US20220081564A1 - Polyamide compositions and articles made therefrom - Google Patents
Polyamide compositions and articles made therefrom Download PDFInfo
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- US20220081564A1 US20220081564A1 US17/457,131 US202117457131A US2022081564A1 US 20220081564 A1 US20220081564 A1 US 20220081564A1 US 202117457131 A US202117457131 A US 202117457131A US 2022081564 A1 US2022081564 A1 US 2022081564A1
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- polyamide
- composition
- extruded
- reinforced
- Prior art date
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- 239000000203 mixture Substances 0.000 title claims abstract description 464
- 229920002647 polyamide Polymers 0.000 title claims abstract description 451
- 239000004952 Polyamide Substances 0.000 title claims abstract description 442
- 229920000098 polyolefin Polymers 0.000 claims abstract description 233
- 238000009833 condensation Methods 0.000 claims abstract description 197
- 230000005494 condensation Effects 0.000 claims abstract description 197
- 238000000034 method Methods 0.000 claims abstract description 120
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims abstract description 28
- 238000010348 incorporation Methods 0.000 claims abstract description 17
- 229910052751 metal Inorganic materials 0.000 claims description 164
- 239000002184 metal Substances 0.000 claims description 164
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- 230000002787 reinforcement Effects 0.000 claims description 121
- 239000004970 Chain extender Substances 0.000 claims description 83
- 239000007795 chemical reaction product Substances 0.000 claims description 82
- 239000003365 glass fiber Substances 0.000 claims description 58
- 239000011253 protective coating Substances 0.000 claims description 38
- 239000000835 fiber Substances 0.000 claims description 21
- 229920006139 poly(hexamethylene adipamide-co-hexamethylene terephthalamide) Polymers 0.000 claims description 19
- 238000005260 corrosion Methods 0.000 claims description 15
- 230000007797 corrosion Effects 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 12
- 229910000831 Steel Inorganic materials 0.000 claims description 11
- 238000006243 chemical reaction Methods 0.000 claims description 10
- 230000002209 hydrophobic effect Effects 0.000 claims description 10
- 239000010935 stainless steel Substances 0.000 claims description 8
- 239000010949 copper Substances 0.000 claims description 7
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 6
- 150000001412 amines Chemical group 0.000 claims description 6
- 230000036961 partial effect Effects 0.000 claims description 6
- 239000007787 solid Substances 0.000 claims description 6
- 239000010962 carbon steel Substances 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims description 4
- 239000002982 water resistant material Substances 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 239000000956 alloy Substances 0.000 claims description 3
- 229910052790 beryllium Inorganic materials 0.000 claims description 3
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 229910001220 stainless steel Inorganic materials 0.000 claims description 3
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims description 2
- 235000019253 formic acid Nutrition 0.000 claims description 2
- 229920001910 maleic anhydride grafted polyolefin Polymers 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 126
- 238000012360 testing method Methods 0.000 description 67
- 239000000463 material Substances 0.000 description 57
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- 239000003063 flame retardant Substances 0.000 description 43
- 229920006122 polyamide resin Polymers 0.000 description 39
- 238000001125 extrusion Methods 0.000 description 37
- 238000009472 formulation Methods 0.000 description 37
- -1 poly(caprolactam) Polymers 0.000 description 36
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 34
- 229920000572 Nylon 6/12 Polymers 0.000 description 34
- 238000004519 manufacturing process Methods 0.000 description 34
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 description 31
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 29
- 238000013329 compounding Methods 0.000 description 27
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 27
- 230000007062 hydrolysis Effects 0.000 description 25
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- 239000000126 substance Substances 0.000 description 20
- 229920001903 high density polyethylene Polymers 0.000 description 19
- 239000004700 high-density polyethylene Substances 0.000 description 19
- NAQMVNRVTILPCV-UHFFFAOYSA-N hexane-1,6-diamine Chemical compound NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 18
- 229920000305 Nylon 6,10 Polymers 0.000 description 16
- 239000004743 Polypropylene Substances 0.000 description 16
- 229920006659 PA12 Polymers 0.000 description 15
- 239000012530 fluid Substances 0.000 description 15
- 239000011592 zinc chloride Substances 0.000 description 15
- 229920000299 Nylon 12 Polymers 0.000 description 14
- 229920002292 Nylon 6 Polymers 0.000 description 14
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- 229920005989 resin Polymers 0.000 description 14
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- 239000000243 solution Substances 0.000 description 13
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- 239000012760 heat stabilizer Substances 0.000 description 12
- 229920001155 polypropylene Polymers 0.000 description 12
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 11
- 239000002356 single layer Substances 0.000 description 11
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 10
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 10
- 238000002156 mixing Methods 0.000 description 10
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- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 9
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- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 8
- 239000004202 carbamide Substances 0.000 description 8
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- 238000010521 absorption reaction Methods 0.000 description 7
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- 229920002943 EPDM rubber Polymers 0.000 description 6
- 239000004609 Impact Modifier Substances 0.000 description 6
- 239000004698 Polyethylene Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 6
- 230000009477 glass transition Effects 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 6
- 238000000691 measurement method Methods 0.000 description 6
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- 229920000573 polyethylene Polymers 0.000 description 6
- 238000012545 processing Methods 0.000 description 6
- 229920000049 Carbon (fiber) Polymers 0.000 description 5
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 5
- 229920000571 Nylon 11 Polymers 0.000 description 5
- 229920006102 Zytel® Polymers 0.000 description 5
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 5
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- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 description 5
- 229910052736 halogen Inorganic materials 0.000 description 5
- 150000002367 halogens Chemical class 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 5
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 5
- 229920000069 polyphenylene sulfide Polymers 0.000 description 5
- 229920006375 polyphtalamide Polymers 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 4
- 239000005977 Ethylene Substances 0.000 description 4
- 239000004957 Zytel Substances 0.000 description 4
- 150000008064 anhydrides Chemical group 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- JBKVHLHDHHXQEQ-UHFFFAOYSA-N epsilon-caprolactam Chemical compound O=C1CCCCCN1 JBKVHLHDHHXQEQ-UHFFFAOYSA-N 0.000 description 4
- 230000003993 interaction Effects 0.000 description 4
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 150000002739 metals Chemical class 0.000 description 4
- 229920000058 polyacrylate Polymers 0.000 description 4
- 238000006068 polycondensation reaction Methods 0.000 description 4
- 229920013636 polyphenyl ether polymer Polymers 0.000 description 4
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 230000000717 retained effect Effects 0.000 description 4
- 239000000779 smoke Substances 0.000 description 4
- 239000003381 stabilizer Substances 0.000 description 4
- 230000002459 sustained effect Effects 0.000 description 4
- 238000010998 test method Methods 0.000 description 4
- JZUHIOJYCPIVLQ-UHFFFAOYSA-N 2-methylpentane-1,5-diamine Chemical compound NCC(C)CCCN JZUHIOJYCPIVLQ-UHFFFAOYSA-N 0.000 description 3
- 229920006309 Invista Polymers 0.000 description 3
- 229920000877 Melamine resin Polymers 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- 229920006355 Tefzel Polymers 0.000 description 3
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 3
- XSAOTYCWGCRGCP-UHFFFAOYSA-K aluminum;diethylphosphinate Chemical compound [Al+3].CCP([O-])(=O)CC.CCP([O-])(=O)CC.CCP([O-])(=O)CC XSAOTYCWGCRGCP-UHFFFAOYSA-K 0.000 description 3
- 229920006018 co-polyamide Polymers 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
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- 239000000314 lubricant Substances 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 3
- 239000003345 natural gas Substances 0.000 description 3
- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 description 3
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- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 229920000388 Polyphosphate Polymers 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 229920005603 alternating copolymer Polymers 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 150000001718 carbodiimides Chemical class 0.000 description 2
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- 150000004985 diamines Chemical class 0.000 description 2
- 125000005442 diisocyanate group Chemical group 0.000 description 2
- ROORDVPLFPIABK-UHFFFAOYSA-N diphenyl carbonate Chemical class C=1C=CC=CC=1OC(=O)OC1=CC=CC=C1 ROORDVPLFPIABK-UHFFFAOYSA-N 0.000 description 2
- TVIDDXQYHWJXFK-UHFFFAOYSA-N dodecanedioic acid Chemical compound OC(=O)CCCCCCCCCCC(O)=O TVIDDXQYHWJXFK-UHFFFAOYSA-N 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 230000008030 elimination Effects 0.000 description 2
- 238000003379 elimination reaction Methods 0.000 description 2
- QHSJIZLJUFMIFP-UHFFFAOYSA-N ethene;1,1,2,2-tetrafluoroethene Chemical compound C=C.FC(F)=C(F)F QHSJIZLJUFMIFP-UHFFFAOYSA-N 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
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- 150000002924 oxiranes Chemical group 0.000 description 2
- XZTOTRSSGPPNTB-UHFFFAOYSA-N phosphono dihydrogen phosphate;1,3,5-triazine-2,4,6-triamine Chemical compound NC1=NC(N)=NC(N)=N1.OP(O)(=O)OP(O)(O)=O XZTOTRSSGPPNTB-UHFFFAOYSA-N 0.000 description 2
- 229910052698 phosphorus Inorganic materials 0.000 description 2
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- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
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- 239000001205 polyphosphate Substances 0.000 description 2
- 235000011176 polyphosphates Nutrition 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 2
- 229920006114 semi-crystalline semi-aromatic polyamide Polymers 0.000 description 2
- ZBFCSRYSLRPAOY-UHFFFAOYSA-M sodium;hydroxy(phenyl)methanesulfonate Chemical compound [Na+].[O-]S(=O)(=O)C(O)C1=CC=CC=C1 ZBFCSRYSLRPAOY-UHFFFAOYSA-M 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000007655 standard test method Methods 0.000 description 2
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- HVLLSGMXQDNUAL-UHFFFAOYSA-N triphenyl phosphite Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)OC1=CC=CC=C1 HVLLSGMXQDNUAL-UHFFFAOYSA-N 0.000 description 2
- 238000009827 uniform distribution Methods 0.000 description 2
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- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical class [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- 0 *.*PCCN.*PCCN1C(=O)CC(C(C)CC)C1=O.B.C.C.C/C=C/C.CCC(C)C1CC(=O)OC1=O.O=C1C=CC(=O)O1.[2HH] Chemical compound *.*PCCN.*PCCN1C(=O)CC(C(C)CC)C1=O.B.C.C.C/C=C/C.CCC(C)C1CC(=O)OC1=O.O=C1C=CC(=O)O1.[2HH] 0.000 description 1
- KCOPAESEGCGTKM-UHFFFAOYSA-N 1,3-oxazol-4-one Chemical compound O=C1COC=N1 KCOPAESEGCGTKM-UHFFFAOYSA-N 0.000 description 1
- AGEILULECXEYHO-UHFFFAOYSA-N 1,6-bis(7-oxoazepan-2-yl)hexane-1,6-dione Chemical compound C1CCCC(=O)NC1C(=O)CCCCC(=O)C1CCCCC(=O)N1 AGEILULECXEYHO-UHFFFAOYSA-N 0.000 description 1
- PBLZLIFKVPJDCO-UHFFFAOYSA-N 12-aminododecanoic acid Chemical compound NCCCCCCCCCCCC(O)=O PBLZLIFKVPJDCO-UHFFFAOYSA-N 0.000 description 1
- ITFDYXKCBZEBDG-UHFFFAOYSA-N 2-(1-methylpyrrol-2-yl)ethanamine Chemical compound CN1C=CC=C1CCN ITFDYXKCBZEBDG-UHFFFAOYSA-N 0.000 description 1
- WTPYFJNYAMXZJG-UHFFFAOYSA-N 2-[4-(2-hydroxyethoxy)phenoxy]ethanol Chemical compound OCCOC1=CC=C(OCCO)C=C1 WTPYFJNYAMXZJG-UHFFFAOYSA-N 0.000 description 1
- VEORPZCZECFIRK-UHFFFAOYSA-N 3,3',5,5'-tetrabromobisphenol A Chemical compound C=1C(Br)=C(O)C(Br)=CC=1C(C)(C)C1=CC(Br)=C(O)C(Br)=C1 VEORPZCZECFIRK-UHFFFAOYSA-N 0.000 description 1
- UPULOMQHYQDNNT-UHFFFAOYSA-N 5h-1,3-oxazol-2-one Chemical class O=C1OCC=N1 UPULOMQHYQDNNT-UHFFFAOYSA-N 0.000 description 1
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- LCFVJGUPQDGYKZ-UHFFFAOYSA-N Bisphenol A diglycidyl ether Chemical compound C=1C=C(OCC2OC2)C=CC=1C(C)(C)C(C=C1)=CC=C1OCC1CO1 LCFVJGUPQDGYKZ-UHFFFAOYSA-N 0.000 description 1
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- XUGISPSHIFXEHZ-GPJXBBLFSA-N [(3r,8s,9s,10r,13r,14s,17r)-10,13-dimethyl-17-[(2r)-6-methylheptan-2-yl]-2,3,4,7,8,9,11,12,14,15,16,17-dodecahydro-1h-cyclopenta[a]phenanthren-3-yl] acetate Chemical compound C1C=C2C[C@H](OC(C)=O)CC[C@]2(C)[C@@H]2[C@@H]1[C@@H]1CC[C@H]([C@H](C)CCCC(C)C)[C@@]1(C)CC2 XUGISPSHIFXEHZ-GPJXBBLFSA-N 0.000 description 1
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- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229910001377 aluminum hypophosphite Inorganic materials 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 125000003277 amino group Chemical group 0.000 description 1
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- LJCFOYOSGPHIOO-UHFFFAOYSA-N antimony pentoxide Inorganic materials O=[Sb](=O)O[Sb](=O)=O LJCFOYOSGPHIOO-UHFFFAOYSA-N 0.000 description 1
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- CDQSJQSWAWPGKG-UHFFFAOYSA-N butane-1,1-diol Chemical compound CCCC(O)O CDQSJQSWAWPGKG-UHFFFAOYSA-N 0.000 description 1
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- 238000004786 cone calorimetry Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- UGQQAJOWXNCOPY-UHFFFAOYSA-N dechlorane plus Chemical compound C12CCC3C(C4(Cl)Cl)(Cl)C(Cl)=C(Cl)C4(Cl)C3CCC2C2(Cl)C(Cl)=C(Cl)C1(Cl)C2(Cl)Cl UGQQAJOWXNCOPY-UHFFFAOYSA-N 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
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- 230000001419 dependent effect Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 125000006159 dianhydride group Chemical group 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
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- ZMUCVNSKULGPQG-UHFFFAOYSA-N dodecanedioic acid;hexane-1,6-diamine Chemical compound NCCCCCCN.OC(=O)CCCCCCCCCCC(O)=O ZMUCVNSKULGPQG-UHFFFAOYSA-N 0.000 description 1
- 239000003651 drinking water Substances 0.000 description 1
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- 230000006353 environmental stress Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- HEAMQYHBJQWOSS-UHFFFAOYSA-N ethene;oct-1-ene Chemical compound C=C.CCCCCCC=C HEAMQYHBJQWOSS-UHFFFAOYSA-N 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
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- 125000000524 functional group Chemical group 0.000 description 1
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- ACCCMOQWYVYDOT-UHFFFAOYSA-N hexane-1,1-diol Chemical compound CCCCCC(O)O ACCCMOQWYVYDOT-UHFFFAOYSA-N 0.000 description 1
- 239000007970 homogeneous dispersion Substances 0.000 description 1
- UCNNJGDEJXIUCC-UHFFFAOYSA-L hydroxy(oxo)iron;iron Chemical compound [Fe].O[Fe]=O.O[Fe]=O UCNNJGDEJXIUCC-UHFFFAOYSA-L 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- LIKBJVNGSGBSGK-UHFFFAOYSA-N iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Fe+3].[Fe+3] LIKBJVNGSGBSGK-UHFFFAOYSA-N 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 230000002262 irrigation Effects 0.000 description 1
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- 238000004898 kneading Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000005297 material degradation process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- ZQKXQUJXLSSJCH-UHFFFAOYSA-N melamine cyanurate Chemical compound NC1=NC(N)=NC(N)=N1.O=C1NC(=O)NC(=O)N1 ZQKXQUJXLSSJCH-UHFFFAOYSA-N 0.000 description 1
- 150000004682 monohydrates Chemical class 0.000 description 1
- 239000010705 motor oil Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 238000005453 pelletization Methods 0.000 description 1
- 239000002530 phenolic antioxidant Substances 0.000 description 1
- ACVYVLVWPXVTIT-UHFFFAOYSA-N phosphinic acid Chemical class O[PH2]=O ACVYVLVWPXVTIT-UHFFFAOYSA-N 0.000 description 1
- AQSJGOWTSHOLKH-UHFFFAOYSA-N phosphite(3-) Chemical class [O-]P([O-])[O-] AQSJGOWTSHOLKH-UHFFFAOYSA-N 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004597 plastic additive Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920006180 poly(hexamethylene terephthalamide)-poly(2-methyl pentamethylene diamine) Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- ULWHHBHJGPPBCO-UHFFFAOYSA-N propane-1,1-diol Chemical compound CCC(O)O ULWHHBHJGPPBCO-UHFFFAOYSA-N 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 239000003507 refrigerant Substances 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 238000007151 ring opening polymerisation reaction Methods 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 229920006012 semi-aromatic polyamide Polymers 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 230000002123 temporal effect Effects 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- DJZKNOVUNYPPEE-UHFFFAOYSA-N tetradecane-1,4,11,14-tetracarboxamide Chemical compound NC(=O)CCCC(C(N)=O)CCCCCCC(C(N)=O)CCCC(N)=O DJZKNOVUNYPPEE-UHFFFAOYSA-N 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 150000004684 trihydrates Chemical class 0.000 description 1
- GTOWTBKGCUDSNY-UHFFFAOYSA-K tris[[ethyl(methyl)phosphoryl]oxy]alumane Chemical compound [Al+3].CCP(C)([O-])=O.CCP(C)([O-])=O.CCP(C)([O-])=O GTOWTBKGCUDSNY-UHFFFAOYSA-K 0.000 description 1
- NSBGJRFJIJFMGW-UHFFFAOYSA-N trisodium;stiborate Chemical compound [Na+].[Na+].[Na+].[O-][Sb]([O-])([O-])=O NSBGJRFJIJFMGW-UHFFFAOYSA-N 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 229940124543 ultraviolet light absorber Drugs 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
- BNEMLSQAJOPTGK-UHFFFAOYSA-N zinc;dioxido(oxo)tin Chemical compound [Zn+2].[O-][Sn]([O-])=O BNEMLSQAJOPTGK-UHFFFAOYSA-N 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
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- C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
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- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
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- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
- C08G69/48—Polymers modified by chemical after-treatment
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08L23/26—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment
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- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
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- F16L9/00—Rigid pipes
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- F16L9/121—Rigid pipes of plastics with or without reinforcement with three layers
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
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- B32B2597/00—Tubular articles, e.g. hoses, pipes
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2203/00—Applications
- C08L2203/30—Applications used for thermoforming
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
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- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
- F16L11/08—Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/14—Hoses, i.e. flexible pipes made of rigid material, e.g. metal or hard plastics
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L9/00—Rigid pipes
- F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
- F16L9/147—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups comprising only layers of metal and plastics with or without reinforcement
Definitions
- the present disclosure provides polyamide compositions, methods for making the compositions and polyamide parts extruded or molded from the compositions, and reinforced conduits including an extruded conduit that includes the composition.
