Extrusion method forming an enhanced property metal polymer composite
First Claim
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1. A method to extrude a metal polymer composite, the composite comprising a metal particulate phase and a polymer phase, the method comprising:
- (a) combining;
(i) about 96 to 45 volume-% of a metal particulate comprising 5 wt-% or less of particles having a particle size of less than 10 microns, the metal having a density greater than 8 gm-cm−
3, in a particulate phase having a particle size distribution having at least 10 wt.-% of particulate within of about 10 to 70 microns, at least 20 wt.-% of the polymer particulate within about 70 to 500 microns, a circularity greater than 13 and an aspect ratio less than 3;
(ii) about 4 to 53 volume-% of a polymer phase; and
(iii) about 0.005 to 3 wt.-% of an interfacial modifier material to form a composite mix; and
(b) extruding the composite mixture at a temperature greater than 100°
C. and at a shear rate of about 1 to 500 sec−
1 to form an extruded metal polymer composite;
wherein the extruded composite has a density greater than about 7 gm-cm−
3 and a storage modulus of greater than 300 MPa.
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Abstract
The invention relates to an extrusion method and to an extrudable metal polymer composite having increased density, improved viscoelastic properties, malleability and ductility and thermoplastic extrusion or injection molding properties.
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Citations
42 Claims
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1. A method to extrude a metal polymer composite, the composite comprising a metal particulate phase and a polymer phase, the method comprising:
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(a) combining; (i) about 96 to 45 volume-% of a metal particulate comprising 5 wt-% or less of particles having a particle size of less than 10 microns, the metal having a density greater than 8 gm-cm−
3, in a particulate phase having a particle size distribution having at least 10 wt.-% of particulate within of about 10 to 70 microns, at least 20 wt.-% of the polymer particulate within about 70 to 500 microns, a circularity greater than 13 and an aspect ratio less than 3;(ii) about 4 to 53 volume-% of a polymer phase; and (iii) about 0.005 to 3 wt.-% of an interfacial modifier material to form a composite mix; and (b) extruding the composite mixture at a temperature greater than 100°
C. and at a shear rate of about 1 to 500 sec−
1 to form an extruded metal polymer composite;wherein the extruded composite has a density greater than about 7 gm-cm−
3 and a storage modulus of greater than 300 MPa. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An injection molding process comprising heating a composite to an elevated temperature and injecting that composite into a mold;
- wherein the composite comprises a polymer, and a metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm−
3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%.
- wherein the composite comprises a polymer, and a metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm−
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11. A compression molding process comprising molding a composite under elevated pressure;
- wherein the composite comprises a polymer, and metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm−
3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%.
- wherein the composite comprises a polymer, and metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm−
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12. A sequential compounding process comprising blending a polymer and metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4gm-cm−
- 3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%.
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13. A sequential compounding process comprising
a first operation of blending a substantially solvent-free mixture of a polymer and metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm− - 3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%, to form a composite, and
a second operation of extruding or molding an object, wherein the molding is compression molding or injection molding.
- 3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%, to form a composite, and
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14. A sequential compounding process comprising
a first operation of blending solvent, polymer, and metal particulate coated with an interfacial modifier, with the metal of the particulate having a density greater than 4 gm-cm− - 3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%, and a second operation of extruding or molding an object, wherein the molding is compression molding or injection molding.
- View Dependent Claims (15)
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16. A sequential compounding process comprising
blending solvent, polymer, and metal particulate coated with an interfacial modifier, with the metal having a density greater than 7 gm-cm− - 3 and the interfacial modifier being in an amount between 0.005 and 1 wt.-%, followed by a solvent degassing of the composite during the melt portion of mixing.
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17. A method of manufacturing a metal polymer composite article comprising:
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(a) forming a metal polymer mixture by combining; (i) a metal particulate, the metal having a density greater than 4 gm-cm−
3 and an excluded volume of about 13 to about 60 volume-%, the metal particulate comprising a coating of an effective composite forming amount of an interfacial modifier; and(ii) a polymer phase comprising a polymer in an amount sufficient to substantially occupy excluded volume of the particulate; (b) blending the metal polymer mixture to form a metal polymer composite blend having a density greater than about 4 gm-cm−
3 and a storage modulus of greater than 300 MPa; and(c) shaping the metal polymer composite blend to form a metal polymer composite article. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A method of manufacturing a metal polymer composite article comprising:
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(a) forming a metal polymer mixture by combining; (i) a metal particulate comprising stainless steel, the steel having a density greater than 4 gm-cm−
3 and an excluded volume of about 13 to about 60 volume-%, the metal particulate comprising a coating of an effective composite forming amount of an interfacial modifier; and(ii) a polymer phase comprising a thermoplastic polymer in an amount sufficient to substantially occupy the excluded volume of the particulate; (b) blending the metal polymer mixture to form a metal polymer composite having a density greater than about 4 gm-cm−
3 and a storage modulus of greater than 300 MPa; and(c) shaping the metal composite to form a metal polymer composite article. - View Dependent Claims (34, 35, 36, 37, 38)
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39. A method of manufacturing a metal polymer composite article comprising:
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(a) forming a metal polymer mixture by combining; (i) a metal particulate comprising a particle blend of first metal particles and second metal particles, the metal having a density greater than 4 gm-cm−
3 and an excluded volume of about 13 to about 60 volume-%, the metal particulate comprising a coating of an effective composite forming amount of an interfacial modifier; and(ii) a polymer phase comprising a thermoplastic polymer in an amount sufficient to substantially occupy the excluded volume of the particulate; (b) blending the metal polymer mixture to form a metal polymer composite having a density greater than about 4 gm-cm−
3 and a storage modulus of greater than 300 MPa; and(c) shaping the metal polymer composite to form a metal polymer composite article. - View Dependent Claims (40, 41, 42)
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Specification