CA2294866A1 - Solventless forming method for heat exchanger panels - Google Patents
Solventless forming method for heat exchanger panels Download PDFInfo
- Publication number
- CA2294866A1 CA2294866A1 CA002294866A CA2294866A CA2294866A1 CA 2294866 A1 CA2294866 A1 CA 2294866A1 CA 002294866 A CA002294866 A CA 002294866A CA 2294866 A CA2294866 A CA 2294866A CA 2294866 A1 CA2294866 A1 CA 2294866A1
- Authority
- CA
- Canada
- Prior art keywords
- weight
- alkyl
- polyamide
- component
- heat exchanger
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 23
- 229920001169 thermoplastic Polymers 0.000 claims abstract 2
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract 2
- 239000000203 mixture Substances 0.000 claims description 31
- 125000004432 carbon atom Chemical group C* 0.000 claims description 18
- 229920002647 polyamide Polymers 0.000 claims description 16
- 125000000217 alkyl group Chemical group 0.000 claims description 15
- 239000004952 Polyamide Substances 0.000 claims description 13
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 claims description 12
- 239000002253 acid Substances 0.000 claims description 12
- -1 alkyl methacrylate Chemical compound 0.000 claims description 12
- 239000003795 chemical substances by application Substances 0.000 claims description 12
- 229920000642 polymer Polymers 0.000 claims description 11
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 10
- 239000005977 Ethylene Substances 0.000 claims description 10
- 238000009472 formulation Methods 0.000 claims description 9
- 150000001408 amides Chemical class 0.000 claims description 8
- 239000012760 heat stabilizer Substances 0.000 claims description 8
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 6
- 125000005250 alkyl acrylate group Chemical group 0.000 claims description 6
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 229920006122 polyamide resin Polymers 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 229910021645 metal ion Inorganic materials 0.000 claims description 5
- 239000002981 blocking agent Substances 0.000 claims description 4
- 239000000178 monomer Substances 0.000 claims description 4
- JZUHIOJYCPIVLQ-UHFFFAOYSA-N 2-methylpentane-1,5-diamine Chemical compound NCC(C)CCCN JZUHIOJYCPIVLQ-UHFFFAOYSA-N 0.000 claims description 3
- WTKWFNIIIXNTDO-UHFFFAOYSA-N 3-isocyanato-5-methyl-2-(trifluoromethyl)furan Chemical compound CC1=CC(N=C=O)=C(C(F)(F)F)O1 WTKWFNIIIXNTDO-UHFFFAOYSA-N 0.000 claims description 3
- 229920002302 Nylon 6,6 Polymers 0.000 claims description 3
- 150000001299 aldehydes Chemical class 0.000 claims description 3
- 125000001931 aliphatic group Chemical group 0.000 claims description 3
- 229920003231 aliphatic polyamide Polymers 0.000 claims description 3
- 150000001350 alkyl halides Chemical class 0.000 claims description 3
- 239000003963 antioxidant agent Substances 0.000 claims description 3
- 150000001541 aziridines Chemical class 0.000 claims description 3
- 150000002118 epoxides Chemical class 0.000 claims description 3
- 229920001038 ethylene copolymer Polymers 0.000 claims description 3
- 125000001475 halogen functional group Chemical group 0.000 claims description 3
- 239000012948 isocyanate Substances 0.000 claims description 3
- 150000002513 isocyanates Chemical class 0.000 claims description 3
- 150000002763 monocarboxylic acids Chemical class 0.000 claims description 3
- TVIDDXQYHWJXFK-UHFFFAOYSA-N n-Dodecanedioic acid Natural products OC(=O)CCCCCCCCCCC(O)=O TVIDDXQYHWJXFK-UHFFFAOYSA-N 0.000 claims description 3
- 239000000049 pigment Substances 0.000 claims description 3
- 229920006012 semi-aromatic polyamide Polymers 0.000 claims description 3
- 150000004756 silanes Chemical class 0.000 claims description 3
- HQHCYKULIHKCEB-UHFFFAOYSA-N tetradecanedioic acid Natural products OC(=O)CCCCCCCCCCCCC(O)=O HQHCYKULIHKCEB-UHFFFAOYSA-N 0.000 claims description 3
- IMSODMZESSGVBE-UHFFFAOYSA-N 2-Oxazoline Chemical compound C1CN=CO1 IMSODMZESSGVBE-UHFFFAOYSA-N 0.000 claims description 2
- 239000006057 Non-nutritive feed additive Substances 0.000 claims description 2
- 239000000654 additive Substances 0.000 claims description 2
- 239000000975 dye Substances 0.000 claims description 2
- 230000000694 effects Effects 0.000 claims description 2
- 239000003063 flame retardant Substances 0.000 claims description 2
- 239000004615 ingredient Substances 0.000 claims description 2
- 239000004014 plasticizer Substances 0.000 claims description 2
- 229920006114 semi-crystalline semi-aromatic polyamide Polymers 0.000 claims description 2
- 239000011261 inert gas Substances 0.000 claims 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims 2
