EXTRUDABLE POLYMER COMPOSITES WITH MEMBRANE BARRIER PROPERTIES

Abstract

The present disclosure generally relates to extrusion die systems. In particular, the present disclosure relates to the cyclical extrusion of materials to generate small sized grain features, generally in the range of nanosized grain features, in a tubular or profile shape, in which the individual nanolayers possess pores and/or polymer crystals oriented parallel to the extrusion flow direction and including products with enhanced permeation properties.

Claims

1. An extruded product with 2-10,000 nano-polymer layers in tubular or profile shapes, wherein the extruded polymer or a component of the polymer comprise pores aligned along the axis of extrusion.

2. A product according to claim 1 wherein the product is a battery or component of a battery.

3. A product according to claim 1 wherein the product is a separator in a battery.

4. A product according to claim 1 wherein the product contains pores and is able to combine or extract fluids, gases or both through the pores.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The accompanying drawings illustrate presently preferred embodiments of the present disclosure, and together with the general description given above and the detailed description given below, serve to explain the principles of the present disclosure. As shown throughout the drawings, like reference numerals designate like or corresponding parts.

[0055] FIGS. 1a and 1b illustrate lamellar crystal nanolayered tubular or polygonal geometries;

[0056] FIGS. 1c and 1d illustrate examples of tubular annular microlayer geometries;

[0057] FIGS. 1e-1h illustrate examples of products with increased interfacial surface areas;

[0058] FIG. 2 illustrates an exemplary multicomponent approach using a feedblock;

[0059] FIG. 3 illustrates an exemplary schematic of layer multiplication;

[0060] FIG. 4 shows two examples of a stream being manipulated into an annular ring.

[0061] FIG. 5 depicts an exemplary merging operation in which four streams are merged together into a single stream.

[0062] FIG. 6 illustrates an example process to create a square stream with an array of internal squares;

[0063] FIG. 7 depicts the conversion of four streams of layers which could merge together to form a cross section with spokes radiating from the center.

[0064] FIG. 8 illustrates an exemplary nanolayer tube including aspects of the disclosed embodiments;

[0065] FIG. 9 illustrates an exemplary product including aspects of the disclosed embodiments;

[0066] FIG. 10 illustrates an exemplary I-beam product including aspects of the disclosed embodiments;

[0067] FIG. 11 illustrates an exemplary tortuous path created by the alignment of particles or crystals in a product FIG. 9 illustrates an exemplary product including aspects of the disclosed embodiments;

[0068] FIG. 12 illustrates an exemplary application with extruded tubular membranes in a system incorporating FIG. 9 illustrates an exemplary product including aspects of the disclosed embodiments.

DETAILED DESCRIPTION

[0069] Rotating small, micro and nano-layer extrusion processes are described in U.S. Pat. No. 7,690,908. Small, micro and nano layer Non-rotating extrusion processes are described in U.S. Patent Publication 2012/0189789.

Example 1

[0070] A nanolayered tube as depicted in FIG. 8 may be constructed according to the extrusion methods described above to extract materials using barrier properties. A nanolayered tube (shown as a solid black layer below) would be permeable to a certain material. The grey annular section is a microlayer barrier or a conventional layer which would be impermeable to the same material. The spokes allow a permeate to flow thru the “black” layer into the voids created by the spokes due to a concentration gradient. This device allows for the transport of a fluid and extract and contain a permeate. [0072] The same product design could also be used to introduce a permeate to the central fluid by flowing a concentrated solution of the permeate in the voids created by the spokes. The concentration gradient would force the permeate through the black layer into the central channel.

a

Example 2: Beams

[0071] Multiple levels of layers containing different compositions can be extruded. Layers can be of variable size and composition with different crystalline properties and with or without a core. Such layering allows for isolation or insulation of conducting layers or optical zones.

[0072] An extruded product may also alternatively contain a hollow core. Another product entails a composite inner core extruded with composite small, micro or nano layers on the exterior. In this product, the layers may have axially oriented crystals while the center core could possess unrelated properties. This product would have outer layers for enhanced anisotropic strength similar to the product above while the inner core would provide alternate properties.

Example 3: I-Beam—See FIG. 10

[0073] The extrusion methods described herein may yield various profile configuration, including cylindrical, I-beam, C-channel, L-shaped, rectangular, square, hollow cylinder. Each of these extrusions may have differential inclusion of fillers and fibers as well as the presence or absence of core material in addition to the layers of lamellar crystal. [0076] The large aspect ratio of certain nanocomposites, such as layered silicates, can affect its barrier properties by providing a tortuous path for a permeate to travel and thus can be used to increase barrier properties. The alignment of particles or crystals creates a tortuous path (see FIG. 11) for any permeate to travel. This path decreases the permeability of polymer nanocomposite.

Example 6—See FIG. 12

[0074] Another application with extruded tubular membranes would be a system for diffusion much like a heat exchanger. A schematic is shown in FIG. 12, above, with fluid 1 flowing through the system around a maze of baffles. Fluid 2 is running through tubular membranes which would be surrounded by fluid 2. An example application of this apparatus would be for the diffusion of oxygen into blood. In this case fluid 1 would be the blood flowing around the tubes filled with oxygen (fluid 2). The oxygen depleted blood entering the inlet would absorb oxygen diffusing through the tubular membranes and eventually leave through the outlet.

[0075] Thus, while there have been shown, described and pointed out, fundamental novel features of the invention as applied to the exemplary embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of devices and methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. Moreover, it is expressly intended that all combinations of those elements and/or method steps, which perform substantially the same function in substantially the same way to achieve the same results, are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.