Abstract: A method for forming a graphene-reinforced polymer matrix composite is disclosed. The method includes distributing graphite microparticles into a molten thermoplastic polymer phase; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphite successively with each event until at least 50% of the graphite is exfoliated to form a distribution in the molten polymer phase of single- and multi-layer graphene nanoparticles less than 50 nanometers thick along the c-axis direction.

Abstract: A flame or heat flux protective coating composition, which includes a dispersion of fiberglass, hollow glass spheres, or a combination of both in silicone. A flame or heat flux protective sheet, which includes hollow glass spheres dispersed in silicone in a sheet form or fiberglass and silicone in a sheet form, wherein the fiberglass is dispersed in the silicone or the fiberglass is a woven cloth coated with the silicone is also presented. Articles incorporating the flame or heat flux protective coating or sheet form and methods for coating an article with the flame or heat flux protective coating composition are also presented.

Abstract: A method for forming a graphene-reinforced-polymer matrix composite by distributing graphite microparticles into a molten thermoplastic polymer phase comprising one or more molten thermoplastic polymers; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphene successively with each event, until tearing of exfoliated multilayer graphene sheets occurs arid produces reactive edges on the multilayer sheets that react with and cross-link the one or more thermoplastic polymers; where the one or more thermoplastic polymers are selected from thermoplastic polymers subject to UV degradation.

Abstract: A method for forming a graphene-reinforced polymer matrix composite is disclosed. The method includes distributing graphite microparticles into a molten thermoplastic polymer phase; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphite successively with each event until at least 50% of the graphite is exfoliated to form a distribution in the molten polymer phase of single- and multi-layer graphene nanoparticles less than 50 nanometers thick along the c-axis direction.

Abstract: A method for forming a graphene-reinforced polymer matrix composite is disclosed. The method includes distributing graphite microparticles into a molten thermoplastic polymer phase; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphite successively with each event until at least 50% of the graphite is exfoliated to form a distribution in the molten polymer phase of single- and multi-layer graphene nanoparticles less than 50 nanometers thick along the c-axis direction.

Abstract: A plastication unit for an injection molding machine, combining a heated plastication barrel with an entrance port and an exit port on opposing ends of the barrel; a hopper positioned to deliver ingredients to be compounded for injection molding to the entrance port of the barrel; and a helical plastication screw rotatably carried within the barrel and running the length of the barrel between the entrance and exit ports, which is operable to rotate and transmit the ingredients along the length of the barrel; wherein the plastication screw has at least one axial fluted extensional mixing element segment and the ingredients include at least one polymer for injection molding. Methods for injection molding with the plastication unit of the present invention and articles formed by the inventive methods are also disclosed.

Abstract: Compression molded articles containing a polymer component and optionally distributed therein between about 1% and about 45% by weight of a glass bead or fiber reinforcing component based on the weight of the finished composite article, wherein the polymer component contains between about 80% and about 100% by weight of HDPE based on the weight of the polymer component, in which at least about 20% or more by weight of said HDPE is post-consumer HDPE. Plastic panels, uses thereof and methods of manufacturing are also disclosed.

Abstract: A plastication unit for an injection molding machine, combining a heated plastication barrel with an entrance port and an exit port on opposing ends of the barrel; a hopper positioned to deliver ingredients to be compounded for injection molding to the entrance port of the barrel; and a helical plastication screw rotatably carried within the barrel and running the length of the barrel between the entrance and exit ports, which is operable to rotate and transmit the ingredients along the length of the barrel; wherein the plastication screw has at least one axial fluted extensional mixing element segment and the ingredients include at least one polymer for injection molding. Methods for injection molding with the plastication unit of the present invention and articles formed by the inventive methods are also disclosed.

Abstract: Modular plastic structural composites formed from a mixture of (A) high density polyolefin and one or both of: (B) a thermoplastic-coated fiber material, or (C) polystyrene, poly(methyl methacrylate), or a combination thereof. Composites molded in the form of I-Beams and bridges constructed therefrom are also disclosed.

Abstract: A method for forming a graphene-reinforced-polymer matrix composite by distributing graphite microparticles into a molten thermoplastic polymer phase comprising one or more molten thermoplastic polymers; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphene successively with each event, until tearing of exfoliated multilayer graphene sheets occurs arid produces reactive edges on the multilayer sheets that react with and cross-link the one or more thermoplastic polymers; where the one or more thermoplastic polymers are selected from thermoplastic polymers subject to UV degradation.

