that
these examples are for illustrative purposes only, and are not to
be construed as limiting this disclosure in any manner.
Examples
Materials
[0092] Glass bubbles were obtained from 3M Company, St. Paul, Minn.
under the trade designations "3M GLASS BUBBLES iM30K" and "3M GLASS
BUBBLES K42HS". These glass bubbles have glass compositions
comprising SiO.sub.2 in a range from 70 to 80 percent by weight,
alkaline earth metal oxide in a range from 8 to 15 percent by
weight, and alkali metal oxide in a range from 3 to 8 percent by
weight, and B.sub.2O.sub.3 in a range from 2 to 6 percent by
weight, each percent by weight based on the total weight of the
glass bubbles.
[0093] Polypropylene (PP) having a density of 0.9 g/cm.sup.3 was
obtained from LyondellBasell Polymers, North America, under the
trade designation "PRO-FAX 6523".
[0094] An impact modifier comprising a maleic anhydride grafted
(MAH) polymer was obtained from Dow Chemical Company, Midland,
Mich. under the trade designation "AMPLIFY GR 216". The density of
the impact modifier was 0.87 g/cm.sup.3, and the melt index
(190.degree. C./2.16 kg) was 1.3 g/10 min.
[0095] Polyamide 6,6, (nylon) having a density of 1.14 g/cm.sup.3
was obtained from DuPont, Wilmington, Del., under the trade
designation "ZYTEL 101".
[0096] Test Methods:
[0097] Average Particle Density Determination: A fully automated
gas displacement pycnometer obtained under the trade designation
"ACCUPYC 1330 PYCNOMETER" from Micromeritics, Norcross, Ga., was
used to determine the density of microspheres according to ASTM
D2840-69, "Average True Particle Density of Hollow
Microspheres".
[0098] Particle Size Determination by Laser Light Diffraction:
Particle size on a volume percent distribution was determined by
laser light diffraction using a particle size analyzer available
under the trade designation "SATURN DIGISIZER" from Micromeritics.
Glass bubbles were dispersed in deaerated deionized water prior to
particle size determination.
[0099] Particle Size Determination by SEM Analysis: Particle size
distribution was also measured in some Examples using Scanning
Electron Microscope (SEM) image analysis wherein the diameter of
each hollow microsphere was measured using a software (Olympus
"measurIT" software) provided with the microscope (model
"Phenom.TM. Scanning Electron Microscope" obtained from FEI
Company, Hillsboro, Oreg.). The glass bubble size data was then
sorted and analyzed to calculate particle percent distribution
(i.e., actual number of particles of a certain diameter, as a
percent of all particles measured).
[0100] Strength Test: The strength of the glass bubbles was
measured using ASTM D3102-72 "Hydrostatic Collapse Strength of
Hollow Glass Microspheres"; with the following modifications. The
sample size (in grams) was equal to 10 times the density of the
glass bubbles. The microspheres were dispersed in glycerol (20.6
g), and data reduction was automated using computer software. The
value reported is the hydrostatic pressure at which 10 and 20
percent by volume of the glass bubbles collapse (Strength at 90%
and 80% survival, respectively).
[0101] Notched Izod Impact resistance: Izod impact resistance of
the composites was measured according to the procedure outlined in
ASTM D256 "Standard Test Methods for Determining the Izod Pendulum
Impact Resistance of Plastics".
[0102] Compression Molding: Pellets of composites were compression
molded at 4 different hold pressures to simulate a targeted process
of injection-compression molding with different compression
pressures. A compression plate comprising a 1/8 inch (in.) (0.32
cm) thick 11 in. by 11 in. (27.94 cm by 27.94 cm) picture frame
mold was used. The frame was wrapped with sturdy aluminum foil and
further comprised two 1/16 in. (0.16 cm) thick plates of steel
disposed on the top and bottom portions of the aluminum-wrapped
frame. A weighed pile of pellets was placed in the center of
compression plate and placed in a 12 in. by 12 in. (30.48 cm)
heated platen compression molder (model 25-12H from Carver Inc.,
Wabash Ind.). The temperature was set at 210.degree. C. The platens
were compressed to the desired pressure slowly to allow the melting
polymer to flow evenly out into the compression plate. Simulated
pressures were 10,000 PSI (69 MPa), 15,000 PSI (103 MPa), 20,000
PSI (138 MPa) and 25,000 PSI (172 MPa). After compression for 5
minutes at the desired temperature, the platens were released and
the sandwich was put on a lab bench, in air, to cool. The steel and
aluminum foil layers were peeled from either side of the
compression plate and the formed compression plaque was cut out of
the picture frame with an exacto knife.