- 239000007789 gas Substances 0.000 claims 2
- 229920006345 thermoplastic polyamide Polymers 0.000 claims 2
- 238000006386 neutralization reaction Methods 0.000 claims 1
- 229910052757 nitrogen Inorganic materials 0.000 claims 1
- 238000003825 pressing Methods 0.000 claims 1
- 229920002554 vinyl polymer Polymers 0.000 claims 1
- 239000004677 Nylon Substances 0.000 abstract description 12
- 229920001778 nylon Polymers 0.000 abstract description 12
- 239000002904 solvent Substances 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 10
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 5
- 229920002292 Nylon 6 Polymers 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- WVDDGKGOMKODPV-UHFFFAOYSA-N Benzyl alcohol Chemical compound OCC1=CC=CC=C1 WVDDGKGOMKODPV-UHFFFAOYSA-N 0.000 description 3
- 229920003182 Surlyn® Polymers 0.000 description 3
- 239000004957 Zytel Substances 0.000 description 3
- 229920006102 Zytel® Polymers 0.000 description 3
- 229920000554 ionomer Polymers 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 239000002530 phenolic antioxidant Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 238000003856 thermoforming Methods 0.000 description 2
- 239000012745 toughening agent Substances 0.000 description 2
- KWSLGOVYXMQPPX-UHFFFAOYSA-N 5-[3-(trifluoromethyl)phenyl]-2h-tetrazole Chemical compound FC(F)(F)C1=CC=CC(C2=NNN=N2)=C1 KWSLGOVYXMQPPX-UHFFFAOYSA-N 0.000 description 1
- 229920003317 Fusabond® Polymers 0.000 description 1
- 239000002671 adjuvant Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910001507 metal halide Inorganic materials 0.000 description 1
- 150000005309 metal halides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920006284 nylon film Polymers 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910001379 sodium hypophosphite Inorganic materials 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/0005—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor characterised by the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/06905—Using combined techniques for making the preform
- B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/266—Auxiliary operations after the thermoforming operation
- B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/06—Constructions of heat-exchange apparatus characterised by the selection of particular materials of plastics material
- F28F21/065—Constructions of heat-exchange apparatus characterised by the selection of particular materials of plastics material the heat-exchange apparatus employing plate-like or laminated conduits
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
- F28F3/14—Elements constructed in the shape of a hollow panel, e.g. with channels by separating portions of a pair of joined sheets to form channels, e.g. by inflation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
- B29C49/786—Temperature
- B29C2049/7864—Temperature of the mould
- B29C2049/78645—Temperature of the mould characterised by temperature values or ranges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/18—Heat-exchangers or parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
Abstract
A method for forming thermoplastic heat exchanger panels without using solvents, wherein a co-extruded film is used to provide a layer of toughened, heat-sealable nylon on a layer of regular nylon, and using such panels in a gas-assisted press bonding process to form the heat exchanger panels.
Description
TITLE
SOLVENTLESS FORMING METHOD FOR HEAT EXCHANGER PANELS
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from US Provisional Application Serial No. 60/048842, filed June 6, 1997.
BACKGROUND OF THE INVENTION
Production of panels (plate type units) for construction of nylon heat exchangers is carried out by a twin sheet thermoforming process with internal gas assist. A phenol solution is applied to the inner, mating surfaces of the two sheets of nylon film employed to effect bonding. This basic concept is discussed in the DuPont "Zytel" Handbook and refinements are presented in US Patents 4,935,462 and 5,039,370 which form the basis for panel production in accordance with US
5,195,240. While bonds formed by this process using phenol are strong and durable, the odor of phenol is undesirable and may be unacceptable during manufacture or in the finished article.
PCT International Application WO 95/15992 discloses heat-sealable polyamide films or layers firmed from polyamides conatining at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backboane, and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole figure of the drawing, Fig. 1, is a plan view of an embodiment of a heat exchanger panel made in accordance with the invention.
