Structurally enhanced plastics with filler reinforcements

[0001] A composition favoring the kinetic mixing of additives in the non-linear zone of viscosity of a fluid, such as a thermoplastic material.

BACKGROUND OF THE INVENTION [0002] The extrusion process is one of the most economical ways of producing engineering structural materials in production. Typically, the extrusion process is used to produce sections of extruded elements with a uniform cross-section. The cross-section of the elements may have various simple shapes, such as round, annular or rectangular. The cross-section of the elements can also be very complicated, including internal support structures and / or having an irregular contour.

[0003] The molding process usually uses thermoplastic polymer compounds which are introduced into the hopper. Thermoplastic polymer compounds may be in the form of a powder, liquid, bar, granule and / or any other extrudable form. The thermoplastic polymer can be an unprocessed polymer, recycled or a mixture of both. An example of a typical extruder is shown in FIG. 1.

[0004] Fillers are used in the plastics industry to reduce resin production costs. Typical fillers include calcium carbonate, talc, wood fiber and many others. In addition to ensuring cost savings, the addition of plastic fillers reduces the coefficient of thermal expansion, increases mechanical strength, and in some cases reduces the density.

[0005] Calcium carbonate and talc do not have structural strength or fiber orientation to increase structural stability. Talc is bound by van der Waals' weak forces, which allow multiple splitting of the material under the pressure applied to its surface. Although the test results show that talc gives many advantages to polypropylene, for example higher rigidity and better dimensional stability, talc acts as a micro-filler with lubricating properties.

[0006] Calcium carbonate has similar properties, but the problem is the absorption of water, which limits its use due to degradation of the natural environment. This problem does not occur with talc because it is hydrophobic.

[0007] Wood fiber increases some degree of dimensional stability due to the properties of the fibers allowing interaction with the plastic, but wood fibers also pose a problem of degradation of the natural environment. All three of these typical fillers are economically viable but have structural limitations.

[0008] For several decades, the plastics industry has been seeking to improve scratch resistance and / or damage and improve the aesthetic appearance. Over the last decade, many improvements have been made to increase scratch resistance and damage, but the technology sought still extends beyond the plastics industry and its scientists. One of the challenges is how to make the plastic harder and maintain the costs without compromising the aesthetic appearance. The Applicant is not aware of any cheap reinforcing filler that would solve the issue of increasing scratch resistance and damage, although research efforts focus on fibers from agricultural waste, such as rice husks, cane fiber, wheat straw and many other fillers intended for use as cheap structural fillers inside plastics. One explanation is the technological gap regarding structural fillers, as it strives to improve physical properties with an emphasis on costs rather than an emphasis on the integrity of the plastic.

[0009] There are three types of commonly used mixing principles regarding the addition of fillers to plastics:

1. Static mixing: liquids flowing around a fixed object or as a result of a flow caused by force, due to the pressure generated by mechanical means, or due to the flow induced by the force of gravity.

2. Dynamic mixing: imparting a mixing motion of a liquid by mechanical mixing using conventional rotors, both vane and shear design, as well as imparting a stirring motion using a double or a single screw.

3. Kinetic mixing: the liquid is mixed thanks to the velocity effects on the surface or the interaction of two or more liquids colliding with each other.

[0010] All three of the above mixing methods have one thing in common that makes it difficult to optimize the mixing regardless of the combined liquids and regardless of whether the mixed materials are polar, apolar, organic or inorganic, etc., and whether the material is filled with compressible fillers or incompressible.

[0011] All incompressible fluids have a boundary effect, i.e. a boundary layer effect, where the fluid velocity is greatly reduced at the wall or mechanical joint. Static mixing systems use this boundary layer to stack or mix liquids, using this resistance force to impart mixing motion.

Due to the presence of the boundary layer, dynamic mixing, regardless of the geometry of the mixing blades or the turbine, leads to dead zones and incomplete mixing. Dynamic mixing uses intensive shear and auger blade designed to use a boundary layer to increase friction and compress by centrifugal forces to realize the mixing motion while maintaining an incompletely mixed boundary layer on the mechanical surfaces.

The impact of the boundary layer on the speed profiles, both of the inlet jets and in the nozzle mouth, has an adverse effect on the kinetic mixing. However, this system is adversely affected by the boundary layer to a minimum, except for the phenomenon of fluid transport.

[0014] A further explanation of the boundary layer is given below. Aerodynamic forces in a complex way depend on the viscosity of the fluid. When the fluid flows around the object, the particles located close to the surface adhere to this surface. Particles just above this surface are slowed down, colliding with particles adhering to the surface. These molecules, in turn, slow down the flow just above them. The further you move from the surface, the less collisions caused by the surface of the object. This creates a thin fluid layer close to the surface where the velocity changes from zero at the surface to the flow rate for the free jet away from the surface. Engineers call this layer a boundary layer because it occurs at the fluid boundary.

[0015] As the object moves in the fluid or when the fluid moves around the object, the fluid molecules near the object are agitated and move around the object. Aerodynamic forces are generated between the fluid and the object. The magnitude of these forces depends on the shape of the object, the speed of the object, the mass of the fluid flowing around the object and the other two important properties of the fluid; viscosity, or adhesion, and compressibility, i.e. the elasticity of the fluid. For proper modeling of these interactions, aviation and aeronautical engineers use similarity parameters, which are the ratios of the magnitude of these interactions to other forces regarding this problem. If two experiments have the same values ​​of similarity parameters, then the relative meanings of forces are modeled correctly.