[0103] Ash density: Composite samples containing glass bubbles were
placed in a kiln (model 300/14 obtained from Nabertherm,
Lilienthal, Germany) The temperature was increased according to the
following procedure: 1 hour at 200.degree. C., 1 hour at
250.degree. C., 1 hour at 300.degree. C., 1 hour at 350.degree. C.,
2 hours at 450.degree. C. and 12 hours at 600.degree. C. Samples
were then removed from the kiln and allowed to cool down to room
temperature. The resulting ash was measured by the above-described
pycnometer density method.
[0104] Flexural Strength and Modulus: Composite samples were
mounted on a tensile strength testing equipment (Sintech 1G model
5401029 obtained from MTS, Eden Prairie, Minn.). Flexural
properties were measured following the procedure outlined in ASTM
D790-10 "Standard Test Methods for Flexural Properties of
Unreinforced and Reinforced Plastics and Electrical Insulating
Materials", using a strain rate of 0.2 in/min (0.51 cm/min).
[0105] Tensile strength and elongation at break and yield:
Composite samples were mounted on the tensile strength testing
equipment. Tensile and elongation were measured following the
procedure outlined in ASTM D638 "Standard Test Method for Tensile
Properties of Plastics", using a separation speed of 3 in/min (7.62
cm/min).
[0106] Melt flow rate (MFR): Composite pellets were placed into a
melt indexer (model MP600 obtained from Tinius Olsen, Horsham, Pa.)
and allowed to equilibrate at 230.degree. C. for 7 minutes. The
pellets were then tested following the procedure outlined in ASTM
D1238-10 "Standard Test Method for Melt Flow Rates of
Thermoplastics by Extrusion Plastometer" for polypropylene
(230.degree. C. and 2.16 kg) and nylon (236.degree. C. and 5
kg).
Glass Bubbles Example 1
[0107] A weighed amount (261 grams) of "3M GLASS BUBBLES iM30K"
glass bubbles was put onto the top of a stack of sieves comprising
USA Standard Testing Sieves in descending mesh opening sizes from
top to bottom. The following sieves were used: 200 mesh (74 .mu.m),
230 mesh (63 .mu.m), 270 mesh (53 .mu.m), 325 mesh (44 .mu.m), and
400 mesh (37 .mu.m). The stack of sieves was then put into a Tyler
vibratory sieve shaker for about 15 minutes. After the screening
process, the material that remained on top of each sieve (i.e.,
"overs") was collected and weighed. Glass bubbles that passed
through all of the sieves used in the stack (38 micron sieve
"unders") were sieved again but this time using an air jet sieve
with vacuum (model "Alpine Augsburg Jet Sieve" obtained from
Hosokawa Alpine, Augsburg, Germany) Only one sieve was used at a
time for the jet sieve. The glass bubbles were first run through
the 32 micron (450 mesh) jet sieve. The "overs" were collected and
weighed. The bubbles that passed through the 450 mesh sieve were
then sieved through a 20 micron (635 mesh) sieve on the jet sieve.
A small amount of material was run through each sieve on the jet
sieve to prevent "blinding", which occurs when the oversized
particles plug the screen of the sieve preventing the smaller
particle sizes from passing through. The jet sieves were blown
clean with air between sieve cycles. The "overs" for the 20 micron
sieve were collected and weighed and are designated Glass Bubbles
Example 1. Particle size distribution was measured for Glass
Bubbles Example 1 using laser light diffraction as described above,
and is reported in Table 1, below. Glass Bubbles Example 1 had an
average true density of 0.5259 g/cm.sup.3, and the hydrostatic
pressure at which ten percent by volume of Glass Bubbles Example 1
collapsed was higher than 30,000 PSI (206.8 MPa).
Comparative Glass Bubbles Example A
[0108] The "overs" for the 38 micron sieve described in Glass
Bubbles Example 1 were collected and designated Comparative Glass
Bubbles Example A, which had an average true density of 0.5779
g/cm.sup.3 and strength at 90% of about 10,213 PSI (70.4 MPa).