SUMMARY OF THE INVENTION
In one aspect of the present invention, there is disclosed the use of multilayer films for formation of panels, wherein the inner layers, or the mating surfaces, of the films used in the twin sheet thermoforming process with internal AMENDED SHEET
gas assist are made of a polyamide modified to be thermally bondable or heat-sealable, eliminating the need for phenol. These films can be produced by coextrusion of a thin bondable layer (0.013-0.076 mm) preferably of a blend of polycaprolactam (19-40% by weight) polymer prepared from equimolar amounts S of 2-methylpentamethylene diamine and 1,12-dodecanedioic acid (20-40% by weight) such as "D-12" high la AhriENUED SHcET
performance nylon sold by DuPont, a copolymer of ethylene and a vinyl carboxylic acid, partially neutralized by a Group lA,2A or 3A metal ion (15-58%
by weight) such as "Surlyn" ionomer sold by DuPont, and a polymeric grafting agent (3-16 % by weight) such as "EBAGMA" grafting agent sold by DuPont, optionally containing heat stabilizers, pigments and other know adjuvants, onto a main structural layer (2-10 mil) of polyamide film. Formulations for the bondable inner layer are further described in US Patent Application No. 60/014,150, filed March 25, 1996, incorporated herein by reference. Panel formation can be carried out with the same equipment, under minor modifications to the process.
The polyamide-based composition of the inner layer of each sheet is a heat formable laminating film made from a mufti-phase thermoplastic resin composition comprising the following main components:
i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000;
ii) at least one polyamide resin comprising at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C;
the polyamides of I) and ii) having graft sites and forming the continuous phase of the composition;
iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an acid containing unsaturated mono-carboxylic acid, and Y is 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion;
SOLVENTLESS FORMING METHOD FOR HEAT EXCHANGER PANELS
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from US Provisional Application Serial No. 60/048842, filed June 6, 1997.
BACKGROUND OF THE INVENTION
Production of panels (plate type units) for construction of nylon heat exchangers is carried out by a twin sheet thermoforming process with internal gas assist. A phenol solution is applied to the inner, mating surfaces of the two sheets of nylon film employed to effect bonding. This basic concept is discussed in the DuPont "Zytel" Handbook and refinements are presented in US Patents 4,935,462 and 5,039,370 which form the basis for panel production in accordance with US
5,195,240. While bonds formed by this process using phenol are strong and durable, the odor of phenol is undesirable and may be unacceptable during manufacture or in the finished article.
PCT International Application WO 95/15992 discloses heat-sealable polyamide films or layers firmed from polyamides conatining at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backboane, and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole figure of the drawing, Fig. 1, is a plan view of an embodiment of a heat exchanger panel made in accordance with the invention.
SUMMARY OF THE INVENTION
In one aspect of the present invention, there is disclosed the use of multilayer films for formation of panels, wherein the inner layers, or the mating surfaces, of the films used in the twin sheet thermoforming process with internal AMENDED SHEET
gas assist are made of a polyamide modified to be thermally bondable or heat-sealable, eliminating the need for phenol. These films can be produced by coextrusion of a thin bondable layer (0.013-0.076 mm) preferably of a blend of polycaprolactam (19-40% by weight) polymer prepared from equimolar amounts S of 2-methylpentamethylene diamine and 1,12-dodecanedioic acid (20-40% by weight) such as "D-12" high la AhriENUED SHcET
performance nylon sold by DuPont, a copolymer of ethylene and a vinyl carboxylic acid, partially neutralized by a Group lA,2A or 3A metal ion (15-58%
by weight) such as "Surlyn" ionomer sold by DuPont, and a polymeric grafting agent (3-16 % by weight) such as "EBAGMA" grafting agent sold by DuPont, optionally containing heat stabilizers, pigments and other know adjuvants, onto a main structural layer (2-10 mil) of polyamide film. Formulations for the bondable inner layer are further described in US Patent Application No. 60/014,150, filed March 25, 1996, incorporated herein by reference. Panel formation can be carried out with the same equipment, under minor modifications to the process.
The polyamide-based composition of the inner layer of each sheet is a heat formable laminating film made from a mufti-phase thermoplastic resin composition comprising the following main components:
i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000;
ii) at least one polyamide resin comprising at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C;
the polyamides of I) and ii) having graft sites and forming the continuous phase of the composition;
iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an acid containing unsaturated mono-carboxylic acid, and Y is 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion;
iv) at least one polymeric grafting agent which contains reactive groups selected from at least one of epoxides, isocyanates, aziridines, silanes, alkyl halides, alpha-halo ketones and aldehydes, or oxazoIine, which reacts with the acid-containing moieties in component iii) and additionally reacts with the graft sites of components i) and ii), and the weight percent of the monomers) containing the reactive groups is 0.5-15 weight percent of the polymeric grafting agent, and the remainder of the polymeric grafting agent contains at least 50 by weight of ethylene and from 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms.
The components are combined as follows:
from about 17 to about 54 % by weight of component i), from about 1 to about 40 % by weight of component ii), from about 5 to about 69 % by weight of component iii), and from about 0.5 to about 45 % by weight of component iv);
such that the sum of components i) and ii) equals from about 29 to about 72 %
by weight.