- thermoplastic condensation polyamide resins for example, poly-hexamethyleneadipamide (Nylon-6,6 or N66 or PA66) have shown limited success.
- Additional thermoplastic resin materials used in production of pipes include polyamide 11 (e.g. coiled N11 high pressure gas pipes at diameters up to 2 inches have been disclosed by Arkema); polyamide 12 (e.g. Evonik Degussa VESTAMID® NRG Polyamide 12 pipe, UBESTA polyamide 12 for burial and rehabilitation of existing cast iron and steel gas mains); polyamide 612 (e.g. DuPont PIPELON® polyamide 612 pipe) and polyvinylidene difluoride (PVDF).
- polyamide 11 e.g. coiled N11 high pressure gas pipes at diameters up to 2 inches have been disclosed by Arkema
- polyamide 12 e.g. Evonik Degussa VESTAMID® NRG Polyamide 12 pipe, UBESTA polyamide 12 for burial and rehabilitation of existing cast iron and steel gas main
- thermoplastic condensation polyamide resins that are molded or extruded suffer from insufficient properties for various end uses such as automotive, electronics, chemical processing, and heat transfer applications.
- Various thermoplastic condensation polyamide resins that are molded or extruded have lower tensile strength, lower chemical resistance, lower stress cracking resistance, or higher melt viscosities (e.g., making extrusion difficult or impossible), than available HDPE, N11, N12, N612 and PVDF materials, especially in pipeline construction.
- thermoplastic pelletizable polymer composition including: (a) a polyamide; and (b) a polymer polymerized from maleic anhydride and an olefin; wherein the polyamide and the polymer are compounded.
- compositions including polyamides with such olefin-maleic anhydride polymers (OMAP).
- OMAP olefin-maleic anhydride polymers
- WO2014/100000A2 relates to polyamide compositions including 60 to 99.9% by weight of a polyamide and 0.5 to 40% by weight of an impact modifier containing maleic anhydride or a functional equivalent thereof. In these compositions, the moisture level is less than the equilibrium moisture content of the polyamide.
- EP2562219A1 relates to thermoplastic molded substances with increased hydrolysis resistance.
- German Patent Application Publication No. DE102008008098A1 relates to polyamide-elastomer-mixtures having improved resistance to hydrolysis.
- the polyamide-elastomer blends can be processed to molded articles useful in the automotive sector.
- the present invention provides a composition including a condensation polyamide.
- the condensation polyamide is at least 30 wt % of the composition.
- the condensation polyamide is the predominant polyamide in the composition.
- the condensation polyamide can be one or more polyamides.
- the composition includes from ⁇ 10 wt % to ⁇ 50 wt % of a maleated polyolefin (e.g., ⁇ 15 wt % to ⁇ 50 wt %).
- the maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone.
- the maleated polyolefin has a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin.
- the condensation polyamide can be any one or more suitable condensation polyamides.
- the maleated polyolefin, or domains thereof, is/are uniformly distributed in the condensation polyamide or in the composition;
- the condensation polyamide can have an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., ⁇ 70 meq/kg and ⁇ 125 meq/kg);
- the condensation polyamide can have an RV of at least 35 (e.g., at least 40, or at least 45, as determined according to ASTM D789);
- the condensation polyamide can include nylon 66/6T, nylon 66/DI, nylon 66, or a combination thereof; or a combination thereof.
- the present invention provides a composition including a condensation polyamide having an AEG of 265 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., ⁇ 70 meq/kg and ⁇ 125 meq/kg).
- the condensation polyamide is at least 30 wt % of the composition.
- the condensation polyamide is the predominant polyamide in the composition.
- the composition also includes from ⁇ 10 wt % to ⁇ 50 wt % of a maleated polyolefin (e.g., ⁇ 15 wt % to ⁇ 50 wt %).
- the maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin.
- the present invention provides a composition including a condensation polyamide.
- the condensation polyamide is at least 30 wt % of the composition.
- the condensation polyamide is the predominant polyamide in the composition.
- the condensation polyamide can be one or more polyamides.
- the composition includes from ⁇ 10 wt % to ⁇ 50 wt % of a maleated polyolefin (e.g., ⁇ 15 wt % to ⁇ 50 wt %).
- the maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone.
- the maleated polyolefin has a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin.
- the condensation polyamide can be any one or more suitable condensation polyamides.
- the maleated polyolefin, or domains thereof, or a reaction product of the maleated polyolefin is/are uniformly
- the present invention provides a reacted composition that is a reaction product of the composition including the condensation polyamide and the maleated polyolefin.
- the reacted composition can include a reaction product of the condensation polyamide and the maleated polyolefin, such as a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin.
- the present invention provides a compounded polyamide composition.
- the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin and/or a reaction product of the composition.
- the compounded polyamide composition also includes one or more other components.
- the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, wherein the maleated polyolefin is ⁇ 10 to ⁇ 50 wt % of the compounded polyamide composition.
- the compounded polyamide composition includes an additional polyamide that is ⁇ 15 to ⁇ 85 wt % of the compounded polyamide composition (e.g., ⁇ 20 to ⁇ 85 wt %), such as nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof.
- the compounded polyamide composition also includes a chain extender that is ⁇ 0.05 to ⁇ 5 wt % of the compounded polyamide composition.
- the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof (e.g., the condensation polyamide and the maleated polyolefin are optionally partially reacted to form a polyamide-polyolefin), wherein the condensation polyamide is 50-80 wt % of the compounded polyamide composition, and wherein the maleated polyolefin is 10-50 wt % of the compounded polyamide composition.
- the compounded polyamide composition also includes 0 to 20 wt % polyamide 612; 0 to 20 wt % modified polyphenylene ether; 0 to 30 wt % flame retardant; 0 to 10 wt % combined chain extender, heat stabilizer and colorant additives; and 0 to 40 wt % combined filler and/or conductive fiber additives.
- the present invention provides an article that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof.
- the article can be characterized by superior resistance, when compared against a control, to at least one selected from: cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure.
- the article is an extrudate, such as a conduit.
- the extrudate can be substantially free of glass fibers and/or can be resistant to glycolysis.
- the article is a molded article.
- the molded article can include glass fibers and/or can be resistant to cold-temperature cracking.
- the present invention provides a reinforced conduit.
- the reinforced conduit includes an extruded conduit that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof.
- the reinforced conduit also includes a metal reinforcement.
- the present invention provides a method of making the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same.
- the method can include combining the condensation polyamide and the maleated polyolefin to form the composition, the reacted composition, the compounded composition, or a combination thereof.
- the present invention provides a method of making the compounded composition, including combining the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, with one or more one or more other components to form the compounded polyamide composition.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes combining the condensation polyamide and the maleated polyolefin before adding a chain extender thereto.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin.
- the method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone.
- the method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone.
- the method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin.
- the method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone.
- the method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone.
- the method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition.
- a barrel of a screw extruder includes the first compounder extruder zone and the second compounder extruder zone.
- the providing of the feed to the first compounder extrusion zone includes providing the feed to a feed inlet of the barrel, the barrel having a length.
- the chain extender is introduced to the second compounder extruder zone at least 1 ⁇ 4 of the length of the barrel from the feed inlet of the barrel.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin.
- the method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone.
- the method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone.
- the method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition.
- the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone includes introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide.
- the present invention provides a method of extruding a polyamide resin.
- the method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a feed zone of an extruder.
- the method includes maintaining extruder barrel conditions sufficiently to obtain the polyamide resin melt inside the extruder.
- the method includes producing extrudate from the extruder while optionally recovering vapor from the extruder via a vacuum draw.
- the present invention provides a method of molding a polyamide resin.
- the method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a mold.
- the method includes producing a molded polyamide resin from the mold.
- condensation polyamides having relatively high amine end group (AEG) numbers (as measured by titration of polymer solution in solvent such as methanol/phenol) together with certain maleated polyolefins, including those polyolefins having a relatively high degree of maleation.
- AEG amine end group
- the present invention provides a polyamide composition and method of making the same that can produce high quality extruded conduit, such as having superior properties to extruded conduit made from other polyamide compositions, such as increased resistance to glycolysis and high tensile strength.
- the present invention provides a polyamide composition that can be molded or extruded to produce an article having suitable properties for various end uses such as automotive, electronics, chemical processing, and heat transfer applications, such as having superior properties as compared to molded or extruded articles formed from other polyamide compositions, such as having higher tensile strength, higher chemical resistance, higher stress cracking resistance, or lower melt viscosities.
- the properties are equal or better than extruded or molded articles formed from HDPE, N11, N12, N612 and PVDF materials.
- the reinforced conduit of the present invention can have certain advantages over other conduits and reinforced conduits.
- the reinforced conduit of the present invention can have any property or advantage described herein for the extruded conduit including a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, and can further include additional properties and/or advantages due to the metal reinforcement such as described herein below.
- Polyamides such as nylon-6,6 normally contain an equilibrium amount of water. Water can promote the corrosion of certain metals such as certain types of steel (e.g., plain steel). Localized corrosion of a metal pipe can compromise strength and structural integrity of the pipe, and can cause delamination of an adjacent polyamide layer. Therefore, reinforced conduits including polyamides and corrodible metal reinforcements can suffer from degradation and failure.
- the reinforced conduit includes a metal reinforcement that includes a type of metal that is resistant to corrosion from water (e.g., aluminum, or a corrosion-resistant steel) and/or includes a metal reinforcement that has a protective coating thereon that reduces or eliminates corrosion of the metal reinforcement.
- Thermal expansion coefficients differ between certain metals and certain polyamides, such that temperature cycles can trigger delamination between the metal and the polyamide.
- carbon steel have a coefficient of expansion (COE) of 10.8 ⁇ 10 ⁇ 6
- HDPE has a COE of 100 ⁇ 10 ⁇ 6 to 200 ⁇ 10 ⁇ 6 .
- the extruded conduit and the metal reinforcement of the reinforced conduit can have a difference between their respective COEs such that the reinforced conduit is more resistant, or is immune, to delamination under the same conditions as compared to other reinforced conduits, such as compared to reinforced conduits including steel and HDPE.
- the COE of nylon-6,6 is about 62 ⁇ 10 ⁇ 6 to about 73 ⁇ 10 ⁇ 6 , which is closer to the COE of carbon steel than the COE of HDPE.
- any extruded conduit in contact with the process fluid need to be compatible with the process fluid.
- HDPE is not resistant to hydrocarbons and has a tendency to absorb hydrocarbons and swell.
- the reinforced conduit of the present invention includes an extruded conduit that includes a polyamide composition with greater compatibility with various process fluids such as hydrocarbons as compared to other extruded conduits, such as compared to extruded conduits including HDPE.
- process fluids such as hydrocarbons as compared to other extruded conduits, such as compared to extruded conduits including HDPE.
- the reinforced conduit of the present invention includes an extruded conduit that includes a polyamide composition (i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof) with higher permeation resistance to hydrogen gas than other polymers, such as compared to HDPE.
- a polyamide composition i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof
- the polyamide composition can have a lower likelihood of embrittlement when exposed to hydrogen gas.
- such embodiments of the reinforced conduit can have a longer lifetime when used for transport of hydrogen gas.
- the extruded conduit of the reinforced conduit can provide enhanced resistance to erosion from process fluids including slurries and/or solids due to the high abrasion resistance of polyamide composition of the extruded conduit (i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof), such as compared to pipes not including an extruded polymer conduit, or as compared to pipes including extruded polymer conduits formed from other materials.
