41
*STTR
Project: Novel Polymer Nanocomposite Processing--ALD
NanoSolution, Inc., 11711 Chase
Court, Westminster, CO
80020;
720-840-1610, www.aldnanosolutions.com
Dr.
Karen J. Buechler, Principal Investigator, buechler@aldnanosolutions.com
Mr.
Robert Morgan, Business Official, rmorgan@aldnanosolutions.com
DOE
Grant No. DE-FG02-03ER86157
Amount:
$750,000
Research Institution
University
of
Colorado
Boulder, CO
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. As
a starting point for the nanocomposite formation, the pre-dispersed ceramic at
the micron lengthscale will be intimately dispersed within the matrix.
In Phase I, LDPE (low density polyethylene) and HDPE (high density
polyethylene) polymer particles were coated with conformal, well-bonded, alumina
nanocoatings of varying thicknesses (between 0.6 and 10 nm), the nanocoated
polymer particles were extruded into test samples, and test samples were
analyzed by the microscopy. The
analysis revealed disperse micron-sized aggregates of submicron alumina
particles. A pilot plant was
preliminarily designed and full scale costs were estimated to be less than $1/kg
for the nanocoating process. Phase
II will develop and optimize pilot scale facilities for coating on kilogram
scales, required to fully test the materials for barrier properties.
Other polymeric substrates will be investigated to broaden the range of
applications for this novel nanocoating technology.
Commercial
Applications and Other Benefits as
described by awardee: The
process should be easily placed 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 the extruder for making
pellets. Applications include the
replacement of metals and co-polymers with more easily recycled and lightweight
nanocomposites.