[0016] FIG. 2A represents a direction of flow of the velocity flux from the free flow to the surface. In fact, these interactions are three-dimensional. On the basis of the law of mass conservation in three directions, the change of velocity in the direction of the flow of the stream also causes the change of speed in other directions. There is a small speed component perpendicular to the surface that moves or moves the flow above it. You can define the thickness of the boundary layer as the value of this displacement. The displacement thickness depends on the Reynolds number, which is the ratio of inertia forces (resistant to change or movement) to the viscous forces (density and stickiness) and is given by the formula:

[0017] As can be seen in FIG. 2A, the boundary layers can be either laminar (layered) or turbulent (unordered), depending on the Reynolds number. With lower Reynolds numbers, the boundary layer is laminar and the velocity in the direction of the flow fluctuates evenly as it moves away from the wall, as shown on the left side of FIG. 2A. In the case of higher Reynolds numbers, the boundary layer is turbulent and the velocity in the direction of the stream flow is characterized by unstable (variable in time) eddy flows inside the boundary layer. The external stream reacts to the edge of the boundary layer just as it would react to the physical surface of the object. Thus, the boundary layer gives each object an "effective" shape that is usually slightly different from the physical shape. The boundary layer can float or "separate" from the body and create an effective shape that differs significantly from the physical shape. This is because the flow in the boundary has very little energy (compared to the free stream) and is easier driven by pressure changes. Separation of the flow is the reason for dragging the wing of the aircraft at a large angle of attack. The effects of the boundary layer on lifting are included in the lift coefficient, and the resistance influences are included in the drag coefficient. Flow at the boundary layer [0018] In this part of the fluid stream, close to the solid surface, the shear stresses are significant and the non-viscous flow assumptions can not be used. All solid surfaces interact with a stream of viscous fluid due to the lack of slip, a physical requirement, so that the liquid and solid have the same velocity at their contact. Thus, the fluid flow is delayed by the stationary solid surface and a finite, slowly moving boundary layer is formed. The requirement that the boundary layer be thin means that the Reynolds number for the body should be large, 10³ or more. Under these conditions, the flow outside the boundary layer is substantially non-sticky and plays the role of a drive mechanism for this layer.

[0019] Referring now to FIG. 2B, the figure shows a typical boundary layer with free flow ie laminar. This picture of the variation of the flow vector in the direction of the flow of the stream near the wall is called the velocity profile. No slip requires, as shown, u (x, 0) = 0, where u is the flow velocity at the boundary layer. The velocity increases monotonically as a function of the distance y from the wall, at the end smoothly reaching the velocity U (x) of the external (non-stick) stream. At any point in the boundary layer, the shear stress in the fluid / ταμ is proportional to the local velocity gradient, assuming the Newtonian fluid. The value of shear stress at the wall is the most important, because it refers not only to the resistance of the body, but also often to its heat exchange. At the edge of the boundary layer, ταμ approaches asymptotically to zero. There is no exact place where ταμ = 0, and therefore the thickness of the boundary layer δ is usually defined as any point where u = 0.99U.

[0020] GB 2143838 discloses extruded compositions of unsaturated polyester resins.

[0021] WO 2006/101440 A1 discloses a material composition comprising particulate or granular material and a binder that is provided as a coating on the material particles or grains.

[0022] WO 01/83371 A2 discloses powders from highly delaminated hexagonal boron nitride and a method for preparing such powders.

[0023] EP 1563983 A1 discloses a method of producing extruded articles by passing a thermoplastically stretched stream of extruded thermoplastic resinous material through the extruder die. A coextrusion system is provided in which the core stream is extruded and at least one boundary stream is extruded outside the core stream.

[0024] US 5945478 discloses a method for improving the surface smoothness of a thermoplastic polymer during extrusion by introducing into the polymer a nucleating agent of the foam cell and extruding the polymer under a laminar flow to form a non-foaming extrudate.

[0025] WO 2008/079438 A1 discloses a moldable composition comprising an organic polymer and another composition comprising graphite and boron nitride. SUMMARY OF THE INVENTION [0026] One aspect provides a method of increasing the flow through the processing device as claimed in claim 1.

[0027] The present patent focuses on technological breakthroughs concerning micro- and nanomixing in the boundary layer, i.e. the interaction of structural mechanical fillers imparting micro- and nanolatile properties using the static film principle in the boundary layer in combination with the coefficient of friction for the moving particle in the border zone of the fluid flowing over the solid particle, to impart acceleration to the stirring.

[0028] The geometry of structural filler particles is based on the fundamental principle of surface roughness that promotes increased adhesion to the zero speed zone at the boundary layer. The boundary layer occurs where the material has its strongest adhesive strength or stickiness. By using a particle with a rough and / or sharp surface of the particle, adhesion to the non-skid zone increases, which promotes better adhesion than with smooth particles with little or no surface properties. The ideal size of the filler particles will vary for different polymers, because viscosity varies, as well as the mixing mechanics resulting from the shear forces and surface polishing on the mechanical surfaces, which creates a difference in the thickness of the boundary layer. The rough and / or sharp surface of the particles allows the particle to act as a rolling kinetic mixing blade in the boundary layer. The technological breakthrough embodied by the present patent is centered on a hardened particle with sharpened edges, running along the boundary layer, producing micromixing with the imparting of a mixing motion over the surface area on which the boundary layer occurs.

[0029] The advantages of this technology are:

• Cost savings by replacing expensive polymers with inexpensive structural material.

• Saving costs by increasing the ability to inject more organic material into the plastic.

• Saving costs by increasing efficiency using large amounts of organic and / or structural materials.

• Better use of additives and / or fillers through increased mixing on large mechanical surfaces produced by mixing at the boundary layer.

• Better mixing of polymers due to the abrasive and cutting action of particles running along a large surface area, since the speed and compression of polymers affects the surface during normal mixing operations.

• Reduction of coefficient of friction on mechanical surfaces caused by boundary layer influences, with resistance replaced by kinetic friction of rolling hard particles in boundary layers.

• Increased production of plastics by reducing the coefficient of friction in the boundary layer in the case of extrusion, blow molding or injection molding processes, in which the coefficient of friction has a direct impact on production efficiency.

• Improvement of the surface quality of plastics, containing or without fillers, due to polishing effects caused by kinetic mixing in the boundary layer on all mechanical surfaces, including nozzles, molds, etc., through which and around which materials flow during final treatment.

• Favoring the removal of the boundary layer by kinetic mixing, and thus the self-cleaning properties of the boundary layer.