In another embodiment of the invention there is provided a novel multi-phase resin composition comprising as the main components:
from about 17 to about 54 % by weight of (i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000, wherein the semi-crystalline polyamides have a melting point greater than 200°C;
from about 1 to about 40 % by weight of (ii) at least one polyamide resin comprising at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence.
of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C;
The components are combined as follows:
from about 17 to about 54 % by weight of component i), from about 1 to about 40 % by weight of component ii), from about 5 to about 69 % by weight of component iii), and from about 0.5 to about 45 % by weight of component iv);
such that the sum of components i) and ii) equals from about 29 to about 72 %
by weight.
In another embodiment of the invention there is provided a novel multi-phase resin composition comprising as the main components:
from about 17 to about 54 % by weight of (i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000, wherein the semi-crystalline polyamides have a melting point greater than 200°C;
from about 1 to about 40 % by weight of (ii) at least one polyamide resin comprising at least one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence.
of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C;
the polyamides of I) and ii) having graft sites and forming the continuous phase of the composition; and with the proviso that the sum of components i) and ii) is from about 29 to about 72 % by weight;
from about 5 to about 69 % by weight of (iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an unsaturated mono-carboxylic acid, and Y is 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion; and from about 0.5 to 45 % by weight of (iv) at least one polymeric grafting agent which contains reactive groups selected from at least one of epoxides, isocyanates, aziridines, silanes, alkyl halides, alpha-halo ketones and aldehydes, or oxazoline, which grafting agents react with the acid-containing moieties in component iii) and additionally react with the graft sites of components i) and ii), and the weight percent of the monomers) containing the reactive groups is 0.5-15 weight percent of the polymeric grafting agent, and the remainder of the polymeric grafting agent contains at least 50 % by weight of ethylene and from 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms.
In a preferred form of the invention, the end group balance of the low temperature nylon has been found to affect the processing and properties of the final film product. In other words, it has been found that high performance nylon, specifically D 12, with balanced or carboxyl rich end groups in the formulation reduces filter pressure drops and melt viscosities during film production, and improves film dimensional stability during heating - compared to the incorporation of D12 having amine-rich ends.
A preferred form of the present formulation comprises from about 17 to about 54 % by weight, more preferably, from about 18 to about 47 % by weight, and most preferably, from about 19 to about 40% by weight of Nylon 6 (component i); from about 1 to about 40% by weight, more preferably about 10 to about 40% by weight; most preferably from about 20 to about 40% by weight of Nylon D12 (low temperature nylon), (component ii); from about 5 to about 69 % , more preferably from about 11 to about 58 % by weight, and most preferably from about 15 to about 48 % by weight of ethylene E/X/Y (component iii); from about 0.5 to about 45 % by weight, more preferably from about 2 to about 28 % , most preferably from about 3 to about 16 % by weight of EBAGMA
(component iv); with the total amount of nylon ranging preferably from about to about 72 % by weight, more preferably from about 38 to about 71 % by weight, and most preferably from about 45 to about 70% by weight.
It should be noted that for the ranges set out above these may be applied to the various generic components also.
In another preferred form of the invention, the formulation comprises from about 55 to about 80% by weight of components (i) and (ii), with the nylon components I) and ii) taken together always in the majority (the iii) component which can be "SURLYN" ionomer produced by DuPont, and the iv) coponent which can be "EBAGMA" comaptibilizer produced by DuPont, are in the minority), but component (i) may range from about 20 to about 60 % by weight, and component (ii) may range from about 10 to about 35 % by weight.
In every instance, the formulations disclosed herein may include antioxidants, heat stabilizers or mixtures thereof. Typically these comprise from about 0.05 to about 5 .0 % by weight, preferably from about 0.05 to about 2.0 %
by weight. Organic heat stabilizers have been found to be better than the metal halide heat stabilizers, such as CuI/KI, in terms of retention of film physical properties after oven aging for one hour at 200°C. "Irganox" 1010/1098 blend of two hindered phenolic antioxidants produced by Ciba Specialty Chemicals is a preferred example of such a material. This substance also reduces filter pluggage and reduces pressure during the production of the film.
Other optional ingredients may be selected from flame retardants, anti-blocking agents, slip additives, pigments or dyes, processing aids, plasticizers and ultra-violet blocking agents. These may be used in suitable quantities as are well known to those skilled in the art.
All of the resin formulations set forth above may be formed into films using techniques well known in the art. Such films form part of the novel aspects of the present invention with respect to the novel resin formulations noted above.
It is to be understood that the terms layer, sheet, and film are used interchangeably herein. The term layer may encompass monolayer and multilayer films as well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this invention, some elements of the technology of US Patent 5.195,240 are used without the need for solvent bonding which is required by that patent.
Fig. 1 is an embodiment of a heat exchanger panel. In this embodiment, orifices 1 and 3 of the inlet and outlet header means, generally indicated by 2 and 4, are located at opposite ends of the heat exchanger panel, which in the embodiment shown is elongated. Such an elongated heat exchanger panel is particularly adapted to be located in, for instance, the radiator of an automobile .