Glass Bubbles Example 2
[0109] Glass Bubbles Example 2 was prepared according to the method
of Glass Bubbles Example 1 except starting with "3M GLASS BUBBLES
K42HS" glass bubbles. Particle size distribution was measured for
Glass Bubbles Example 2 using laser light diffraction as described
above, and is reported in Table 1, below. Glass Bubbles Example 2
had an average true density of 0.42 g/cm.sup.3, and the hydrostatic
pressure at which ten percent by volume of Glass Bubbles Example 2
collapsed was 16,000 PSI (110 MPa).
Glass Bubbles Example 3
[0110] The "overs" for the 32 micron sieve described in Glass
Bubbles Example 2 were collected and designated Glass Bubbles
Example 3, which had an average true density of 0.3370 g/cm.sup.3
and strength at 90% of about 11,453 PSI (78.9 MPa).
[0111] Particle size distribution was measured for Glass Bubbles
Examples 1 to 3 and Comparative Glass Bubbles Example A using laser
light diffraction as described above, and is reported in Table 1,
below.
TABLE-US-00001 TABLE 1 Particle size distribution Example D90 D50
D10 Glass Bubbles Example 1 27.2 17 0.37 Glass Bubbles Example 2
31.7 20.9 8.8 Comparative Glass Bubbles Ex. A 46.3 17 6.7 Glass
Bubbles Example 3 39.1 30.1 0.21
[0112] Particle size distribution was also measured for Glass
Bubbles Examples 1 and 2 and starting materials "3M GLASS BUBBBLES
iM30K" and "3M GLASS BUBBLES K42HS" using the SEM image analysis
method described above. The total number of particles (expressed in
number % particles) below each whole number diameter between 1 and
45 is shown in Table 2, below.
TABLE-US-00002 TABLE 2 Particle size distribution using SEM image
analysis method. % particles Particle "3M GLASS "3M GLASS diameter
BUBBLES BUBBLES Glass Bubbles Glass Bubbles (.mu.m) iM30K" K42HS"
Example 1 Example 2 1 0.00 0.00 0.00 0.00 2 0.00 1.59 0.00 0.50 3
0.00 4.78 0.00 0.99 4 1.28 9.96 0.00 1.49 5 6.41 15.54 0.00 5.45 6
7.69 27.89 0.00 8.42 7 10.26 37.85 0.00 10.40 8 10.26 51.00 4.35
14.85 9 14.10 59.36 5.80 23.76 10 15.38 64.54 11.59 30.20 11 20.51
68.53 15.94 42.08 12 24.36 74.10 17.39 51.98 13 32.05 77.69 20.29
56.93 14 34.62 79.68 24.64 64.36 15 39.74 81.67 27.54 68.32 16
44.87 83.67 28.99 74.26 17 48.72 84.86 33.33 79.21 18 56.41 86.85
39.13 82.67 19 58.97 86.85 46.38 83.66 20 61.54 87.65 52.17 85.64
21 66.67 88.05 56.52 87.62 22 66.67 90.04 62.32 89.11 23 67.95
90.44 68.12 92.08 24 70.51 91.24 69.57 94.55 25 73.08 92.83 73.91
95.54 26 73.08 94.02 73.91 96.53 27 75.64 94.42 76.81 96.53 28
76.92 96.02 78.26 97.03 29 78.21 96.81 84.06 97.52 30 83.33 97.61
89.86 97.52 31 84.62 97.61 98.55 98.02 32 85.90 98.01 100.00 98.51
33 87.18 98.01 -- 98.51 34 89.74 98.01 -- 99.01 35 91.03 98.01 --
99.50 36 92.31 98.01 -- 99.50 37 92.31 99.20 -- 100.00 38 93.59
99.20 -- -- 39 96.15 99.20 -- -- 40 96.15 99.20 -- -- 41 97.44
99.20 -- -- 42 98.72 99.20 -- -- 43 100.00 99.60 -- -- 44 -- 99.60
-- -- 45 -- 100.00 -- --
[0113] Average density and strength at 90% survival of "3M GLASS
BUBBLES iM30K" and "3M GLASS BUBBLES K42HS" glass bubbles, Glass
Bubbles Examples 1 to 3, and Comparative Glass Bubbles Example A
were measured and are shown in Table 3, below.