• Increased heat exchange due to kinetic mixing at the boundary layer, considered as a static film, where conduction is the predominant heat exchange, however, mixing of a static film gives a forced convection on the heat exchange surface.

[0030] Particles used for kinetic mixing at the boundary layer need to have the following characteristics:

• The physical geometry of the particles should have a characteristic that gives the particles the ability to roll or tumble along the surface of the boundary layer.

• The mixing efficiency of the particles increases with the surface roughness for interaction with the zero speed zone or the non-slip polymer surface, to stimulate kinetic friction rather than static friction.

• The particles should be hard enough to allow the fluid to deform around the particle, to promote kinetic mixing due to the rolling effect or tumbling of the particle.

• The particles should have a size proportional to the boundary layer for the materials used so that the particles roll or tumble using the rolling kinetic friction so that the particles do not encounter a resistance layer in the boundary layer that increases the negative interactions of the boundary layer based on the increased surface roughness or which may cause removing the particle from the boundary layer to the mass of the fluid.

• The particles should be able to reconnect in the boundary layer by passing from the mass of liquid during the mixing process, depending on the particle size and surface roughness.

The particles can be solid materials or porous, synthetic or naturally occurring minerals and / or rocks.

Physical geometry of particles:

[0031] Spherical particles are not ideal due to the two following phenomena that occur simultaneously. The first phenomenon concerns the surface friction of the particle in the non-slip zone, and the second concerns the driving force imparted to the particle by the velocity of the fluid, which affects the ability of the particles to roll or tumble. The driving force is generated by the flow of fluid in the upper half of the boundary layer. The shapes of the particles may be spherical, triangular, rhomboidal, square or similar, but semi-flat or flat objects are less desirable because they do not tumble well. Half-flat or flat objects do not tumble well, because the cross-sectional area has a low resistance to fluid friction applied to its thickness. However, because it is desirable to broadcast traffic in the form of mixing, chaotic forms of tumbling are preferred because chaotic tumbling creates dynamic, randomly generated mixing zones. These random mixing zones are analogous to large mixing blades working with small mixing blades. Some rotate quickly, and some rotate slowly, but the end result is that they all mix. In the case of a material with a higher viscosity with less inelastic properties, kinetic mixing through the particles leads to a chopping and grinding effect resulting from the roughness of the surface and the sharp edges of the particles. Some rotate quickly, and some rotate slowly, but the end result is that they all mix. In the case of a material with a higher viscosity with less inelastic properties, kinetic mixing through the particles leads to a chopping and grinding effect resulting from the roughness of the surface and the sharp edges of the particles. Some rotate quickly, and some rotate slowly, but the end result is that they all mix. In the case of a material with a higher viscosity with less inelastic properties, kinetic mixing through the particles leads to a chopping and grinding effect resulting from the roughness of the surface and the sharp edges of the particles.

[0032] Typical extruded as well as injection-molded plastics are PP, PE, PB HDPP, HDPE, HDPB, nylon, ABS and PVC, being some types of industrial plastics whose hardness is proportional to the material properties of the plastic. By adding hard fillers to the plastic, a stronger, more durable plastic can be made that is more resistant to scratches and / or damage than a plastic with natural physical properties. Commonly used fillers are calcium carbonate and talc, each of which has a Mohs hardness of 1. However, it is desirable to use structural fillers with a hardness of at least 2.5. [0033] The plastics industry has not commercially evaluated many environmentally stable materials suitable for use as hard structural fillers. These fillers are of structural nature, they are hard, light and durable in the natural environment. Some reasons that these fillers have not been used commercially are that they are difficult to formulate and manipulate. In addition, these materials may not be as cost-effective as the fillers used previously. The following lightweight structural fillers are similar in terms of hardness, density and particle size, within the micrometer range, but have not been widely accepted for use in the plastics industry. they are hard, light and durable in the natural environment. Some reasons that these fillers have not been used commercially are that they are difficult to formulate and manipulate. In addition, these materials may not be as cost-effective as the fillers used previously. The following lightweight structural fillers are similar in terms of hardness, density and particle size, within the micrometer range, but have not been widely accepted for use in the plastics industry. they are hard, light and durable in the natural environment. Some reasons that these fillers have not been used commercially are that they are difficult to formulate and manipulate. In addition, these materials may not be as cost-effective as the fillers used previously. The following lightweight structural fillers are similar in terms of hardness, density and particle size, within the micrometer range, but have not been widely accepted for use in the plastics industry.

[0034] Glass or ceramic microspheres have been available on the market for decades. The spheres have had some success in the production of plastics, but they were mainly used on the market of coatings, adhesives and composites.

[0035] Perlite is a naturally occurring silicate rock mainly used in construction products, as an insulator in masonry, in light concrete and as food additives.

[0036] The potassium sodium aluminosilicate (volcanic glaze) is a micrometer sized powder used as a plastic flow modifier to increase the yield and also to improve the mixing characteristics of the additives.

[0037] The above-mentioned structural fillers have a hardness of 5.5 on the Mohs scale, which is equal to the hardness of the window pane, sand and knife blade made of good quality steel, and thus the addition of particles of such hardness to typical materials may scratch the surface of the plastic. Such structural fillers are not held together by weak forces. Therefore, they maintain a rigid shape and do not have lubricating properties associated with the cleavage of weak chemical bonds between the layers of molecules, as is the case with talc. Particles with a hardness of 5.5 on the Mohs scale are as hard as what would normally damage a plastic surface. Thus, scratch resistance and / or damage due to the usual hardness of the filler incorporated in the plastic composition is improved. The structural fillers are preferably light, with a density in the range of 0.18 - 0.8 g / cm³, while calcium carbonate and talc have a density in the range of 2.50 - 2.80 g / cm³. Therefore, hard structural fillers reduce the density of the plastic composition.

[0038] Recently, the use of microspheres in extruded plastics has been of interest due to their increased strength, which allows them to withstand mechanical pressures without crushing. As the strength of microspheres increases, the manufacturing cost is reduced, which makes microspheres an ideal material for structural fillers for plastics.

