Nanocomposite master batch composition and method of manufacture

1. A method for production of a polymer nanocomposite master batch, comprising:

dissolving a polymer in a solvent to produce a polymer solution;

adding a dispersing aide to the polymer solution;

further combining a nanomaterial filler to the polymer solution to produce a dissolved composite solution; and

causing the precipitation of the dissolved composite solution to produce a nanocomposite master batch.

2. The method according to claim 1 , wherein said filler material includes halloysite clay comprising tubules.

3. The method according to claim 1 , wherein said filler material is selected from the group consisting of:

clays;

nanoclays;

nanoclays comprising tubules;

layered inorganic clay material;

talc;

carbon black;

cellulose fibers;

silica; and

alumina.

4. The method according to claim 3 , wherein said layered inorganic clay material includes smectite, kaolin, boulangerite, and imogolite.

5. The method according to claim 1 , wherein said polymer is selected from the group consisting of: themoplastics, thermoplastic polymers, and blends thereof, co-polymers, thermosets, and elastomers.

6. The method according to claim 5 , wherein said themoplastics are selected from the group consisting of: Polyolefins, including Polypropylene, Polyethylene, and the like; Polyaramide; Polyarylamide; Polycarbonate; Polystyrene; Polyvinyl chloride; Styrene Acrylonitrile; Acrylonitrile Butadiene Styrene; Acetal; Polysulfone; Polybutylene Terephthalate; Polyethylene Terephthalate; Polyethylene; Thermoplastic Polyurethane Elastomer; Polyphenylene Sulfide; Polyether Sulfone; Polyphenylene Oxide; Vinyl polymers; Acrylic polymers; Polyurethanes; Polyetherimide; Polyetheretherketone; Polyetherketone; Polymethylpentene; Perfluoroalkoxy; Ethylene Tetrafluroethylene; Polyvinylidene Fluoride; Fluorinated Ethylrene Propylene; Liquid Crystal Polymers; Polyphthalamide; Thermoplastic polyimide; and polyamide.

7. The method according to claim 1 , wherein said dispersing agent is selected from the group consisting of: quaternary amines, silanes, titanates, organic acids, coupling agents and block co-polymers.

8. The method of claim 7 wherein said quaternary amines include quat compounds.

9. The method according to claim 1 , further comprising the step of compounding the nanocomposite master batch with neat polymer to form a nanocomposite material.

10. A method of making a polymer nanocomposite, comprising:

dissolving a polymer in a solvent to produce a polymer solution;

adding a dispersing aide to the polymer solution;

further combining at least one filler material to the polymer solution to produce a dissolved composite solution; and

causing the precipitation of the dissolved composite solution to produce a nanocomposite material.

11. The method according to claim 10 , wherein said filler material is selected from the group consisting of:

clays;

talc;

carbon black;

cellulose fibers;

silica; and

alumina.

12. The method according to claim 11 , wherein said clays include a layered inorganic clay material selected from the group consisting of: smectite, kaolin, boulangerite, and imogolite.

13. The method according to claim 10 , wherein said filler material includes halloysite.

14. The method according to claim 10 , wherein said filler material includes halloysite clay comprising tubules.

15. The method according to claim 10 , wherein said polymer is selected from the group consisting of: themoplastics; thermoplastic polymers, and blends thereof; co-polymers; thermosets; and elastomers.

16. The method according to claim 15 , wherein said themoplastics are selected from the group consisting of: Polyolefins, including Polypropylene, Polyethylene, and the like; Polyaramide; Polyarylamide; Polycarbonate; Polystyrene; Polyvinyl chloride; Styrene Acrylonitrile; Acrylonitrile Butadiene Styrene; Acetal; Polysulfone; Polybutylene Terephthalate; Polyethylene Terephthalate; Polyethylene; Thermoplastic Polyurethane Elastomer; Polyphenylene Sulfide; Polyether Sulfone; Polyphenylene Oxide; Vinyl polymers; Acrylic polymers; Polyurethanes; Polyetherimide; Polyetheretherketone; Polyetherketone; Polymethylpentene; Perfluoroalkoxy; Ethylene Tetrafluroethylene; Polyvinylidene Fluoride; Fluorinated Ethylrene Propylene; Liquid Crystal Polymers; Polyphthalamide; Thermoplastic polyimide; and polyamide.

17. The method according to claim 10 , wherein said dispersing agent is selected from the group consisting of: quaternary amines; silanes; titanates; organic acids; coupling agents; and block co-polymers.

18. The method according to claim 10 , further comprising the step of forming the nanocomposite material.

19. The method according to claim 18 , wherein forming the nanocomposite is accomplished using a forming process selected from the group consisting of: molding; compounding; extrusion; co-extrusion; rotomolding; thermoforming; vacuum forming; calendaring; matched-die molding; hand lay-up; filament winding; casting; and forging.