Novel Polymer Nanocomposite Processing

72212T03-I The uniform dispersion of nanoceramic filler particles within a polymer matrix, for producing high quality polymer/ceramic nanocomposites, is a very time-and energy-intensive process. The development of efficient methods for uniformly dispersing nanoceramic inclusions, which are well-adhered to the polymer throughout the polymer matrix, and for fabricating parts from such composites at low cost are significant challenges. This project will develop technology for achieving immediate and complete dispersion of the ceramic, by utilizing micron-sized polymer particles that have been individually pre-coated with a nanometers-thick ceramic layer. In Phase I, Atomic Layer Deposition (ALD) will be used to coat polymer particles with conformal, well-bonded, alumina nanocoatings of varying thicknesses (between 0.6 and 10 nm); the nanocoated polymer particles will be extruded into test samples; and the test samples will be analyzed by microscopy. The analysis will reveal the efficiency of the dispersion of nanoceramic inclusions in the polymer matrix as well as the size and shape of the inclusions. A pilot plant will be designed for Phase II, and a cost evaluation will be carried out for a commercial-scale plant. Commercial Applications and Other Benefits as described by awardee: The process should be amenable to easy placement in an existing production line for the millions of tons of polymers made by gas phase polymerization. The process would conveniently fit between an existing gas phase, fluidized bed, polymer particle synthesis process and pellet-making extrusion. Applications would include the replacement of metals and co-polymers with more easily recycled and lightweight nanocomposites