In Fig. 1, the inlet and outlet header means 2 and 4 are connected by a series of substantially linear fluid flow passages 5 and 6 that are interspaced with similarly elongated sections in which the panels of the heat exchanger are sealed together; in particular embodiments, the linear fluid flow passages have a width of less than 12.5 mm and especially in the range of 1.2-2.5 mm.
EXAMPLES
A film was produced by coextrusion of a layer (0.051 mm) of a blend of "Zytel" FN 727 flexible nylon produced by DuPont) (70 % by weight), and polymer prepared from 2-methylpentamethylene diamine and 1,12-dodecanedioic acid (30% by weight) onto a main structural layer (0.153 mm) of nylon 6,6 blended with CFE8005 polyoleflnic toughener sold by DuPont (20% by weight).
from about 5 to about 69 % by weight of (iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an unsaturated mono-carboxylic acid, and Y is 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion; and from about 0.5 to 45 % by weight of (iv) at least one polymeric grafting agent which contains reactive groups selected from at least one of epoxides, isocyanates, aziridines, silanes, alkyl halides, alpha-halo ketones and aldehydes, or oxazoline, which grafting agents react with the acid-containing moieties in component iii) and additionally react with the graft sites of components i) and ii), and the weight percent of the monomers) containing the reactive groups is 0.5-15 weight percent of the polymeric grafting agent, and the remainder of the polymeric grafting agent contains at least 50 % by weight of ethylene and from 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms.
In a preferred form of the invention, the end group balance of the low temperature nylon has been found to affect the processing and properties of the final film product. In other words, it has been found that high performance nylon, specifically D 12, with balanced or carboxyl rich end groups in the formulation reduces filter pressure drops and melt viscosities during film production, and improves film dimensional stability during heating - compared to the incorporation of D12 having amine-rich ends.
A preferred form of the present formulation comprises from about 17 to about 54 % by weight, more preferably, from about 18 to about 47 % by weight, and most preferably, from about 19 to about 40% by weight of Nylon 6 (component i); from about 1 to about 40% by weight, more preferably about 10 to about 40% by weight; most preferably from about 20 to about 40% by weight of Nylon D12 (low temperature nylon), (component ii); from about 5 to about 69 % , more preferably from about 11 to about 58 % by weight, and most preferably from about 15 to about 48 % by weight of ethylene E/X/Y (component iii); from about 0.5 to about 45 % by weight, more preferably from about 2 to about 28 % , most preferably from about 3 to about 16 % by weight of EBAGMA
(component iv); with the total amount of nylon ranging preferably from about to about 72 % by weight, more preferably from about 38 to about 71 % by weight, and most preferably from about 45 to about 70% by weight.
It should be noted that for the ranges set out above these may be applied to the various generic components also.
In another preferred form of the invention, the formulation comprises from about 55 to about 80% by weight of components (i) and (ii), with the nylon components I) and ii) taken together always in the majority (the iii) component which can be "SURLYN" ionomer produced by DuPont, and the iv) coponent which can be "EBAGMA" comaptibilizer produced by DuPont, are in the minority), but component (i) may range from about 20 to about 60 % by weight, and component (ii) may range from about 10 to about 35 % by weight.
In every instance, the formulations disclosed herein may include antioxidants, heat stabilizers or mixtures thereof. Typically these comprise from about 0.05 to about 5 .0 % by weight, preferably from about 0.05 to about 2.0 %
by weight. Organic heat stabilizers have been found to be better than the metal halide heat stabilizers, such as CuI/KI, in terms of retention of film physical properties after oven aging for one hour at 200°C. "Irganox" 1010/1098 blend of two hindered phenolic antioxidants produced by Ciba Specialty Chemicals is a preferred example of such a material. This substance also reduces filter pluggage and reduces pressure during the production of the film.
Other optional ingredients may be selected from flame retardants, anti-blocking agents, slip additives, pigments or dyes, processing aids, plasticizers and ultra-violet blocking agents. These may be used in suitable quantities as are well known to those skilled in the art.
All of the resin formulations set forth above may be formed into films using techniques well known in the art. Such films form part of the novel aspects of the present invention with respect to the novel resin formulations noted above.
It is to be understood that the terms layer, sheet, and film are used interchangeably herein. The term layer may encompass monolayer and multilayer films as well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this invention, some elements of the technology of US Patent 5.195,240 are used without the need for solvent bonding which is required by that patent.
Fig. 1 is an embodiment of a heat exchanger panel. In this embodiment, orifices 1 and 3 of the inlet and outlet header means, generally indicated by 2 and 4, are located at opposite ends of the heat exchanger panel, which in the embodiment shown is elongated. Such an elongated heat exchanger panel is particularly adapted to be located in, for instance, the radiator of an automobile .
