Abstract: A method for combining materials (such as impregnating materials with functional materials) uses a combination of supercritical fluid technology and polymer melt processing technology. The functional material is soluble in a near supercritical or supercritical fluid, which dissolves in the matrix/bulk material during melt processing. Controlling the processing conditions facilitates a change of state for the fluid, which results in the precipitation of the functional material in the bulk material. The impregnated bulk material may be shaped using conventional polymer based processing techniques such as extrusion and injection moulding.

Abstract: The present invention uses supercritical and near supercritical fluid technology for the processing of polymer-containing formulations without induced foaming, giving benefits of either reduced melt viscosity and/or lower melt temperatures. Its application is particlarly beneficial to difficult to process materials, including unplasticised PVC, polycarbonate, PTFE, UHMWPE and polymers containing high loadings of fillers of organic origin. Shear and thermally sensitive materials can also be processed using this method with less risk of degradation, due to the lower shear input and reduced processing temperatures necessary. The production of foamed ceramic materials and metallic components by such a method is also disclosed.