[0039] Other filler materials contemplated include expanded perlite. Expanded perlite was not commercially used in the plastics industry in extrusion processes due to its microbubbles and channels, which are a natural feature of the material and can not withstand the pressure prevailing during extrusion without crushing. Cracking of fillers increases the non-homogeneity of the volume flow, which affects the dimensional stability of the extruded product, which may or may not be acceptable depending on the application. For this reason, perlite has not achieved commercial viability as a structural filler in the field of plastics. Perlite can be thoroughly ground, which greatly increases the strength of the crushing product, thus giving the material the ability to withstand pressures during the mechanical extrusion process, thereby achieving dimensional stability. One of the reasons why this material has not been accepted as a filler is that in its original form this material has the ability to crumble under pressure.

[0040] Finely ground pearlite has the same physical properties, only finer grains that withstand higher pressures. Finely ground perlite is currently used in water purification systems as a filter medium.

[0041] For example, the hard sphere rolling on a soft material moves in a movable recess. The material is compressed at the front, and it expands at the back and when the material is perfectly elastic, the energy stored in the compressed material is returned to the sphere in its rear part. However, the actual materials are not perfectly flexible, so energy dissipation occurs, resulting in kinetic rolling energy. By definition, fluid is a continuous matter that is not inable to withstand static shear stress. In contrast to an elastic solid that reacts to shear stress by a reversible deformation, the liquid reacts with irreversible flow. The irreversible flow can be used as the driving force of kinetic mechanical mixing in the boundary layer. On the principle of kinetic rolling friction and due to the increased adhesion of the liquid at the surface of the non-slip zone adhesive joints are formed, while the speed in the boundary layer generates inertia force acting on the particle. The inertia force rotates the particle along the surface of the mechanical processing device, regardless of the mixing mechanics used, i.e. static, dynamic or kinetic.

BRIEF DESCRIPTION OF THE DRAWINGS [0042]

FIG. 1 is a diagram of an extruder.

FIG. 2A is a graphical explanation of the concept of the boundary layer.

FIG. 2B is a graphical explanation of the low-speed boundary layer, i.e. the laminar boundary layer.

FIG. 3 is a graph showing the effect of perlite addition on the flow rate of a thermoplastic material through an extruder.

FIG. 4 is a graph showing the effect of potassium sodium aluminosilicate on the flow rate of a thermoplastic material through an extruder.

FIG. 5 is a graph showing the effect of wood particles on the thermoplastic flow rate through an extruder.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0043] During the jet milling process, the particles hit each other to form a sharp edge due to the shell fracture. Even if certain groups of particles of the chosen size will interact differently with different selected polymers, it is the edge effect that triggers their action. The edge effect in the case of potassium sodium aluminosilicate facilitates the introduction of fillers, structural fillers, pigments, fibers and a variety of other materials for thermoplastic and polymer materials.

[0044] Materials that, as a result of jet milling, provide a sharp edge effect include: pumice, perlite, volcanic enamel, sand, flint, slate and granite among a variety of other fossil materials. There are many different synthetic materials, such as steel, aluminum, brass, ceramics and recycled and / or new window glass, which can be processed either by jet milling or other related grinding processes to produce sharp edges at small particle sizes. In addition to the examples mentioned, other materials may also be suitable as long as these materials have sufficient hardness of an estimated 2.5 on the Mohs hardness scale.

[0045] As can be clearly seen from the hardness scale, there are many different materials that are harder than 2.5, and which could be probable candidates for a sharpened edge effect and thus act as a surface tension modifier, as well as a filler structural introduced into current modern plastics, polymers, paints and adhesives. The scale of Mohs is presented

<td colspan="3">below.</td>

<td>Hardness</td><td>Mineral a</td><td>Absolute hardness</td>

<td>ο 1</td><td>Talc (Mg3Si4O10 (OH) 2)</td><td>1</td>

<td>2</td><td>Gypsum (CaSO4YH2O)</td><td>2</td>

<td>3</td><td>Calcite (CaCO3)</td><td>9</td>

<td>4</td><td>Fluorite (CaF2)</td><td>21</td>

<td>5</td><td>Apatite (Ca5 (PO4) 3 (OH-, Cl-, F-)</td><td>48</td>

<td>6</td><td>Ortoclase, feldspar (KAlSi3O8)</td><td>72</td>

<td>7</td><td>Quartz (SiO2)</td><td>100</td>

<td>8</td><td>Topaz (Al2SiO4 (OH-, F-) 2)</td><td>200</td>

<td>9</td><td>Korund (Al2O3)</td><td>400</td>

<td>10</td><td>Diamond (C)</td><td>1500</td>

[0046] The Mohs scale is a purely ordinal scale. For example, corundum (9) is twice as hard as topaz (8), but diamond (10) is almost four times harder than corundum. The table below shows the comparison with absolute hardness measured with a sclerometer.

[0047] The table below contains additional substances that can be located between levels:

<td>Hardness</td><td>Substance or mineral</td>

<td>1</td><td>Talc</td>

<td>2</td><td>Gypsum</td>

<td>2.5 to 3</td><td>Pure gold, silver and aluminum</td>

<td>3</td><td>Calcite, copper</td>

<td>4</td><td>Fluorite</td>

<td>4 to 4.5</td><td>Platinum</td>

<td>4 to 5</td><td>Iron</td>

<td>5</td><td>Apatite</td>

<td>6</td><td>orthoclase</td>

<td>6</td><td>Titanium</td>

<td>6.5</td><td>Iron pyrite</td>

<td>6 to 7</td><td>Glass, glassy pure silica</td>

<td>7</td><td>Quartz</td>

<td>7 to 7.5</td><td>Grenade</td>

<td>7 to 8</td><td>Hardened steel</td>

<td>Hardness</td><td>Substance or mineral</td>

<td>8</td><td>Topaz</td>

<td>9</td><td>corundum</td>

<td>9 to 9.5</td><td>Carborundum</td>

<td>10</td><td>Diamond</td>

<td>&gt; 10</td><td>Ultrahard fulerite</td>

<td>&gt; 10</td><td>Aggregated diamond nanorods</td>

Characteristics of the surface of particles:

