Abstract: A process for the manufacture of thermoplastic polymer particles, including combining a first solution including a thermoplastic polymer and an organic solvent with a second solution including an aqueous solvent and a surfactant to provide an emulsion. The emulsion is transferred into a receiving water to remove the organic solvent and form an aqueous dispersion including a plurality of thermoplastic polymer particles dispersed in the aqueous solvent. The thermoplastic polymer particles having a D50 of 20 to 100 ?m are recovered in a yield of greater than 85%. Thermoplastic polymer particles prepared according to the method are also disclosed.

Abstract: Disclosed is a process to produce an improved formulated vinylidene chloride polymer comprising a solid inorganic additive and producing improved vinylidene chloride polymer film products. The process includes adding the inorganic solid additive (such as magnesium hydroxide and/or other inorganic acid scavenger) in a dispersion of a liquid, such as a liquid plasticizer or stabilizer to improve distribution through the polymer and reduction of relatively large sized particles or agglomerates in the polymer and film.

Abstract: A process to produce a dispersion comprising feeding ethylcellulose polymer and a dispersant into a melt and mix zone of an extruder wherein the ethylcellulose polymer and dispersant are melted and mixed together to form a melt; conveying the melt to an emulsification zone of the extruder in which the temperature and pressure are controlled; feeding a base and water into the emulsification zone wherein the melt is dispersed to form a high internal phase emulsion; conveying the emulsion to a dilution and cooling zone of the extruder; and feeding water into the dilution and cooling zone to dilute the high internal phase emulsion thereby forming an aqueous dispersion is provided.

Abstract: Coalesced rubber particles having an average particle size of 5-50 microns are produced by: (1) adding simultaneously to a latex of pre-crosslinked rubber particles a solvent and an electrolyte solution to form swollen rubber aggregation particles, wherein the solvent has a lower boiling point than water and a capacity of swelling the rubber by at least 10 wt %, and the electrolyte is a solution of at least one metal salt; (2) removing the solvent under atmospheric pressure or low vacuum and at temperature greater than 80° C. to coalesce the rubber into particles having an average particle size of 5-50 50 microns; (3) filtering and washing with methanol; and (4) filtering the washed particles to remove methanol. An epoxy resin is blended with the particles and residual methanol removed, to obtain a blend containing coalesced rubber particles having an average particle size of 5-50 microns in the blended state.

Abstract: The invention is directed to a process and apparatus for carrying out reactions with reaction mixtures comprising different physical phases. In a first aspect, the present invention is directed to a process for carrying out chemical reactions comprising a step wherein a reaction mixture comprising at least two different physical phases, wherein at least one of these phases being liquid, is subjected to the action of Dean vortices, which Dean vortices result from said liquid flowing through a channel having at least two curvatures, wherein the channel comprises for at least a fraction of its total length a smooth inner surface.

Abstract: An apparatus for heat-treating a toner includes a raw-material supply unit configured to supply a toner treatment space with a raw-material toner, a hot-air supply unit configured to heat-treat the raw-material toner in the toner treatment space, a suction and ejection unit configured to eject hot air used for the heat treatment of the raw-material toner, and a waste-heat recovery and supply unit configured to recover heat from the hot air ejected by the suction and ejection unit and supply the hot-air supply unit with the recovered heat.

Abstract: A process is provided for producing discrete solid beads of polymeric material e.g. phenolic resin having a mesoporous structure, which process may produce resin beads on an industrial scale without aggregates of resin building up speedily and interrupting production. The process comprises the steps of: (a) combining a stream of a polymerizable liquid precursor e.g. a novolac and hexamine as cross-linking agent dissolved in a first polar organic liquid e.g. ethylene glycol with a stream of a liquid suspension medium which is a second non-polar organic liquid with which the liquid precursor is substantially or completely immiscible e.g. transformer oil containing a drying oil; (b) mixing the combined stream to disperse the polymerizable liquid precursor as droplets in the suspension medium e.g.

