US4247498A
Expired / Lapsed
US
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Methods for making microporous products
Assignee: Akzona Inc
•
Filing: 1978-11-24
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Granted: 1981-01-27
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Expires: 1998-11-24
Abstract
Abstract Novel microporous polymers in forms ranging from films to blocks and intricate shapes from synthetic thermoplastic polymers, such as, olefinic, condensation, and oxidation polymers, are disclosed. In one embodiment the microporous polymers are characterized by a relatively homogeneous, three-dimensional cellular structure having cells connected by pores of smaller dimension. Also disclosed is a process for making microporous polymers from such thermoplastic polymers by heating a mixture of the polymer and a compatible liquid to form a homogeneous solution, cooling said solution under non-equilibrium thermodynamic conditions to initiate liquid-liquid phase separation, and continuing said cooling until the mixture achieves substantial handling strength. Also disclosed are microporous polymer products which contain relatively large amounts of functionally useful liquids and behave as solids.
Inventors
- 👤 Anthony J. Castro
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 05:26
CPC Classifications
C; C09; C09K; C09K3/00; C09K3/14; C09K3/149; A; A01; A01N; A01N25/00; A01N25/08; A01N25/10; B; B41; B41N; B41N7/00; C08; C08J; C08J9/00; C08J9/28; B41N2207/00; B41N2207/02; B41N2207/14; C08J2201/00; C08J2201/04; C08J2201/052; C08J2201/054; C08J2201/0542; C08J2201/0543; C08J2201/0545; C08J2201/0546
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
109 words
A method of preparing a relatively homogeneous, isotropic, three-dimensional microporous polymer structure comprising heating a mixture of a synthetic thermoplastic polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, allowing said solution to assume a desired shape, cooling said solution in said desired shape at a rate and to a temperature sufficient to initiate thermodynamic, non-equilibrium liquid-liquid phase separation, continuing cooling to form a solid, and removing at least a substantial portion of the liquid from the resulting solid to form the microporous polymer structure.
Claim 2
Independent Claim
109 words
A method of preparing a relatively homogeneous, isotropic, three-dimensional microporous polymer structure comprising heating a mixture of a synthetic thermoplastic polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, allowing said solution to assume a desired shape, cooling said solution in said desired shape at a rate and to a temperature sufficient to initiate thermodynamic, non-equilibrium liquid-liquid phase separation, continuing cooling to form a solid, and removing at least a substantial portion of the liquid from the resulting solid to form the microporous polymer structure.
Claim 3
Dependent Claim
13 words
The method of claim 1 wherein essentially all of the liquid is removed.
Claim 4
Dependent Claim
20 words
The method of claim 1 wherein said mixture comprises from about 10 to about 90% by weight of the liquid.
Claim 5
Dependent Claim
18 words
The method of claim 1 wherein the homogeneous solution is cast into a film as it is cooled.
Claim 6
Dependent Claim
21 words
The method of claim 1 wherein the homogeneous solution is cast into the form of a block as it is cooled.
Claim 7
Dependent Claim
16 words
The method of claim 5 wherein the block has a thickness up to about 21/2 inches.
Claim 8
Dependent Claim
36 words
The method of claim 1 wherein the homogeneous liquid, as it is cooled, is cast onto a substrate which forms an essentially non-cellular skin on the surface of the microporous polymer in contact with said substrate.
Claim 9
Dependent Claim
14 words
The method of claim 7 wherein the skin formed is relatively impervious to liquids.
Claim 10
Dependent Claim
12 words
The method of claim 1 wherein the polymer is a non-acrylic polyolefin.
Claim 11
Dependent Claim
48 words
The method of claim 1 wherein the polymer is selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene, polystyrene, polyvinylchloride, acrylonitrile-butadiene-styrene terpolymers, styrene-acrylonitrile copolymers, styrene butadiene copolymers, poly (4-methyl-pentene-1), polybutylene, polyvinylidene chloride, polyvinyl butryal, chlorinated polyethylene, ethylenevinyl acetate copolymers, polyvinyl acetate and polyvinyl alcohol.
Claim 12
Dependent Claim
12 words
The method of claim 1 wherein the polymer is an acrylic pololefin.
Claim 13
Dependent Claim
26 words
The method of claim 1 wherein the polymer is selected from the group consisting of polymethyl-methacrylate, polymethyl-acrylate, ethylene-acrylic acid copolymers, and ethylene-acrylic acid metal salt copolymers.
Claim 14
Dependent Claim
12 words
The method of claim 1 wherein the polymer is an oxidation polymer.
Claim 15
Dependent Claim
11 words
The method of claim 1 wherein the polymer is polyphenylene oxide.
Claim 16
Dependent Claim
30 words
The method of claim 1 wherein the polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, Nylon 6, Nylon 11, Nylon 13, Nylon 66, polycarbonates and polysulfone.
Claim 17
Independent Claim
104 words
A method of preparing a relatively homogeneous, isotropic, three-dimensional microporous polymer structure comprising heating a mixture of a polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, forming at substantially the same time a plurality of liquid droplets of substantially the same size in a continuous liquid polymer phase by cooling the solution, continuing said cooling to solidify the polymer, and removing at least a substantial portion of the liquid from the resulting solid to form the cellular polymer structure.
