Abstract: The present invention relates to polymer particles shaped as platelets and to a process of manufacturing such particles. The particles according to the invention exhibit a faster rate of dissolution in aqueous media than art-known particles.

Abstract: A method of bonding materials. The method comprises providing a polymer; providing a second material; contacting the polymer and the second material at a low contact pressure in the absence of a solvent or an adhesive; maintaining the polymer at a temperature less than a bulk Tg of the polymer; introducing a gas at low pressure; and bonding the polymer and the second material.

Abstract: Nano-sized particles such as nano-clays can be mixed with polymers through either melt compounding or in-situ polymerization. By modifying the particle surface with various surfactants and controlling processing conditions, we are able to achieve either intercalated (partial dispersion) or exfoliated (full dispersion) nano-clay distribution in polymers with the clay content up to 35% by weight. When a blowing agent is injected into the nanocomposite in an extruder (a continuous mixer) or a batch mixer, polymeric foam can be produced. Supercritical carbon dioxide, an environmentally friendly, low-cost, non-flammable, chemically benign gas is used as the blowing agent. This process forms a microcellular foam with very high cell density (>109 cells/cc) and small cell size (<5 microns) can be achieved by controlling the CO2 content, melt and die temperature, and pressure drop rate.