In Fig. 1, the inlet and outlet header means 2 and 4 are connected by a series of substantially linear fluid flow passages 5 and 6 that are interspaced with similarly elongated sections in which the panels of the heat exchanger are sealed together; in particular embodiments, the linear fluid flow passages have a width of less than 12.5 mm and especially in the range of 1.2-2.5 mm.
EXAMPLES
A film was produced by coextrusion of a layer (0.051 mm) of a blend of "Zytel" FN 727 flexible nylon produced by DuPont) (70 % by weight), and polymer prepared from 2-methylpentamethylene diamine and 1,12-dodecanedioic acid (30% by weight) onto a main structural layer (0.153 mm) of nylon 6,6 blended with CFE8005 polyoleflnic toughener sold by DuPont (20% by weight).
The film so formed was found to give seal strength of 16.1 kg/linear cm (14 lb/linear inch) when sealed at 180C, pressure of 117 kg/cm2 (40 psi) and dwell time of 10 seconds. Heat exchanger panels formed from this film according to US 5,195,240, omitting the phenol/benzyl alcohol coating, at 175C
and dwell time of 6-20 seconds, were well formed and required internal air pressure of 205 kg/cm2 (70 psi) to rupture, compared to 234-293 kg/cm2 (80-100 psi) for panels formed according to US 5,195,240. Although this is a lower level of strength, it has the advantage of being done without solvents and is useful for making heat exchangers.
"Zytel" FN 727 partially-grafted flexible nylon, produced by DuPont, is a blend by weight of 40 % nylon 6; 46 % "Surlyn"9320 ionomer produced by DuPont; 10 % "EBAGMA" EP4934-6 compatibilizer produced by DuPont; 2 % zinc stearate; and 2 % "Irgonox" 1010 hindered phenolic antioxidant produced by Ciba Specialty Chemicals. It is in US Patent 5,091,478 - Saltman et al., incorporated by reference.
"CFE8005" polyolefinic toughener, produced by DuPont, can be made as a blend by weight of 75.8% nylon 6,6; the functional equivalent of 17.2 % Fusabond MF416D EP rubber, grafted with malefic annhydride, compatibilizer produced by DuPont; 4.4 % carbon black 40 % concentrate in nylon 6; "DER 732" diepoxy ethylene oligomer with a MW of about 300 produced by Dow Chemical; and 1500 ppm sodium hypophosphite. It is in US
Patent 4,174,358 - Epstein.
and dwell time of 6-20 seconds, were well formed and required internal air pressure of 205 kg/cm2 (70 psi) to rupture, compared to 234-293 kg/cm2 (80-100 psi) for panels formed according to US 5,195,240. Although this is a lower level of strength, it has the advantage of being done without solvents and is useful for making heat exchangers.
"Zytel" FN 727 partially-grafted flexible nylon, produced by DuPont, is a blend by weight of 40 % nylon 6; 46 % "Surlyn"9320 ionomer produced by DuPont; 10 % "EBAGMA" EP4934-6 compatibilizer produced by DuPont; 2 % zinc stearate; and 2 % "Irgonox" 1010 hindered phenolic antioxidant produced by Ciba Specialty Chemicals. It is in US Patent 5,091,478 - Saltman et al., incorporated by reference.
"CFE8005" polyolefinic toughener, produced by DuPont, can be made as a blend by weight of 75.8% nylon 6,6; the functional equivalent of 17.2 % Fusabond MF416D EP rubber, grafted with malefic annhydride, compatibilizer produced by DuPont; 4.4 % carbon black 40 % concentrate in nylon 6; "DER 732" diepoxy ethylene oligomer with a MW of about 300 produced by Dow Chemical; and 1500 ppm sodium hypophosphite. It is in US
Patent 4,174,358 - Epstein.