TABLE-US-00003 TABLE 3 Average density and strength at 90%. Average
Strength at 90% Examples density (g/cm.sup.3) PSI (MPa) "3M GLASS
BUBBLES 0.601 30,000 (207) iM30K" "3M GLASS BUBBLES 0.420 11,500
(79) K42HS" Glass Bubbles Ex. 1 0.526 28,950 (200) Glass Bubbles
Ex. 2 0.420 16,800 (116) Comp. Glass Bubbles Ex. A 0.578 10,200
(70) Glass Bubbles Ex. 3 0.337 11,460 (79)
Control Example 1
[0114] Pellets of PP were fed into a 24-mm twin screw extruder
(model "Prism" obtained from Thermo Fisher Scientific, Waltham,
Mass.) equipped with a side stuffer and heated to 200.degree. C.
The extruder speed was set at 200 rpm. Test bodies of the extruded
PP were prepared using an injection molding machine (model Boy 22D
obtained from Boy Limited, Northants, UK) and an ASTM test specimen
mold. The injection molder barrel was heated to 220.degree. C. and
the mold was held at 50.degree. C. PP was injected into the mold at
conditions that maximized the molding pressure. At the highest
pressures, the injection pressure was 3,200 PSI (22 MPa). The
injection molding machine had an intensification ratio of 6.6 so
the ultimate pressure felt by the composites was approximately
21,200 PSI (146 MPa).
Comparative Composite Example A
[0115] A composite of "3M GLASS BUBBLES iM30K" glass bubbles and PP
with a desired target density of 0.813 g/cm.sup.3 was prepared.
Pellets of PP and the glass bubbles were fed into the twin screw
extruder heated to 200.degree. C. on a 78.5/21.5 percent by weight
ratio. Test bodies of Comparative Composite Example A were prepared
as described above in Control Example 1.
Comparative Composite Example B
[0116] A composite of "3M GLASS BUBBLES K42HS" glass bubbles and PP
with a desired target density of 0.816 g/cm.sup.3 was prepared as
described in Comparative Composite Example A. The PP/glass bubbles
weight ratio was about 91/9. Test bodies of Comparative Composite
Example B were prepared as described above in Control Example
1.
Composite Example 1
[0117] A composite of Glass Bubbles Example 1 and PP with a desired
target density of 0.813 g/cm.sup.3 was prepared as described in
Comparative Composite Example A. The PP/glass bubbles weight ratio
was about 85/15. Pellets of the composite were injection molded in
a Boy 22D injection molder using an ASTM test specimen mold at a
temperature of 50.degree. C. and an injection pressure of 3,200 PSI
(22 MPa). Test bodies of Composite Example 1 were prepared as
described in Control Example 1.
Composite Example 2
[0118] A composite of Glass Bubbles Example 2 and PP with a desired
target density of 0.816 g/cm.sup.3 was prepared as described in
Comparative Composite Example B. The PP/glass bubbles weight ratio
was about 91/9. Test bodies of Composite Example 2 were prepared as
described in Control Example 1.
Control Example 2
[0119] Pellets of PP and impact modifier (IM) "AMPLIFY GR 216" were
fed into the twin screw extruder on a 90/10 percent by weight ratio
to produce an impact modified polypropylene (Control Example 2)
having a target density of 0.897 g/cm.sup.3. Test bodies of Control
Example 2 were prepared as described in Control Example 1.
Comparative Composite Example C
[0120] Comparative Composite Example C was prepared as described in
Control Example 2, except that "3M GLASS BUBBLES iM30K" glass
bubbles were also fed into the twin screw extruder to produce a
composite having a target density of 0.812 g/cm.sup.3. The ratio of
PP/IM/glass bubbles was 68.5/10/21.5 percent by weight. Test bodies
of Comparative Composite Example C were prepared as described in
Control Example 1.
Comparative Composite Example D
[0121] Comparative Composite Example D was prepared as described in
Control Example 2, except that "3M GLASS BUBBLES K42HS" glass
bubbles were also fed into the twin screw extruder to produce a
composite having a target density of 0.814 g/cm.sup.3. The ratio of
PP/IM/glass bubbles was 81/10/9 percent by weight. Test bodies of
Comparative Composite Example D were prepared as described in
Control Example 1.
Composite Example 3
[0122] An impact-modified composite was prepared as described in
Control Example 2, except that Glass Bubbles Example 1 were also
fed into the twin screw extruder to produce a composite having a
target density of 0.811 g/cm.sup.3. The ratio of PP/IM/glass
bubbles was 75/10/15 percent by weight. Test bodies of Composite
Example 3 were prepared as described in Control Example 1.
