A New Processing Technique to Fabricate Polymer Articles with Improved Mechanical and Thermal Properties

Alan Lesser, Ph.D.

• Semi-crystalline polymer articles, sheets and rods with improved mechanical and thermal properties
• Low-cost, light weight, high-strength, and heat-resistant polymeric articles for metal replacement

•       Improvements in mechanical and thermal properties of processed polymers as compared to melt-processed polymers:

o       Increased mechanical stiffness (>50% for polypropylene)

o       Increased mechanical strength (>40% for polypropylene)

o       Increased melting temperature (> 6% for polypropylene)

•       Unique diagnostic signature in the processed polymer including Increased crystal volume fraction and increased crystal size

•       Cost saving by replacing costly materials

•       Applicable to commodity polymer materials

This invention provides a new polymer processing technique, termed Melt-Mastication, which improves the properties of commodity semi-crystalline polymers, such as polypropylene. Compared with conventional methodology for processing polymers, Melt-Mastication creates unique microstructures in the polymer material, which results in improved mechanical and thermal properties of the polymer material and enables commodity polymers to compete with more costly materials in a variety of industries.