Claims (15)
1. A method for the manufacture of a panel heat exchanger from a thermoplastic polyamide, said heat exchanger consisting essentially of first and second panels and inlet and outlet header means (2) and (4) with said panels being bonded together to define fluid flow passages (5) and (6) extending between the inlet and outlet header means (2) and (4), each of said panels being generally planar and formed from a sheet of said polyamide having a thickness of less than 0.7 mm, said polyamide sheet having at least two layers comprising an inner layer and an outer layer, wherein said inner layer of said first panel is a polyamide-based composition which seals with heat to the inner layer of said second panel, said panels having orifices (1) and (3) therein cooperatively located at each of the inlet and outlet header means (2) and (4), said method consisting essentially of the sequential steps of (a) placing the two sheets of thermoplastic polyamide in face-to-face contact between moulds in a heated press, each of said moulds being heated to a temperature in the range of 140°-200°C and the surfaces of at least one of said moulds having a recessed pattern thereon corresponding to the fluid flow passages (5) and (6) of the panel heat exchanger, such that (i) the sheets are in face-to-face contact with each other over substantially the entire face of the sheets; and (b) pressing said heated moulds to effect bonding between the sheets and between the sheets and the ends of the distributors and applying as inert gas between said inlet and outlet header means (2) and (4), said inert gas being applied for at least one cycle of increasing the gas pressure to 1.3-2.75 MPa, thereby bonding said sheets together whilst forming fluid flow passages between the inlet and outlet header means;
wherein the polyamide-based composition of the inner layer of each sheet is a heat-sealable film formed from a multi-phase thermoplastic rain composition comprising in combination the following main components:
(i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000, having graft sites and forming the continuous phase. of the composition, wherein the semi-crystalline polyamides have a melting point greater than 200°C;
(ii) at least one polyamide resin comprising at toast one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C, having graft sites and also forming the continuous phase of the composition;
(iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an acid containing unsaturated mono-carboxylic acid, and Y is 0-49% by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion;
(iv) at least one polymeric grafting agent containing reactive groups selected from at least one of epoxides, isocyanates, aziridines, silanes, alkyl halides, alpha-halo ketones and aldehydes, or oxazoline, which reacts with the acid-containing moieties in component (iii) and additionally react with the graft sites of components (i) and (ii), and the weight percent of the monomer(s) containing the reactive groups is 0.5-15 weight percent of the polymeric grafting agent, and the remainder of the polymeric grafting agent contains at least 50 % by weight of ethylene and from 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl other, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms.
wherein the polyamide-based composition of the inner layer of each sheet is a heat-sealable film formed from a multi-phase thermoplastic rain composition comprising in combination the following main components:
(i) at least one polyamide resin selected from aliphatic and semi-aromatic polyamides that can be either semi-crystalline or amorphous in structure having a number average molecular weight of at least about 5000, having graft sites and forming the continuous phase. of the composition, wherein the semi-crystalline polyamides have a melting point greater than 200°C;
(ii) at least one polyamide resin comprising at toast one pendant alkyl branch having 1 to 3 carbon atoms within at least two amide linkages along the polymer backbone and at least one sequence of at least seven consecutive carbon atoms, excluding carbon atoms in pendant alkyl branches, if any, within at least two amide linkages along the polymer backbone, the melting point of the polyamide being less than 200°C, having graft sites and also forming the continuous phase of the composition;
(iii) at least one ethylene copolymer, E/X/Y, where E is ethylene and is at least 50 % by weight of E/X/Y, X is from 1-35 % by weight of an acid containing unsaturated mono-carboxylic acid, and Y is 0-49% by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms, and further wherein the acid groups in the acid-containing moiety are neutralized from 0-100% by weight of a metal ion;
(iv) at least one polymeric grafting agent containing reactive groups selected from at least one of epoxides, isocyanates, aziridines, silanes, alkyl halides, alpha-halo ketones and aldehydes, or oxazoline, which reacts with the acid-containing moieties in component (iii) and additionally react with the graft sites of components (i) and (ii), and the weight percent of the monomer(s) containing the reactive groups is 0.5-15 weight percent of the polymeric grafting agent, and the remainder of the polymeric grafting agent contains at least 50 % by weight of ethylene and from 0-49 % by weight of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, alkyl vinyl other, carbon monoxide, sulfur dioxide, or mixtures thereof where the alkyl groups contain 1-12 carbon atoms.
2. The method of Claim 1, wherein the components are combined in accordance with the following formulation:
from about 17 to about 54% by weight of component (i), from about 1 to about 40% by weight of component (ii), from about 5 to about 69% by weight of component (iii), and from about 0.5 to about 45% by weight of component (iv).
from about 17 to about 54% by weight of component (i), from about 1 to about 40% by weight of component (ii), from about 5 to about 69% by weight of component (iii), and from about 0.5 to about 45% by weight of component (iv).
3. The method of Claim 2, wherein the sum of components (i) and (ii) equals from about 29 to about 72% by weight.
4. The method of Claim 1 or 2, wherein there are also present antioxidants, heat stabilizers or mixtures thereof.
5. The method of Claim 4, wherein the heat stabilizer is an organic heat stabilizer.
6. The method of Claim 4, wherein additional optional ingredients are present selected from flame retardants, anti-blocking agents, slip additives, pigments or dyes, processing aids, plasticizers and ultra-violet blocking agents.
7. The method of Claim 4, wherein the amount of antioxidants, heat stabilizers and mixtures thereof ranges from about 0.05 to about 5.0% by weight.