[0048] The particle agitation efficiency increases as the surface roughness of the particles increases. Increasing the surface roughness has a twofold effect. The first effect is that the surface roughness and geometry of the particles increases the adhesion of the surface to the non-slip zone or in the viscous region, which generates resistance from rolling or tumbling particles. The second result is the addition of resistance to the ability of particles to roll or tumble, which results in stronger mechanical interaction with the colliding fluid. In the example of a smooth spherical rolling ball rolling across the surface caused by interactions, adhesion to the non-slip zone is minimal, and the impact on the polymer does not cause significant dynamic mixing. If the material is rugged and / or spicy or has both of these features, then dynamic mixing generates resistance against rolling, thus creating a tumbling effect similar to the action of the blade, which results in imparting a stirring movement due to the roughness and mechanical kinetic rotation. Hardness and Strength of Particles [0049] Mixing vanes and high shear mixing devices are typically made of tempered steel and the polymers are softer than the mechanical imparting of the mixing motion applied during mixing. Because the particles flow, they must be able to maintain their shape to function properly. Chemical interactions between molecules were investigated and ordered based on their hardness. A minimum Mohs hardness of 2.5 or more, determined starting from copper, will be sufficient for one-passage particles,

[0050] The filler particles should have a size proportional to the area of ​​the boundary layer. Size is usually defined arbitrarily as the point at which u = 0.99U. Thus, the theoretical initial particle diameter is the height measured perpendicular to the surface, where u = 0.99U. There are many factors that pose additional difficulties when calculating parameters related to kinetic mixing in the border zone, for example:

1. Filling with filler that gives diverse interactions at the boundary layer.

2. Heat exchange through the walls, creating viscosity differentiation.

3. Shearing effects and constantly increasing compression caused by the transmission of the mixing motion through the screw.

4. Chemical reactions in which the physical properties of materials such as viscosity, density etc. change.

[0051] Mixing dynamics is one of the most complex mechanical chemical interactions in industrial processes. The particle size will vary from product to product and optimization may or may not be required. Research suggests that there seems to be no major difference between the 25 mesh product and 800 mesh particles. In both cases, the particle has a dramatic effect on the mixing zone at the boundary layer.

[0052] One approach to selecting a suitable particle size is to determine when a given particle size causes an adverse effect at the boundary layer, increasing the drag coefficient. In most processes, this can be identified by monitoring the increase in amperes of the current consumption of the motor during the mixing cycle. If the number of amperes increases, the particle size should be reduced. [0053] Another approach is to check whether the speed of the mixing motion can be increased without the ampere increase in the current consumption of the motor, reflecting a reduction in friction due to kinetic mixing at the boundary layer. For example, FIG. 3 shows the flow rate of a thermoplastic material through an extruder at a given screw revolution per minute. You can see

[0054] FIG. 4 shows that the addition of potassium sodium aluminosilicate to the base material allows the extruder to run at a higher rpm than was possible before, which generates a higher flow rate for the same device. Due to the limitations of the device, it was not possible to set the upper limit of RPM.

[0055] FIG. 5 shows that even if the wood content is 52% to 73% of the plastic mixture, 2% perlite and wood, a higher flow rate can still be achieved than with a 49% non-pearlite wood content.

[0056] The chemical industry has created test methods and tables for a homogeneous liquid and relative boundary layer thicknesses for calculating fluid flow properties for selected mechanical devices and heat transfer properties. The same profile assumption is included in this patent as a starting point for such particle size that they function in the boundary layer, increasing mixing.

Recombination of particles with the boundary layer [0057] Particles may be selected to react again with the boundary layer if they are entrained into the mass of the liquid during mixing. All liquid materials flowing through the mechanical mixing of the mixing motion take the path of the least resistance. When transmitting the mixing motion, particles resistant to movement in a viscous environment have an impact on the velocity profile. Thus, particles that resist the flow of fluid are usually directed towards the boundary layer so that the fluid can flow freely. When the particle is large in size, it can be bound in the liquid suspension because the cohesion forces in the boundary layer are not sufficient to resist the force of the fluid velocity applied to the surface of the boundary layer, which causes the particle to flow back into the liquid suspension.

[0058] Mineral processing technologies have existed for centuries and are highly specialized. They have the ability to separate particles by various methods, as well as to shape them into smaller particles. In the case of these highly specialized solids or porous materials to produce the desired three-dimensional blade-like characteristics, with sharpened edges with an aspect ratio greater than 0.7, the material must be subjected to a jet or beard milling process. Impact-jet milling is a process in which the material to be treated hits high-speed against a hardened surface, resulting in the breakdown of particles. In the case of jet milling, the opposite nozzles cause the material to be treated to hit itself, resulting in a breakdown, i.e. shells in the material. The effectiveness of the kinetic mixing particle due to the sharpness of its surface, i.e. the edge-like edges (see Annex 1).