- polyamide composition of the extruded conduit i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof
- Horizontal directional drilling is an attractive method of installing pipe, but imparts extreme wear on the outside of the pipeline being installed.
- the extruded conduit of the reinforced conduit can provide enhanced resistance to wear on the outside of the reinforced conduit, enabling the reinforced conduit to be installed via HDD or other wear-intensive methods more easily and at lower cost.
- values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
- a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range.
- the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.
- substantially refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.
- substantially free of can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt/o to about 5 wt % of the composition is the material, or about 0 wt % to about 1 wt %, or about 5 wt % or less, or less than, equal to, or greater than about 4.5 wt %, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt/o or less, or about 0 wt %.
- polymer refers to a molecule having at least one repeating unit and can include copolymers.
- conduit or “conduit structure”, as used herein, may refer to a hollow channel or duct suitable for conveying a fluid or passage for laying down and enclosing thin electrical wires and cables.
- the conduit cross-section may have a single hole or multiple holes depending on the application requirement.
- pipe may embody either right-cylindrical geometry, i.e., having circular cross-sectional shape, and other cross-sectional shapes which may be elongated in one axis perpendicular to the conduit long axis, for example, obround and oval cross-sectional shapes.
- N6 or “Nylon 6”, as used herein, refers to a polymer synthesized by polycondensation of caprolactam.
- the polymer is also known as polyamide 6, PA6, or poly(caprolactam).
- N66 or “nylon-6,6”, as used herein, refers to a polymer synthesized by polycondensation of hexamethylenediamine (HMD) and adipic acid.
- the polymer is also known as Polyamide 66 (or PA66), Nylon 66, nylon 6-6, nylon 6/6 or nylon-6,6.
- N12 or “Nylon 12”, as used herein, refers to a polymer synthesized by polycondensation of ⁇ -aminolauric acid or ring-opening polymerization of laurolactam.
- the polymer is also known as Polyamide 12 (or PA12), Nylon 12, poly(laurolactam), Poly(dodecano-12-lactam), poly(12-aminododecanoic acid lactam).
- N612 or “Nylon 612”, as used herein, refers to a polymer synthesized by polycondensation of hexamethylenediamine (HMD) and ⁇ , ⁇ -dodecanedioic acid [or C12 diacid].
- the polymer is also known as Polyamide 612 (or PA612), PA 6/12, Nylon 6/12.
- ylon 66/6T refers to a co-polymer obtained from N66 and a polymer of N6-terephthalic acid (TPA).
- PA610 or “nylon-6,10” is a semi-crystalline polyamide prepared from hexamethylenediamine (C 6 diamine, abbreviated as HMD) and decanedioic acid (C 10 diacid). It is commercially available from Arkema, BASF, and such.
- PA66/DI or “nylon-66/DI” refers to a type of co-polyamide of polyhexamethyleneadipamide (nylon-6,6 or N66 or PA66) and “DI” which is a combination of 2-methyl-pentamethylenediamine (or “MPMD”) and isophthalic acid.
- MPMD is commercially available as INVISTA Dytek® A amine and industrially known as “D” in the abbreviated formulation labeling.
- Isophthalic acid is commercially available and industrially known as “I” in the abbreviated formulation labeling.
- Composition Including a Condensation Polyamide and a Maleated Polyolefin.
- the present invention provides a composition including a condensation polyamide.
- the condensation polyamide is at least 30 wt % of the composition.
- the condensation polyamide is the predominant polyamide in the composition.
- the composition includes from ⁇ 10 wt % to ⁇ 50 wt % of a maleated polyolefin (e.g., ⁇ 15 wt % to ⁇ 50 wt %).
- the maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone.
- the maleated polyolefin has a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin.
- the maleated polyolefin, or domains thereof can have a uniform distribution in the condensation polyamide or composition (e.g., uniform molecular distribution of the maleated polyolefin in the condensation polyamide or composition, or uniform distribution of maleated polyolefin domains in the condensation polyamide or composition);
- the condensation polyamide can have an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., ⁇ 70 meq/kg and ⁇ 125 meq/kg);
- the condensation polyamide can have an RV of at least 35 (e.g., at least 40, or at least 45);
- the condensation polyamide can include nylon 66/6T, nylon 66/DI, nylon 66, or a combination thereof; or a combination thereof.
- the condensation polyamide can be one or more polyamides that can be formed via condensation (e.g., via reaction of an amine and carboxylic acid group to form an amide and release water).
- the condensation polyamide can include any suitable one or more condensation polyamides.
- the condensation polyamide can include nylon 66, nylon 66/6T, nylon 66/DI, or a combination thereof.
- the condensation polyamide can be nylon 66.
- the condensation polyamide can be substantially free of polyamides (prior to being combined into the composition and combining with any other polyamides therein) other than one or more of nylon 66, nylon 66/6T, and nylon 66/DI.
- the condensation polyamide can be nylon 66, and the condensation polymer (prior to being combined into the composition) can be substantially free of polyamides other than nylon 66.
- the condensation polyamide is the predominant polyamide in the composition, such that the condensation polyamide has a higher concentration in the composition than any other polyamide in the composition.
- the condensation polyamide can have any suitable relative viscosity (RV), such as determined via a formic acid method (e.g., ASTM D789), such as equal to or greater than 35, 40, or 45, or such as equal to or less than 100, 90, or 80, or such as less than or equal to 100 but equal to or greater than 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95, or such as 30-80, 35-75, or 42-50, or such as 35-100, 40-90, or 45-80.
- RV relative viscosity
- the condensation polyamide can be 30-99.9 wt % of the composition, 30-99.9 wt %, 60-99.9 wt %, or 90-99.9 wt %, or equal to or greater than 30 wt %, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, or 99.9 wt % of the composition.
- the condensation polyamide can have any suitable amount of amine end groups (AEG), such as ⁇ 80 meq/kg and ⁇ 125 meq/kg, ⁇ 80 meq/kg and ⁇ 120 meq/kg, or less than or equal to 125 meq/kg but greater than or equal to 80 meq/kg, 85, 90, 95, 100, 105, 110, 115, or 120 meq/kg.
- AEG amine end groups
- the composition can further include (in addition to the condensation polyamide) one or more other polyamides, copolymers thereof, or combinations thereof.
- the one or more other polyamides, copolymers thereof, or combination thereof can be different than the condensation polyamide (e.g., can be different polyamides having different structures and/or properties than the condensation polyamide).
- the additional polyamide can be or can include nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof.
- the one or more additional polyamides can form any suitable proportion of the composition, such as ⁇ 15 to ⁇ 85 wt %, ⁇ 20 to ⁇ 85 wt %, ⁇ 15 to ⁇ 80 wt %, ⁇ 15 to ⁇ 75 wt %, ⁇ 15 to ⁇ 70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %.
- the maleated polyolefin includes a polyolefin or polyacrylate backbone having pendant maleic anhydride groups grafted thereto.
- the polyolefin component can optionally be an ionomer.
- the polyolefin can be any suitable polyolefin polymer or copolymer.
- the polyolefin can include EPDM, ethylene-octene, polyethylene, polypropylene, or a combination thereof. In various aspects, the maleated polyolefin is free of EPDM.
- the maleated polyolefin can have any suitable grafted maleic anhydride incorporation, such as a grafted maleic anhydride incorporation of less than 10 wt %, or of 0.01 to 10 wt %, based on total weight of the maleated polyolefin, such as ⁇ 0.1 to ⁇ 1.4 wt %, ⁇ 0.15 to ⁇ 1.25 wt %, or less than or equal to 1.25 wt % but equal to or greater than 0.1 wt %, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, or 1.3 wt %.
- a suitable grafted maleic anhydride incorporation such as a grafted maleic anhydride incorporation of less than 10 wt %, or of 0.01 to 10 wt %, based on total weight of the maleated polyolefin, such as ⁇ 0.1 to ⁇ 1.4 wt %, ⁇
- the maleated polyolefin can have any suitable glass transition temperature (T g ), such as ⁇ 70° C. to ⁇ 0° C., ⁇ 60° C. to ⁇ 20° C., ⁇ 60° C. to ⁇ 30° C., or less than or equal to 0° C. but greater than or equal to ⁇ 70° C., ⁇ 65, ⁇ 60, ⁇ 55, ⁇ 50, ⁇ 45, ⁇ 40, ⁇ 35, ⁇ 30, ⁇ 25, ⁇ 20, ⁇ 15, ⁇ 10, or ⁇ 5° C.
- T g glass transition temperature
- the maleated polyolefin can form any suitable proportion of the composition, such as ⁇ 10 wt % to ⁇ 50 wt %, ⁇ 15 wt % to ⁇ 50 wt %, or less than or equal to 50 wt % but greater than or equal to 10 wt %, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 41, 42, 43, 44, 45, 46, 47, 48, or 49%.
- the maleated polyolefin can be any suitable maleic anhydride-grafted polyolefin.
- a variety of maleated polyolefins are commercially available. These may include, but are not limited to, AMPLIFY® GR Functional Polymers commercially available from Dow Chemical Co.
- Modification Level (wt %) in Polyolefin means the functionalized level in the polyolefin tested.
- polypropylene with 0.2-0.5 wt % modification level means it is a modified polyolefin having 0.2-0.5% grafted maleic anhydride content.
- the composition can include glass fibers or other glass reinforcements, or the composition can be substantially free of glass fibers or other glass reinforcements.
- the composition can include ⁇ 1 wt % to ⁇ 50 wt % glass fibers, ⁇ 10 wt % to ⁇ 42 wt %, ⁇ 10 wt % to ⁇ 35 wt %, ⁇ 15 wt % to ⁇ 30 wt %, or less than or equal to 50 wt % but equal to or greater than 5 wt %, 10, 15, 20, 25, 30, 35, 40, or 45 wt %.
- Disclosed compositions containing glass fiber can lend themselves to mixing, extrusion and molding more easily than would be predicted from the performance of more closely balanced (lower AEG) condensation polyamides.
- the present invention provides a reacted composition that is a reaction product of the composition including the condensation polyamide and the maleated polyolefin.
- the reacted composition can include a reaction product of the condensation polyamide and the maleated polyolefin, such as a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin.
- the reacted composition can include the composition including the condensation polyamide and the maleated polyolefin wherein any suitable proportion of the condensation polyamide has reacted with the maleated polyolefin.
- the reacted composition can include the polyamide-polyolefin copolymer in a concentration range of ⁇ 50 to ⁇ 7500 ppmw, ⁇ 100 to ⁇ 4900 ppmw, ⁇ 225 to ⁇ 3750 ppmw, or less than or equal to 7500 ppmw but greater than or equal to 50, 100, 250, 500, 750, 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 6,000, 7,000, or 8,000 ppmw.
- the reacted composition can include the same components in the same proportions as the composition including the condensation polyamide and the maleated polyolefin, with the exception that the condensation polyamide and the maleated polyolefin are at least partially reacted.
- PA means a polyamide (structure D).
- Polyamide is a type of synthetic polymer made by the linkage of an amino group of one molecule and a carboxylic acid group of another. Polyamides are also generically referred to as nylons.
- the olefin copolymer (structure A) may be any copolymer of ethylene, propylene, or butylene.
- the olefin copolymer may contain a suitable degree of maleation, e.g., maleic content, for example, between 0.05 to 1.5% by weight.
- This material can be referred to as “modified polyolefin” or “maleated polyolefin” (structure C).
- degree of maleation or “modification level”, as used interchangeably herein, means the extent of which the olefin copolymer (structure A) has been reacted with maleic anhydride (structure B).
- the polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin is structure E.
- the maleated polyolefin, domains thereof, or reaction products thereof with the condensation polyamide can have any suitable distribution in the condensation polyamide (and in any additional polyamides present) or in the composition.
- the maleated polyolefin, or domains thereof can have a uniform or homogeneous distribution in the condensation polyamide (and any additional polyamides present) or in the composition on a molecular level, such that the molecules of the maleated polyolefin are homogeneously distributed therein.
- the maleated polyolefin or reaction product thereof can forms domains within the condensation polymer (and any other polyamides present) or within the composition; in some aspects, the maleated polyolefin or reaction product thereof can be at least partially immiscible with the condensation polymer.
- the condensation polymer (and any other polyamides present), or all polymeric components other than the maleated polyolefin, or the remainder of the composition can form a continuous phase, and the maleated polyolefin can form a discontinuous phase (domains) therein.
- the compounded polyamide composition described herein can include a uniform or homogeneous distribution of the maleated polyolefin, reaction products thereof, or domains of the maleated polyolefin or reaction products thereof.
- extruded materials described herein formed from the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, can include a uniform or homogeneous distribution of the maleated polyolefin, reaction products thereof, or domains of the maleated polyolefin or reaction products thereof.
- the present invention provides a compounded polyamide composition.
- the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin and/or a reaction product of the composition.
- the compounded polyamide composition also includes one or more other components.
- the compounded polyamide can be extrudable, such that the compounded polyamide can be extruded to form an extrudate or an extruded article.
- the compound polyamide can be moldable, such that the polyamide can be placed into a mold and cooled to form a molded article.
- the one or more other components can include any suitable one or more components.
- the one or more other components can include a modified polyphenylene ether, an impact modifier, a flame retardant, a chain extender, a heat stabilizer (e.g., Zytel® additives [DuPont], Irganox® sterically hindered additives [BASF], and such), a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof.
- a modified polyphenylene ether an impact modifier, a flame retardant, a chain extender, a heat stabilizer (e.g., Zytel® additives [DuPont], Irganox® sterically hindered additives [BASF], and such), a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof.
- a heat stabilizer e.g., Zytel
- Non-limiting examples of optional additives include adhesion promoters, biocides, anti-fogging agents, anti-static agents, anti-oxidants, bonding, blowing and foaming agents, catalysts, dispersants, extenders, smoke suppressants, impact modifiers, initiators, lubricants, nucleants, pigments, colorants and dyes, optical brighteners, plasticizers, processing aids, release agents, silanes, titanates and zirconates, slip agents, anti-blocking agents, stabilizers, stearates, ultraviolet light absorbers, waxes, catalyst deactivators, and combinations thereof.
- the one or more other components can include a chain extender.
- the chain extender can be capable of reacting with the amine and/or acid terminal groups of the condensation polyamide and/or of the reaction product thereof with the maleated polyolefin, thereby connecting two polyamide chains.
- the chain extender can be any suitable chain extender, such as a dialcohol (e.g., ethylene glycol, propanediol, butanediol, hexanediol, or hydroquinone bis(hydroxyethyl)ether), a bis-epoxide (e.g., bisphenol A diglycidyl ether), polymers having epoxide functional groups (e.g., as pendant and/or terminal functional groups), polymers including anhydride functional groups, bis-N-acyl bis-caprolactams (e.g., isophthaloyl bis-caprolactam (IBS), adipoyl bis-caprolactam (ABC), or terephthaloyl bis-caprolactam (TBC)), diphenyl carbonates, bisoxazolines, oxazolinones, diisocyanates, organic phosphites (triphenyl phosphite, caprolactam phosphite
- the chain extender can be a polymer including anhydride functional groups, such as a maleic anhydride-polyolefin copolymer (e.g., an alternating copolymer of maleic anhydride and ethylene).
- anhydride functional groups such as a maleic anhydride-polyolefin copolymer (e.g., an alternating copolymer of maleic anhydride and ethylene).
- chain extenders that are known to improve hydrolysis resistance are preferred.
