Abstract: Processes for decrosslinking crosslinked plastic and devulcanizing vulcanized rubber include advancing such materials through single screw or twin screw extruders including special ultrasonic treatment zones wherein threadless shaft (single screw) or shafts (twin screw) rotate under an ultrasonic horn having a distal end aligned with the shaft or shafts and being shaped complimentary thereto. Special arcuate (single screw) or double-arcuate ultrasonic treatment flow paths confine the materials to flow under the horn where the material is subjected to ultrasonic waves to decrosslink the material, in the case of crosslinked plastic, or devulcanize the material, in the case of vulcanized rubber, with the extrudate leaving the die as a continuous stream or rope as is typical of virgin plastic or rubber.

Abstract: The present invention relates to a polymer scaffold design and method for treating segmental long bone defects without amputation that permits permanent regrowth of bone in the area of the segmental defect, without external fixation or other problems inherent in current systems. The polymer scaffold is preferably made from a poly(ester urea) polymer and includes an outer shell, sized to fit over a segmental defect in a bone, and a collagen containing material. In some embodiments, the collagen containing material is placed in a polymer insert sized to fit within the segmental bone defect and within said outer shell. In some embodiments, the outer shell may contain struts running longitudinal struts along the inside surface of the outer shell. In some of these embodiments, the insert will have a corresponding set of grooves sized to receive the struts.

Abstract: Rubber formulations include a rubber and a norbornylized seed oil. The norbornylized seed oil is a seed oil that is modified with norbornylene groups. The norbornylized seed oil can replace petroleum oils currently often used in rubber formulations. A process for creating a rubber formulation includes the steps of adding a norbornylized seed oil to a rubber, wherein the norbornylized seed oil is a seed oil modified with norbornylene groups.

Abstract: Processes for decrosslinking crosslinked plastic and devulcanizing vulcanized rubber include advancing such materials through single screw or twin screw extruders including special ultrasonic treatment zones wherein threadless shaft (single screw) or shafts (twin screw) rotate under an ultrasonic horn having a distal end aligned with the shaft or shafts and being shaped complimentary thereto. Special arcuate (single screw) or double-arcuate ultrasonic treatment flow paths confine the materials to flow under the horn where the material is subjected to ultrasonic waves to decrosslink the material, in the case of crosslinked plastic, or devulcanize the material, in the case of vulcanized rubber, with the extrudate leaving the die as a continuous stream or rope as is typical of virgin plastic or rubber.

Abstract: Processes for decrosslinking crosslinked plastic and devulcanizing vulcanized rubber include advancing such materials through single screw or twin screw extruders including special ultrasonic treatment zones wherein threadless shaft (single screw) or shafts (twin screw) rotate under an ultrasonic horn having a distal end aligned with the shaft or shafts and being shaped complimentary thereto. Special arcuate (single screw) or double-arcuate ultrasonic treatment flow paths confine the materials to flow under the horn where the material is subjected to ultrasonic waves to decrosslink the material, in the case of crosslinked plastic, or devulcanize the material, in the case of vulcanized rubber, with the extrudate leaving the die as a continuous stream or rope as is typical of virgin plastic or rubber.

Abstract: The present invention relates to a polymer scaffold design and method for treating segmental long bone defects without amputation that permits permanent regrowth of bone in the area of the segmental defect, without external fixation or other problems inherent in current systems. The polymer scaffold is preferably made from a poly(ester urea) polymer and includes an outer shell, sized to fit over a segmental defect in a bone, and a collagen containing material. In some embodiments, the collagen containing material is placed in a polymer insert sized to fit within the segmental bone defect and within said outer shell. In some embodiments, the outer shell may contain struts running longitudinal struts along the inside surface of the outer shell. In some of these embodiments, the insert will have a corresponding set of grooves sized to receive the struts.

Abstract: Rubber formulations include a rubber and a norbornylized seed oil. The norbornylized seed oil is a seed oil that is modified with norbornylene groups. The norbornylized seed oil can replace petroleum oils currently often used in rubber formulations. A process for creating a rubber formulation includes the steps of adding a norbornylized seed oil to a rubber, wherein the norbornylized seed oil is a seed oil modified with norbornylene groups.

Abstract: Processes for decrosslinking crosslinked plastic and devulcanizing vulcanized rubber include advancing such materials through single screw or twin screw extruders including special ultrasonic treatment zones wherein threadless shaft (single screw) or shafts (twin screw) rotate under an ultrasonic horn having a distal end aligned with the shaft or shafts and being shaped complimentary thereto. Special arcuate (single screw) or double-arcuate ultrasonic treatment flow paths confine the materials to flow under the horn where the material is subjected to ultrasonic waves to decrosslink the material, in the case of crosslinked plastic, or devulcanize the material, in the case of vulcanized rubber, with the extrudate leaving the die as a continuous stream or rope as is typical of virgin plastic or rubber.

Abstract: The present invention relates to nanocomposites and a process for preparing polymer nanocomposites (e.g., a continuous process). More particularly, the present invention relates to polymer nanocomposites containing a combination of one or more polymers (e.g., one or more polyolefins or one or more polyamides) with one or more types of nanoparticles, and to methods to produce such nanocomposites. In one embodiment, the present invention relates to polyamide nanocomposites wherein organoclay particles are intercalated with a polyamide polymer.

Abstract: The present invention relates to processes for producing high performance polymer composites via ultrasonic treatment after initial mixing. These high performance polymer composites made from a combination of polymer and nanofibers and/or nanotubes. The ultrasonic treating method of the disclosed allows a more highly dispersed polymer composite mixture which provides increased thermal, mechanical and electrical properties.

