Patent ID: 6770340
Filing Date: 2004-08-03
Classification: B29B,B29C,Y10T

Abstract:
A method for the production of a multiphase composite material, wherein the composite material comprises a major phase component and at least one minor phase component arranged in a desired predefined morphological structure in which said major phase component and said at least one minor phase component have predefined size and shape characteristics the method comprising the steps of:supplying said major phase component to a chaotic mixer in a substantially continuous manner; supplying said at least one minor phase component to said chaotic mixer in a substantially continuous manner; chaotically mixing said major phase component with said at least one minor phase component within said chaotic mixer according to controlled mixing parameters such that said major phase component and said at least one minor phase component form an in-situ structured arrangement of predetermined and controllable morphology within said chaotic mixer and wherein at least one of the group consisting of said major phase component and said at least one minor phase component is in a substantially liquid state during mixing, and further, wherein the chaotically mixing step comprises a plurality of substantially discrete, controllable mixing stages of differing functionality to produce predetermined staged morphological changes with in the group consisting of said major phase component and said at least one minor phase component, and still further, wherein the controlling step includes selectively varying the shear rate in the chaotic mixer during the chaotically mixing step; continuously discharging said in-situ structured arrangement from the chaotic mixer in the form of a structured extrudate of controllable morphological character; controlling the chaotic mixing step to controllably and progressively develop the morphologies of said major phase component and said at least one minor phase component within said structured extrudate; and controllably forming said structured extrudate into a substantially solid construction having said predefined morphological structure.