- the chain extender can be any suitable proportion of the compounded polyamide composition, such as ⁇ 0.05 to ⁇ 5 wt % or ⁇ 0.05 to ⁇ 2 wt % of the compounded polyamide composition, or less than or equal to 5 wt % but greater than or equal to 0.05 wt %, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, or 4.8 wt %.
- the compounded polyamide composition can include the condensation polyamide and the maleated polyolefin and/or a reaction product thereof, wherein the maleated polyolefin is ⁇ 10 to ⁇ 50 wt % of the compounded polyamide composition.
- the compounded polyamide composition can include an additional polyamide (different than the condensation polyamide) that is ⁇ 15 to ⁇ 85 wt %, ⁇ 20 to ⁇ 85 wt %, ⁇ 15 to ⁇ 80 wt %, ⁇ 15 to ⁇ 75 wt %, or ⁇ 15 to ⁇ 70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %, such as nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT,
- the compounded polyamide composition can include 50-80 wt % of the condensation polyamide and 10-50 wt % of the maleated polyolefin, and/or a reaction product thereof.
- the compounded polyamide composition can further include 0 to 20 wt % polyamide 612; 0 to 20 wt % modified polyphenylene ether; 0 to 30 wt % flame retardant; 0 to 10 wt % combined chain extender, heat stabilizer and colorant additives; and 0 to 40 wt % combined filler and/or conductive fiber additives.
- the compounded polyamide composition can include glass fibers or other glass reinforcements, or the compounded composition can be substantially free of glass fibers or other glass reinforcements.
- the compounded composition can include ⁇ 1 wt % to ⁇ 50 wt % glass fibers, ⁇ 10 wt % to ⁇ 42 wt %, ⁇ 10 wt % to ⁇ 35 wt %, ⁇ 15 wt % to ⁇ 30 wt %, or less than or equal to 50 wt % but equal to or greater than 5 wt %, 10, 15, 20, 25, 30, 35, 40, or 45 wt %.
- Disclosed compositions containing glass fiber can lend themselves to mixing, extrusion and molding more easily than would be predicted from the performance of more closely balanced (lower AEG) condensation polyamides.
- composition, reaction product thereof, or compounded polyamide composition can be provided in a granulate physical form, such as 3 mm diameter 3-5 mm length cylindrical pellets.
- the compounded polyamide composition can include 70-80 wt % of a condensation polyamide that is PA66 having an RV of 35-50 and an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., equal to or less than 80 wt % and greater than or equal to 70 wt %, 71, 72, 73, 74, 75, 76, 77, 78, or 79 wt %), and 20-30 wt % of the maleated polyolefin (e.g., less than or equal to 30 wt % and greater than or equal to 20 wt %, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 wt %).
- a condensation polyamide that is PA66 having an RV of 35-50 and an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., equal to or less than 80 wt % and greater
- the compounded polyamide composition can include 30-50 wt % of a condensation polyamide that is PA66 having an RV of 35-50 and an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., less than or equal to 50 wt % and greater than or equal to 30 wt %, 32, 34, 36, 38, 39, 40, 41, 42, 43, 44, 45, 46, 48, or 49%), 20-40 wt % of an additional polyamide that is PA66/DI (e.g., equal to or less than 40 wt % and greater than or equal to 20 wt %, 22, 24, 26, 28, 30, 32, 34, 36, 38, or 239 wt %), 20-30 wt % of the maleated polyolefin (e.g., less than or equal to 30 wt % and greater than or equal to 20 wt %, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 a condensation poly
- Table 2 gives examples of component ranges for the compounded polyamide composition, given in parts b weight.
- the present invention provides an article that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same.
- the article (or the composition, reaction product thereof, or the compounded composition) can be characterized by superior resistance, when compared against a control, to at least one selected from: cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure.
- the superior properties can be retained after aging, such as greater than or equal to 50% retention of the superior properties after heat aging at 100-200° C., or 130-160° C., or 140° C., or 150° C.
- the salt can be any suitable salt, such as ZnCl 2 .
- the resistance to cold-temperature cracking can include resistance to cracking when cycled from room temperature, such as 20° C., to extreme low temperatures such as ⁇ 30° C., ⁇ 40° C., ⁇ 50° C. or lower.
- such cold-temperature cracking resistant compositions are suitable for automotive end-uses in extreme environments such as arctic climates.
- the control can differ by at least one of AEG, weight percentage of maleated polyolefin, and degree of maleation of the maleated polyolefin.
- the control can have the same composition as the article, the composition, the reaction product thereof, or the compounded composition, except that the polyamide in the control can have an AEG of ⁇ 60 meq/kg (or ⁇ 80 meq/kg, or ⁇ 70 meq/kg).
- the control can have the same composition as the article, the composition, the reaction product thereof, or the compounded composition, except that the control can be free of the maleated polyolefin, or, for example, can contain less than 0.05 wt % of maleated polyolefin, with the control having the condensation polyamide in place of the maleated polyolefin (e.g., the balance of the control is the condensation polyamide).
- the article, the composition, the reaction product thereof, or the compounded composition can be characterized by superior mechanical strength compared to the control.
- the article, the composition, the reaction product thereof, or the compounded composition can have a tensile strength of at least 30 MPa, or 30-200 MPa, or 40-150 MPa, or less than or equal to 200 MPa but greater than or equal to 30 MPa, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa.
- the article, the composition, the reaction product thereof, or the compounded composition can have any suitable melt strength, such as a melt strength of at least 0.1 Newton.
- the article, the composition, the reaction product thereof, or the compounded composition can have any suitable Flame Resistance rating, such as a Flame Resistance rating of V-0.
- the article, the composition, the reaction product thereof, or the compounded composition can have any suitable moisture level, such as less than or equal to 0.2 wt %.
- the article, the composition, the reaction product thereof, or the compounded composition can have a tensile strength, measured according to ISO 527 on dry-as-molded specimens, of at least 40 MPa (e.g., 40 MPa, or 40-200 MPa, or 40-150 MPa, or less than or equal to 200 MPa but greater than or equal to 40 MPa, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa), and a notched Charpy impact energy, measured at ⁇ 30° C.
- 40 MPa e.g., 40 MPa, or 40-200 MPa, or 40-150 MPa, or less than or equal to 200 MPa but greater than or equal to 40 MPa
- a notched Charpy impact energy measured at ⁇ 30° C.
- the “1eA” specifies the sub-method that was used.
- the sub-method specifies: (a) that the sample was tested edgewise and that the notch was prepare to a specified notch diameter.
- the article, the composition, the reaction product thereof, or the compounded composition can retain ⁇ 50% (e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%) of the tensile yield strength, tensile elongation at break, and/or tensile break strength after undergoing 1:1 (vol/vol) ethylene glycol:water exposure at 120° C.-130° C. for 1000 hrs.
- ⁇ 50% e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%
- the article, the composition, the reaction product thereof, or the compounded composition can retain ⁇ 50% (e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%) of the tensile yield strength, tensile elongation at break, and/or tensile break strength after undergoing 50 wt % aqueous zinc chloride solution exposure at 23° C. for 200 hours under 3% applied strain to the test specimens.
- ⁇ 50% e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%
- the article, the composition, the reaction product thereof, or the compounded composition, upon heat aging at 140° C. for 1000 hours, can have a tensile yield strength, measured according to ISO 527, of at least 40 MPa, and/or a notched Charpy impact energy, measured at 23° C. and according to ISO 179/1eA of at least 45 kJ/m 2 (e.g., at least 45, 55, 65, or 75 kJ/m 2 ).
- the article, the composition, the reaction product thereof, or the compounded composition, which upon heat aging at 140° C. for 1000 hours has a tensile break strength measured according to ISO 527 of at least 30 MPa (e.g., 30 MPa, or 30-200 MPa, or 30-150 MPa, or less than or equal to 200 MPa but greater than or equal to 30 MPa, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa), and/or a tensile elongation at break measured according to ISO 527 of at least 5%.
- 30 MPa e.g., 30 MPa, or 30-200 MPa, or 30-150 MPa, or less than or equal to 200 MPa but greater than or equal to 30 MPa
- the article is a molded article.
- the molded article can include glass fibers (e.g., ⁇ 1 to ⁇ 50% glass fiber, 10 wt. % to 45 wt. %, or 15 wt. % to 42 wt. %) and/or other glass reinforcements and/or can be resistant to cold-temperature cracking.
- the compounded glass-fiber reinforced materials of the present disclosure are also suitable for making Injection Molded (IM) parts for applications in the petrochemical and chemical treatment industry.
- IM Injection Molded
- Enhanced structural and cracking resistance performance of such molded parts and articles are particularly suitable for diesel-operated commercial vehicle filter housing applications, wherein impact resistance and toughness under the standard automotive OEMs temperature cycling protocols (for e.g.: ⁇ 40° C. to ambient temperatures) are desirable.
- One specific application is a filter housing molded part used in an aqueous urea solution injection system for selective catalytic reduction (SCR) of NO x emissions from a diesel combustion engine.
- SCR selective catalytic reduction
- the article is an extrudate, such as a conduit (e.g., a pipe).
- the extrudate can be substantially free of glass fibers or other glass reinforcements and/or can be resistant to glycolysis.
- the conduit can be chosen from rigid, flexible, curved, straight, bent (e.g., 90 degree bend or a bend with another angle), serpentine, partially corrugated, fully corrugated, and a combination thereof.
- the conduit can have a cross-section chosen from round, oval, oblong, square, rectangle, triangle, star, polygonal, and a combination thereof.
- the conduit can have any suitable dimensions, such as an outside diameter of 3 mm to 100 mm or 8 mm to 50 mm, and such as a wall thickness of 0.2 mm to 10 mm, or 0.5 mm to 3 mm.
- the extruded conduit that is substantially free of glass fibers can be selected from the group consisting of rigid, flexible, curved, bent, serpentine, partially corrugated and fully corrugated.
- a cross-section of the extruded conduit that is substantially free of glass fibers can be selected from the group consisting of round, oval, oblong, square, rectangle, triangle, star and polygonal.
- the extruded conduit that is substantially free of glass fibers can be a tube.
- the extruded conduit that is substantially free of glass fibers can be a pipe.
- a conduit may embody either right-cylindrical geometry, i.e., having circular cross-sectional shape, and other cross-sectional shapes which may be elongated in one axis perpendicular to the conduit long axis, for example, obround and oval shapes.
- a tube is characterized by its aspect ratio [L/D], i.e., a geometric ratio of tube length “L” to tube diameter “D”.
- L/D aspect ratio
- a tube having a diameter of 1 cm and 10 cm long will have the Aspect Ratio of 10 [10:1 L/D].
- the tube Aspect Ratio can have any range depending on the end-use application.
- the tube diameter “D” can be specified to be inside tube diameter or outside tube diameter.
- the tube can be straight, curved, bent, serpentine or corrugated along its length.
- various tube shapes may include short-length and long-length straight tube, angle bent tube [any angle from >0° and ⁇ 180° ], right angle or 90° bent tube, single-curvature or multiple-curvature tube such as a C-shaped, N-shaped, S-shaped, U-shaped, V-shaped, W-shaped, Z-shaped, etc., partially corrugated tube, fully corrugated tube, and other combinations.
- the conduit can have any suitable shape and any suitable number of layers.
- the conduit can have a single layer of material.
- the conduit can have two (e.g., outer and inner) or three (e.g., outer, middle, and inner) layers, or more than three layers.
- the individual layer thicknesses may be varied for the desirable mechanical, structural and burst strength performance.
- the industrial utility of the solution presented in this disclosure is apparent in an automotive application as heat exchanging conduit systems.
- Thin-walled, small-diameter conduits, both straight and corrugated, prepared according to the present disclosure can be effectively assembled for under-the-hood and electric component (e.g.: battery systems) cooling and heat transfer systems.
- Such conduit systems can be designed and engineered to circulate heat exchange medium (e.g.: water, glycol mixtures, coolants, refrigerants) across the various heat generating components for heat removal in a closed loop manner.
- heat exchange medium e.g.: water, glycol mixtures, coolants, refrigerants
- Current materials used for such purposes are low-cost EPDM rubber and high-cost PA11/PA12/PA612 specialty polyamides.
- the EPDM systems are bulky, heavy and require reinforcement wrapping.
- the specialty polyamides are light-weight and can be flexible but come at a great cost.
- the present solution addresses the current unmet need in this industrial application space.
- Examples of uses for pipes extruded from the composition, reacted composition, and/or compounded polyamide composition can include, but are not limited to, fluid flow lines, gas gathering, water management, oil and liquified NG (LNG) gathering in the oil and gas industry; municipal, industrial, wastewater, potable and irrigation water systems; hydrogen gas industry; electric cable conduits; and other applications where robust and durable piping is desirable.
- LNG oil and liquified NG
- extruded conduit of the present invention can be used as a component of a reinforced conduit, as described below
- the present invention provides a reinforced conduit.
- the reinforced conduit includes an extruded conduit including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof.
- the reinforced conduit also includes a metal reinforcement.
- the reinforced conduit can correspond to any suitable example of an extruded conduit described herein that includes the extruded conduit including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof, and that also includes a metal reinforcement.
- the extruded conduit can have any suitable wall thickness, such as 0.1 mm to 100 mm, or 1 mm to 20 mm, or 2 mm to 10 mm, or less than or equal to 100 mm and greater than or equal to 0.1 mm, 0.2, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 mm.
- any suitable wall thickness such as 0.1 mm to 100 mm, or 1 mm to 20 mm, or 2 mm to 10 mm, or less than or equal to 100 mm and greater than or equal to 0.1 mm, 0.2, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35,
- the extruded conduit can have any suitable diameter, such as an inside or outside diameter of 1 mm to 1000 mm, or 5 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 1 mm, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, or 950 mm.
- any suitable diameter such as an inside or outside diameter of 1 mm to 1000 mm, or 5 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 1 mm, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240
- the reinforced conduit can have any suitable diameter, such as an inside or outside diameter of 10 mm to 1000 mm, or 20 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 10 mm, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, or 650 mm.
- any suitable diameter such as an inside or outside diameter of 10 mm to 1000 mm, or 20 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 10 mm, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, or
- the reinforced conduit can have any suitable total conduit wall thickness, such as a thickness of 0.2 mm to 500 mm, or 1 mm to 200 mm, or less than or equal to 500 mm and greater than or equal to 0.2 mm, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, or 450 mm.
- any suitable total conduit wall thickness such as a thickness of 0.2 mm to 500 mm, or 1 mm to 200 mm, or less than or equal to 500 mm and greater than or equal to 0.2 mm, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6,
- the metal reinforcement can include any suitable type of metal or metals that function to reinforce the extruded conduit, and/or that can be reinforced by the extruded conduit.
- the metal reinforcement can include steel, aluminum, beryllium, copper, an alloy thereof, or a combination thereof.
- the metal reinforcement can include corrosion-resistant steel, such as stainless steel, austenitic steel, 304, 304L, 316, 316L, or a combination thereof.
- the metal reinforcement can include non-corrosion-resistant steel, such as carbon steel.
- the metal reinforcement can be free of protective coatings to protect the metal reinforcement from corrosion.
- the metal reinforcement include a protective coating that reduces and/or prevents corrosion of the metal, such as from water.
- Polyamides have a tendency to include water and to take up water from the environment, which can corrode metals that are not corrosion-resistant and that lack a protective coating that reduces and/or prevents corrosion of the metal.
