| abstract |
A process for forming a nano-composite including mixing a first and second thermoplastic polymer in a molten state forming a molten polymer blend. The second polymer is soluble in a first solvent and the first polymer is insoluble in the first solvent. The first polymer forms discontinuous regions in the second polymer. Next, the polymer blend is subjected to extensional flow, shear stress, and heat forming nanofibers where less than about 30% by volume of the nanofibers are bonded to other nanofibers. n Next the polymer blend with nanofibers is cooled and the first intermediate is formed into a pre-consolidation formation. The pre-consolidation formation is then consolidated causing nanofiber movement, randomization, and at least 70% by volume of the nanofibers to fuse to other nanofibers. According to one aspect, the second intermediate is then subjected to the first solvent to the dissolving away at least a portion of the second polymer. |