BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to polymer-based articles having increased structural deformability. More particularly, the invention relates to polymer-based articles containing fullerenes molecules which are combined to form openings which are occupied by polymer chains thereby imparting structural deformability to the polymer chains.

2. Description of Related Art

The use carbon as a reinforcing agent in the preparation of both polymer and non-polymer-based articles is known. For example, United States Patent No. 3,864,305 to Jordan et al. which issued February 4, 1975 discloses the use of a certain class of carbon black pigment as a reinforcing agent in the preparation of rubber composition. Conventional carbon blacks are effective in the preparation of rubber vulcanizates having improved reinforced properties such as tensile strength, modulus and tread wear for vehicle tires. Amorphous forms of carbon such as carbon black have relatively large specific surface areas and improved reinforcing properties, but tend to be poor resistors against heat built-up. Likewise, graphitic carbon molecules which consist of hexagonal arranged carbon atoms are used throughout the chemical and manufacturing industries for reinforcing compounds such as synthetic and natural rubbers. Graphitic carbon tends to be a good conductor of electricity and heat, but is extremely soft and malleable in bulk form.

Ideally, compounds used as a reinforcing agent will be good conductors of electricity and heat, should have a large specific surface area with improved reinforcing properties, will have a high modulus of elasticity and will impart good fatigue and cut resistance characteristics.

It is therefore a primary object of the present invention to provide polymer-based structures which include fullerenes molecules having a plurality of

openings therethrough to be occupied by polymer chains to aid in mechanically locking this polymer to the fullerenes.

A further advantage of the present invention is to provide polymer-based products formed from a combination of polymer chains and fullerenes molecules wherein the polymer-based product is resistant to deformation caused by excessive heat.

A further advantage of the present invention is to provide polymer-based products formed from a combination of polymer chains and fullerenes molecules wherein the polymer-based product is resistant to deformation caused by physical contact with other objects.

Other advantages and features will become apparent from the following specification taken in connection with accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross-sectional side view of the end of a graphitic carbon molecule engaged by a polymer molecule.

Figure 2 is a perspective view of a fullerene carbon molecule which includes a plurality of openings therethrough in the exterior surface of the series of fullerenes that have joined together.

Figure 3 is a perspective view of the molecule provided in Figure 2 engaged by a plurality of polymer chains.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to Figure 1 a cross-sectional view of the end of a graphitic carbon molecule 12 comprised of carbon atoms 18 and engaged by a polymer molecule 14 is shown. Shortly, after introducing graphitic carbon molecules into a mass of polymer molecules, but prior to being subject to physical deformation due to some outside force, formation of the desired part or deformation of a formed article of manufacture, and vulcanizing, polymer molecules 14 often tend to be aligned contiguously along the relatively flat surfaces of the graphitic carbon molecules and sheets of graphitic carbon 12. Due to the flat hexagonal shape of graphitic carbon

molecules 12, graphitic carbon molecules and crystalline forms (i.e., sheets) of graphitic carbon tend to have relatively sharp edges 13. Polymer molecules 14 tend to generally overhang the edges 13 of the graphitic carbon molecules 12. Since the polymer molecules 14 tend to overhang the graphitic carbon molecules 12 the bending radius of the polymer molecule tends to be short and at very large angles over the ends of graphitic carbon molecules 12.

The graphitic carbon molecule 12 and the polymer molecule 14 are shown wherein the polymer molecule 14 is being excessively deformed over the graphitic carbon molecule's edges 13 by temperature, or mechanically applied forces. Deformation of the polymer molecule 14 can occur in any one of a number of ways. For example, deformation occurs as a result of strenuous mixing of the polymer molecules and graphitic carbon molecules as they are mixed into a polymer mass as in the case of compounding rubber, before the rubber is cross-linked or vulcanized. Deformation also occurs during formation of the desired part or article using the polymer mix containing polymer chains and carbon molecules as fillers for structural reinforcement. Deformation can also occur as a result of deforming the part or article which is made from the polymer mix through physical contact with other articles or by the formed articles.

When physical deformation occurs the polymer molecule 14 engages the sharp edges 13 of the graphitic carbon molecule 12. To a certain extent the graphitic carbon molecule 12 may flex slightly to accommodate subtle deformations, however, when the polymer molecule 14 is subjected to a force that exceeds the ability of the graphitic molecule 12 to flex along with the polymer molecule 14, the polymer molecule cannot resist the displacement forces and tend to break the polymer molecule. This deflection of the polymer molecule 14 is referred to herein as the bend radius.

