Polymeric Nanocomposites via Organic Solvent Solution Process
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Solution Overview
Problem
Current methods for producing polymeric nanocomposites lack efficiency and scalability, particularly in achieving optimal flexibility and high throughput, and are not well-suited for commercial production processes.
Innovation Solution
A solution process using organic solvents and mixtures of solvents to produce polymeric nanocomposites by contacting elastomers with layered fillers, resulting in a cured nanocomposite with improved oxygen transmission rates and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If melt blending is used to produce nanocomposites, then the process is simple and well-established, but the method lacks flexibility and scalability for commercial production
Solution Approach 1:
The patent changes the fundamental parameter of the process medium from melt state to solution state, enabling the use of solvents to dissolve polymers and disperse fillers uniformly. This allows for better control over composition and structure while maintaining ease of manufacture through solution-based processing.
Solution Approach 2:
The patent introduces solvents as intermediary substances that facilitate the interaction between polymer matrices and filler particles. The solvents act as mediators that enable uniform dispersion and controlled formation of nanocomposites, which can then be removed or retained depending on the application requirements.
2Device complexity
If traditional methods are used to produce nanocomposites, then the process design is straightforward, but high throughput and commercial-scale production are not achieved
Solution Approach 1:
The patent enables continuous processing by using solution-based methods that allow for continuous mixing, reaction, and formation of nanocomposites. This eliminates batch processing limitations and enables sustained high-throughput production suitable for commercial scale operations.
Solution Approach 2:
The patent performs preliminary dissolution of polymers in solvents and pre-dispersion of fillers before the actual nanocomposite formation. This preliminary preparation ensures uniform distribution and reduces processing time during the main production phase, thereby increasing overall throughput.
3Object-affected harmful factors
If aqueous solutions are used to produce coatings with elastomers and fillers, then the process is environmentally friendly, but the oxygen transmission rate does not achieve the desired barrier properties
Solution Approach 1:
The patent changes the solvent system from aqueous to organic solvent-based systems, which enable better compatibility with elastomers and fillers. This parameter change results in improved dispersion quality and enhanced oxygen barrier properties while maintaining controlled processing conditions.
Solution Approach 2:
The patent creates optimized composite structures by carefully selecting and combining specific elastomers, fillers, and organic solvents. The resulting nanocomposite architecture provides superior oxygen barrier performance through improved interfacial adhesion and uniform distribution of filler particles within the elastomer matrix.
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 process enables the production of nanocomposites with enhanced oxygen barrier properties, specifically an oxygen transmission rate of 150 mm·cc/[m2·day] at 40° C. or less, and improved mechanical properties, suitable for commercial-scale production.
Implementation Method 1
A solution process using organic solvents and mixtures of solvents to produce polymeric nanocomposites
Implementation Method 2
contacting elastomers with layered fillers, resulting in a cured nanocomposite
Implementation Method 3
removing the at least one solvent and the at least one hydrocarbon from the contact product
Data Source
AI summary
The present invention relates to processes to produce nanocomposites. In particular, the invention relates to solution processes using organic solvents and mixtures of solvents to produce polymeric nanocomposites.