Composites with oriented particles and particle networks with method

Abstract

A method and types of composites in which particles are oriented within a melt-processable material or are arranged into networks in response to chaotic advection. A masterbatch comprising a melt-processable material and particles is supplied to a blender in which chaotic advection is maintained for a specified period. A second, melt-processable material may be supplied to the blender simultaneously. Resulting composites include extrusions with oriented inorganic platelets that reduce permeation or electrically conducting plastics and other functional materials.

1 . A method to produce a composite with controllably oriented particles comprising: 
 a. selecting a melt-processable material;    b. selecting a particle type;    c. processing said polymer melt and said particle to yield a masterbatch;    d. feeding said masterbatch into a machine capable of inducing chaotic advection;    e. discharging the resulting composite following a predefined amount of chaotic advection; and    f. processing said resultant composite into a product.    
     
     
         2 . The method of  claim 1  wherein said melt-processable material is polyethylene.  
     
     
         3 . The method of  claim 1  wherein said particle type is a low permeation material.  
     
     
         4 . The method of  claim 3  wherein said particle type is a clay.  
     
     
         5 . The method of  claim 3  wherein said low permeation material is graphite.  
     
     
         6 . The method of  claim 1  wherein said particle type is an electrical conducting material.  
     
     
         7 . The method of  claim 6  wherein said electrical conducting material is carbon black.  
     
     
         8 . The method of  claim 6  where said electrical conducting material is a metal.  
     
     
         9 . A method of producing composites with controllably oriented particles comprising the steps of: 
 a. selecting a first melt-processable material;    b. selecting a particle type;    c. processing said first melt-processable material and particles of said selected particle type to yield a master batch;    d. selecting a second melt-processable polymer;    e. feeding said master batch and said second melt-processable material simultaneously into a machine capable of chaotic advection;    f. operating said machine so as to subject said master batch and said second melt-processable material to a defined amount of chaotic advection to produce a composite with oriented particles;    g. discharging the resultant composite from said machine; and    h. processing said discharged composite for a use.    
     
     
         10 . A method of producing networks among particles to yield a composite with unique features comprising the steps of: 
 a. selecting a first melt-processable material;    selecting a particle type;    b. processing said first melt-processable material and particles of said particle type to yield a master batch;    c. selecting a second melt-processable material;    d. feeding said master batch and said second melt-processable material simultaneously into a machine capable of inducing chaotic advection;    e. operating said machine so as to subject said masterbatch and said second melt-processable material to chaotic advection to a degree to produce a composite with networks formed among particles;    f. discharging the resultant composite from machine; and    g. processing said discharged composite for use.    
     
     
         11 . The method of  claim 10  wherein said unique feature is directed to directional electrical conductivity.  
     
     
         12 . The method of  claim 10  wherein said unique property is electrical conductivity attained at particle concentrations as low as 1%.  
     
     
         13 . A composite derived from a masterbatch wherein said masterbatch comprises a first melt-processable material and particles and further wherein said particles are oriented into numerous layers.  
     
     
         14 . The composite of  claim 13  wherein said first melt-processable material is one of the following materials: nylon, polypropylene, polypropylene-g-maleic anhydride or linear, low density polyethylene.  
     
     
         15 . The composite of  claim 13  wherein said particles are one of the following (clay, graphite, or silica).  
     
     
         16 . A composite derived from a masterbatch wherein said masterbatch comprises a first melt-processable material, and particles, and further wherein said composite further is derived from a second melt-processable material and wherein said particles are oriented into numerous layers.  
     
     
         17 . The composite of  claim 16  wherein said first melt-processable material is one of the following (nylon, polypropylene, polypropylene-g-maleic anhydride, or low density polyethylene), and said second melt-processable material is one of the following (nylon, polypropylene, polypropylene-g-malaeic acid, or low density polyethylene), and said particles are one of the following (clay, graphite, or silica), and further wherein said particles are oriented into numerous layers.  
     
     
         18 . A composite derived from a masterbatch wherein said masterbatch comprises a first melt-processable material and particles wherein said particles form numerous, interconnecting networks.  
     
     
         19 . The composite of  claim 18  wherein said first melt-processable material is one of the following (nylon, polypropylene, polypropylene-g-maleic anhydride, or low density polyethylene).  
     
     
         20 . The composite of  claim 18  wherein said particles are one of the following (carbon black, nickel, iron, or copper).  
     
     
         21 . A composite derived from a masterbatch wherein said masterbatch comprises a first melt-processable material and particles and further derived from a second melt-processable material wherein said particles form numerous, interconnecting networks.  
     
     
         22 . The composite of  claim 21  wherein said first melt-processable material is one of the following nylon, polypropylene, propylene-g-maleic anhydride, or low density polyethylene), said second melt-processable material is one of the following (nylon, polypropylene, propylene-g-maleic anhydride, or low density polyethylene), and said particles are one of the following (carbon black, nickel, iron, or copper).