Abstract: The invention is directed to a process and apparatus for carrying out reactions with reaction mixtures comprising different physical phases. In a first aspect, the present invention is directed to a process for carrying out chemical reactions comprising a step wherein a reaction mixture comprising at least two different physical phases, wherein at least one of these phases being liquid, is subjected to the action of Dean vortices, which Dean vortices result from said liquid flowing through a channel having at least two curvatures, wherein the channel comprises for at least a fraction of its total length a smooth inner surface.

Abstract: A composition comprising a fluid, and a material dispersed in the fluid, the material made up of particles having a sharp blade-like surface, the particles having an aspect ratio larger than 0.7 for promoting kinetic boundary layer mixing in a non-linear-viscosity zone. The composition may further include an additive dispersed in the fluid. The fluid may be a thermopolymer material. A method of extruding the fluid includes feeding the fluid into an extruder, feeding additives into the extruder, feeding a material into the extruder, passing the material through a mixing zone in the extruder to disperse the material within the fluid wherein the material migrates to a boundary layer of the fluid to promote kinetic mixing of the additives within the fluid, the kinetic mixing taking place in a non-linear viscosity zone.

Abstract: In a method for synthesizing polymeric microstructures, a monomer stream is flowed, at a selected flow rate, through a fluidic channel. At least one shaped pulse of illumination is projected to the monomer stream, defining in the monomer stream a shape of at least one microstructure corresponding to the illumination pulse shape while polymerizing that microstructure shape in the monomer stream by the illumination pulse.

Abstract: A process for producing a colorant comprises the step of mixing a coloring material and a block copolymer in a flow channel of a microreactor to obtain a dispersion comprising a colorant as a dispersoid. The flow-mixing channel may have a cross-sectional area of not less than 0.5 mm2, and the ratio of the total cross-sectional areas of flow channels connected with the flow-mixing channel to the cross-sectional area of the flow-mixing channel ranges from 0.01 to 0.1, and a rectangular cross-section having a ratio of a flow channel depth to a flow channel width of not less than 0.5.

Abstract: A method of making a polymer-binder composite, and the composite thus created. The method employs a high shear device that mixes together polymer with binder, and optionally with additive. The mixing is accomplished in less than one hour, less than 30 minutes or less than 3 minutes, and done at high shear rates. The shear conditions are defined by scalar shear quantity greater than 10,000, 20,000 or 25,000, resident time of greater than 0.5, 1.0 or 5 seconds, and energy utilized per unit mass of greater than 0.5, 1.0 or 2.0 KW/KG. The composite thus produced can be made with a high percentage of polymers. It can be cooled and cut into pellets that are dry and stable at normal temperatures and which can be stored or transported without heating to secondary mixing locations. The composite pellets are quickly soluble in the additional binder.

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.

Abstract: The present invention relates generally to novel systems and methods for polymerizing nanoparticles within a polymer matrix and to novel methods for fabricating materials containing nanoparticles in a polymer matrix.

Abstract: The present invention provides a process to create without mechanical agitation a zone of low shear, low turbulence flow pattern within a continuous phase liquid contained in a vessel by a continuous or periodic injection of an inert, immiscible, low density fluid, preferably gas, into the liquid to form such a flow pattern, recovering the fluid above the free surface of the liquid and, preferably, reinjecting it into the liquid. The invention is particularly useful if the continuous liquid contains a dispersed phase which should be distributed within the continuous liquid without excessive particle agglomeration or breakups in order to largely preserve the initial particle size distribution, or if the initial particle size distribution needs to be modified by controlled breakups of the largest particles, particularly during the subsequent batch processing.

Abstract: The present invention provides a process to create without mechanical agitation a zone of low shear, low turbulence flow pattern within a continuous phase liquid contained in a vessel by a continuous or periodic injection of an inert, immiscible, low density fluid, preferably gas, into the liquid to form such a flow pattern, recovering the fluid above the free surface of the liquid and, preferably, reinjecting it into the liquid. The invention is particularly useful if the continuous liquid contains a dispersed phase which should be distributed within the continuous liquid without excessive particle agglomeration or breakups in order to largely preserve the initial particle size distribution, or if the initial particle size distribution needs to be modified by controlled breakups of the largest particles, particularly during the subsequent batch processing.

