Method of compounding thermo-plastic polymeric materials and fillers

Claim 1

The method of compounding thermoplastic polymeric material and filler, comprising the steps of: a. mixing particles of thermoplastic polymeric material with particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material while melting surface portions of the particles of polymeric material, whereby the filler is blended with the melting surface portions of said polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the polymeric particles by the mixing action; and, b. continuing both the mixing of the particles of thermoplastic polymeric material with the filler and the melting of surface portions of said particles with the resulting blending of the melting surface portions and filler and the removal of the resultant blend of melted polymeric material and filler from said particles of polymeric material to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polyeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of filler adhesively embraced by a film-like mass of polymeric material.

Claim 2

The method of compounding thermoplastic polymeric material and filler, comprising the steps of: a. mixing particles of thermoplastic polymeric material with particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material while melting surface portions of the particles of polymeric material, whereby the filler is blended with the melting surface portions of said polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the polymeric particles by the mixing action; and, b. continuing both the mixing of the particles of thermoplastic polymeric material with the filler and the melting of surface portions of said particles with the resulting blending of the melting surface portions and filler and the removal of the resultant blend of melted polymeric material and filler from said particles of polymeric material to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polyeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of filler adhesively embraced by a film-like mass of polymeric material.

Claim 12

The method of compounding thermoplastic polymeric material with filler, comprising the steps of: a. mixing with high energy and high velocity particles of thermoplastic polymeric material and particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material, and heating the surface portions of the particles of polymeric material to at least approximately the melting temperature of the polymeric material and thereby melting said surface portions of the polymeric particles whereby the filler is blended with the melting surface portions of the polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the particles by the attrition effects of the mixing action; and, b. continuing the high energy and high velocity mixing action with the heating and melting surface portions of said particles of polymeric material and the resulting blending of the melted surface portions and filler and the removal of the resultant blend of melted polymeric material and filler to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 13

The method of compounding thermoplastic polymeric material with filler, comprising the steps of: a. mixing with high energy and high velocity particles of thermoplastic polymeric material and particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material, and heating the surface portions of the particles of polymeric material to at least approximately the melting temperature of the polymeric material and thereby melting said surface portions of the polymeric particles whereby the filler is blended with the melting surface portions of the polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the particles by the attrition effects of the mixing action; and, b. continuing the high energy and high velocity mixing action with the heating and melting surface portions of said particles of polymeric material and the resulting blending of the melted surface portions and filler and the removal of the resultant blend of melted polymeric material and filler to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 20

The method of compounding thermoplastic polyolefin polymeric material and filler, comprising the steps of: a. mixing particulate thermoplastic ethylene polymeric material of at least one member selected from the group consisting of polyethylene, blends of polyethylene and other polymers, and copolymers of ethylene and other polymerizable materials, and particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the ethylene polymeric material while melting surface portions of the particles of ethylene polymeric material, whereby the filler is blended with the melting surface portions of said particles of ethylene polymeric material and the resultant blend of the melted material and filler is removed from the remaining portions of the particles of ethylene polymeric material by the mixing action; and, b. continuing the mixing of the particulate thermoplastic ethylene polymeric material with the filler and the melting of surface portions of said particles with the resulting blending of the melting surface portions and filler and the removing of the resultant blend of melted material and filler to effect a progressive melting and diminution of the said particles of ethylene polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said ethylene polymeric material and filler are substantially completely compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 21

The method of compounding thermoplastic polyolefin polymeric material and filler, comprising the steps of: a. mixing particulate thermoplastic ethylene polymeric material of at least one member selected from the group consisting of polyethylene, blends of polyethylene and other polymers, and copolymers of ethylene and other polymerizable materials, and particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the ethylene polymeric material while melting surface portions of the particles of ethylene polymeric material, whereby the filler is blended with the melting surface portions of said particles of ethylene polymeric material and the resultant blend of the melted material and filler is removed from the remaining portions of the particles of ethylene polymeric material by the mixing action; and, b. continuing the mixing of the particulate thermoplastic ethylene polymeric material with the filler and the melting of surface portions of said particles with the resulting blending of the melting surface portions and filler and the removing of the resultant blend of melted material and filler to effect a progressive melting and diminution of the said particles of ethylene polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said ethylene polymeric material and filler are substantially completely compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 30

