# US 9,518,162 B2 · Process of making a continuous dielectric film comprising dispersed nanoparticles

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- Number: US 9,518,162 B2
- Document ID: US9518162B2
- Status: Granted
- Kind: B2
- Application number: 14/413,458
- Filed: 2013-07-12
- Published: 2015-10-15
- Granted: 2016-12-13
- Earliest claimed: 2012-07-13
- Assignees: The Secretary of State for Defence
- Applicants: The Secretary of State for Defence
- Inventors: Matthew Adrian Brown; Michelle Silverstone Lang
- Web page: https://patentgrep.com/patent/US9518162B2

## CPC

- C08J 5/18: Manufacture of films or sheets
- B29C 48/022: {characterised by the choice of material}
- B29C 48/08: flexible, e.g. films
- B29C 48/142: {using force fields, e.g. gravity or electrical fields (B29C48/9165 takes precedence)}
- B29C 48/16: Articles comprising two or more components, e.g. co-extruded layers
- B29C 48/287: {Raw material pre-treatment while feeding (B29C48/78 takes precedence)}
- B29C 48/288: {in solid form, e.g. powder or granules}
- B29C 48/914: {Cooling drums}
- C08K 3/08: Metals
- C08K 3/22: of metals
- H01B 3/442: {from aromatic vinyl compounds}
- H01G 4/18: of synthetic material, e.g. derivatives of cellulose (H01G4/16 takes precedence)
- H01G 4/206: {inorganic and synthetic material}
- B29B 7/90: Fillers or reinforcements {, e.g. fibres}
- B29C 43/222: {characterised by the shape of the surface}
- B29C 48/10: flexible, e.g. blown foils
- B29C 2948/92219: Degree of crosslinking, solidification, crystallinity or homogeneity
- B29C 2948/92714: Degree of crosslinking, solidification, crystallinity or homogeneity
- B29K 2025/06: {PS, i.e. polystyrene}
- B29K 2105/122: {microfibres or nanofibers}
- B29K 2105/124: {Nanofibers}
- B29K 2105/162: {Nanoparticles}
- B29K 2505/00: Use of metals, their alloys or their compounds, as filler
- B29K 2505/14: Noble metals, e.g. silver, gold or platinum
- B29K 2995/0006: Dielectric
- C08J 2325/06: Polystyrene
- C08K 2003/0806: {Silver}
- C08K 2003/2241: {Titanium dioxide}
- H01G 4/14: Organic dielectrics
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

The invention provides a process of making a continuous freeform thermoplastic dielectric film (25) that is evenly loaded with dispersed nanoparticles comprising the steps of; feeding thermoplastic granules (21) into an extruder (23), injecting a secondary feed (27) comprising a suspension of nanoparticles in a liquid carrier to create a nanocomposite, and extruding said composite onto cooled rollers (26) at a preset rate thereby enabling the crystalline structure of the nanocomposite film (25) to be controlled wherein the secondary feed (27) is mixed continuously by an ultrasonicator (29) whilst being injected into the extruder (23). By selecting the size of the nano particles based on their de Broglie wavelength in the crystalline polymer the dielectric can be produced in bulk to make high capacitance high energy density storage capacitors

## Claims

### Claim 1

A process of making a continuous freeform thermoplastic dielectric film for use at high voltage that is evenly loaded with dispersed nanoparticles comprising the steps of:
feeding thermoplastic granules into an extruder;
injecting a secondary feed comprising a suspension of nanoparticles in a liquid carrier to create a nanocomposite;
continuously mixing the secondary feed by an ultrasonicator whilst injecting it into the extruder;
and extruding the nanocomposite onto cooled rollers at a preset rate thereby enabling the crystalline structure of the dielectric film to be controlled;
wherein the nanoparticles are geometrically controlled to each have no diameter that is greater than the De Broglie wavelength of an electron in the thermoplastic granules.

### Claim 2 (depends on 1)

A process according to claim 1 in which the secondary feed is further ultrasonicated by a flow cell.

### Claim 3 (depends on 1)

A process according to claim 1 in which the nanoparticles comprise titanium dioxide.

### Claim 4 (depends on 1)

A process according to claim 1 where the liquid carrier is toluene.

### Claim 5 (depends on 1)

A process according to claim 1 where the liquid carrier is ethyl acetate.

### Claim 6 (depends on 1)

A process according to claim 1 that further comprises the step of injecting an additional feed of nanoparticles that are selected to provide extra electrons.

### Claim 7 (depends on 6)

A process according to claim 6 in which the nanoparticles in the additional feed comprise silver.