Referring to Figure 2, a perspective view of a combination fullerene carbon molecule which is formed by combining a plurality of smaller fullerene carbon molecules, such that the enlarged fullerene carbon molecule 20 includes a plurality of openings 22, on the exterior of the smaller fullerene molecules, therethrough is provided. Generally, the fullerene molecules readily share their associative fields

with other fullerene molecules to form an enlarged molecule 20 having a hollow center 24 shown as solid circles and a plurality of openings 22 therethrough. The pure uncombined fullerene carbon molecule is a recently discovered form of carbon having an overall truncated icosohedron shape, in the case of 60 carbon atoms, comprising a number of regular pentagon and hexagon shaped portions which tend to be good conductors of electricity and heat and is fatigue and cut resistant. The enlarged fullerene carbon molecule 20 of the present invention has a structure similar to that of a piece of open cell foam wherein the hollow cells of the foam are connected forming a structure having a plurality of openings throughout and a hollow center of each fullerene combination of carbon atoms.

According to the teachings of the present invention, enlarged fullerene molecules 20 having a plurality of openings 22, throughout are combined with a polymer mass, such as those which make up elastomers and plastics, to give the polymer molecules or polymer chains 14 contained in the polymer mass structural integrity against excessive deformation. As previously noted, deformation of the polymer molecules can occur in a number of ways. Physical deformation can occur due to physical contacts subjected upon the polymer molecule, such as when the polymer molecule is flexed or bent over the diameter of the carbon molecules which are used as reinforcing agents. Unlike the small bend radius which occurs at the molecular edges 13 of graphitic carbon molecules 12, the enlarged fullerene molecules 20 of the present invention have a large bend radii due to the size of the molecule. When the polymer molecule 14 is subjected to physical deformation, the polymer molecule bends over the large radius of the enlarged fullerene molecule 20 such that the stress is more evenly distributed over the length of the polymer molecule than it is when the polymer molecule is bent over the edges 13 of the graphitic carbon molecules. Additionally, because the edges of the enlarged fullerene molecule 20 are substantially less sharp than the edges of a diamond or graphitic carbon molecule 12, fullerene molecules do not have the natural occurring stress points such as those presented by the edges of diamond or graphitic carbon molecules. Since, the polymer-based articles which incorporate the enlarged fullerene molecules 20 are much less subject to breaking than polymer-based articles formed with graphitic

carbon molecules as reinforcing agents, the polymer-based articles which are structurally supported by the enlarged fullerene molecules 20 tend to be stronger and exhibit better mechanical properties.

Increased internal stresses can also occur by exposing the polymer mix or formed article made with the polymer mix to excessive heat. An increase in the temperature of the polymer mix or article made with the polymer mix increases the "Brownian" type motion of the atoms within the molecular chain of the polymer and any attached chemical groups. This increase in movement or Brownian motion often gives rise to greater internal stresses in the polymer chains. Typically these internal stresses result in a smaller bend radius making it more likely that the polymer chain is subject to breaking. The enlarged fullerene molecules 20 tend to reduce the internal stresses of the polymer molecules 14 by absorbing excess heat, and limits the reduction and bend radius of the polymer chain, in a manner similar to the resistance to breaking as a result of externally applied mechanical force. As shown with reference to Figure 3, some of the polymer chains 14 contained within the polymer mass occupy the openings provided in the enlarged fullerene carbon molecules 20 to enhance the mechanical properties of the polymer mass. The tensile strength of each polymer chain which occupies one of the aforementioned openings is increased, and contributes to the overall strength of the polymer mass. The polymer molecules 14 tend to become mechanically interlocked within the openings 22 and therefore are not subjected to the bending which normally occurs during the mixing of the polymer mass. This mechanical interlocking of the polymer chains 14 throughout the enlarged fullerene carbon molecules 20 also reduces the friction which would occur during mixing if the polymer chains were free standing in the presence of the reinforcing agent or agents. It is contemplated that the polymer chains 14 can also be chemically bonded to the enlarged fullerene molecules 20 that occurs during mixing. By using enlarged fullerene carbon molecules 20 as described herein, the resulting polymer masses will have increased mechanical strength, improved resistance to deformation, improved heat resistance and increased chemical resistance. Likewise, non-carbon atoms 30, which are shown as squares, can be substituted for one or more of the carbon atoms of the fullerene

molecule 20 to promote the attaching and support of the polymer to the fullerene molecules.

While it will be apparent that the preferred embodiment of the invention disclosed is well calculated to provide the advantages stated above, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the subjoined claims.