US2018009964A1PendingUtilityA1

Reduced density hollow glass microsphere polymer composite

74
Assignee: TUNDRA COMPOSITES LLCPriority: Apr 29, 2009Filed: Aug 18, 2017Published: Jan 11, 2018
Est. expiryApr 29, 2029(~2.8 yrs left)· nominal 20-yr term from priority
Inventors:Kurt E. HeikkilaRodney K. WilliamsJohn S. Kroll
C08K 2003/2227C08K 2201/005Y10T428/249974C08J 2327/18C08L 21/00C08K 9/00C08K 9/04C08K 3/22C08J 5/04B60C 1/00C08K 7/28C08J 2327/16C08J 2327/20
74
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Claims

Abstract

The invention relates to a hollow glass microsphere and polymer composite having enhanced viscoelastic and rheological properties.

Claims

exact text as granted — not AI-modified
1 - 61 . (canceled) 
     
     
         62 . A method of manufacturing a hollow glass microsphere and polymer composite from a mixture, said method comprising:
 (a) pre-treating a hollow glass microsphere with an effective composite forming amount of an interfacial modifier coating wherein the hollow glass microsphere has a particle size of at least about 5 microns;   (b) combining a polymer phase with about 30 to 95 volume % of a pre-treated interfacial modifier coated hollow glass microsphere, in an amount sufficient to substantially occupy excluded volume of a hollow glass microsphere particle distribution in the composite; and   (c) compounding the mixture to form the composite comprising the pre-treated hollow glass microspheres within the polymer phase;   
       wherein the hollow glass microsphere exhibits a circularity greater than 13 and an aspect ratio less than 1:3; and wherein the interfacial modifier coating allows for greater freedom of movement between the pre-treated hollow glass microsphere within the polymer phase compared to the same composite without the exterior coating on the hollow glass microsphere, when measured under the same conditions. 
     
     
         63 . The method according to  claim 63 , wherein about 5 to 60 volume % of the hollow glass microsphere composite comprises the polymer phase. 
     
     
         64 . The method according to  claim 63 , wherein the composite comprises about 0.005 to 8 wt.-% of the interfacial modifier. 
     
     
         65 . The method of  claim 63  wherein the polymer phase comprises a polyamide, a nylon, a poly(ethylene-co-vinyl acetate), a synthetic rubber, a polyvinyl chloride, a fluoropolymer or fluoroelastomer, a polyolefin, a thermoset polymer, or a high-density polyolefin. 
     
     
         66 . The method of  claim 63 , wherein the composite has a density of about 0.20 to 15 gm-cm −3 . 
     
     
         67 . The method of  claim 63  wherein the composite additionally comprises a solid particulate or a fiber, the particulate having a particle size (P s ) of about 5 to 1000 microns and the fiber having an aspect ratio of greater than 10. 
     
     
         68 . A method of manufacturing a hollow glass microsphere composite, said method comprising:
 (a) pre-treating a hollow glass microsphere with an effective composite forming amount of an interfacial modifier coating wherein the hollow glass microsphere has a particle size of at least about 5 microns;   (b) compounding a polymer phase with about 30 to 95 volume % of a pre-treated interfacial modifier coated hollow glass microsphere, in an amount sufficient to substantially occupy excluded volume of a hollow glass microsphere particle distribution in a blend; and   (c) extruding the blend to form the hollow glass microsphere composite comprising the pretreated hollow glass microspheres within the polymer phase; and wherein the interfacial modifier coating allows for a greater freedom of movement between the pre-treated hollow glass microspheres within the polymer phase compared to the same composite without the exterior coating on the hollow glass microsphere, when measured under the same conditions.   
     
     
         69 . The method according to  claim 68 , wherein about 5 to 60 volume % of the hollow glass microsphere composite comprises the polymer phase. 
     
     
         70 . The method according to  claim 68 , wherein the composite comprises about 0.005 to 8 wt.-% of the interfacial modifier. 
     
     
         71 . The method of  claim 68  wherein the polymer phase comprises a polyamide, poly(ethylene-co-vinyl acetate), a synthetic rubber, a polyvinyl chloride, a fluoropolymer, a polyolefin, a thermoset polymer. 
     
     
         72 . The method of  claim 68 , wherein the composite has a density is about 0.20 to 15 gm-cm −3 . 
     