Composite Example 4
[0123] An impact-modified composite was prepared as described in
Control Example 2, except that Glass Bubbles Example 2 were also
fed into the twin screw extruder to produce a composite having a
target density of 0.814 g/cm.sup.3. The ratio of PP/IM/glass
bubbles was 81/10/9 percent by weight. Test bodies of Composite
Example 4 were prepared as described in Control Example 1.
Control Example 3
[0124] Pellets of nylon were fed into the twin screw extruder as
described in Control Example 1 to produce an polyamide composite
(Control Example 3) having a density of 1.14 g/cm.sup.3. Test
bodies of Control Example 3 were prepared as described in Control
Example 1, except that the injection molder barrel was heated to
270.degree. C.
Comparative Composite Example E
[0125] Comparative Composite Example E was prepared as described in
Control Example 3, except that "3M GLASS BUBBLES iM30K" glass
bubbles were also fed into the twin screw extruder to produce a
composite having a target density of 0.970 g/cm.sup.3. The ratio of
nylon/glass bubbles was 80.54/19.46 percent by weight. Test bodies
of Comparative Composite Example E were prepared as described in
Control Example 1.
Comparative Composite Example F
[0126] Comparative Composite Example F was prepared as described in
Control Example 3, except that "3M GLASS BUBBLES K42HS" glass
bubbles were also fed into the twin screw extruder to produce a
composite having a target density of 0.985 g/cm.sup.3. The ratio of
nylon/glass bubbles was 90.85/9.15 percent by weight. Test bodies
of Comparative Composite Example F were prepared as described in
Control Example 1.
Composite Example 5
[0127] A composite of Glass Bubbles Example 1 and nylon with a
desired target density of 0.940 g/cm.sup.3 was prepared as
described in Comparative Composite Example A, except that Nylon was
used. The nylon/glass bubbles weight ratio was about 85/15. Test
bodies of Composite Example 5 were prepared as described in Control
Example 1.
Composite Example 6
[0128] A composite of Glass Bubbles Example 2 and nylon with a
desired target density of 0.986 g/cm.sup.3 was prepared as
described in Comparative Composite Example A, except that Nylon was
used. The nylon/glass bubbles weight ratio was about 90/10. Test
bodies of Composite Example 6 were prepared as described in Control
Example 1.
[0129] A summary of Control Examples 1, 2 and 3, and the composites
prepared as described in Comparative Composite Examples A-F and
Composite Examples 1-6 is shown in Table 4, below.
[0130] Impact resistance (impact), flexural modulus (flex modulus),
tensile strength (tensile), and melt flow rate (MFR) for test
bodies prepared as described in Control Examples 1 and 2,
Comparative Composite Examples A-F, and Composite Examples 1-6 were
measured as described above and are reported in Table 5, below. All
results are reported as an average of 5 tests for each Example.
TABLE-US-00004 TABLE 4 Composites Composite Target Impact
PP/microspheres/IM Density Examples Glass bubbles modifier (IM)
weight ratio (g/cm.sup.3) Control Example 1 None None 100 0.9 Comp.
Composite Ex. A "3M GLASS None 78.5/21.5 0.813 BUBBLES iM30K" Comp.
Composite Ex. B "3M GLASS None 91/9 0.816 BUBBLES K42HS" Composite
Example 1 Glass Bubbles Ex. 1 None 85/15 0.813 Composite Example 2
Glass Bubbles Ex. 2 None 91/9 0.816 Control Example 2 None Amplify
GR 90/0/10 0.897 216 Comp. Composite Example C "3M GLASS Amplify GR
68.5/21.5/10 0.811 BUBBLES iM30K" 216 Comp. Composite Ex. D "3M
GLASS Amplify GR 81/9/10 0.814 BUBBLES K42HS" 216 Composite Example
3 Glass Bubbles Ex. 1 Amplify GR 75/15/10 0.811 216 Composite
Example 4 Glass Bubbles Ex. 2 Amplify GR 81/10/9 0.814 216 Control
Example 3 None None 100 1.14 Comp. Composite Ex. E "3M GLASS None
80.54/19.46 0.970 BUBBLES iM30K" Comp. Composite Ex. F "3M GLASS
None 90.85/9.15 0.985 BUBBLES K42HS" Composite Example 5 Glass
Bubbles Ex. 1 None 85/15 0.970 Composite Example 6 Glass Bubbles
Ex. 2 None 90/10 0.986
TABLE-US-00005 TABLE 5 Impact resistance, flexural modulus, tensile
strength and melt flow rate. Impact Tensile Resistance Flex Modulus
Strength (MPa) MFR Examples (J/m.sup.2) (MPa) [kpsi] [kpsi] (g/10
min) Control Example 1 2952 597.91 [86.72] 30.34 [4.4] 4.774 Comp.
