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 . A composition comprising:
 a fluid; and   a material dispersed in said fluid, said material comprised of particles having a sharp blade-like surface, said particles having an aspect ratio larger than 0.7 for promoting kinetic boundary layer mixing in a non-linear-viscosity zone.   
     
     
         2 . The composition according to  claim 1  further comprising an additive dispersed in said fluid. 
     
     
         3 . The composition according to  claim 1  wherein said fluid is a thermopolymer material. 
     
     
         4 . The composition according to  claim 1  wherein said particles have a Mohs hardness value of greater than 2.5 
     
     
         5 . The composition according to  claim 3  wherein said sharp blade-like surface of said particles is sized for grinding and cutting of polymers of said thermopolymer material during a mixing operation. 
     
     
         6 . The composition according to  claim 1  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 particle. 
     
     
         7 . The composition according to  claim 1  wherein said particles are of a size that remain primarily in the boundary layer of said fluid, said particles having an appropriate size with respect to the boundary layer such that fluid forces flowing over said boundary layer cause rolls or tumbles of said particles, for creating kinetic rolling thereby producing mixing in said boundary layer. 
     
     
         8 . The composition of  claim 1  wherein said particles promote boundary layer renewal of said fluid by kinetic mixing. 
     
     
         9 . The composition according to  claim 1  wherein said material is selected from a group consisting of porous materials, manmade materials, and naturally occurring minerals. 
     
     
         10 . A method of extruding a fluid including:
 feeding a fluid into an extruder;   feeding additives into said extruder;   feeding a material into said extruder, said material comprised of particles having a sharp blade-like surface, said particles having an aspect ratio greater than 0.7;   passing said material through a mixing zone in said extruder to disperse the material within the fluid wherein said material migrates to a boundary layer of said fluid to promote kinetic mixing of said additives within said fluid, said kinetic mixing taking place in a non-linear viscosity zone.   
     
     
         11 . The method according to  claim 10  wherein said fluid is a thermoplastic material. 
     
     
         12 . The method according to  claim 10  wherein said additive is a filler. 
     
     
         13 . The method according to  claim 10  wherein said additive is a pigment. 
     
     
         14 . The method according to  claim 10  wherein said additive is a fiber. 
     
     
         15 . The method according to  claim 10  further comprising the step of:
 using conchoidal fracturing techniques with a jet milled process to produce said material prior to said step of feeding said material into said extruder.   
     
     
         16 . The method according to  claim 11  wherein the step of:
 passing said material through a mixing zone in said extruder comprises mixing said thermoplastic material by grinding and cutting effects generated by said particles of said material that are rolling along a large surface area as in said boundary layer, said thermoplastic material fluid flow geometry of said surface being in continuous contact where said particle impacts said material through kinetic tumbling of said particle created by said fluid flowing over said surface.   
     
     
         17 . The method according to  claim 10  further comprising the step of:
 self-cleaning of the boundary layer on the majority of fixed and moving mechanical parts of said extruder including molds by said step of kinetic mixing by continuous hard particle interaction through tumbling during kinetic mixing over said surface where said fluid is moving.   
     
     
         18 . The method according to  claim 10  wherein said step of kinetic mixing comprises particle rolling or tumbling of said particles along the boundary layer surface. 
     
     
         19 . The method according to  claim 10  wherein said material is selected from a group consisting of: solid materials, porous materials, manmade materials, naturally occurring minerals. 
     
     
         20 . A method of increasing flow through a member of a fluid including:
 feeding a fluid into said member;   feeding a material into said member, said material comprised of particles having a sharp blade-like surface, said particles having an aspect ratio greater than 0.7;   dispersing said the material within the fluid wherein said material migrates to a boundary layer of said fluid to promote kinetic mixing within said fluid, said kinetic mixing taking place in a non-linear viscosity zone resulting in reduced coefficient of friction caused by drag in the boundary layer.   
     
     
         21 . The method according to  claim 20  wherein said member is a pump or process equipment having connections that are open ended single path or are continuous for recycle operations. 
     
     
         22 . The method according to  claim 20  wherein said fluid is filled. 
     
     
         23 . The method according to  claim 20  wherein said fluid is unfilled. 
     
     
         24 . A composition comprising:
 a fluid; and   a material dispersed in said fluid, said material comprised of particles having a complex three-dimensional surface area, said particles having an aspect ratio larger than 0.7 for promoting kinetic boundary layer mixing in a non-linear-viscosity zone.   
     
     
         25 . The composition according to  claim 24  wherein said complex three-dimensional surface area comprises a smooth, sharp blade-like surface. 
     
     
         26 . The composition according to  claim 24  wherein said complex three-dimensional surface area comprises needle-like shapes. 
     
     
         27 . The composition according to  claim 24  wherein said complex three-dimensional surface area comprises a thin smooth curved shape. 
     
     
         28 . The composition according to  claim 24  further comprising an additive dispersed in said fluid. 
     
     
         29 . The composition according to  claim 24  wherein said fluid is a thermopolymer material. 
     
     
         30 . The composition according to  claim 24  wherein said particles have a Mohs hardness value of greater than 2.5 
     
     
         31 . The composition according to  claim 24  wherein said complex three-dimensional surface area of said particles is sized for grinding and cutting of polymers of said thermopolymer material during a mixing operation. 
     