- the metal reinforcement can directly contact the extruded conduit.
- the reinforced conduit can be substantially free of direct contact between the metal reinforcement and the extruded conduit, and contact that occurs between the metal reinforcement and the extruded conduit can occur via the protective coating.
- the protective coating can be any suitable protective coating, such as a hydrophobic and/or water-resistant material.
- the protective coating can include a polyolefin, a polycarbonate, a polyester, or a combination thereof.
- the protective coating can include polyethylene, polypropylene, a polyacrylate, a bio-derived polyolefin, or a combination thereof.
- the protective coating can include materials prepared from renewable raw materials.
- the protective coating can be adequately flexible to allow the metal component to be wrapped around the extruded conduit without cracking or damaging the coating.
- the protective coating can have any suitable thickness, such as a thickness of 1 micron to 5 mm, 50 microns to 2 mm, 100 microns to 1 mm, or less than or equal to 5 mm and greater than or equal to 1 micron, 2, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 250, 300, 400, 500, 600, 800 microns, 1 mm, 1.5, 2, 2.5, 3, 3.5, 4, or 4.5 mm.
- the metal reinforcement including any protective coating thereon can have any suitable thickness, such as a thickness of 0.01 microns to 100 mm, or 0.01 microns to 50 mm, or 0.01 microns to 1 mm, or 0.01 microns to 100 microns, or 0.1 microns to 60 microns, or 5 mm to 50 mm, or 10 mm to 30 mm, or less than or equal to 100 mm and greater than or equal to 0.01 microns, 0.05, 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, 1 mm, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90,
- the metal reinforcement can contact the extruded conduit, such as along the length of the extruded conduit.
- the extruded conduit can contact the metal reinforcement on an exterior of the extruded conduit, an interior of the extruded conduit, or a combination thereof.
- the metal reinforcement can be partially or fully embedded within the extruded conduit.
- the metal reinforcement can have any suitable shape.
- the metal reinforcement can include a sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof.
- the sleeve can include an unperforated solid sleeve, a perforated sleeve, a mesh sleeve, a braided sleeve, or a combination thereof.
- conventional metal component wrapping/winding techniques can be used and can in some aspects avoid or eliminate gaps in wrapping or wind of the metal reinforcement.
- the metal reinforcement can include a metal pipe, wherein the pipe can contact an exterior of the extruded conduit.
- the extruded conduit can be a liner in the pipe.
- the metal reinforcement can include a metal pipe, wherein the pipe can contact an interior of the extruded conduit.
- the pipe can be encased by the extruded conduit.
- the reinforced conduit can include a single one of the extruded conduits and a single one of the metal reinforcements, or the reinforced conduit can include more than one of the extruded conduits, the metal reinforcements, or more than one of both.
- the reinforced conduit can include one and not more than one of the metal reinforcements, or can include more than one of the metal reinforcements.
- the reinforced conduit can include one and not more than one of the extruded conduits, or can include more than one of the extruded conduits.
- each of the extruded conduits can have a composition that is independently selected, and each of the extruded conduits can have a composition that is the same or different.
- each of the metal reinforcements can be the same or different type and/or composition of metal reinforcement (e.g., sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof).
- metal reinforcement e.g., sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof.
- the reinforced conduit can further include one or more second extruded conduits.
- Each of the one or more second extruded conduits can be the same as the extruded conduit of the present invention (e.g., including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof), or can include a different extruded composition including one or more polymers.
- the reinforced conduit can include more than one of the extruded conduits, wherein each extruded conduit has a composition that is independently selected.
- the extruded conduits can be attached to one another end-to-end (e.g., the extruded conduits can be fused end-to-end and/or attached end-to-end via a fitting).
- each extruded conduit can be a different layer in the reinforced conduit.
- two or more of the extruded conduits can contact one another along their length (e.g., free of intervening layers), or two or more of the extruded conduits can be substantially free of contact between two or more of the extruded conduits along their length (e.g., includes one or more intervening layers between the extruded conduits, such as the metal reinforcement).
- the metal reinforcement can be present between two or more of the extruded conduits along their length.
- the metal reinforcement can be within inside surfaces of two or more of the extruded conduits along their length.
- the metal reinforcement can be outside of two of more of the extruded conduits along their length.
- the radial placement of the metal reinforcement layer between the inner and outer extruded conduit layers can depend on the processing conditions, the type of intended use of the reinforced conduit, and the operating environment of the reinforced conduit.
- the metal reinforcement layer can be closer to the outer surface than the inner surface when the external operating pressure will be higher than the internal operating pressure.
- the metal replacement layer can be closer to the inner surface than the outer surface when the internal operating pressure will be higher than the external operating pressure.
- the metal replacement layer can be approximately midway between the inner surface and the outer surface.
- Reinforced conduits for applications such as high pressure or vacuum can include multiple metal components and/or thicker metal components.
- two or more of the extruded conduits in the reinforced conduit have approximately the same thickness.
- two or more of the extruded conduits in the reinforced conduit can have different thicknesses.
- the reinforced conduit can include an inner layer including the extruded conduit; a middle layer contacting the inner layer, the middle layer including the metal reinforcement, and an outer layer contacting the middle layer, the outer layer including another one of the extruded conduits.
- the metal reinforcement can include any suitable metal reinforcement, such as a metal sleeve, a wound layer of metal fibers, a metal tape, or a combination thereof.
- the metal reinforcement can include a protective coating, or can be free of a protective coating that reduces and/or prevents corrosion.
- the reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm.
- the inner layer can have a thickness (i.e., wall thickness) of 1 mm to 20 mm, or 3 mm to 15 mm.
- the middle layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm.
- the outer layer can have a thickness of 1 mm to 20 mm, or 3 mm to 15 mm.
- the reinforced conduit can include an inner layer including the extruded conduit; and an outer layer contacting the inner layer, the outer layer including the metal reinforcement, wherein the metal reinforcement includes a metal pipe or metal sleeve.
- the metal reinforcement can include a protective coating, or the metal reinforcement can be free of a protective coating that reduces and/or prevents corrosion.
- the reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm.
- the inner layer can have a thickness of 1 mm to 50 mm, or 3 mm to 35 mm.
- the outer layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm.
- the reinforced conduit can include an inner layer including the metal reinforcement, wherein the metal reinforcement includes a metal pipe or metal sleeve.
- the reinforced conduit can also include an outer layer contacting the inner layer, wherein the outer layer includes the extruded conduit.
- the metal reinforcement can include a protective coating, or the metal reinforcement can be free of a protective coating that reduces and/or prevents corrosion.
- the reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm.
- the inner layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm.
- the outer layer can have a thickness of 1 mm to 50 mm, or 3 mm to 35 mm.
- the reinforced conduit can have any suitable length. For example, shorter segments can be up to the length of a flatbed truck, and longer segments can be coiled. Metal and/or mechanical fittings can be used to fuse the reinforced conduit into a continuous pipeline.
- the reinforced conduit can be useful for a wide variety of applications.
- the reinforced conduit can be used underground, above-ground, sub-sea.
- the reinforced conduit can be used for aerospace applications such as atmospheric applications and space applications.
- the reinforced conduit can be used for transporting fluids, irrigation, agricultural infrastructure, oilfield fluids, sub-sea drilling, off-shore platforms, and the like.
- the reinforced conduit can be used for conveying/transporting light hydrocarbons such as natural gas (NG or LNG), propane (LPG), C 1 -C 2 hydrocarbons and hydrogen mixtures; various liquids of industrial use such as irrigation water, waste water, salt water, and cooling water; chemically compatible solvents/reagents, acids, and bases; slurries that may be abrasive to the contact surfaces, for example, coal liquids/slurries, cement slurries, on-shore/off-shore oilfield liquids; intermediate process streams in industrial manufacturing plant facilities, brine, fire water retention and transport, natural gas and/or hydrogen mixtures, and sour gas (H 2 S-containing); and combinations thereof.
- NG or LNG natural gas
- propane (LPG) propane
- C 1 -C 2 hydrocarbons and hydrogen mixtures hydrogen mixtures
- various liquids of industrial use such as irrigation water, waste water, salt water, and cooling water
- chemically compatible solvents/reagents, acids, and bases such as slurries that may be
- the article, the composition, the reaction product thereof, or the compounded composition can have any suitable Flame Resistance rating, such as a Flame Resistance rating of V-0 or V-1.
- any suitable Flame Resistance rating such as a Flame Resistance rating of V-0 or V-1.
- Underwriters' Laboratories Test No. UL 94 serves as one Industry Standard test for flame retardant thermoplastic compounds. “UL 94 Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances” gives details of the testing method and criteria for rating.
- the test method ASTM D635 is Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position;
- the test method ASTM D3801 is Standard Test Method for Measuring the Comparative Burning Characteristics of Solid Plastics in a Vertical Position.
- Vertical burning test ratings e.g.: V-0, V-1, V-2
- Horizontal burning ratings HB-1, HB-2, HB-3.
- the V-0 rating is distinguished from V-1 and V-2 ratings, which are less acceptable if one is seeking the best flame retardance rating. For certain uses, V-1 is acceptable.
- the UL 94 Flammability test performance rating may be assessed at various thicknesses, for instance and without limitation, 3.18 mm, 3.0 mm, 1.5 mm, 0.71 mm, 0.4 mm.
- a UL 94 V-0 rating at a thickness as thin as 3.18 mm, it is known that a plastic article having any larger thickness will also achieve a UL 94 V-0 rating.
- Obtaining a V-0 rating is more difficult to achieve in thinner test specimens, such as for 0.4 mm or 0.71 mm thicknesses, than thicker ones.
- Rate flammability tests such as but not limited to, the Limiting Oxygen Index (LOI) test (ASTM 2863); the cone calorimetry instrument (which measures amount and rate of heat release during combustion) ASTM E 1354 and ISO 5660-1 Standards are both based upon this instrument; Glow Wire Flammability (IEC 60695-2-12); Glow Wire Ignition (IEC 60695-2-13).
- LEO Limiting Oxygen Index
- ASTM E 1354 and ISO 5660-1 Standards are both based upon this instrument
- Glow Wire Flammability IEC 60695-2-12
- Glow Wire Ignition tests which exist to rate flame retardancy which are application specific, these include but are not limited to applications such as; apparel fabrics, upholstery fabrics, airbag fabrics, carpets, rugs.
- flame retardant additives and flame retardant additive systems well known in the art.
- flame retardant additives and flame retardant additive systems for instance and without limitation: halogen-containing flame retardants, halogen-containing flame retardants with synergists, phosphorus-containing flame retardants, inorganic flame retardants, nitrogen-containing flame retardants, nitrogen-containing flame retardants with synergists, these may be used alone or in combination.
- Plastics Additive Handbook, 5 th Ed., Ed Hans Zweifel, Hanser, 2000, ISBN 1-56990-295-X, Chapter 12 speaks to the general topic and in Table 12.1 p 688 exemplifies typical flame retardant additive system and the levels of flame retardant additives used in polyamides.
- Plastic Additives 4 th Ed., ed R Gumbleter and H Müller, Hanser, 1993, ISBN 3-446-17571-7, Chapter 12 speaks to the general topic and in Table 7 p 739 exemplifies flame retardant additives and the levels of flame retardant additives used in polyamides. Flame Retardants for Plastics and Textiles Practical Applications, Ed Edward D. Weil, Sergei V. Levchik. 2nd Edition, Hanser 2016, ISBN: 978-1-56990-578-4, Chapter 5, p 117 speaks to the topic of flame retardant additives and flame retardant additive systems for polyamides and exemplifies flame retardant additives and the levels of flame retardant additives used in polyamides throughout.
- Flame Retardants for Polyamides (General Application Data on Flame-Retardants for Polyamides 6 and 6,6), historically available at http://icl-ip.com/wp-content/uploads/2012/02/Polyamide-gnl-130729.pdf.
- Halogen-containing flame retardant additives include, but not limited to: brominated polystyrene; poly(dibromostyrene); poly(pentabromobenzylacrylate); brominated polyacrylate; brominated epoxy polymer; epoxy polymers derived from tetrabromobisphenol A and epichlorohydrin; ethylene-1,2-bis(pentabromophenyl); Dechlorane Plus; chlorinated polyethylene; and mixtures thereof.
- Halogen-containing flame retardant additives with synergists include, but are not limited to: the halogen-containing flame retardant additive together with a synergist, such as but not limited to: antimony (III) oxide, antimony (V) oxide, sodium antimonate; iron (II) oxide, iron (II/III) oxide, iron (III) oxide, zinc borate, zinc phosphate, zinc stannate, and mixtures thereof.
- a synergist such as but not limited to: antimony (III) oxide, antimony (V) oxide, sodium antimonate; iron (II) oxide, iron (II/III) oxide, iron (III) oxide, zinc borate, zinc phosphate, zinc stannate, and mixtures thereof.
- Phosphorus-containing flame retardant additives include, but are not limited to: red phosphorus, ammonium polyphosphate, melamine polyphosphate, melamine pyrophosphate, metal dialkylphosphinates (such as but not limited to aluminum methylethylphosphinate, and aluminum diethylphosphinate), aluminum hypophosphite, and mixtures thereof.
- Inorganic flame retardant additives include, but are not limited to: magnesium hydroxide, alumina monohydrate, alumina trihydrate, aluminum hydroxide, and mixtures thereof.
- Nitrogen-containing flame retardant additives include, but not limited to: melamine cyanurate, melamine polyphosphate, melamine pyrophosphate, melamine, melan, and mixtures thereof.
- Nitrogen-containing flame retardant additives with synergists include, but not limited to: nitrogen-containing flame retardant additives together with a synergist, such as but not limited to, Novalac resins. Small amounts of polytetrafluoroethylene are often incorporated into a flame retardant additive system to retard dripping.
- the literature of flame retardant additive systems also speaks to the different mechanisms by which the flame retardant additive imparts its flame retardant properties which may be active in the condensed phase, the gas phase or both.
- the flame retardant additive may act as a heat sink or may participate in the formation of char (called an intumescent system) limiting heat and mass transportation, or provide conduction of heat away by evaporation, or mass dilution.
- the gas phase flame retardants may act by interrupting the combustion chemistry by providing volatile species that form radicals in the gas phase which quench the radical chain reactions that would otherwise initiate or propagate the fire.
- the composition, reacted composition, compounded polyamide composition, or article formed therefrom may aid the effectiveness by which these flame retardant mechanisms may work.
- the present invention provides a method of making the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same.
- the method can include combining the condensation polyamide and the maleated polyolefin to form the composition, the reacted composition, the compounded composition, or a combination thereof.
- a method of forming the article can include making the composition, reaction product thereof, or compounded polyamide composition; alternatively, the composition, reaction product thereof, or compounded polyamide composition can be pre-formed before the onset of a method of forming the article.
- the present invention provides a method of making the compounded composition, including combining the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, with one or more one or more other components to form the compounded polyamide composition.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition can be a method of improving glycolysis resistance of the condensation polyamide, wherein the composition, reaction product thereof, or compounded composition including one or both of the same, has greater glycolysis resistance than the condensation polyamide.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition can include combining the condensation polyamide and the maleated polyolefin, or compounding the composition or reaction product thereof, in the absence of added glass fibers.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes combining the condensation polyamide and the maleated polyolefin (e.g., and allowing the two to at least partially react to form a reaction product thereof) before adding a chain extender thereto.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes combining the condensation polyamide, the maleated polyolein, and the chain extender at once without allowing any extra time for the condensation polyamide and the maleated polyolefin to react.
