Method of manufacturing a functionally graded article

• US 9,731,456 B2
• Filed: 03/14/2013
• Issued: 08/15/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Inventors: Kushalappa, Poovanna Theethira, Marur, Sudhakar Ramamoorthy, Ramalingam, Hariharan, Golakrishanan, Sadasivam
• Primary Examiner(s): Lee, Edmund
• Application Number:
  US13/827,012
• Publication Number:
  US 20140272119A1
• Time in Patent Office: 1,615 Days
• Field of Search: None
• CPC Class Codes: B29C 45/0013 using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29C 70/62 the filler being oriented during moulding for short fibres B29C70/14
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: B29C 70/882 partly or totally electrically conductive, e.g. for EMI shielding conductive floors or floor coverings H05F3/025; EMI shielding in general H05K9/00
• CPC Class Codes: B29K 2995/0003 having particular electrical or magnetic properties, e.g. piezoelectric
• CPC Class Codes: C08J 2323/06 Polyethene
• CPC Class Codes: C08J 2323/12 Polypropene
• CPC Class Codes: C08J 2325/06 Polystyrene
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2367/04 Polyesters derived from hydroxy carboxylic acids, e.g. lactones C08J2367/06 takes precedence
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 5/00 Manufacture of articles or shaped materials containing macromolecular substances manufacture of semi-permeable membranes B01D67/00 - B01D71/00
• CPC Class Codes: C08J 5/041 with metal fibres
• CPC Class Codes: C08K 2003/0843 Cobalt
• CPC Class Codes: C08K 2003/0856 Iron
• CPC Class Codes: C08K 2003/0862 Nickel
• CPC Class Codes: C08K 2003/2272 Ferric oxide (Fe2O3)
• CPC Class Codes: C08K 2003/2275 Ferroso-ferric oxide (Fe3O4)
• CPC Class Codes: C08K 2003/2293 of nickel
• CPC Class Codes: C08K 2201/01 Magnetic additives
• CPC Class Codes: C08K 9/02 : Ingredients treated with inorganic substances
• CPC Class Codes: C08K 9/04 : Ingredients treated with organic substances treated with macromolecular compounds C08K9/08
• CPC Class Codes: C08K 9/10 : Encapsulated ingredients
• CPC Class Codes: C23C 26/00 : Coating not provided for in groups C23C2/00 - C23C24/00

Abstract

Disclosed herein are methods for manufacturing a functionally graded polymer material. The methods comprise preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler dispersed in the thermoplastic polymer, molding the melted polymer mixture and applying a magnetic field to a portion of the melted polymer mixture to form a functionally graded polymer material. The resulting functionally graded polymer material has a magnetic filler gradient formed through a thickness of the material.

Claims

1. A method of manufacturing a functionally graded article, comprising:

modifying a magnetic filler with at least one of a functionalization material and an encapsulating material;

preparing a melted polymer mixture comprising a thermoplastic polymer and the magnetic filler, wherein the magnetic filler is dispersed in the thermoplastic polymer, wherein the magnetic filler is present in an amount of 0.01 to 15 wt % based on the total weight of the melted polymer mixture;

injecting the melted polymer mixture into a mold; and

applying a magnetic field from a magnet incorporated into the mold to a portion of the melted polymer mixture to form the functionally graded article, wherein the functionally graded article has a magnetic filler gradient.

2. The method of claim 1, wherein the magnetic field alters distribution of the magnetic filler within the molten polymer to concentrate the magnetic filler in an area of the polymer.

3. The method of claim 1, wherein the filler gradient is formed through a portion of a thickness of the functionally graded article, wherein the portion of the thickness is less than the entire thickness of the functionally graded article.

4. The method of claim 1, wherein the magnetic field draws the magnetic filler through the molten polymer towards a magnetic field source.

5. The method of claim 1, wherein the molding comprises injection molding.

6. The method of claim 1, wherein the magnetic field is applied by a magnet placed within the mold.

7. The method of claim 1, wherein a temperature of the melted polymer mixture during the molding is 120 to 400°

C.

8. The method of claim 1, wherein the magnetic filler is further modified by coating, chemical modification, or a combination comprising at least one of the foregoing.

9. The method of claim 1, wherein the magnetic field is applied prior to curing or hardening of the melted polymer mixture.

10. The method of claim 1, wherein the magnetic filler comprises iron, nickel, cobalt, ferrites, rare earth magnets, or a combination comprising at least one of the foregoing.

11. The method of claim 1, wherein the magnetic filler comprises magnetic particles, magnetic fibers, or a combination comprising at least one of the foregoing.

12. The method of claim 11, wherein the magnetic fibers are metal fibers, metal-coated fibers or a combination of metal fibers and metal-coated fibers.

13. The method of claim 1, wherein the functionalization material is selected from diallyl based moieties, vinyl functionalized based monomer or polymer, siloxane based materials, or combinations thereof, and wherein the encapsulating material is selected from titanium dioxide, talc, calcium carbonate, and combinations thereof.

14. The method of claim 1, further comprising controlling the temperature of the melted polymer, wherein controlling the temperature of the melted polymer comprises maintaining the melted polymer in a melted state until the functionally graded article has attained a desired functional gradation.

19. The method of claim 1, wherein the functionally graded article has a continuously changing magnetic filler gradient.

15. A method of manufacturing a functionally graded article, comprising:

preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler, wherein the magnetic filler is dispersed in the thermoplastic polymer, and wherein the thermoplastic polymer has a thermoplastic polymer melt temperature;

injecting the melted polymer mixture into a mold;

controlling the temperature of the melted polymer, wherein controlling the temperature of the melted polymer comprises maintaining the melted polymer mixture at a temperature within 10°

C. of the thermoplastic polymer melt temperature;

applying a magnetic field from a magnet incorporated into the mold to a portion of the melted polymer mixture to form the functionally graded article, wherein the functionally graded article has a magnetic filler gradient.

16. A method of manufacturing a functionally graded polymer material, comprising:

modifying a magnetic filler with a functionalization material, wherein the functionalization material is selected from diallyl based moieties, vinyl functionalized based monomer or polymer, siloxane based materials, or combinations thereof;

preparing a melted polymer mixture comprising a thermoplastic polymer and the modified magnetic filler, wherein the magnetic filler is dispersed in the thermoplastic polymer, wherein the magnetic filler is present in an amount of 0.01 to 15 wt % based on the total weight of the melted polymer mixture;

injecting the melted polymer mixture into a mold; and

applying a magnetic field from a magnet incorporated into the mold to a portion of the melted polymer mixture to form the functionally graded polymer material, wherein the functionally graded polymer material has a magnetic filler gradient.

17. The method of claim 16, wherein the method of modifying the magnetic filler further comprises coating, encapsulation, or a combination thereof.

18. A method of manufacturing a functionally graded article, comprising:

preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler, wherein the magnetic filler is dispersed in the thermoplastic polymer;

injecting the melted polymer mixture into a mold with a magnet incorporated into the mold; and

applying a magnetic field from the magnet to a portion of the melted polymer mixture as the melted polymer mixture flows into the mold, to form the functionally graded article, wherein the functionally graded article has a continuously changing magnetic filler gradient;

wherein the functionally graded article has a thickness and wherein the magnetic filler gradient is formed across a portion of the thickness, and wherein the portion of the thickness is less than the entire thickness.