Structurally enhanced plastics with filler reinforcements

Abstract

A composition comprising a fluid, and a material dispersed in the fluid, the material made up of particles having a complex three dimensional surface area such as a sharp blade-like surface, the particles having an aspect ratio larger than 0.7 for promoting kinetic boundary layer mixing in a non-linear-viscosity zone. The composition may further include an additive dispersed in the fluid. The fluid may be a thermopolymer material. A method of extruding the fluid includes feeding the fluid into an extruder, feeding additives into the extruder, feeding a material into the extruder, passing the material through a mixing zone in the extruder to disperse the material within the fluid wherein the material migrates to a boundary layer of the fluid to promote kinetic mixing of the additives within the fluid, the kinetic mixing taking place in a non-linear viscosity zone.

1 - 62 . (canceled) 
     
     
         63 . An improved additive for use in a fluid flowing through equipment where the flowing fluid has a stream velocity (U) and a boundary layer flow velocity (u), wherein (U) and (u) are affected by filler loading, heat transfer, shear effects and chemical reactions, wherein the improvement comprises:
 particles having a sharp conchoidal surface and a complex three-dimensional surface area, said particles having a diameter approximately equal to a theoretical starting diameter;   wherein said particle theoretical starting diameter is defined by a height measured perpendicular to a surface where u=0.99U.   
     
     
         64 . The improved additive according to  claim 63  wherein said complex three-dimensional surface area comprises a smooth, sharp surface. 
     
     
         65 . The improved additive according to  claim 63  wherein said complex three-dimensional surface area comprises a smooth, sharp, blade-like surface. 
     
     
         66 . The improved additive according to  claim 63  wherein said complex three-dimensional surface area comprises a smooth, curved surface. 
     
     
         67 . The improved additive according to  claim 63  wherein said particles comprise a jet milled material. 
     
     
         68 . The improved additive according to  claim 63  wherein said particles comprise an impact jet milled material. 
     
     
         69 . The improved additive according to  claim 63  wherein said particles comprise a ball milled material. 
     
     
         70 . The improved additive according to  claim 63  wherein said particles comprise a roller milled material. 
     
     
         71 . The improved additive according to  claim 63  wherein said particles have a Mohs hardness value of greater than 2.5 
     
     
         72 . The improved additive according to  claim 63  wherein said particles have a hardness sufficient to deform said fluid as it flows around said particles, thereby promoting kinetic mixing through the tumbling or rolling effect of the particles. 
     
     
         73 . The improved additive according to  claim 63  wherein said particles are of a size that remain primarily in a boundary layer of said flowing fluid, said particles having an appropriate size with respect to the boundary layer such that fluid flowing over said boundary layer cause rolls or tumbles of said particles, for creating kinetic rolling thereby producing mixing in said boundary layer. 
     
     
         74 . The improved additive of  claim 63  wherein said particles promote boundary layer renewal of said flowing fluid by kinetic mixing. 
     
     
         75 . The improved additive according to  claim 63  wherein said particles are selected from a group consisting of porous materials, manmade materials, and naturally occurring minerals. 
     
     
         76 . (canceled) 
     
     
         77 . The improved additive according to  claim 63  wherein said equipment is a pump or process equipment having connections that are open ended single pass or are continuous for recycle operations. 
     
     
         78 . The improved additive according to  claim 63  wherein said particle diameter results in particle interaction in a boundary layer of said flowing fluid to achieve one of an increase in additive dispersion in said fluid, or to increase surface quality of said fluid exiting said equipment. 
     
     
         79 . The improved additive according to  claim 63  wherein said particles are incorporated into said fluid by providing pellets which have said particles contained therein, and forming the fluid from said pellets, said fluid of which has the particles dispersed therein. 
     
     
         80 . The improved additive according to  claim 63  wherein said particles are incorporated into oil. 
     
     
         81 . The improved additive according to  claim 63  wherein said particles are incorporated into a paint. 
     
     
         82 . The improved additive according to  claim 63  wherein said particles are incorporated into a fire retardant. 
     
     
         83 . The improved additive according to  claim 63  wherein said particles are incorporated into a heat transfer fluid. 
     
     
         84 . The improved additive according to  claim 63  wherein said particles are incorporated into a pigment. 
     
     
         85 . The improved additive according to  claim 63  wherein said particles have an aspect ratio greater than 0.7. 
     
     
         86 . The improved additive according to  claim 63  wherein said fluid is a plastic. 
     
     
         87 . The improved additive according to  claim 63  wherein said fluid is a polymer.