     
         32 . The composition according to  claim 24  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 particle. 
     
     
         33 . The composition according to  claim 24  wherein said particles are of a size that remain primarily in the boundary layer of said fluid, said particles having an appropriate size with respect to the boundary layer such that fluid forces flowing over said boundary layer cause rolls or tumbles of said particles, for creating kinetic rolling thereby producing mixing in said boundary layer. 
     
     
         34 . The composition of  claim 24  wherein said particles promote boundary layer renewal of said fluid by kinetic mixing. 
     
     
         35 . The composition according to  claim 24  wherein said material is selected from a group consisting of porous materials, manmade materials, and naturally occurring minerals. 
     
     
         36 . The composition according to  claim 24  wherein said particles comprise greater than 2 wt % of said composition. 
     
     
         37 . The composition according to  claim 24  wherein pressure from said fluid acts to change the size of said particles while maintaining said complex three-dimensional surface area so that said particles tend to stay in said boundary layer. 
     
     
         38 . A method of extruding a fluid including:
 feeding a fluid into an extruder;   feeding additives into said extruder;   feeding a material into said extruder, said material comprised of particles having a complex three-dimensional surface area, said particles having an aspect ratio greater than 0.7;   passing said material through a mixing zone in said extruder to disperse the material within the fluid wherein said material migrates to a boundary layer of said fluid to promote kinetic mixing of said additives within said fluid, said kinetic mixing taking place in a non-linear viscosity zone.   
     
     
         39 . The method according to  claim 38  wherein said complex three-dimensional surface area comprises a smooth, sharp blade-like surface. 
     
     
         40 . The method according to  claim 38  wherein said complex three-dimensional surface area comprises needle-like shapes. 
     
     
         41 . The method according to  claim 38  wherein said complex three-dimensional surface area comprises a thin smooth curved shape. 
     
     
         42 . The method according to  claim 38  wherein said fluid is a thermoplastic material. 
     
     
         43 . The method according to  claim 38  wherein said additive is a filler. 
     
     
         44 . The method according to  claim 38  wherein said additive is a pigment. 
     
     
         45 . The method according to  claim 38  wherein said additive is a fiber. 
     
     
         46 . The method according to  claim 38  further comprising the step of:
 using conchoidal fracturing techniques with a jet milled process to produce said material prior to said step of feeding said material into said extruder.   
     
     
         47 . The method according to  claim 38  further comprising the step of:
 using a mechanical roller mill process thereby promoting conchoidal fracturing to produce said material prior to said step of feeding said material into said extruder.   
     
     
         48 . The method according to  claim 38  wherein the step of:
 passing said material through a mixing zone in said extruder comprises mixing said thermoplastic material by grinding and cutting effects generated by said particles of said material that are rolling along a large surface area as in said boundary layer, said thermoplastic material fluid flow geometry of said surface being in continuous contact where said particle impacts said material through kinetic tumbling of said particle created by said fluid flowing over said surface.   
     
     
         49 . The method according to  claim 38  further comprising the step of:
 self-cleaning of the boundary layer on the majority of fixed and moving mechanical parts of said extruder including molds by said step of kinetic mixing by continuous hard particle interaction through tumbling during kinetic mixing over said surface where said fluid is moving.   
     
     
         50 . The method according to  claim 38  wherein said step of kinetic mixing comprises particle rolling or tumbling of said particles along the boundary layer surface. 
     
     
         51 . The method according to  claim 38  wherein said material is selected from a group consisting of: solid materials, porous materials, manmade materials, naturally occurring minerals. 
     
     
         52 . The method according to  claim 38  wherein said particles comprise greater than 2 wt % of said composition. 
     
     
         53 . The method according to  claim 38  wherein pressure from said fluid acts to change the size of said particles while maintaining said complex three-dimensional surface area so that said particles tend to stay in said boundary layer. 
     
     
         54 . A method of increasing flow through a member of a fluid including:
 feeding a fluid into said member;   feeding a material into said member, said material comprised of particles having a complex three-dimensional surface area, said particles having an aspect ratio greater than 0.7;   dispersing said the material within the fluid wherein said material migrates to a boundary layer of said fluid to promote kinetic mixing within said fluid, said kinetic mixing taking place in a non-linear viscosity zone resulting in reduced coefficient of friction caused by drag in the boundary layer.   
     
     
         55 . The method according to  claim 54  wherein said complex three-dimensional surface area comprises a sharp blade-like surface. 
     
     
         56 . The method according to  claim 54  wherein said complex three-dimensional surface area comprises needle-like shapes. 
     
     
         57 . The method according to  claim 54  wherein said complex three-dimensional surface area comprises a thin smooth curved shape. 
     
     
         58 . The method according to  claim 54  wherein said member is a pump or process equipment having connections that are open ended single path or are continuous for recycle operations. 
     
     
         59 . The method according to  claim 54  wherein said fluid is filled. 
     
     
         60 . The method according to  claim 54  wherein said fluid is unfilled. 
     
     
         61 . The method according to  claim 54  wherein said particles comprise greater than 2 wt % of said composition. 
     
     
         62 . The method according to  claim 54  wherein pressure from said fluid acts to change the size of said particles while maintaining said complex three-dimensional surface area so that said particles tend to stay in said boundary layer.