Abstract: A method of preparing an object with a radially-varying property is disclosed which includes the steps of providing a preform reactor including an outer container having a bottom, an inner container installed in the outer container, the inner container having a bottom, a rotating rod installed at a position in the outer container, and a sealing member for sealing the outer and inner containers at the bottoms thereof; filling the inner container with an inner material and a space between the inner container and the outer container with an outer material wherein the outer material has a different property from the inner material; removing the inner container; and rotating the rotating rod for laminar mixing of the inner and outer materials. An apparatus for carrying out the inventive method, and objects formed in accordance with the inventive method, are also disclosed.

Abstract: The present invention relates generally to novel systems and methods for polymerizing nanoparticles within a polymer matrix and to novel methods for fabricating materials containing nanoparticles in a polymer matrix.

Abstract: The present invention is directed to a polymer feed system and a method of using the same wherein clogging of the polymer input line is avoided by the use of air to purge the system of any unwanted polymer or electrolyte. The purging avoids the contact of the water with the polymer and the build-up of unwanted activated polymer and clogging in the supply and in the subsequent conduits.

Abstract: The invention relates to a process for the preparation of a composition to be extruded comprising a polymer and a filler of solid particles comprising a stage of mixing the filler of solid particles with particles or granules of the said polymer, if appropriate in the form of an aqueous suspension. The invention is particularly simple, and the final material is in better mechanical properties than those obtained by direct incorporation of the solid filler in the polymer or copolymer. This improvement is very substantial, in particular with regard to the impact strength of the final material. The invention also relates to a polypropylene-based composition comprising a filler of solid particles, such as kaolin, exhibiting a high flexural modulus and a good impact strength.

Abstract: Incorporation of neutral water soluble inorganic salts into a precipitated silica improves the filler dispersion in a compounded rubber, reduces rolling resistance (hysteresis), and improves processability. These properties are achieved without loss of the expected reinforcement effect due to the substitution of inorganic salt for SiO2 in the silica. The properties are seen when a variety of silanes and processing aids are added to the silica.

Abstract: An improvement in a continuous process for making high internal phase emulsions that are typically polymerized to provide microporous, open-celled polymeric foam materials capable of absorbing aqueous fluids, especially aqueous body fluids such as urine. The improvement involves recirculating a portion (about 50% or less) of the emulsion withdrawn from the dynamic mixing zone of this continuous process. This increases the uniformity of the emulsion ultimately obtained from this continuous process in terms of having the water droplets homogeneously dispersed in the oil phase. This also improves the stability of the HIPE and expands the temperature range for pouring and curing this HIPE during subsequent emulsion polymerization. The improvement also eliminates the need for a static mixer outside the dynamic mixing zone, and allows for processing where relatively low pressure drops are required across the mixing zone.

Abstract: In a process for producing filler-containing thermoplastic molding compositions by mixing fillers with thermoplastics in the melt,a) the fillers are mixed in a mixing apparatus in the melt with a low molecular weight thermoplastic having a melt viscosity of at most 30 Pas (measured at 20.degree. C. above the melting point of the thermoplastic compound and at a shear gradient of 1,000 s.sup.-1),b) the product thus obtained is removed from the mixing apparatus, cooled and comminuted, andc) the comminuted product is then subjected in the solid phase to a post-condensation.

