Process for dispersing a thermally sensitive additive into a...

Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...

Reexamination Certificate

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C523S313000

Reexamination Certificate

active

07468404

ABSTRACT:
A continuous process for incorporating a thermally sensitive additive into a polymer melt of virgin polymer at a temperature at least 10° C. below a temperature at which the virgin polymer is typically processed. The virgin polymer is first processed in an apparatus which extensively shear-thins the polymer until its normally entangled molecules are substantially disentangled. This is preferably done in a TekFlow® processor. The additive is then added to the resulting modified melt which is then processed in a high-shear apparatus, e.g. a co-rotating, twin-screw extruder, but more preferably in a second TekFlow® processor. This novel process allows making concentrates having a level of additive which could not be made to date and yet have the additive substantially uniformly dispersed. In particular a concentrate of polypropylene having a 30% by wt concentration of an organoclay in which the platelets are substantially uniformly dispersed, at least 10% more strongly intercalated than prior to treatment, and substantially fully exfoliated, is made with this process.

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International Preliminary Report on Patentability for PCT/US2005/001231 issued by the International Bureau of WIPO on Jul. 17, 2006.

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