8. The method of Claim 7, wherein the range is from about 0.05 to about 2.0% by weight.
9. The method of Claim 1 or 2, in which the gas is nitrogen.
10. The method of Claim 1 or 2, in which the polyamide of the outer layer of each sheet is polyhexamethylene adipamide.
11. The method of Claim 10 in which the temperature of said mould is in the range of 150°-180°C.
12. The method of Claim 11, in which the pressure of inert gas is in the range of 1.5-2.5 MPa.
13. The method of Claim 1 or 2, in which the panel heat exchanger has liner fluid flow passages with a width in the range of 1.2-2.5 mm.
14. The method of Claim 2, wherein the formulation of the inner layer comprises:
from about 20 to about 49% by weight of component (i), which has a number average molecular weight of greater than or equal to 7500, from about 5 to about 35% by weight of component (ii), the total of components (i) and (ii) being equal to from about 34 to about 69% by weighs, from about 12 to about 62% by weight of component (iii), wherein E is greater than or equal to 55% by weight, X is from about 3 to about 30% by weight, Y is from about 0 to about 35% by weight based on the total of component (iii), and the percent by weight neutralization of acid groups in X by metal ion is from about 0 to about 80, and from about 2 to about 29% by weight of component (iv), of which from about 1 to about 10% by weight of monomers containing reactive groups are present therein, the percent by weight of ethylene is greater than or equal to therein, and the alkyl moiety therein is from about 0 to about 35 percent by weight.
from about 20 to about 49% by weight of component (i), which has a number average molecular weight of greater than or equal to 7500, from about 5 to about 35% by weight of component (ii), the total of components (i) and (ii) being equal to from about 34 to about 69% by weighs, from about 12 to about 62% by weight of component (iii), wherein E is greater than or equal to 55% by weight, X is from about 3 to about 30% by weight, Y is from about 0 to about 35% by weight based on the total of component (iii), and the percent by weight neutralization of acid groups in X by metal ion is from about 0 to about 80, and from about 2 to about 29% by weight of component (iv), of which from about 1 to about 10% by weight of monomers containing reactive groups are present therein, the percent by weight of ethylene is greater than or equal to therein, and the alkyl moiety therein is from about 0 to about 35 percent by weight.
15. The method of Claim 14 wherein the polyamide of ii) is an equimolar polymer of 2-methylpentamethylene diamine with 1,12-dodecanedioic acid.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US4884297P | 1997-06-06 | 1997-06-06 | |
US60/048,842 | 1997-06-06 | ||
US8988898A | 1998-06-04 | 1998-06-04 | |
US09/089,888 | 1998-06-04 | ||
PCT/CA1998/000569 WO1998055815A1 (en) | 1997-06-06 | 1998-06-05 | Solventless forming method for heat exchanger panels |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2294866A1 true CA2294866A1 (en) | 1998-12-10 |
Family
ID=26726585
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002294866A Abandoned CA2294866A1 (en) | 1997-06-06 | 1998-06-05 | Solventless forming method for heat exchanger panels |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0988500A1 (en) |
JP (1) | JP2002504870A (en) |
CA (1) | CA2294866A1 (en) |
WO (1) | WO1998055815A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2000079199A1 (en) * | 1999-06-22 | 2000-12-28 | Dupont Canada Inc. | Heat exchanger formed from tubes joined by thermal bonding |
SG189224A1 (en) * | 2010-10-04 | 2013-05-31 | Oasys Water Inc | Thin film composite heat exchangers |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5091478A (en) * | 1986-11-14 | 1992-02-25 | E. I. Du Pont De Nemours And Company | Partially grafted thermoplastic compositions |
US4955435A (en) * | 1987-04-08 | 1990-09-11 | Du Pont Canada, Inc. | Heat exchanger fabricated from polymer compositions |
US5195240A (en) * | 1988-04-15 | 1993-03-23 | Du Pont Canada Inc. | Method for the manufacture of thermoplastic panel heat exchangers |
GB9325032D0 (en) * | 1993-12-07 | 1994-02-02 | Du Pont Canada | Polyamides,heat-sealable layers formed therefrom and packages incorporating them |
CA2248123A1 (en) * | 1996-03-25 | 1997-10-02 | Nicholas Farkas | Polyamide formulations for embossed laminates |
-
1998
- 1998-06-05 EP EP98928030A patent/EP0988500A1/en not_active Withdrawn
- 1998-06-05 JP JP50119999A patent/JP2002504870A/en active Pending
- 1998-06-05 WO PCT/CA1998/000569 patent/WO1998055815A1/en not_active Application Discontinuation
- 1998-06-05 CA CA002294866A patent/CA2294866A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
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EP0988500A1 (en) | 2000-03-29 |
JP2002504870A (en) | 2002-02-12 |
WO1998055815A1 (en) | 1998-12-10 |
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Date | Code | Title | Description |
---|---|---|---|
FZDE | Discontinued |