US2005122834A1PendingUtilityA1

Method for producing a well-exfoliated and dispersed polymer silicate nanocomposite by ultrasonication

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Assignee: FORD GLOBAL TECH LLCPriority: Jan 11, 2002Filed: Nov 9, 2004Published: Jun 9, 2005
Est. expiryJan 11, 2022(expired)· nominal 20-yr term from priority
Inventors:Ellen Cheng-Chi LeeDeborah Frances Mielewski
C08J 3/201
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Claims

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.

Claims

exact text as granted — not AI-modified
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 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 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.

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