[0059] In the ball milling process, the material is rotated in a batch process, which removes the desired surface properties, e.g. sharpness. For use as particles in the extrusion process of thermoplastics, solid minerals or rocks should be transformed into particles from 10 to 20 mesh or smaller. This is a typical starting point for a batch material in a jet-blasting or jet milling process. This can be achieved by a variety of methods that are widely available and known in the industry for particle size production. The beneficial mineral or rock should be able to give shell passages. This provides knife-like edge effects with three-dimensional shapes. See Annex 1 for images of shell fractures. In the case of porous minerals or rocks, the characteristics of pores broken up and shattering under impacts during impact-jet or jet milling create three-dimensional particles with edges shaped like knives. Although rough and uneven surfaces may be sufficient in some mixing applications, in which case the stronger the particle, the better the results. See Annex 1 for reference particle sizes after jet milling. Synthetic materials such as glass, ceramics and metals may be used, as well as a variety of other types of materials meeting the minimum hardness condition of 2.5 on the Mohs scale, which give sharp edges with a three-dimensional shape and a shape factor of greater than 0.7. The jet-hammer or jet milling of these materials typically results in particles with an arithmetic average of 5 - 60 mm in one pass. Synthetic materials, such as glass, can be processed into desired three-dimensional, sharp-edged particles with an aspect ratio of 0.7 or more using a mechanical particle mill instead of jet milling. This is clearly shown in the pictures from the Annexes, showing the batch material in the form of small glass particles before jet milling. can be processed into desired three-dimensional, sharp-edged particles with an aspect ratio of 0.7 or more using a mechanical particle mill instead of jet milling. This is clearly shown in the pictures from the Annexes, showing the batch material in the form of small glass particles before jet milling. can be processed into desired three-dimensional, sharp-edged particles with an aspect ratio of 0.7 or more using a mechanical particle mill instead of jet milling. This is clearly shown in the pictures from the Annexes, showing the batch material in the form of small glass particles before jet milling.

[0060] Another filler material commonly used in combination with thermoplastics is wood fiber. The best approach to checking if the material actually increases mixing is to mix the material with high viscosity and poor flow properties with a high density polypropylene material containing inorganic material and wood fiber, which is compressible and organic. The reason why it is significant is that inorganic and organic materials are difficult to mix.

[0061] The factor limiting the extrusion of polymer-wood composites is the "edge effect" when the material exhibits a Christmas-like effect on the edges. In some cases, this Christmas-like effect results from improper mixing and resistance of the material which, when leaving the extruder, extends into the nozzle, which is caused by the interactions of the boundary layer producing rough edges. To avoid this problem, lubricants are commonly added to the composition in the industry. Lubricants facilitate the flow of material over the boundary layer, which allows the flow speed to increase by increasing the number of rotations of the extruder screws per minute until the edge effect occurs, indicating the maximum flow rate of the material being processed.

Experience No. 1

Base composition expressed as percentage by weight [0062]

3% lubricant: zinc stearate and ethylene bis-stearamide wax 7% talc: Nicron 403 from Rio Tinto

41% thermoplastic: HDPE with a MFI (melt index) of 0.5 and a density of 0.953

49% wood-filler: commercial grade 60 mesh pine purchased from American Wood Fibers [0063] The materials were dry mixed using a 4-foot-diameter tumbler and 1.5-foot tumbler for 5 minutes prior to loading.

[0064] The extruder was a 35 mm conical, counter-rotating, twin screw extruder with an L / D of 23.

[0065] The process temperature was 320 ° F and was constant in all runs.

[0066] Two other materials were used and added to the base composition to prove the concept. The inert, hard fillers were:

1. potassium sodium aluminosilicate (volcanic glaze), which is a micrometer powder used as a plastic flow modifier to increase the yield, as well as to obtain improved mixing properties of additives. 800 mesh solid material with a hardness of 5.5 on the Mohs hardness scale (Rheolite 800 powder); and

2. Expanded perlite is a naturally occurring silicate rock used mainly in construction products, as an insulator in masonry, in light concrete and as food additives. Porous material 500 mesh with a hardness of 5.5 Mohs scale.

Experiment No. 2 [0067]

Maximum flow rate of the base material before the edge effect occurs at 19 revolutions per minute = 13.13 The maximum flow velocity before the edge effect occurs with 0.5% potassium sodium aluminosilicate at 22 revolutions per minute = 15.75, overall increase in flow speed 19.9% ​​or around 20%

1% at 22 revolutions per minute = 19.5 and a general increase in flow velocity of 48.5% effect of perlite addition on extrusion

The maximum flow rate of the base material before the edge effect occurs at 19 revolutions per minute = 13.13

Experience No. 3

Maximum flow rate using pearlite [0068] Experiment 3 results can be found in FIG. 2.

8%, 45 rpm = 21.13, overall increase in flow speed 60.9%

16%, 45 revolutions per min = 21.13, overall increase in flow velocity 44.7%

25%, 45 rpm = 21.13, overall increase in flow rate 5.33%

33%, 45 rpm = 21.13, overall increase in flow rate 16.1 [0069] The reason for choosing a high percentage of perlite was to avoid the possibility that this material would only be a filler. Edge effects for three-dimensional knife blade particles interacting with the boundary layer even at 33% still showed improvement by 16% compared to the base material. The material flow rate could be higher, but the extruder speed per minute was limited to 45 and the material was fed by hand, which is why we believe that at 25% the flow rate decreased due to the difficulty in feeding such light material for the first time, as we stated having reached 33%.

Experience No. 4

Effect of wood on flow velocity [0070] Experiment results 4 can be found in FIG. 4.

[0071] The maximum flow rate of the base material prior to the edge effect at 25 rpm = 17.68 was maintained a constant concentration of pearlite at an initial level of 2%

52%, 45 rpm = 27.60, overall increase in flow speed 60.9%

59%, 45 rpm = 26.25, overall increase in flow speed 48.7%

64%, 45 rpm = 17.00, overall increase in flow rate 36%

69%, 45 rpm = 24.33, overall increase in flow rate 37%,

74%, 30 rpm = 19.46, overall increase in flow rate 10%. The reason why this test was chosen was that when the inorganic material load is increased with a light organic filler, the edge effects appear very quickly. Again, the maximum flow rate was not achieved because the maximum speed was used up to 74%, when the speed per minute had to be reduced to 30 to prevent the edge effect. In the extrusion process, the compressible fibers act as broom strokes along the boundary layer. Wood fiber is a compressible filler whose density varies from 0.04 g / cm to 1.2 g / cm after extrusion at the wall, which can lead to the encapsulation of these hard particles in the boundary layer and their permanent removal.

[0073] It has been verified that this material functions in the boundary layer and is self-cleaning. On the first day of the test, we passed the materials in the order shown in the charts. On the second day of the test carried out before the experiment with the wood filler under the same conditions, with the same materials and weather conditions, the base material showed a significant increase in the flow velocity.