Claim 18
Independent Claim
104 words
A method of preparing a relatively homogeneous, isotropic, three-dimensional microporous polymer structure comprising heating a mixture of a polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, forming at substantially the same time a plurality of liquid droplets of substantially the same size in a continuous liquid polymer phase by cooling the solution, continuing said cooling to solidify the polymer, and removing at least a substantial portion of the liquid from the resulting solid to form the cellular polymer structure.
Claim 19
Dependent Claim
13 words
The method of claim 16 wherein essentially all of the liquid is removed.
Claim 20
Dependent Claim
20 words
The method of claim 16 wherein said mixture comprises from about 10 to about 90% by weight of the liquid.
Claim 21
Dependent Claim
18 words
The method of claim 16 wherein the homogeneous solution is cast into a film as it is cooled.
Claim 22
Dependent Claim
21 words
The method of claim 16 wherein the homogeneous solution is cast into the form of a block as it is cooled.
Claim 23
Dependent Claim
16 words
The method of claim 20 wherein the block has a thickness up to about 21/2 inches.
Claim 24
Dependent Claim
36 words
The method of claim 20 wherein the homogeneous liquid, as it is cooled, is cast onto a substrate which forms an essentially non-cellular skin on the surface of the microporous polymer in contact with said substrate.
Claim 25
Dependent Claim
14 words
The method of claim 22 wherein the skin formed is relatively impervious to liquids.
Claim 26
Dependent Claim
12 words
The method of claim 16 wherein the polymer is a non-acrylic polyolefin.
Claim 27
Dependent Claim
48 words
The method of claim 16 wherein the polymer is selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene polystyrene, polyvinylchloride, acrylonitrile-butadiene-styrene terpolymers, styrene-acrylonitrile copolymers, styrene butadiene copolymers, poly (4-methyl-pentene-1), polybutylene, polyvinylidene chloride, polyvinyl butyral, chlorinated polyethylene, ethylenevinyl acetate copolymers, polyvinyl acetate and polyvinyl alcohol.
Claim 28
Dependent Claim
12 words
The method of claim 16 wherein the polymer is an acrylic polyolefin.
Claim 29
Dependent Claim
26 words
The method of claim 16 wherein the polymer is selected from the group consisting of polymethyl-methacrylate, polymethyl-acrylate, ethylene-acrylic acid copolymers, and ethylene-acrylic acid metal salt copolymers.
Claim 30
Dependent Claim
12 words
The method of claim 16 wherein the polymer is an oxidation polymer.
Claim 31
Dependent Claim
11 words
The method of claim 16 wherein the polymer is polyphenylene oxide.
Claim 32
Dependent Claim
30 words
The method of claim 16 wherein the polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, Nylon 6, Nylon 11, Nylon 13, Nylon 66, polycarbonates and polysulfone.
Claim 33
Independent Claim
168 words
A method of preparing a relatively homogeneous isotropic, three-dimensional microporous cellular polymer structure comprising heating a mixture of a polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, forming at substantially the same time a plurality of liquid droplets of substantially the same size in a continuous liquid polymer phase by cooling the solution, continuing cooling to solidify the polymer, at least partially displacing the compatible liquid with a member selected from the group consisting of an intermediate displacing liquid and a functionally useful liquid selected from the group consisting of lubricants, surfactants, slip agents, moth repellents, pesticides, plasticizers, medicinals, fuel additives, polishing agents, stabilizers, insect repellents, fragrances, flame retardants, antioxidants, odor masking agents, antifogging agents and perfumes, with the proviso that when an intermediate displacing liquid is used the intermediate displacing liquid is thereafter at least partially displaced with a functionally useful liquid.
Claim 34
Independent Claim
168 words
A method of preparing a relatively homogeneous isotropic, three-dimensional microporous cellular polymer structure comprising heating a mixture of a polymer selected from the group consisting of olefinic polymers, condensation polymers, oxidation polymers, and blends thereof, and a compatible liquid to a temperature and for a time sufficient to form a homogeneous solution, forming at substantially the same time a plurality of liquid droplets of substantially the same size in a continuous liquid polymer phase by cooling the solution, continuing cooling to solidify the polymer, at least partially displacing the compatible liquid with a member selected from the group consisting of an intermediate displacing liquid and a functionally useful liquid selected from the group consisting of lubricants, surfactants, slip agents, moth repellents, pesticides, plasticizers, medicinals, fuel additives, polishing agents, stabilizers, insect repellents, fragrances, flame retardants, antioxidants, odor masking agents, antifogging agents and perfumes, with the proviso that when an intermediate displacing liquid is used the intermediate displacing liquid is thereafter at least partially displaced with a functionally useful liquid.
Claim 35
Dependent Claim
13 words
The method of claim 31 wherein said compatible liquid is essentially completely displaced.
Claim 36
Dependent Claim
16 words
The method of claim 32 wherein said compatible liquid is displaced by an intermediate displacing liquid.
Claim 37
Dependent Claim
19 words
The method of claim 33 wherein said intermediate displacing liquid is substantially completely displaced by said functionally useful liquid.
Claim 38
Dependent Claim
12 words
The method of claim 31 wherein the polymer is an olefinic polymer.
Claim 39
Dependent Claim
12 words
The method of claim 31 wherein the polymer is a condensation polymer.
Claim 40
Dependent Claim
12 words
The method of claim 31 wherein the polymer is an oxidation polymer.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-01-27 | 1984-07-28 | 1985-01-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-01-27 | 1988-07-28 | 1989-01-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-01-27 | 1992-07-28 | 1993-01-27 | $7700.00 | Window Closed / Lapsed |