Composite Ex. A 1405 982.50 [142.5] 17.24 [2.5] 2.141 Comp.
Composite Ex. B 1603 700.78 [101.64] 22.75 [3.3] 2.968 Composite
Example 1 1491 775.93 [112.54] 19.99 [2.9] 2.522 Composite Example
2 1681 787.24 [114.18] 22.06 [3.2] 2.943 Control Example 2 7686
564.96 [81.94] 26.20 [3.8] 4.559 Comp. Composite Ex. C 2810 648.93
[94.12] 20.68 [3.0] 1.505 Comp. Composite Ex. D 2998 602.33 [87.36]
22.75 [3.3] 2.688 Composite Example 3 2898 591.43 [85.78] 21.37
[3.1] 2.234 Composite Example 4 3168 671.55 [97.4] 22.75 [3.3]
2.563 Control Example 3 4288 3939.66 [271.4] 67.71 [9.82] 47.0
Comp. Composite Ex. E 1793 2602.77 [377.5] 55.16 [8.0] 19.2 Comp.
Composite Ex. F 1976 2129.10 [308.8] 65.50 [9.5] 27.3 Composite
Example 5 1924 2441.43 [354.1] 59.29 [8.6] 21.1 Composite Example 6
1937 2155.99 [312.7] 64.81 [9.4] 26.7
[0131] Ash density for microspheres (neat), pellets (after
extrusion), and injection molded plaques prepared as described in
Comparative Composite Examples A-F and Composite Examples 1-6 was
measured. The difference between the initial density (measured for
microspheres) and the final density (measured for pellets and/or
plaques) was calculated and is expressed as % density increase.
Initial density (g/cm.sup.3), ash density (g/cm.sup.3), and density
increase (%) are reported in Table 6, below.
TABLE-US-00006 TABLE 6 Density, ash density and density increase
with injection molded plaques. Extruded Pellets Density Injected
Plaques Glass Bubbles Ash density increase Ash density Density
Examples Density (g/cm.sup.3) (g/cm.sup.3) (%) (g/cm.sup.3)
increase (%) Comp. Composite Ex. A 0.601 0.674 12.07 0.685 13.97
Comp. Composite Ex. B 0.422 0.551 30.53 0.651 54.28 Composite
Example 1 0.526 0.596 9.16 0.605 10.77 Composite Example 2 0.420
0.515 22.67 0.527 25.50 Comp. Composite Ex. C 0.601 0.658 9.39
0.662 10.11 Comp. Composite Ex. D 0.422 0.519 23.11 0.641 51.96
Composite Example 3 0.526 0.584 6.94 0.600 9.86 Composite Example 4
0.420 0.493 17.36 0.527 25.40 Comp. Composite Ex. E 0.601 0.666
6.48 0.678 7.67 Comp. Composite Ex. F 0.422 0.524 10.18 0.603 18.06
Composite Example 5 0.526 0.589 6.34 0.592 6.58 Composite Example 6
0.42 0.495 7.5 0.544 12.35
[0132] Pellets of the composites were subjected to 4 different
compression pressures, as described above. Ash density was measured
for the compression plaques and is reported in Table 7, below.
TABLE-US-00007 TABLE 7 Ash density measured after compression
molding. Ash density of Compression Plaques (g/cm.sup.3) 10,000 PSI
15,000 PSI 20,000 PSI 25,000 PSI Examples (69 MPa) (103 MPa) (138
MPa) (172 MPa) Comp. Composite Example A 0.682 0.699 0.714 0.735
Comp. Composite Example B 0.601 0.679 0.787 0.854 Composite Example
1 0.596 0.597 0.601 0.623 Composite Example 2 0.517 0.518 0.533
0.601
[0133] This disclosure may take on various modifications and
alterations without departing from its spirit and scope.
Accordingly, this disclosure is not limited to the above-described
embodiments but is to be controlled by the limitations set forth in
the following claims and any equivalents thereof. This disclosure
may be suitably practiced in the absence of any element not
specifically disclosed herein. All patents and patent applications
cited above are hereby incorporated by reference into this document
in their entirety.
* * * * *