The method of compounding thermoplastic polymeric material and filler, comprising the steps of: a. mixing particles of thermoplastic polymeric material with particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material in a high velocity impeller mixer while melting surface portions of the particles of polymer material, whereby the filler is blended with the melting surface portions of said polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the polymeric particles by the mixing action; and, b. continuing both the mixing of the particles of thermoplastic polymeric material with the filler in the high velocity impeller mixer and the melting of the surface portions of said particles with the resulting blending of the melting surface portions and filler and the removal of the resultant blend of the melted polymeric material and filler from said particles of polymeric material to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded with said compound comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 31

The method of compounding thermoplastic polymeric material and filler, comprising the steps of: a. mixing particles of thermoplastic polymeric material with particulate filler proportioned in amounts ranging from at least 5 to about 200 parts by weight of the filler per 100 parts by weight of the polymeric material in a high velocity impeller mixer while melting surface portions of the particles of polymer material, whereby the filler is blended with the melting surface portions of said polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the polymeric particles by the mixing action; and, b. continuing both the mixing of the particles of thermoplastic polymeric material with the filler in the high velocity impeller mixer and the melting of the surface portions of said particles with the resulting blending of the melting surface portions and filler and the removal of the resultant blend of the melted polymeric material and filler from said particles of polymeric material to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded with said compound comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 34

The method of compounding thermoplastic ethylene-containing polymeric material and filler, comprising the steps of: a. mixing with high energy and high velocity particles of ethylene-containing polymeric material of at least one member selected from the group consisting of polyethylene, blends of polyethylene and other polymers, and copolymers of ethylene and other polymerizable materials sized substantially within the range of approximately 2 to approximately 8 millimeters in diameter with particulate filler sized substantially within the range of approximately 149 microns to approximately 37 microns in diameter, said particles of polymeric material and filler being proportioned in amounts ranging from about 25 to about 200 parts by weight of filler per 100 parts by weight of polymeric material, in a high velocity impeller mixer, and heating the surface portions of the particles of ethylene-containing polymeric material to at least approximately the melting temperature of the polymeric material and thereby melting said surface portions of the polymeric particles whereby the filler is blended with the melting surface portions of the polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the particles by the attrition effects of the mixing action; and, b. continuing the high energy and high velocity mixing action in the high velocity impeller mixer with the heating and melting of surface portions of said particles of polymeric material and the resulting blending of the melted surface portions and filler and the removal of the resultant blend of melted polymeric material and filler to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.

Claim 35

The method of compounding thermoplastic ethylene-containing polymeric material and filler, comprising the steps of: a. mixing with high energy and high velocity particles of ethylene-containing polymeric material of at least one member selected from the group consisting of polyethylene, blends of polyethylene and other polymers, and copolymers of ethylene and other polymerizable materials sized substantially within the range of approximately 2 to approximately 8 millimeters in diameter with particulate filler sized substantially within the range of approximately 149 microns to approximately 37 microns in diameter, said particles of polymeric material and filler being proportioned in amounts ranging from about 25 to about 200 parts by weight of filler per 100 parts by weight of polymeric material, in a high velocity impeller mixer, and heating the surface portions of the particles of ethylene-containing polymeric material to at least approximately the melting temperature of the polymeric material and thereby melting said surface portions of the polymeric particles whereby the filler is blended with the melting surface portions of the polymeric particles and the resultant blend of the melted polymeric material and filler is removed from the remaining portion of the particles by the attrition effects of the mixing action; and, b. continuing the high energy and high velocity mixing action in the high velocity impeller mixer with the heating and melting of surface portions of said particles of polymeric material and the resulting blending of the melted surface portions and filler and the removal of the resultant blend of melted polymeric material and filler to effect a progressive melting and diminution of the said particles of polymeric material until greater than 50% of the particulate polymeric material has become expended by melting and at least a majority of greater than 50% of the filler has become substantially assimilated into the polymeric material whereby said polymeric material and filler are substantially compounded to a free flowing particulate form comprising discrete particles of the compounded blend of polymeric material and filler with said blend comprising fundamental units predominantly structured essentially of a stratified layer of the filler adhesively embraced by a film-like mass of polymeric material.