Abstract: In one embodiment, the present invention relates to a continuous method of forming a polymer nanoparticle composite, the method comprising: (a) combining at least one polymer and at least one type of nanoparticles to form a polymer nanoparticle mixture; and (b) subject the polymer nanoparticle mixture to an energy source, wherein the energy source has a frequency in the range of about 15 KHz to about 200 MHz, wherein the polymer nanoparticle mixture is in a melted state and wherein the polymer nanoparticle mixture is subjected to the energy source for less than 60 seconds.

Abstract: In general, the present invention provides a process for increasing the crystallinity of a slow crystallizable polymer. In this process, at least one slow crystallizable polymer is introduced to a pressurized treatment zone along a flow direction, and is subjected, at the pressurized treatment zone, to longitudinal vibrations of ultrasonic waves. In a particularly preferred process, the ultrasonic waves propagate in a direction perpendicular to the flow direction of the at least one slow crystallizable polymer.

Abstract: In general, the present invention provides a process for increasing the crystallinity of a slow crystallizable polymer. In this process, at least one slow crystallizable polymer is introduced to a pressurized treatment zone along a flow direction, and is subjected, at the pressurized treatment zone, to longitudinal vibrations of ultrasonic waves. In a particularly preferred process, the ultrasonic waves propagate in a direction perpendicular to the flow direction of the at least one slow crystallizable polymer.

Abstract: This invention relates to a process for making polymer blends and copolymers by ultrasonic treatment during or after mixing the polymers. In the process of the present invention, an unexpected phenomenon occurs. The process brings about enhancement of the mechanical properties when compared with identical blends not subjected to ultrasonic treatment. The ultrasonic treatment of the blends is believed to enhance intermolecular interaction and improve adhesion between dissimilar polymers and make chemical bonds between polymers that otherwise are incompatible or immiscible with each other.

Abstract: This invention relates to a process for making polymer blends and copolymers by ultrasonic treatment during or after mixing the polymers. In the process of the present invention, an unexpected phenomenon occurs. The process brings about enhancement of the mechanical properties when compared with identical blends not subjected to ultrasonic treatment. The ultrasonic treatment of the blends is believed to enhance intermolecular interaction and improve adhesion between dissimilar polymers and make chemical bonds between polymers that otherwise are incompatible or immiscible with each other.

Abstract: This invention relates to a continuous ultrasonic method and apparatus for breaking the carbon-sulfur (C--S), sulfur-sulfur (S--S), and if desired, carbon-carbon (C--C) bonds in a vulcanized elastomer. It is well known that vulcanized elastomers having a three-dimensional chemical network, cannot flow under the effect of heat and/or pressure. This creates a huge problem in the recycling of used tires and other elastomeric products. Through the application of certain levels of ultrasonic amplitudes in the presence of pressure and optionally heat, the three-dimensional network of vulcanized elastomer can be broken down. As a most desirable consequence, ultrasonically treated cured rubber becomes soft, thereby enabling this material to be reprocessed and shaped in a manner similar to that employed with uncured elastomers.

Abstract: A shaped reinforced thermoplastic composite, such as composite laminate (10 or 10A), comprises a thermoplastic matrix polymer (22) and a plurality of fibers (20) of a liquid crystal polymer (LCP) which are formed in situ in the matrix polymer. This composite is formed by forming a prepreg as a plurality of individual sheets or layers (50), each of which comprises essentially unidirectionally oriented fibers (20) of said LCP in a thermoplastic polymer matrix (22). A lay-up is formed by cutting each individual sheet or layer into pieces so that the direction of fiber orientation in each such piece is either parallel to one pair of edges or at angles of 45.degree. to all of the edges. The lay-up is shaped under heat and pressure to form the composite.

Abstract: Composite laminates are prepared from thin sheets of thermotropic liquid crystal polymer blends. A preferred blend contains 2 thermotropic liquid crystal polymers, i.e., a first liquid crystal polymer in LCP-1, and a second liquid crystal polymer (LCP-2), the second liquid crystal polymer having a higher melting point than the first. The second liquid crystal polymer is molecularly oriented and is preferably at least partially in the form of microscopic fibers in a matrix of the first liquid crystal polymer. The two liquid crystal polymers are phase separated in the solid phase and have overlapping melt processing temperatures.

Abstract: A self-reinforced polymer composite in the form of a non-laminated shaped article is prepared by (a) melt blending (I) a matrix polymer which is a melt processable flexible chain polymer or first liquid crystal polymer (LCP) and (2) a fiber forming melt processable second LCP under high strain mixing conditions inducing fiber formation, cooling and stretching the resulting blend, and (b) shaping the resulting blend by injection molding or extrusion at a temperature which is above the minimum melt processing temperature of the matrix polymer but below that of the fiber forming second LCP. By shaping at a temperature below the minimum processing temperature of the fiber-forming LCP, the fiber structure formed during cooling is preserved. The resulting shaped articles have outstanding mechanical properties, e./g., tensile strength, modulus and impact strength.

Abstract: This invention relates to a continuous ultrasonic method for breaking the carbon-sulfur (C--S), sulfur-sulfur (S--S), and if desired, carbon-carbon (C--C) bonds in a vulcanized elastomer. It is well known that vulcanized elastomers having a three-dimensional chemical network, cannot flow under the effect of heat and/or pressure. This creates a huge problem in the recycling of used tires and other elastomeric products. Through the application of certain levels of ultrasonic amplitudes in the presence of pressure and optionally heat, the three-dimensional network of vulcanized elastomer can be broken down. As a most desirable consequence, ultrasonically treated cured rubber becomes soft, thereby enabling this material to be reprocessed and shaped in a manner similar to that employed with uncured elastomers.