Ultrasound assisted continuous process for making polymer blends and copolymers

Abstract

This invention relates to a process for making polymer blends and copolymers by ultrasonic treatment during or after mixing the polymers. In the process of the present invention, an unexpected phenomenon occurs. The process brings about enhancement of the mechanical properties when compared with identical blends not subjected to ultrasonic treatment. The ultrasonic treatment of the blends is believed to enhance intermolecular interaction and improve adhesion between dissimilar polymers and make chemical bonds between polymers that otherwise are incompatible or immiscible with each other.

What is claimed is:  
     
         1 . An apparatus for the production of polymer blends and copolymers comprising: 
 a continuous mixer having a mixing section selected from the group consisting dispersive mixers and/or distributive mixers; and    an ultrasonic horn communicating with said continuous mixer.    
     
     
         2 . An apparatus as in  claim 1 , wherein said continuous mixer is selected from the group consisting of single-screw extruders twin-screw extruders, and modular twin screw extruders.  
     
     
         3 . An apparatus as in  claim 2 , wherein said ultrasonic horn communicates with said continuous mixer at the exit of said continuous mixer.  
     
     
         4 . An apparatus as in  claim 2 , wherein said continuous mixer includes a die attachment and said ultrasonic horn communicates with said die attachment.  
     
     
         5 . An apparatus for the production of polymer blends and copolymers comprising: 
 a twin-screw extruder;    a pressurized treatment zone; and    an ultrasonic horn communicating with said pressurized treatment zone.    
     
     
         6 . An apparatus as in  claim 5 , wherein said pressurized treatment zone is provided at the exit of said twin-screw extruder, said ultrasonic horn being positioned proximate said exit.  
     
     
         7 . An apparatus as in  claim 5 , further comprising a die attachment, said pressurized treatment zone being within said die attachment, and said ultrasonic horn communicating with said die attachment.  
     
     
         8 . An apparatus as in  claim 6 , wherein said twin screw extruder is a modular twin screw extruder.  
     
     
         9 . An apparatus for the production of polymer blends and copolymers comprising: 
 a batch mixer having at least one wall defining an interior of said batch mixer;    an ultrasonic horn communicating with said interior through said at least one wall;    rotors within said batch mixer and providing, upon the operation thereof, a pressurized zone proximate said ultrasonic horn.    
     
     
         10 . An apparatus as in  claim 9 , wherein said batch mixer is selected from the group consisting of Banbury mixers, Farrel mixers, and Haake mixers.