Abstract: Disclosed herein in are a magnetic paint composed of a kneaded composition comprising fine magnetic iron based alloy particles, acicular fine magnetic iron oxide particles or plate-like fine magnetic ferrite particles, a binder resin and an organic solvent, the solid content of the fine magnetic iron based alloy particles, the acicular fine magnetic iron oxide particles or plate-like fine magnetic ferrite particles and the binder resin in the kneaded composition being from 65 to 85% by weight, the binder resin being from 5 to 30% by weight based on the fine magnetic iron based alloy particles, the acicular fine magnetic iron oxide particles or plate-like fine magnetic ferrite particles, and a gloss at 45.degree. after dispersion for 6 hours being not less than 120% when formed into a coating film; and a method of preparing the same.

Abstract: A process and an apparatus for the direct, continuous and flexible modification of polymer melts by branching off a brand melt stream from the main melt stream to be modified, dispersing the initially introduced additive in the melt in a specially designed twin-screw extruder, and subsequent recycling of the additive melt concentrate to the melt stream to be modified.

Abstract: Polymer activation apparatus for activating a batch of dry polymer in dilution water includes a tank which contains the dilution water in a mixing vessel and a mixing assembly within the mixing vessel. The dilution water is circulated at a high rate through the mixing assembly to create a high shear flow condition within the mixing assembly. The polymer is introduced into the mixing assembly to disperse the polymer in the dilution water and form a slurry in the vessel without causing agglomeration of the dry polymer. After dispersion and before hydration of the polymer, the rate of circulation through the mixing assembly is reduced to create a low shear flow condition. The low shear condition is maintained as the viscosity of the solution increases.

Abstract: High molecular weight polymer that can form a viscous aqueous solution is chemically modified by mixing the previously formed polymer (as a powder, reverse phase dispersion or oil-in-water emulsion) with water and the reagent for effecting the chemical modification so as to form a viscous aqueous mixture having a viscosity of at least 1OOO cps (Brookfield RVT) and then feeding this mixture as intermittent batches into one end of a tower through which it moves with substantially plug flow and from which it is withdrawn, at the end of the reaction, as intermittent batches. The apparatus for this purpose is also novel.

Abstract: A polymer activation apparatus for activating and diluting a liquid polymer with water includes, a vessel defining a cylindrical chamber divided into first and second processing zones, the polymer and water being supplied to the first processing zone, an impeller located in the first processing zone subjecting the polymer to a high shear rate for a short contact time to initiate dissolution and activation of the polymer, and the polymer being moved to the second processing zone under the force of the water supplied to the first processing zone, a second impeller in the second processing zone subjecting the polymer to a lower shear rate for a longer period to continue the polymer dissolution and activation process.

Abstract: Polymer activation apparatus for activating a liquid polymer emulsion in dilution water includes a first processing zone in which the polymer solution is subjected to a high mean shear rate for a predetermined period of time, and a second processing zone in which the polymer solution is subjected to a low mean shear rate for a longer period of time. The shear rates and residence times in the zones are selected to produce maximum activation in less total processing and aging time than that required in known apparatus.

Abstract: Apparatus for diluting and activating polymer molecules includes primary polymer dilution and activation apparatus, secondary dilution apparatus, and apparatus for diverting a desired amount of dilution water around the primary dilution and activation apparatus to the secondary dilution apparatus. The primary dilution and activation apparatus includes a cylindrical first processing zone in which the polymer and dilution water are initially mixed. The first processing zone subjects the polymer molecules to relatively high shear conditions for a relatively short period of time, after which the solution passes into a second cylindrical or annular processing zone in which the solution is subjected to continuously decreasing shear forces over a longer period of time. When the solution leaves the primary activation apparatus, it flows into the secondary activation apparatus, which is a static mixer.

Abstract: A method of preparing droplets wherein a dispersion phase, insoluble or sparingly soluble in water, is injected in the form of a laminar flow into an aqueous continuous phase through an orifice. The viscosity ratio between the two phases is adjusted to a specific range to produce droplets of uniform diameter at a specified jet velocity.

Abstract: A method for isolating polymer resins from organic solvents is provided wherein the organic solvent is vaporized in a separation medium comprised of water and an organic anti-solvent for said polymer without significant vaporization of the organic anti-solvent. The polymer precipitates as a powder without high-speed, high-shear agitation and without the formation of a sticky globular mass.

