# US 2019/0168186 A1 · Reduced polymer content and bonding in polymer particulate composite

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- Number: US 2019/0168186 A1
- Document ID: US20190168186A1
- Status: Published application
- Kind: A1
- Application number: 16/323,038
- Filed: 2017-08-04
- Published: 2019-06-06
- Earliest claimed: 2016-08-04
- Assignees: Tundra Composites, LLC
- Applicants: Tundra Composites, LLC
- Inventors: Kurt Heikkila
- Web page: https://patentgrep.com/patent/US20190168186A1

## CPC

- B01J 20/26: Synthetic macromolecular compounds
- B01J 20/043: {Carbonates or bicarbonates, e.g. limestone, dolomite, aragonite}
- B01J 20/103: {comprising silica}
- B01J 20/18: Synthetic zeolitic molecular sieves
- B01J 20/28004: {Sorbent size or size distribution, e.g. particle size}
- B01J 20/28026: {Particles within, immobilised, dispersed, entrapped in or on a matrix, e.g. a resin}
- B01J 20/3042: {Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent}
- C08K 7/24: inorganic
- C08K 9/04: Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)}
- C08K 3/34: Silicon-containing compounds
- C08K 3/36: Silica
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

Disclosed is a composite of a particulate and polymer, the composite characterized by less than enough polymer to fully occupy the available excluded volume of the particulate of the composite. The resulting composite is characterized by the particulate partially covered by the polymer leaving a substantial surface area uncovered.

## Claims

### Claim at position 1

1-17. (canceled)

### Claim 18

A friable extruded composite comprising
(a) a polymer phase,
(b) a dispersed particulate phase comprising particulate having a particle surface, the particulate phase being present in an amount of at least the critical packing volume in the polymer,
(c) a coating comprising an interfacial modifier on the particle surface, and
(d) a distribution of void spaces within the polymer phase, wherein the void spaces leave the particle surface exposed, and wherein a proportion of the void spaces is up to 40 vol. % of the composite.

### Claim 19 (depends on 18)

The composite of claim 18 wherein the void spaces comprise 1-35 vol. % of the composite and a bulk density is at most 95% of a filled material.

### Claim 20 (depends on 18)

The composite of claim 18 wherein the void spaces comprise 2-30 vol. % of the composite.

### Claim 21 (depends on 18)

The composite of claim 18 wherein the particulate comprises 40-95 vol. % of the composite having 0.001 to 8 vol. % of an interfacial modifier coating on the particle surface.

### Claim 22 (depends on 18)

The composite of claim 18 wherein the particulate comprises 10-70 vol. % of the composite having 0.001 to 8 vol. % of an interfacial modifier coating on the particle surface.

### Claim 23 (depends on 18)

The composite of claim 18 wherein the composite comprises a blend of two or more different particulates, wherein a difference is in particle size or composition.

### Claim 24 (depends on 18)

The composite of claim 18 wherein the particulate further comprises 0.2 to 3 wt. % of an interfacial modifier on the particle surface, wt. % based on the composite.

### Claim 25 (depends on 18)

The composite of claim 18 wherein the particulate comprises a carbon source, a silicate, an aluminosilicate, a zeolite, a carbonate or mixtures thereof.

### Claim 26 (depends on 18)

The composite of claim 18 wherein the polymer phase has a melt index of greater than 30 g-10 sec−1.

### Claim 27 (depends on 18)

The composite of claim 18 wherein the polymer phase has a melt index of 500 to 1500 g-10 sec−1.

### Claim 28 (depends on 18)

The composite of claim 18 wherein the composite comprises less than 50% of a particulate surface area available to contact by the absence of polymer.

### Claim 29 (depends on 18)

The composite of claim 18 comprising a bi-disperse particulate with 50-90 vol. % of a blend of two or more different particulates, each particulate having a particle size less than 500 microns, wherein each particulate comprises 0.2 to 4 wt. % of the interfacial modifier on the particle surface, the composite has less than 90% of a particulate excluded volume occupied by the polymer, and the particulate has greater than 10% of a particulate surface area available to contact by the absence of polymer.

### Claim 30 (depends on 29)

The composite of claim 29 wherein the composite comprises greater than 15% of the particulate surface area available to contact by an absence of polymer.

### Claim 31 (depends on 18)

A particulate comprising the composite of claim 18 comprising a particle size of 0.01 to 5 mm.

### Claim 32 (depends on 30)

A particulate comprising the composite of claim 30 comprising a particle size of 0.01 to 5 mm.

### Claim 33

A method of making a friable solid composite comprising steps of: (a) introducing particulate and a polymer into a compounding extruder, the particulate comprising particles having a particle surface and an interfacial modifier on the particle surface, the particulate and polymer being introduced in relative amounts sufficient to provide a particulate content of at least a critical packing volume in the polymer and greater than 60 vol. % of the composite, and a bulk density of less than 95% of a filled polymer and (b) forming the composite at a temperature greater than a melting temperature of the polymer.

### Claim 34 (depends on 33)

The method of claim 33 wherein the polymer and particulate in pellet and powder form are combined before introduction into the compounding extruder.