[0074] Day one, maximum flow rate of the base material before the edge effect occurred at 19 rpm = 13,13 Day two, maximum flow rate of the base material before the edge effect occurred at 25 rpm = 17.68, with a general an increase of 34.6%. This was caused by the polishing of the inside of the device by the high perliter used on the first day, ensuring the self-cleaning of the boundary layer. This polished surface on the second day should have had a negative impact on the kinetic mixing experience at the boundary layer because the boundary layer was reduced or thinner due to the fact that the coefficient of friction induced by resistance on the polished surface is smaller. Means,

[0075] Particles providing kinetic mixing at the boundary layer can be introduced in the industry in various ways. For example, on the plastics market:

• Particles can be introduced into the granules by the plastic producer and sold as plastic to increase production.

• Particles can be introduced into colored granules by pigment suppliers and sold as a fast dispersing granular pigment.

• The particles can be incorporated as granules with inorganic or organic filler and sold as a self-moistening filler.

• The particles can be incorporated into dry powders and sold as self-moistening powders, such as flame retardants, fungicides and fillers, etc.

• The particles can be introduced into the liquid as a dispersant for liquid dyes, plasticizers, UV stabilizers, blowing agents and lubricants, etc.

[0076] Particles providing kinetic mixing in the boundary layer can be used by the paint and varnish industry:

• Particles can be incorporated into the paint to increase the dispersion properties of pigments, plasticizers, fungicides, UV stabilizers, flame retardants, etc.

The particles can be incorporated into the pigments at mixing points on order from paint shops to facilitate the dispersion of the material present in a small amount and to obtain the same color through better mixing and dispersing properties.

• Particles can be incorporated into dry powders from manufacturers of additives to aid in the dispersion of flame retardants, fillers, etc.

The particles may be introduced into aerosol containers to increase mixing along walls that promote mixing in the boundary layer.

• The particles can be incorporated into binary mixtures to ensure better mixing on the surface or mixing in the boundary layer and the boundary layer at the liquid-liquid interface when mixing urethanes, urea and epoxides, etc.

• Particles can be incorporated into a lubricant kit used to clean spray equipment by continuously recirculating chemical cleaning agents.

[0077] Particles providing kinetic mixing in the boundary layer can be used by the lubricant industry.

These particles can be incorporated into the oils to provide a better surface flow by reducing the friction zone in the boundary layer giving better wetting without a drop in temperature in this addition, as it is a solid particle: oils for external use and oils for internal use in cars, boats , airplanes, bicycles, etc.

[0079] The particles can be incorporated into oils as general household cleaners, which allows an even distribution of the oil in the form of a thinner layer which, with less likelihood, will become viscous over time as the layer is thinner.

[0080] The particles can be introduced into brake fluids, hydraulic fluids of all types to achieve a better reaction to fluid movement, because under pressure the boundary layer is shifted by a kinetic movement.

[0081] Particles may be incorporated into fuel additives, providing better fuel utilization as well as self-cleaning effect, due to the interaction of particles in the boundary layers along the entire flow path in the combustion system, including the exhaust system, where the particles still have a cleaning effect.

[0082] Particles can be added as a lubricant and dispersants directly in the refinery. Particles will not only support lubrication in cars and system cleaning, but also particles will increase the life of gasoline pumps in terms of the accumulation of sludge material in the boundary layers.

[0083] Particles providing kinetic mixing in the boundary layer can be used to improve flow properties. Most of the liquid materials flowing through pipes, the pump system and / or processing equipment are subjected to a boundary layer interaction based on a resistance coefficient independent of the surface geometry, and this technique can reduce resistance by favoring kinetic mixing in the boundary layer with the self-cleaning effect. This allows the pipes and processing equipment to work at the optimum level.

[0084] Particles providing kinetic mixing at the boundary layer can be used to increase heat exchange. Because the boundary layer is subject to kinetic movement and is no longer a stationary zone for heat exchange of the fluid, it increases the heat transfer properties on both sides. Now this stationary boundary layer has changed into a zone with forced convection not only on one side, but on both sides, fluid-liquid and fluid-surface.

[0085] Particles providing kinetic mixing at the boundary layer can be used in the food, pharmaceutical and agricultural industries. Because selected particles can be approved for use in food and medicine, food processing can be improved, from production facilities to packaging and processing equipment can mix ingredients more accurately.

[0086] The present invention is therefore well adapted to achieving the objectives and achieving the effects and benefits mentioned above, as well as those associated with them.

While the present preferred embodiments have been described for the purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed by the spirit of the present invention as defined in the claims.