Abstract: A process is disclosed for converting polyacrylamide gel into dilute aqueous solutions suitable for use in secondary oil recovery. Polyacrylamide gel is initially converted into a slurry of small gel particles in water from which forms a homogeneous solution concentrate which is then readily diluted to give the final drive fluid without any significant polymer degradation. The process may additionally be adapted to the drilling site or to other on site operations requiring polyacrylamide solutions such as water treating, mining or paper making.

Abstract: A method for preparing dilute aqueous polymer solutions, especially dilute aqueous partially hydrolyzed polyacrylamide solutions, for use in secondary and tertiary oil recovery processes. The method comprises producing a concentrated polymer solution in a polymerization reactor and diluting the resulting gel-like, relatively high concentration polymer solution to obtain a free-flowing, relatively low concentration polymer solution by means of a staged dilution process. In each stage, an aqueous diluent is combined with the polymer solution to produce a nonuniform mixture which is maintained in a vessel in a quiescent state until the mixture becomes uniform. The stages are repeated as many times as necessary until the free-flowing, relatively low concentration polymer solution is obtained.

Abstract: A method for the on-site continuous preparation of aqueous solutions of polymers, especially aqueous solutions of partially hydrolyzed polyacrylamides, for use in secondary and tertiary oil recovery processes. The method utilizes an apparatus comprised of a polymerization reactor and a post polymerization reactor. Successive batches of an initiated reaction mixture are sequentially fed into the polymerization reactor in discrete volumes. The volumes are moved through the polymerization reactor at a rate such that when a volume reaches the outlet of the polymerization reactor, the reaction will have gone to substantial completion. The resulting polymer solution is withdrawn from the polymerization reactor and continuously conveyed to the post polymerization reactor. Enroute dilution water and a polymer modifying agent are continuously introduced into the polymer solution to form a second reaction mixture.

Abstract: What is disclosed is a method for making a water-in-oil emulsion of a water soluble polymer of high molecular weight of polymerization of an aqueous monomer solution emulsified in an oil, even in large batches or continuously, comprising not moving the emulsion in a turbulent flow pattern at the start of polymerization and not mixing the emulsion at the start of polymerization with portions of emulsion which have been exposed to polymerization conditions for less time. Once polymerization has started, it is continued by the action of an initiator which decomposes to yield free radicals.

Abstract: Apparatus and method for the on-site, continuous preparation of aqueous solutions of polymers, especially aqueous solutions of partially hydrolyzed polyacrylamides, for use in secondary and tertiary oil recovery operations. The apparatus comprises a polymerization reactor and a post reactor. Successive batches of a pre-prepared reaction mixture are continuously fed into the polymerization reaction in a manner to form zones or layers in the reactor, each zone or layer comprising a reaction mixture which has reached a different stage or level of completion of the reaction than the zone or layer below and above it. The zones or layers are continuously moved through the polymerization reactor at a rate such that when a zone or layer reaches the outlet of the polymerization reactor, the reaction will have gone to substantial completion. The zones or layers are continuously conveyed from the polymerization reactor to the post reactor.

Abstract: A pretreatment process to remove entrapped air from liquid polyester blends intended as the matrix of cast marble is disclosed. The formulated blend is subjected to a simultaneous evacuating, vibrating and shearing step which is critical within broad parameters. The thus treated blend, after casting, will be non-porous in cross section, thereby making it suitable for countertops and other parts which must be field cut to specifications.

Abstract: This invention is an improvement to the continuous method to polymerize caprolactam at temperatures over 220.degree. but below 280.degree. C. in the presence of free water, a catalyst capable of generating phosphoric acid at the reaction conditions, in the hydrolyzer to form a prepolymer, with subsequent stripping of water and other low boiling compounds, and with completion of polymerization in a final finisher under a vacuum. The improvement comprises limiting the amount of free water fed to the polymerization process to less than about 1.5 percent but above 0.