- the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin.
- the method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone.
- the method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone.
- the method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition.
- the second compounder extruder zone is downstream of the first compounder extruder zone and can be any suitable distance from the first compounder extruder zone; the chain extender can be added at any suitable location along the length of the screw extruder barrel.
- the first compounder extruder zone can be substantially free of the chain extender, and/or of any chain extender.
- the chain extender can be ⁇ 0.05 to ⁇ 5 wt % of the second compounded polyamide melt.
- the method can further include producing an article from the second compounded polyamide melt; for example, the method can include producing extrudate from the second compounded polyamide melt, or producing a molded article from the second compounded polyamide melt.
- the extruder used to make the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition can be a screw extruder (e.g., a single screw extruder, a vented twin-screw extruder, or an unvented twin-screw extruder).
- a barrel of the screw extruder can include the first compounder extruder zone and the second compounder extruder zone.
- Providing the feed to the first compounder extrusion zone can include providing the feed to a feed inlet of the barrel.
- the chain extender can be introduced to the second compounder extruder zone in the barrel a suitable distance away from the feed inlet.
- the chain extender can be introduced to the second compounder extruder zone at least 1 ⁇ 4 of the length of the barrel from the feed inlet of the barrel.
- the chain extender can be introduced to the second compounder extruder zone at least 1 ⁇ 2 of the length of the barrel from the feed inlet of the barrel.
- the chain extender can be introduced to the second compounder extruder zone at least 3 ⁇ 4 of the length of the barrel from the feed inlet of the barrel.
- the chain extender can be introduced to the second compounder extruder zone sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt, and equal to or greater than 1 ⁇ 4 of the length of the barrel from the feed inlet of the barrel, or 1 ⁇ 2, 3 ⁇ 4, or more.
- the chain extender can be introduced to the second compounder extruder zone sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt, and equal to or greater than 20% of the length of the barrel from the feed inlet of the barrel, or 30%, 40, 50, 60, 70, 80, 90, or 95% or more of the length of the barrel from the feed inlet of the barrel.
- the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone can include introducing the chain extender to the first compounded polyamide melt after a certain weight percentage of the maleated polyolefin has incorporated into the condensation polyamide or into the composition.
- Incorporation into the condensation polyamide or into the composition can include homogeneous blending of the chain extender with the condensation polyamide or the composition (e.g., on a molecular level, or of domains of the maleated polyolefin or a reaction product thereof), formation of a reaction product of the maleated polyolefin (e.g., with the condensation polyamide), formation of domains of the maleated polyolefin or a reaction product thereof in the condensation polyamide or the composition, or a combination thereof.
- the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone can include introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide, or greater than or equal to 50%, 60%, 70%, 80%, 90%, greater than or equal to 95%, or after about 100% of the maleated polyolefin has incorporated into the condensation polyamide.
- the present invention provides a method of extruding a polyamide resin (e.g., a method of forming an extruded article).
- the method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a feed zone of an extruder.
- the method includes maintaining extruder barrel conditions sufficiently to obtain the polyamide resin melt inside the extruder.
- the method includes producing extrudate (e.g., a conduit) from the extruder while optionally recovering vapor from the extruder via a vacuum draw.
- compounded polyamide resin pellets can be added to an extrusion apparatus and the polyamide resin can be melted.
- thermoplastic resins into conduits or tubes of desired shapes and forms
- melting may be done in an extruder with single screw or twin-screw to produce a homogeneous melt.
- Tube head temperature can be maintained within 280-300° C. of the melt temperature of polymer.
- the extrudate can be cooled in air or using coolant.
- coolant method a calibrator with a coolant, such as water in the temperature range of 40-70° C., can also be used.
- the flow rate of water in the cooling tank is maintained such that outside skin freezes instantaneously upon contact, and the outside tube temperature is within 5-10° C. of the glass transition temperature of polymer.
- the extrusion apparatus includes a static mixer and a rotating screw design configured to melt the polyamide containing thermoplastic resin.
- a single screw extruder, a twin-screw extruder, a vented single screw extruder, or a vented twin screw extruder is used.
- the polyamide thermoplastic resin can be melted at temperature ranging from 240 to 320° C., or from 250 to 310° C.
- thermoplastic tube The melted polyamide thermoplastic resin is then extruded and passed through a tube forming zone of the extrusion apparatus to form the thermoplastic tube. Positive pressure may be applied to the internal cavity of the formed tube through mandrel or pin.
- the process further includes the step of passing the portion of a thermoplastic tube through a dryer.
- the residence time from extrusion to tube forming is less than 60 minutes, for example, less than 50 minutes, for example, less than 40 minutes.
- tube forming zones include, but are not limited to, spiral or basket shaped die head, transition zone, a heated mandrel with or without a heated pin which forms at least a portion of a thermoplastic tube.
- positive pressure may be applied to the internal cavity of the formed tube through mandrel or pin.
- the process of the present invention further includes passing the melted polyamide thermoplastic resin through a screen to remove any contaminants or un-melted portions prior to extrusion.
- the screen may be reinforced by a breaker plate to create pressure in the extruding apparatus.
- An extruded conduit can be a multi-layer conduit including one or more layers formed from the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, or a monolayer conduit formed from the composition.
- Monolayer conduits can optionally include up to 2 wt % (actives) UV-grade colorant.
- Multi-layered conduits can include inside/outside surface skin layers and can include up to 1 wt % (actives) non-UV grade colorant.
- the extruded conduit the article can be characterized, when compared against a control, by superior resistance to at least one selected from cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure.
- the present invention provides a method of molding a polyamide resin (e.g., a method of forming a molded article).
- the method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a mold.
- the method includes producing a molded polyamide resin from the mold.
- a twin-screw vented extruder having 18-mm diameter co-rotating screw with a 40-56 L/D (i.e., L/D ratio of 40-56) was used for compounding.
- the unit had one main feeder and at least three side feeders.
- a feed rate of at least 1 kg/hr was used.
- the twin-screw co-rotating/turning at least 1000 RPM was sufficient to provide high shear for effective compounding.
- the total compounder throughput was at least 15 kg/hr.
- the compounding unit had at least three vent ports: one atmospheric port and two vacuum ports.
- a knock-out pot was provided in this operation.
- the rotating twin screws imparted forward momentum to the heated mass inside the barrel.
- the barrel was heated along its length to melt the polymer. Typically, 240-320° C. was used for nylon 66.
- the processing section of the twin-screw compounder was set up to suit various process needs and to allow a wide variety of processes, such as compounding processes.
- Polymer, fillers, and additives (as desired) were continuously fed into the first barrel section of the twin screw using a metering feeder.
- the products were conveyed along the screw and were melted and mixed by kneading elements in the plastification section of the barrel.
- the polymer then traveled along to a side port where fillers (if desired), such as but not limited to glass fiber, could be added.
- the polymer then traveled on to degassing zones and from there to a pressure build zone where it then exited the die via an at least 3-mm hole as a lace.
- the cast lace was fed into a water bath to cool and to enable it to be cut into chips via a pelletizer.
- the unit was able to withstand at least 70 bar die pressure.
- the compounded pellet having a diameter of 3 mm and a length of 3-5 mm was produced using the above equipment.
- the moisture content of the pelletized material was ⁇ 0.2 wt. %.
- Flammability testing was established by performing a test functionally equivalent to the UL 94 Standard.
- the compounded polyamide resin pellets were added to an extrusion apparatus and the polyamide resin was melted.
- the extrusion apparatus included a static mixer and a rotating screw design configured to melt the polyamide-containing thermoplastic resin, generally at a temperature between 260 and 310° C.
- Use of the static mixer in the was found to significantly improve the surface quality of the inside surface of the tube. When a static mixer was used in the process, the inside surface of the tube was observed to have a glossy finish.
- Other advantages of using a static mixer included thermal homogenization, minimization of melt memory, uniform viscosity and density, enhanced mixing of colors and minor additives, efficient use of all raw materials, elimination of streaks or clouds in the pipe, consistent quality, and higher yield (e.g., less rejects).
- the process further includes the step of passing the portion of a thermoplastic tube through a dryer.
- Feedstock PA66 polyamide is a commercially available INVISTA nylon 66 (or N66) grade under the Tradename INVISTATM U4800 polyamide resin.
- the PA66 has standard RV range of 42-50.
- the feedstock PA66 may also have RV ranging from 80 to 240.
- High-AEG polyamide 66 or “High AEG N66” is commercially available from INVISTA.
- High-AEG polyamide 66 is characterized by its RV range of 30-80, for example 35-75 RV, for example, 35-70 RV, and AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg of the polyamide resin, for example 270 meq/kg and ⁇ 125 meq/kg, ⁇ 75 meq/kg and ⁇ 125 meq/kg, ⁇ 80 meq/kg and ⁇ 125 meq/kg, 290 meq/kg and ⁇ 120 meq/kg of the polyamide resin.
- PA 66/6T refers to a type of partially aromatic polyamide that is commercially available from manufacturers including Arkema, BASF, DuPont, DSM and EMS.
- PA 66/6T is a type of co-polyamide prepared from PA66 and “6T”.
- the 6T part is a combination of hexamethylene diamine and terephthalic acid “T”.
- PPE is commercially available from Asahi Kasei, SABIC, Mitsubishi and LG Chem.
- “Amplify® GR216” is a maleic anhydride grafted and is commercially available from Dow Chemical.
- PA612 is commercially available from DuPont, EMS, Shakespeare, Nexis.
- PA612 is a semi-crystalline polyamide prepared from hexamethylenediamine (C6 diamine, abbreviated as HMD) and dodecanedioic acid (C 12 diacid, abbreviated as DDDA).
- Epolene E-43P is commercially available from Westlake Chemical.
- ZeMac E60 is a chain extender that is a copolymer of maleic anhydride and ethylene and is commercially available from Vertellus.
- BK34 is a colorant additive and is commercially available from AmeriChem, Clariant.
- Zerotel FE7108 is commercially available from DuPont, AmeriChem.
- Diethylphosphinic Acid Aluminum salt (CAS No. 225789-38-8) belongs to a family of dialkyl phosphinic acid salts. It is commercially available for use as flame retardant in engineering plastics such as polyamides, polyesters, thermosets and elastomers.
- Rianox® U-Pack B1171 a commercial polymer additive product of Rianlon, is a blend of hindered phenolic antioxidant and a phosphite for processing and long-term thermal stabilization.
- Staxol® P100 is a type of hydrolysis stabilizer commercially available from Lanxess.
- ASTM D789 Relative viscosity (RV) measurement method.
- ASTM D638-14 Tensile strength (MPa) measurement method.
- ISO 75 Heat Deflection Temperature [HDT] measurement method.
- ISO 178 Flexural Stress and Flexural Modulus measurement method.
- ISO 180 Izod Notched Impact Strength (23° C., kJ/m2) measurement method.
- ISO 188 Method of heat aging used for test samples.
- ISO 307 Viscosity Number (VN) method using sulfuric acid.
- ISO 527 Tensile Modulus and % Elongation-at-Break measurement method.
- UL 94 Std. Flammability [V-0/V-1/V-2] Rating Determination method.
- ISO 179/2-1eU Notched and Un-Notched Charpy Impact.
- ISO 11357 Melting point via DSC.
- Injection molded tensile and impact bars were used for testing.
- a mixture of glycol/water at 1:1 volume ratio was prepared and cast into a pressure vessel. Then, the bars were fully immersed in the glycol/water mixture and the pressure vessel was sealed. Pressure and temperature were both slowly increased to achieve the desired level. The exposure temperature and time were 100-130° C. and 1000-3000 hours, respectively. Test bars were removed for tensile and impact testing at the interval of 500 hours.
- Injection molded tensile and impact bars were used for testing. Bars were heat-aged according to ISO 188. After heat-aging, the bars were cooled to room temperature in the lab, and tensile stress, elongation at break, and impact properties were measured using the appropriate methods listed above.
- Tables 4A and 4B give compositional ranges for the several polyamide samples that were compounded using the general procedure detailed above.
- the compounded polyamide specimens A through M in Tables 4A-B were obtained as cylindrical pellets of dimension 3 mm diameter and 3-5 mm length.
- a conduit was extruded from melted compounded polyamide resins of Examples 1 (A-M) using a vented twin-screw extruder.
- the molten polymer was passed through a screen into a heated spiral or basket-type die head where the polymer came in contact with a mandrel.
- the melted polymer then flowed into the gap between the pin of the mandrel and the sleeve, referred to as the die-gap, where the polymer was cooled down.
- the conduit wall thickness was controlled by the die-gap, swell ratio, and orientation ratio.
- Typical extrusion conditions are as follows: Screw RPM 40-200; Grooved bush temp 40-200° F.; Barrel Temps. (5 barrels) 505-580° F.; Die Temp. (5 die heads) 500-550° F.
- the compounded resin composition was passed through the die-gap, it was then passed through a calibrator ring, which was used to size the conduit to the correct outer diameter. Water may or may not be used in the calibrator ring as a lubricant to minimize sticking.
- the calibrator ring also has the ability to pull a vacuum for correctly sizing the outer diameter of the conduit.
- the conduit was then moved through two or more cooling tanks with either water spray of atomized droplets or a water bath to cool the conduit to less than 150° C.
- the extruded conduit (or tube) used in most Examples herein has standard Aspect Ratio (L/D) of between 5 and 100 with 0.8-5 cm outside diameter and wall thickness in the range of up to 3 mm.
- the extruded conduit (tube) was produced in a continuous fashion to either make continuous coils or cut into straight section of desired length using a saw. However, the same or similar conditions can be utilized to manufacture bigger or smaller tube sizes with standard L/D ranging from 5 to 1000.
- Examples A-H compounded resins were extruded in the form of a cylindrical conduit of dimension 8-50 mm outside diameter ⁇ variable linear length, with a wall thickness in the range 0.5-3 mm.
- the extruded cylindrical conduits included straight and corrugated designs. These conduit specimens were tested for flexibility, mechanical strength, chemical resistance (particularly, salt resistance), glycolysis resistance, hydrolysis resistance, heat aging, and flame resistance.
- extruded conduits according to the present Example showed improved performance with respect to their mechanical strength, chemical resistance (ZnCl 2 salt resistance), glycolysis resistance, hydrolysis resistance, heat aging, and flame resistance.
- the extruded conduits according to the present Example showed improved flexibility without causing any stress cracking for a long in-use duration.
- Example Example Performance Property 1A 1E 1F Moisture Absorption, at 50% RH (%) 2.1 1.9 2.2
- Notched Charpy Impact DAM 102 101 107 (kJ/m 2 ) 23° C.
- Notched Charpy Impact at 130 128 132 50%RH (kJ/m 2 ) ⁇ 30° C.
- Notched Charpy Impact DAM 47 61 90 (kJ/m 2 ) ⁇ 30° C. Notched Charpy Impact at 71 67 85 50%RH (kJ/m 2 ) 23° C. Un-Notched Charpy Impact, DAM NB NB NB NB ⁇ 30° C. Un-Notched Charpy Impact, DAM NB NB NB Flexural Modulus, DAM (MPa) 1530 1500 1430 Melt Temperature (° C.) 262 255 262 RH—Relative Humidity; DAM—Dry as Molded; NB—No Break
- Notched Charpy Impact 122 100 96 COND (kJ/m 2 ) ⁇ 30° C.Notched Charpy Impact 33 87 15 DAM (kJ/m 2 ) ⁇ 30° C. Notched Charpy Impact, 38 92 21 COND (kJ/m 2 ) 23° C. Un-Notched Charpy NB/NB NB/NB NB/NB Impact, DAM/COND ⁇ 30° C.