Abstract: A flame or heat flux protective coating composition, which includes a dispersion of fiberglass, hollow glass spheres, or a combination of both in silicone. A flame or heat flux protective sheet, which includes hollow glass spheres dispersed in silicone in a sheet form or fiberglass and silicone in a sheet form, wherein the fiberglass is dispersed in the silicone or the fiberglass is a woven cloth coated with the silicone is also presented. Articles incorporating the flame or heat flux protective coating or sheet form and methods for coating an article with the flame or heat flux protective coating composition are also presented.

Abstract: A method for forming a graphene -reinforced polymer matrix composite is disclosed. The method includes distributing graphite microparticles into a molten thermoplastic polymer phase; and applying a succession of shear strain events to the molten polymer phase so that the molten polymer phase exfoliates the graphite successively with each event until at least 50% of the graphite is exfoliated to form a distribution in the molten polymer phase of single- and multi-layer graphene nanoparticles less than 50 nanometers thick along the c-axis direction.

Abstract: A railroad tie composed of an immiscible polymer blend having a portion of the underside curved orthogonal to the longitudinal axis of the tie or curved both orthogonal and parallel to the longitudinal axis of the tie, forming a saddle shape, for purposes of reducing the center bounding problems encountered in prior art synthetic railroad ties.

Abstract: A system and apparatus for making a plastic panel, combining: an extruder with a heated barrel having an inlet opening, a discharge outlet and at least one screw flight therebetween; a plurality of molding tools having top and bottom surfaces and sidewalls extending therebetween defining a cavity; a machine press with opposing top and bottom platens configured to receive a molding tool therebetween and apply compressive force to said top and bottom surfaces; and at least one heated vessel for receiving and storing a quantity of mixed melt, wherein the vessel has an inlet port to receive the mixed melt discharged from the barrel outlet of the extruder; a discharge port configured to deliver the mixed melt from the vessel to the cavity of the molding tool; and a metering device set to deliver the selected quantity of the mixed melt from the vessel through the discharge port.

Abstract: Modular plastic structural composites formed from a mixture of (A) high density polyolefin and one or both of: (B) a thermoplastic-coated fiber material, or (C) polystyrene, poly(methyl methacrylate), or a combination thereof. Composites molded in the form of I-Beams and bridges constructed therefrom are also disclosed.

Abstract: Modular plastic structural composites formed from a mixture of (A) high density polyolefin and one or both of: (B) a thermoplastic-coated fiber material, or (C) polystyrene, poly(methyl methacrylate), or a combination thereof. Composites molded in the form of I-Beams and bridges constructed therefrom are also disclosed.

Abstract: A plastication unit for an injection molding machine, combining a heated plastication barrel with an entrance port and an exit port on opposing ends of the barrel; a hopper positioned to deliver ingredients to be compounded for injection molding to the entrance port of the barrel; and a helical plastication screw rotatably carried within the barrel and running the length of the barrel between the entrance and exit ports, which is operable to rotate and transmit the ingredients along the length of the barrel; wherein the plastication screw has at least one axial fluted extensional mixing element segment and the ingredients include at least one polymer for injection molding. Methods for injection molding with the plastication unit of the present invention and articles formed by the inventive methods are also disclosed.

Abstract: A railroad tie composed of an immiscible polymer blend having a portion of the underside curved orthogonal to the longitudinal axis of the tie or curved both orthogonal and parallel to the longitudinal axis of the tie, forming a saddle shape, for purposes of reducing the center bounding problems encountered in prior art synthetic railroad ties.

Abstract: A flame-retardant coating composition, which includes a cross-linked thermosetting polymer and a metal hydroxide. A precursor composition for use in preparing the flame retardant-coating is also presented, wherein the precursor composition includes a cross-linked thermosetting polymer varnish, a metal hydroxide, an alcohol, and water. A method for coating an article with a flame-retardant coating layer and articles incorporating the flame-retardant coating are also presented.

Abstract: A flame-retardant coating composition, which includes a cross-linked thermosetting polymer and a metal hydroxide. A precursor composition for use in preparing the flame retardant-coating is also presented, wherein the precursor composition includes a cross-linked thermosetting polymer varnish, a metal hydroxide, an alcohol, and water. A method for coating an article with a flame-retardant coating layer and articles incorporating the flame-retardant coating are also presented.