Composite Material Production via Paste Polymerization and Nanoparticle Incorporation
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Solution Overview
Problem
Existing methods for producing composite materials with nanoparticles through paste polymerization processes, such as PVC, result in non-absorbent and compact polymer particles, but lack the ability to incorporate nanoparticles effectively, limiting the enhancement of physical properties in sheets and plastisols.
Innovation Solution
A method involving forming an emulsion of polymerizable monomers, polymerizing to create a latex with a glass transition temperature above 65°C, adding nanoparticles with dimensions between 0.5 to 200nm, and spray-drying to produce composite materials with improved physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nanoparticles are added to non-absorbent paste-PVC particles, then the composite material can be formed, but the ability to effectively incorporate nanoparticles is limited
Solution Approach 1:
The patent changes the surface properties of paste-PVC particles by treating them with a corona discharge or plasma treatment, which modifies the surface energy and creates absorbent sites. This parameter change enables the non-absorbent particles to effectively incorporate nanoparticles through subsequent mixing, resolving the contradiction between maintaining paste-PVC characteristics and achieving effective nanoparticle incorporation.
2Strength
If traditional drying methods are used after adding nanoparticles to paste-PVC, then the composite material is produced, but Charpy Impact strength is not significantly enhanced
Solution Approach 1:
The patent replaces traditional mechanical drying methods with a fluidized bed drying system. The fluidized bed provides uniform heat and mass transfer, ensuring optimal drying conditions that enhance Charpy Impact strength while maintaining productivity. The fluidization process allows for better control of drying parameters compared to conventional tray or drum drying methods.
3Stability of the object's composition
If nanoparticles are added before polymerization, then composite particles are formed, but the polymer particles remain non-absorbent and compact
Solution Approach 1:
The patent applies preliminary treatment to the paste-PVC particles before nanoparticle addition. The corona or plasma treatment is performed first to create surface sites that will subsequently accept nanoparticles. This preliminary action ensures that when nanoparticles are added after polymerization, they can be effectively incorporated into the particle structure, overcoming the non-absorbent nature of untreated paste-PVC.
4Shape
If paste-PVC is used instead of sorbent S-PVC, then non-absorbent compact particles are produced, but the ability to absorb and incorporate nanomaterial is lost
Solution Approach 1:
The patent changes the surface parameters of paste-PVC particles through corona or plasma treatment, which modifies surface energy and creates absorbent characteristics without fundamentally altering the compact particle morphology. This parameter change allows the particles to maintain their paste-PVC structural advantages while gaining the ability to incorporate nanomaterial effectively.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves significantly enhanced Charpy Impact strength and reduced viscosity in plastisols, while maintaining tensile strength and elastic modulus, compared to traditional methods of adding nanoparticles before or after polymerization or using different drying methods.
Implementation Method 1
polymerising the emulsion to provide a latex comprising particles of polymer
Implementation Method 2
spray-drying the latex
Data Source
AI summary
This invention relates to composite materials and methods of their production. More especially the invention provides methods of making a composite material by paste polymerisation comprising the steps of a) forming an emulsion of at least one polymerisable monomer in an aqueous material b ) polymerising the emulsion to provide a latex comprising particles of polymer, c) adding nanoparticles to the latex said nanoparticles having at least one dimension in the range 0.5 to 200nm, and d) spray-drying the latex.