- the inventive test specimens according to the present Example have the following properties: Tensile strength >40 MPa (DAM) and >30 MPa (at 50% RH). Elongation @ Break >100% (DAM) and >200% (at 50% RH). Notched Charpy Impact @ 23° C.>100 kJ/m 2 and @ ⁇ 30° C.>20 kJ/m 2 . Un-Notched Charpy Impact @ 23° C. and @ ⁇ 30° C. “No Break”. Moisture uptake ⁇ 2.5% at 50% RH conditioned specimens. Low water vapor permeation of ⁇ 30 mg/h/m 2 . Low conductivity of >10 12 Ohm ⁇ cm. Extruded or molded articles sustain 1.5-2.5 bars (5 bars maximum) operating pressure.
- Chemical exposure or aging performance Retained ⁇ 50% mechanical properties after 50:50 (vol/vol) glycol:water exposure at 100° C. for 2000 hours or at 130° C. for 1000 hours; Retained ⁇ 50% mechanical properties after 50% zinc chloride solution exposure at 23° C. for 200 hours; Retained ⁇ 50% mechanical properties after heat aging at 110° C. or 140° C. for 1000 hours.
- test bar specimens prepared from the Example 1 formulations were exposed to 50% aqueous zinc chloride (ZnCl 2 ) solution.
- the exposure time was 200 hours at 23° C. and under 3% sustained strain to simulate the tube bending condition.
- the salt resistance test was performed according to the SAE J2260 (1996) Test Method Section 7.5.
- Table 6 provides the measured Break Strength (in MPa), Tensile Elongation of Break (%), and Tensile Modulus (in MPa) for the tested specimens exposed to salt solution at 23° C. and under 3% strain.
- the test results labeled “Before” are for test specimens that were not exposed to the salt solution.
- the test results labeled “After 3%” are for test specimens that had been exposed to salt solution for 200 hours with 3% sustained strain applied.
- Example 1A Example 1E
- Example 1F Before After 3% Before After 3% Before After 3% Before After 3% Break strength (MPa) 42 41 41 40 44 42
- Tensile Elongation at break (%) 99 162 56 237 133
- Tensile Modulus (MPa) 2065 1717 2144 1924 1903 1662
- the surface porosity of the extruded articles is controlled to a desired distribution.
- the multi-layer tubes have a round cross-sectional profile, with a wall that includes an inner layer and an outer layer, with a middle layer sandwiched between and in contact with the inner layer and the outer layer.
- Table 7A provides the details for the three co-extruded multi-layered tubes.
- Table 7B provides the details for co-extruded multi-layered pipes according to the present Examples. It will be understood that there no limit on the number of co-extruded layers and their combinations will depend on the end-use application.
- Inner Layer Thickness 0.5-5 mm [No inner 0.5-5 mm Material Any of the layer] Any of the modified PP, modified PP, modified modified HDPE, PA12, HDPE, PA12, PA6, 12, PPS, PA6, 12, PPS, PPA, ETFE PPA, ETFE Middle Layer Thickness 4.5-75 mm 4.5-75 mm 4-70 mm Material Modified 10-50% 10-50% PA66 glass/carbon glass/carbon fiber/carbon fiber/carbon black filled black filled PA66 PA66 Outer Layer Thickness [No outer 0.5-5 mm 0.5-5 mm Material layer] Any of the Any of the modified modified PP, modified PP, modified HDPE, PA12, HDPE, PA12, PA6, 12, PPS, PA6, 12, PPS, PPA, ETFE PPA, ETFE
- the co-extruded multi-layer pipes shown in Table 7B are useful in oil and gas processing, water management systems, and in other such applications as conduits for electrical and fiber optic cabling, hydrogen gas processing, and the like.
- the inner and/or outer layer (or conduit skin) materials may be appropriately selected to be chemically compatible in end-use fluid flow applications where the fluid is in direct contact.
- test bar specimens prepared from the Example 1 formulations, were exposed to 50% aqueous glycol solution. The exposure time was maintained for 504 hours and 1008 hours at the constant test temperature of 120° C.
- Table 8 provides the measured Break Strength (in MPa), Tensile Elongation of Break (%), and Tensile Modulus (in MPa) for the tested specimens exposed to glycol at 120° C.
- the test results labeled “Before” are for test specimens that have not been exposed to glycol solution. Surprisingly, the elongation at break was observed to be >100% for Example 1 (F) even after 1008 hrs of glycol exposure at 120° C.
- Example 1A Example 1E
- Example 1F 504 1008 504 1008 504 1008 before hr hr Before hr hr Before hr hr Break strength (MPa) 42 27 23 41 26 25 44 28 26
- MPa 1008 504 1008 Before hr hr Before hr hr Before hr hr Break strength (MPa) 42 27 23 41 26 25 44 28 26
- MPa Tensile Elongation at break 99 101 55 56 97 43 133 112 105 (%)
- Heat aging performance testing was performed at 140° C. for some of the test bar specimens prepared from the Example 1 formulations.
- Table 9 provides the measured Break Strength (in MPa), Tensile Modulus (in MPa), and Notched Charpy 23° C. (kJ/m 2 ) for the tested specimens.
- the property measurements were conducted at 200 hr, 400 hr, 600 hr and 1000 hr heat aging increments.
- the test results labeled “Before” are for test specimens before the heat aging test.
- Example 1A Example 1E
- Example 1F 200 400 600 1000 200 400 600 1000 200 600 1000 Before h h h h Before h h h Before h 400 h h Break 47 48 48 46 43 46 45 46 43 46 47 46 46 41 strength (MPa)
- Modulus (MN) Notched 102 85
- 64 49 101 80 65 57 47 107 88 74 68
- Charpy 23° C. (kJ/m 2 )
- Formulations 1A and 1F were compounded with chopped E-glass fiber (ChopVantage® HP 3610 chopped strands) to obtain reinforced materials that are suitable for injection molded applications, as shown in Table 10 (all values are on the weight basis).
- chopped E-glass fiber ChopVantage® HP 3610 chopped strands
- the compounded polyamide formulation in the present disclosure may include from 1 wt. % up to 50 wt. % glass fiber, of the total weight, for example, from 10 wt. % up to 45 wt. % glass fiber, for example from 15 wt. % up to 42 wt. % glass fiber.
- test specimens of Table 10 had unexpected mechanical, chemical resistance, hydrolysis resistance, salt resistance, and fuel/oil resistance properties, as listed below.
- Hydrolysis Resistance Properties Hydrolysis resistance after exposed to glycol/water 50/50 at 130° C. for 1008 hrs. Tensile strength: 70-90 MPa. Elongation at break: >5%. Un-Notched Charpy at 23° C.: 40-50 kJ/m 2 .
- Urea Resistance Properties Urea resistance after exposed to aqueous urea solution at 60-80° C. for 3000 hrs. Tensile strength: 70-90 MPa. Elongation at break: >5%. Un-Notched Charpy at 23° C.: 50-70 kJ/m 2 .
- Fuel/Oil Resistance Properties Motor oil resistance after exposure at 150 ZC for 5000 hrs. Tensile strength: 90-110 MPa. Elongation at break: 3-5%. Un-Notched Charpy at 23° C.: 40-70 kJ/m 2 .
- the glass-fiber reinforced materials from Examples 9A-B were injection molded into suitable shaped parts depending on the end-use application. These IM parts were subjected to the standard temperature cycling protocols practiced in the automotive OEM industry.
- Table 11 lists compositional ranges and some embodiments of several polyamide samples that were compounded using the general procedure detailed above.
- the compounding for the Table 11 compositions was performed using a conventional screw type extruder and in the 240-265° C. temperature range.
- This instant interaction between the chain extension additive and the polyamide component(s) may lead to a rapid rise in the molecular weight build and viscosity, both being detrimental for compounding process operability.
- the interaction can be controlled by adding the chain extender a suitable distance away from the polyamide and modified polyolefin addition point (e.g., the main throat of the compounding extruder) to allow suitable time for the polyamide and modified polyolefin to react, by avoiding adding chain extender until a suitable percentage of the modified polyolefin has incorporated and/or reacted with the polyamide, or a combination thereof.
- the above-compounded polyamide specimens Q through Z in Table 11 are obtained as cylindrical extruded pellets of dimension 2-4 mm diameter and 3-5 mm length.
- a round cross-section pipe was extruded from melted compounded polyamide resins of Examples 11Q-Z using a vented twin-screw extruder, as described in Example 2.
- the extruded pipe herein has standard Aspect Ratio (L/D) of up to 15,000 with 5.08-61 cm (2′′ to 24′′) outside diameter “D” and wall thickness in the range of 5 to 80 mm.
- the extruded pipe is produced in a continuous fashion to either make continuous long section that can be loosely coiled or cut into straight short sections of desired lengths.
- a 7.62 cm (3′′) outside diameter pipe having 10 mm thickness wall and about 1500 cm (50 ft) length straight section is continuously extruded (200 Aspect Ratio).
- a 10.16 cm (4′′) outside diameter pipe having 20 mm thickness wall and about 2000 cm ( ⁇ 100-ft) length straight section is continuously extruded (300 Aspect Ratio).
- Such multi-layered conduits may include annular layers or a surface skin or a jacket.
- Materials suitable for layering may include modified polypropylene, modified HDPE, PA12, PA612, PPS, PPA, ETFE, and such.
- the extruded pipe section may contain an inner layer (or skin) having a thickness of between 0.5-4 mm.
- the extruded pipe section may contain an outer layer (or skin) having a thickness of between 0.5-4 mm.
- the extruded pipes may include straight designs for mono- as well as multi-layered piped of desired diameters, wall thicknesses, and linear lengths.
- test specimens of Table 11 have the mechanical and structural performance described in Table 12A-F.
- Table 12A-F data is measured for dry as molded (DAM) test specimens unless otherwise indicated.
- the measured heat deflection temperature (HDT) ranges for Table 12 formulations (DAM specimens) were 50-60° C. at 1.8 MPa and 75-90° C. at 0.45 MPa.
- the moisture absorption for the below test specimens was ⁇ 2.1 wt % at equilibrium conditions.
- Formulation 1F was compounded with chopped E-glass fiber (e.g.: ChopVantage® HP 3610 chopped strands) and polyamide (e.g., nylon-6,6 such as 45 RV High AEG PA66) to obtain reinforced materials having glass fiber reinforcement in the 35-45 wt. % range. Such reinforced compounded materials are suitable for injection molded applications. Tables 13A-C (weight basis) show these compounded materials.
- chopped E-glass fiber e.g.: ChopVantage® HP 3610 chopped strands
- polyamide e.g., nylon-6,6 such as 45 RV High AEG PA66
- the polyamide used was poly(hexamethylene adipamide) or nylon-6,6.
- Tables 14A-L list the measured mechanical strength properties characteristics of some of the Table 13A-C compounded materials prepared and tested according to the present disclosure. All specimens were tested under a dry-as-molded (DAM) condition unless otherwise indicated.
- DAM dry-as-molded
- Example ID 14G 14I 14J 0 hr 500 hr 0 hr 500 hr 0 hr 500 hr hr
- Tensile strength (MPa) 149.9 71.3 164.2 76.8 135.0 71.3 Elongation @ break (%) 5.3 6.7 4.7 5.9 5.9 6.7 Chord Modulus (GPa) 10.5 3.788 11.2 4.660 9.5 4.220
- a round cross-section monolayer pipe was extruded from melted compounded polyamide resin formulation “T” of Example 11 (Table 11) except that the black MB colorant additive used was a UV-grade carbon black at about 2.0 wt. % active concentration level in the total formulation.
- Pipe extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section pipe sections can be extruded using any of the formulations described in Table 11 of Example 11.
- Example 16 Extrusion of Compounded Resins of Example 11 in Multi-Layer Pipe Shape
- a round cross-section multi-layer pipe was extruded from melted compounded polyamide resin formulation “W” of Example 11 (Table 11) that contains about 1.0 wt. % (active in total) non-UV grade black MB colorant. Pipe extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section pipe sections can be extruded using any of the formulations described in Table 11 of Example 11.
- the multilayer wall pipe section included a 20-mm thickness annular core section of formulation “W” of Table 11 (Example 11) having an inside 3-mm thick as well as outside 3-mm thick surface skin of HDPE.
- the multilayer wall pipe section was about 4.5′′ O.D. and 50-ft long.
- Such durable pipe is industrially useful for conveying flowable materials that are compatible with direct HDPE surface contact.
- Example 17A-D formulations Component [basis: wt. %] 17A 17B 17C 17D Fed at the main throat (or hopper) of compounding extruder 48 RV PA66 (U4800) — — 75.1 — High AEG PA66 (45 RV) 68 38.8 — 37.8 PA66/DI (45 RV) — 29 — 29 Impact Modifier (e.g.: Dow 25 25 22 25 Amplify TM GR216 or ExxonMobil VA1840) Black Colorant (e.g.: carbon 1-3 % loading black (CB), or Nigrosine For example - 1% active loading black dye) of non-UV grade carbon black or 2% active loading of UV grade Heat Stabilizer (e.g.: Cu- 0.5-2.0 based or organic based such as Irganox ® B1171) Fed at mid-way (side feed) of compounding extruder High AEG PA66 (45 RV) 4.75 4.75 — 4.5 Chain Extender (
- the High AEG PA66 feed was split with a major portion fed at the main throat (or hopper) of the compounding extruder with other listed ingredients. The remaining portion was blended with the chain extender additive and the blend is fed at mid-way (side feed) of the compounding extruder. Homogeneous dispersion and mixing of the ingredients were observed in each case.
- the compounding extruder was a vented twin-screw extruder, as described in Example 2.
- the screw speed is 450 RPM with 70-80% torque.
- the compounded resin, in each case, was pelletized into 3 mm diameter and 3-4 mm extrudates with a moisture level of below 0.15 wt %.
- extrudates obtained as above were suitable for extruding conduits and pipes of the desired dimensions.
- Example 18 Extrusion of Compounded Resins of Example 11 in Monolayer Conduit Shape
- round cross-section, 2.54 cm (1′′) outside diameter ( ⁇ 3 mm wall thickness) monolayer conduits were extruded from each of the melted compounded polyamide resin formulations “Q” and “W” of Example 11 (Table 11) that contained about 1.0 wt. % (active in total) non-UV grade black MB colorant. Extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section conduits can be extruded using any of the formulations described in Table 11 of Example 11. The extruded conduit lengths can be varied to as short as inches to continuous large coilable sections, for example, 10-ft, 100-ft, 200-ft, 500-ft, and such.
- Example 19 Extrusion of Compounded Resins of Example 11 in Monolayer Conduit Shape
- round cross-section, 10.16 cm (4′′) outside diameter [ ⁇ 3 mm wall thickness] monolayer conduits are extruded from each, melted compounded polyamide resin formulations “Q” and “W” of Example 11 (Table 11) except that the black MB colorant additive used is a UV-grade carbon black at about 2.0 wt. % active concentration level in the total formulation.
- Extrusion was performed using a vented twin-screw extruder, as described in Example 2.
- Similar round cross-section conduits can be extruded using any of the formulations described in Table 11 of Example 11.
- the extruded conduit lengths can be varied to as short as inches to continuous large coilable sections, for example, 10-ft, 50-ft, 100-ft, 500-ft, and such.