     
         73 . The method of  claim 68  wherein the composite additionally comprises a solid particulate or a fiber, the particulate having a particle size (P s ) of about 5 to 1000 microns and the fiber having an aspect ratio of greater than 10. 
     
     
         74 . A method of manufacturing a hollow glass microsphere composite, said method comprising:
 (a) pre-treating a hollow glass microsphere with an effective composite forming amount of an interfacial modifier coating wherein the hollow glass microsphere has a particle size of at least about 5 microns;   (b) compounding a polymer phase with about 30 to 95 volume % of the pre-treated interfacial modifier coated hollow glass microsphere, in an amount sufficient to substantially occupy excluded volume of a hollow glass microsphere particle distribution in the composite; and   (c) melt processing the composite to form the hollow glass microsphere composite comprising the pre-treated hollow glass microspheres within the polymer phase;   
       wherein the interfacial modifier coating allows for a greater freedom of movement between the pre-treated hollow glass microspheres within the polymer phase compared to the same composite without the exterior coating on the hollow glass microspheres, when measured under the same conditions. 
     
     
         75 . The method according to  claim 74 , wherein said method is a sequential method. 
     
     
         76 . The method of  claim 74  wherein the melt processing comprises extruding the hollow glass microsphere composite. 
     
     
         77 . The method according to  claim 74 , wherein said melt processing comprises injection molding the hollow glass microsphere composite. 
     
     
         78 . The method according to  claim 74 , wherein said melt processing comprises compression molding the hollow glass microsphere composite. 
     
     
         79 . The method according to  claim 74 , wherein the composite comprises about 0.005 to 4 wt. % of the interfacial modifier. 
     
     
         80 . The method according to  claim 74 , wherein about 5 to 60 volume % of the hollow glass microsphere composite comprises the polymer phase. 
     
     
         81 . The method according to  claim 74 , wherein the composite comprises about 0.005 to 8 wt.-% of the interfacial modifier. 
     
     
         82 . The method of  claim 74  wherein the polymer phase comprises a polyamide, a poly (ethylene-co-vinyl acetate), a synthetic rubber, a polyvinyl chloride, a fluoropolymer, a polyolefin or blends thereof. 
     
     
         83 . The method of  claim 74 , wherein the composite has a density is about 0.20 to 15 gm-cm −3 . 
     
     
         84 . The method of  claim 74  wherein the comprises additionally comprises a solid particulate or a fiber, the particulate having a particle size (P s ) of about 5 to 1000 microns and the fiber having an aspect ratio of greater than 10. 
     
     
         85 . A composite formulation comprising:
 greater than about 59 to 90 vol. % of a glass microsphere having a coating of about 0.0005 to 8 wt. % an interfacial modifier; and   a natural or synthetic rubber phase, wherein the coating on the glass microsphere allows for greater freedom of movement of the glass within the rubber phase, and the percentages are based on the composite formulation.   
     
     
         86 . The composite formulation of  claim 85  wherein the microsphere is a hollow glass microsphere. 
     
     
         87 . The composite formulation of  claim 85  wherein the composite formulation has a density is about 0.2 to 5 gm-cm −3 . 
     
     
         88 . The composite formulation of  claim 85  wherein the rubber phase has a density greater than 1.7 gm-cm −3 . 
     
     
         89 . The composite formulation of  claim 85  wherein the composite formulation has a tensile strength of about 0.1 to 10 times that of the rubber phase. 
     
     
         90 . The composite of  claim 85  wherein the composite formulation has a tensile strength of about 0.1 to 10 times that of the rubber phase and a tensile elongation of about 15% to 90% of the rubber phase. 
     
     
         91 . The composite of  claim 85  wherein the composite formulation has a thermoplastic shear at least about 5 sec −1 . 
     
     
         92 . The composite formulation of  claim 85  wherein the composite formulation has a tensile strength of at least 0.2 MPa and a thermoplastic shear of at least 5 sec −1 . 
     
     
         93 . The composite formulation of  claim 85  wherein the composite formulation comprises a hollow glass microsphere, a majority of the microspheres having a particle size P S  of about 10 to 1000 microns. 
     
     
         94 . The composite formulation of  claim 85  wherein the hollow glass microsphere has a particle size P S  of about 5 to 300 microns. 
     
     
         95 . The composite formulation of claim  106  wherein the hollow glass microsphere has a particle size P S  of about 15 to 250 microns.

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