ATTACHMENT 1

<td>Image no</td><td>Title</td>

<td>1</td><td>200 Novacite Processed 1</td>

<td>2</td><td>200 Novacite Processed 2</td>

<td>3</td><td>200 Novacite Processed 3</td>

<td>4</td><td>200 Novacite Unprocessed 1</td>

<td>5</td><td>200 Novacite Unprocessed 2</td>

<td>6</td><td>200 Novacite Unprocessed 3</td>

<td>7</td><td>Ash 1</td>

<td>8</td><td>Ash 2</td>

<td>9</td><td>Ash 3</td>

<td>10</td><td>Pumice Hess grade 2 Processed 1</td>

<td>11</td><td>Pumice Hess grade 2 Processed 2</td>

<td>12</td><td>Pumice Hess species 2 Processed 3</td>

<img file="PL2365993T3_D0001.tif" />

<img file="PL2365993T3_D0002.tif" />

<img file="PL2365993T3_D0003.tif" />

<img file="PL2365993T3_D0004.tif" />

<img file="PL2365993T3_D0005.tif" />

<img file="PL2365993T3_D0006.tif" />

<img file="PL2365993T3_D0007.tif" />

<img file="PL2365993T3_D0008.tif" />

icc.V SpotMagn Det WD | -1 50jum .00kV6.0 1000x SE 17.8

<img file="PL2365993T3_D0009.tif" />

<img file="PL2365993T3_D0010.tif" />

<img file="PL2365993T3_D0011.tif" />

<img file="PL2365993T3_D0012.tif" />

Acc.V SpotMagn Det WD | -1 20μηι

3.00 kV 6.0 2500x TLD 19.4

ANNEX 2

<td>Image no</td><td>Title</td>

<td>1</td><td>Pumice Hess grade 2 Unprocessed 2</td>

<td>2</td><td>Pumice Hess grade 2 Unprocessed 3</td>

<td>3</td><td>Pumice Hess grade 2 Unprocessed 4</td>

<td>4</td><td>Mineral from Kansas 1</td>

<td>5</td><td>Mineral from Kansas 2</td>

<td>6</td><td>Mineral from Kansas 3</td>

<td>7</td><td>Pumice Grade 3 Processed 1</td>

<td>8</td><td>Pumice Grade 3 Processed 2</td>

<td>9</td><td>Pumice Grade 3 Processed 3</td>

<td>10</td><td>Pumice Grade 3 Unprocessed 1</td>

<td>11</td><td>Pumice Grade 3 Unprocessed 2</td>

<td>12</td><td>Pumice Grade 3 Unprocessed 3</td>

<td>13</td><td>Pumice Grade 3 Unprocessed 4</td>

<td>14</td><td>Fine-grained Pumice Pearlite 2</td>

<td>15</td><td>Fine-grained Pumice Pearlite 3</td>

<td>16</td><td>Fine-grained Pumice Pearlite 1-2 series</td>

<td>17</td><td>Fine-grained Pumice Pearlite series 1-3</td>

<img file="PL2365993T3_D0013.tif" />

(cc.V SpotMagn Det WD | -1 50μηι .00kV6.0 1000x TLD18.9

<img file="PL2365993T3_D0014.tif" />

Acc.V Spot Magu Det WD | -1 20 ^ m

3.00 kV 6.0 2500x TLD 18.9

<img file="PL2365993T3_D0015.tif" />

, cc.V SpotMagn Det WD | -1 200μηι .00 kV 6.0 150x TLD 18.9

<img file="PL2365993T3_D0016.tif" />

<img file="PL2365993T3_D0017.tif" />

tec.V Spot Magn .00kV6.0 1000x

<img file="PL2365993T3_D0018.tif" />

icc.V SpotMagn Det WD .00kV6.0 2500x SE 18.0

<img file="PL2365993T3_D0019.tif" />

uirfoo

<img file="PL2365993T3_D0020.tif" />

Acc.V SpotMagn Det WD | -1 50μηι

3.00 kV 6.0 1000x SE 19.2

<img file="PL2365993T3_D0021.tif" />

<img file="PL2365993T3_D0022.tif" />

&lt;cc.V SpotMagn Det WD | -1 100 μηι .00 kV 4.0 500x SE 18.7

<img file="PL2365993T3_D0023.tif" />

Acc.V Spot Magn Det WD | -1 50μηι

3.00 kV 4.0 1000x SE 18.7

<img file="PL2365993T3_D0024.tif" />

ιο μηι

<img file="PL2365993T3_D0025.tif" />

<img file="PL2365993T3_D0026.tif" />

lcc.V SpotMagn Det WD | -1 50μηι .00 kV 6.0 1000x TLD 19.3

<img file="PL2365993T3_D0027.tif" />

<img file="PL2365993T3_D0028.tif" />

<img file="PL2365993T3_D0029.tif" />

ANNEX 3

<td>Image no</td><td>Title</td>

<td>1</td><td>Fine-grained Pumice Pearlite 1</td>

<td>2</td><td>Fine-grained Pumice Pearlite 1-1 series</td>

<td>3</td><td>Silbro 27.M 1</td>

<td>4</td><td>Silbro 27.M 2</td>

<td>5</td><td>Silbro 27.M 3</td>

<td>6</td><td>Strategic material 1</td>

<td>7</td><td>Strategic material 2</td>

<td>8</td><td>Strategic material 3</td>

<td>9</td><td>Strategic material 4</td>

<td>10</td><td>Strategic material series 5 3</td>

<td>11</td><td>Strategic material series 5 1</td>

<td>12</td><td>Strategic material series 5 2</td>

<td>13</td><td>White Rock 1</td>

<td>14</td><td>White Rock 2</td>

<td>15</td><td>White Rock 3</td>

<img file="PL2365993T3_D0030.tif" />

<img file="PL2365993T3_D0031.tif" />

icc.V SpotMagn Det WD | -1 100μηι .00 kV 6.0 500x TLD 19.3

<img file="PL2365993T3_D0032.tif" />

'Acc.V SpotMagn Det WD | -1 100μηι ^ 3.00 kV 6.0 500x TLD 17.8

<img file="PL2365993T3_D0033.tif" />

<img file="PL2365993T3_D0034.tif" />

Det WD

II

<img file="PL2365993T3_D0035.tif" />

tcc.V Spot Magn Det WD | -1 100 jum .00kV6.0 500x SE 17.7

<img file="PL2365993T3_D0036.tif" />

icc.V SpotMagn Det WD | -1 50 μιτι .00 kV 6.0 1000x SE 17.7

<img file="PL2365993T3_D0037.tif" />

icc.V SpotMagn Det WD | -1 200jum .00kV6.0 150x SE 17.7

<img file="PL2365993T3_D0038.tif" />

<img file="PL2365993T3_D0039.tif" />

<img file="PL2365993T3_D0040.tif" />

tcc.V SpotMagn Det WD | -1 100 .00kV6.0 500x SE 19.3

<img file="PL2365993T3_D0041.tif" />

<img file="PL2365993T3_D0042.tif" />

Aec.V SpotMagn Det WD | -1 100pn

5.00 kV 6.0 500x TLD 17.8

<img file="PL2365993T3_D0043.tif" />

icc.V SpotMagn Det WD | -1 50 μιτι .00 kV 6.0 1000x TLD 17.8

<img file="PL2365993T3_D0044.tif" />