- Example 20 2-8′′-Outside Diameter, Metal-Reinforced Modified PA66 Flow Conduit
- Example 1 and Example 11 are extruded into conduits as described in Examples 2 and 12, respectively, to fabricate a 6′′-outside diameter cylindrical-shaped flow conduit.
- the polyamide pellets are fed to a pipe extrusion equipment.
- a 0.5 mm to 20 mm thick metal sleeve layer is designed to be embedded in the polyamide matrix.
- the overall flow conduit thickness is 12 to 15 mm and the longitudinal length of the section is 5.4 meters (for a “stick”) to 152 meters (for a coiled product).
- Example 21 2-8′′-Outside Diameter, Metal-Reinforced Modified PA66 Flow Conduit
- a metal reinforced modified PA66 flow conduit is prepared according to Example 20 except the metal layer is wrapped around polymer liner (used for chemical and temperature resistance) and an external polymer shell/sleeve is used for abrasion (parallel) and impact (perpendicular) resistances to allow for faster and easier installation.
- the flow conduit also allows for the metal to be protected from corrosion thus removing the need for cathodic protection.
- Example 22 6′′-Outside Diameter Continuous Metal-Reinforced Modified PA66 Flow Conduit
- modified PA66 flow conduit section ends prepared according to Example 20, are melt-fused together to assemble a long flow conduit line and for use in the fluid transport service.
- the long line can be installed underground, above-ground or the combination of the two.
- the metal reinforcement of the modified PA66 flow line is beneficial for structural strength, integrity, and durability/life.
- Table 16 shows examples of various 3-layer reinforced conduits, which have modified PA66 layers that are prepared according to Example 20.
- Conduit Conduit Conduit Metal- Cross-section Cross-section cross-section reinforced having having having Conduit continuous wound wound Construction metal layer metal fiber metal tape Number of 3 3 3 layers Total conduit 20-50 min 20-50 mm 20-50 mm wall thickness Conduit 1′′ to 12′′ 1′′ to 12′′ 1′′ to 12′′ outside diameter Conduit Inside 142 for PA66 via 142 for PA66 via 142 for PA66 via Surface Williams-Hazen Williams-Hazen Williams-Hazen Roughness Coefficient Coefficient Coefficient Conduit length Vanes depending on end-use application Short segments suitable for handling on a flatbed truck to long coilable segment (up to 2000 feet) Conduit segments joined by fittings and fusing for a continuous flow path Inner Layer Total Thickness 5-10 mm 5-10 mm 5a-10 mm Material modified PA66 modified PA66 modified PA66 having chemical having chemical having chemical compatibility, compatibility, compatibility, hydrolysis hydrolysis hydrolysis resistance, salt resistance, salt resistance, salt cracking cracking cracking resistance resistance resistance resistance resistance
- Table 17 shows examples of various 2-layer reinforced conduits, which have modified PA66 layers that are prepared according to Example 20.
- Conduit Cross- Conduit Cross- Metal-reinforced section having section having Conduit continuous wound Construction metal layer metal fiber Number of layers 2 2 Total conduit wall 15-60 mm 15-60 mm thickness Conduit outside 1′′ to 12′′ 1′′ to 12′′ diameter Conduit Inside 142 for PA66 via About 135 to Surface Williams-Hazen about 145 via Roughness Coefficient Williams-Hazen Coefficient Conduit length Varies depending on end-use application Short segments suitable for handling on a flatbed truck to long coilable segment (up to 2000 feet) Conduit segments joined by fittings and fusing for a continuous flow path Inner Layer Total Thickness 5-30 mm 10-30 mm Material modified PA66 metal sleeve having chemical optionally compatibility, having a hydrolysis hydrophobic resistance, salt skin cracking [500 micron] resistance on both sides Outer Layer Total Thickness 10-30 mm 5-30 mm Material metal sleeve modified PA66 optionally having a having chemical hydrophobic skin compatibility, [500
- Aspect 1 provides a composition comprising
- condensation polyamide wherein the condensation polyamide is at least 30 wt % of the composition, wherein the condensation polyamide is the predominant polyamide in the composition;
- a maleated polyolefin e.g., ⁇ 15 wt % to ⁇ 50 wt %
- the maleated polyolefin comprises omaleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin;
- the maleated polyolefin, or domains thereof is/are uniformly distributed in the condensation polyamide or in the composition (e.g., with domains having a largest dimension of less than 1 micron, or 5 nm to less than 1,000 nm, or from 9 to 400 nm), or
- the condensation polyamide has an AEG of 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., ⁇ 70 meq/kg and ⁇ 125 meq/kg), or
- the condensation polyamide has an RV of at least 35 (e.g., at least 40, or at least 45), or
- the condensation polyamide comprises nylon 66, nylon 66/6T, nylon 66/DI, or a combination thereof, or
- Aspect 2 provides the composition of Aspect 1, wherein the condensation polyamide is chosen from nylon 66, nylon 66/6T, nylon 66/DI, and a combination thereof.
- Aspect 3 provides the composition of any one of Aspects 1-2, wherein the condensation polyamide is nylon 66.
- Aspect 4 provides the composition of any one of Aspects 1-3, wherein the condensation polyamide is 30-99.9 wt % of the composition.
- Aspect 5 provides the composition of any one of Aspects 1-4, wherein the condensation polyamide is 60-99.9 wt % of the composition.
- Aspect 6 provides the composition of any one of Aspects 1-5, wherein the condensation polyamide is 90-99.9 wt % of the composition.
- Aspect 7 provides the composition of any one of Aspects 1-6, wherein the composition further comprises one or more other polyamides, copolymers thereof, or combinations thereof, in addition to the condensation polyamide.
- Aspect 8 provides the composition of any one of Aspects 1-7, wherein the composition further comprises an additional polyamide comprising nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof.
- Aspect 9 provides the composition of Aspect 8, wherein the additional polyamide comprises nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, or a combination thereof.
- Aspect 10 provides the composition of any one of Aspects 8-9, wherein the additional polyamide is ⁇ 15 to ⁇ 85 wt % of the composition.
- Aspect 11 provides the composition of any one of Aspects 8-10, wherein the additional polyamide is ⁇ 20 to ⁇ 70 wt % of the composition.
- Aspect 12 provides the composition of any one of Aspects 1-11, wherein the condensation polyamide has an AEG of ⁇ 80 meq/kg and ⁇ 125 meq/kg.
- Aspect 13 provides the composition of any one of Aspects 1-12, wherein the condensation polyamide has an AEG of ⁇ 80 meq/kg and ⁇ 120 meq/kg.
- Aspect 14 provides the composition of any one of Aspects 1-13, comprising ⁇ 1 wt % to ⁇ 50 wt % glass fibers.
- Aspect 15 provides the composition of any one of Aspects 1-14, comprising ⁇ 10 wt % to ⁇ 42 wt % glass fibers.
- Aspect 16 provides the composition of any one of Aspects 1-15, comprising ⁇ 10 wt % to ⁇ 35 wt % glass fibers.
- Aspect 17 provides the composition of any one of Aspects 1-16, comprising ⁇ 15 wt % to ⁇ 30 wt % glass fibers.
- Aspect 18 provides the composition of any one of Aspects 1-17, wherein the maleated polyolefin comprises a polyolefin backbone that comprises EPDM, ethylene-octene, polyethylene, polypropylene, or a combination thereof.
- Aspect 19 provides the composition of any one of Aspects 1-18, wherein the maleated polyolefin is free of EPDM.
- Aspect 20 provides the composition of any one of Aspects 1-19, wherein the maleated polyolefin has a grafted maleic anhydride incorporation of ⁇ 0.1 to ⁇ 1.4 wt % based on total weight of the maleated polyolefin.
- Aspect 21 provides the composition of any one of Aspects 1-20, wherein the maleated polyolefin has a grafted maleic anhydride incorporation of ⁇ 0.15 to ⁇ 1.25 wt % based on total weight of the maleated polyolefin.
- Aspect 22 provides the composition of any one of Aspects 1-21, wherein the maleated polyolefin has a glass transition temperature (T g ) of ⁇ 70° C. to ⁇ 0° C.
- T g glass transition temperature
- Aspect 23 provides the composition of any one of Aspects 1-22, wherein the maleated polyolefin has a glass transition temperature (T g ) of ⁇ 60° C. to ⁇ 20° C.
- T g glass transition temperature
- Aspect 24 provides the composition of any one of Aspects 1-23, wherein the maleated polyolefin has a glass transition temperature (T g ) of ⁇ 60° C. to ⁇ 30° C.
- Aspect 25 provides a reacted composition that is a reaction product of the composition of any one of Aspects 1-24, wherein the reacted composition comprises a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin of the composition of any one of Aspects 1-24.
- Aspect 26 provides the reacted composition of Aspect 25, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ⁇ 50 to ⁇ 7500 ppmw, based on the total weight of the reacted composition.
- Aspect 27 provides the reacted composition of any one of Aspects 25-26, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ⁇ 100 to ⁇ 4900 ppmw, based on the total weight of the reacted composition.
- Aspect 28 provides the reacted composition of any one of Aspects 25-27, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ⁇ 225 to ⁇ 3750 ppmw, based on the total weight of the reacted composition.
- Aspect 29 provides a composition comprising:
- condensation polyamide having an AEG of ⁇ 65 milliequivalents per kg (meq/kg) and ⁇ 130 meq/kg (e.g., ⁇ 70 meq/kg and ⁇ 125 meq/kg), wherein the condensation polyamide is nylon 66 and is at least 30 wt % of the composition, wherein the nylon 66 is the predominant polyamide in the composition;
- a maleated polyolefin e.g., ⁇ 15 wt % to ⁇ 50 wt %
- the maleated polyolefin comprises maleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ⁇ 0.05 to ⁇ 1.5 wt % based on total weight of the maleated polyolefin.
- Aspect 30 provides a reacted composition that is a reaction product of the composition of Aspect 29, wherein the reacted composition comprises a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin of the composition of Aspect 29.
- Aspect 31 provides a compounded polyamide composition comprising:
- composition of any one of Aspects 1-24 the reacted composition of any one of Aspects 25-28, or a combination thereof;
- Aspect 32 provides the compounded polyamide composition of Aspect 31, wherein the compounded polyamide composition is extrudable.
- Aspect 33 provides the compounded polyamide composition of any one of Aspects 31-32, wherein the one or more other components comprise a modified polyphenylene ether, an impact modifier, a flame retardant, a chain extender, a heat stabilizer, a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof.
- the one or more other components comprise a modified polyphenylene ether, an impact modifier, a flame retardant, a chain extender, a heat stabilizer, a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof.
- Aspect 34 provides the compounded polyamide composition of any one of Aspects 31-33, wherein the one or more other components comprise a chain extender, wherein the chain extender is ⁇ 0.05 to ⁇ 5 wt % of the compounded polyamide composition.
- Aspect 35 provides the compounded polyamide composition of any one of Aspects 31-34, wherein the chain extender comprises a dialcohol, a bis-epoxide, a polymer comprising epoxide functional groups, a polymer comprising anhydride functional groups, a bis-N-acyl bis-caprolactam, a diphenyl carbonate, a bisoxazoline, an oxazolinone, a diisocyanate, an organic phosphite, a bis-ketenimine, a dianhydride, a carbodiimide, a polymer comprising carbodiimide functionality, or a combination thereof.
- the chain extender comprises a dialcohol, a bis-epoxide, a polymer comprising epoxide functional groups, a polymer comprising anhydride functional groups, a bis-N-acyl bis-caprolactam, a diphenyl carbonate, a bisoxazoline, an o
- Aspect 36 provides the compounded polyamide composition of any one of Aspects 31-35, wherein the chain extender comprises a maleic anhydride-polyolefin copolymer, such as an alternating copolymer of maleic anhydride and ethylene.
- the chain extender comprises a maleic anhydride-polyolefin copolymer, such as an alternating copolymer of maleic anhydride and ethylene.
- Aspect 37 provides the compounded polyamide composition of any one of Aspects 31-36 comprising:
- the maleated polyolefin that is ⁇ 10 to ⁇ 50 wt % of the compounded polyamide composition
- a chain extender that is ⁇ 0.05 to ⁇ 5 wt % of the compounded polyamide composition.
- Aspect 38 provides the compounded polyamide composition of any one of Aspects 31-37 comprising:
- nylon 66 and the maleated polyolefin are optionally partially reacted to form a polyamide-polyolefin.
- Aspect 39 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or the compounded polyamide composition of any one of Aspects 31-38, comprising an additional polyamide comprising nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof, wherein the additional polyamide is ⁇ 15 to ⁇ 85 wt % of the composition, or ⁇ 20 to ⁇ 85 wt %, ⁇ 15 to ⁇ 80 wt %, ⁇ 15 to ⁇ 75 wt %, ⁇ 15 to ⁇ 70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80
- Aspect 40 provides an article comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof.
- Aspect 41 provides the article of Aspect 40, wherein the article is an extrudate.
- Aspect 42 provides the article of any one of Aspects 40, wherein the article is a molded article.
- Aspect 43 provides the article of any one of Aspects 40-41, wherein the article is a conduit.
- Aspect 44 provides the article of Aspect 43, wherein the article is an extruded conduit, such as a monolayer or multi-layer conduit.
- Monolayer conduits can optionally include up to 2 wt % (actives) UV-grade colorant.
- Multi-layered conduits can include inside/outside surface skin layers and can include up to 1 wt % (actives) non-UV grade colorant.
- Aspect 45 provides the article of Aspect 44, wherein the extruded conduit is substantially free of glass fibers.
- Aspect 46 provides the article of Aspect 45, wherein the extruded conduit is selected from the group consisting of rigid, flexible, curved, bent, serpentine, partially corrugated and fully corrugated.
- Aspect 47 provides the article of Aspects 45-46, wherein a cross-section of the extruded conduit that is substantially free of glass fibers is selected from the group consisting of round, oval, oblong, square, rectangle, triangle, star and polygonal.
- Aspect 48 provides the article of Aspects 45-47, wherein the extruded conduit that is substantially free of glass fibers is a tube.
- Aspect 49 provides the article of Aspects 45-48, wherein the extruded conduit that is substantially free of glass fibers is a pipe.
- Aspect 50 provides the article of any one of Aspects 44-49, wherein the extruded conduit is resistant to glycolysis.
- Aspect 51 provides the article of any one of Aspects 43-50, wherein the conduit is chosen from rigid, flexible, curved, bent, serpentine, partially corrugated, fully corrugated, and a combination thereof.
- Aspect 52 provides the article of any one of Aspects 43-51, wherein the conduit has a cross-section chosen from round, oval, oblong, square, rectangle, triangle, star, polygonal, and a combination thereof.
- Aspect 53 provides the article of any one of Aspects 40-44 or 50-52, wherein the article comprises from ⁇ 15 to ⁇ 50% glass fiber and exhibits superior resistance to at least one of chemical, fuel/oil, hydrolysis, glycolysis, and salt exposure, as compared to a control, wherein the control differs by at least one of AEG, weight percentage of maleated polyolefin, and degree of maleation of the maleated polyolefin.
- Aspect 54 provides a reinforced conduit comprising:
- an extruded conduit comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof;
- Aspect 55 provides the reinforced conduit of Aspect 54, wherein the metal reinforcement comprises steel, aluminum, beryllium, copper, an alloy thereof, or a combination thereof.
- Aspect 56 provides the reinforced conduit of any one of Aspects 54-55, wherein the metal reinforcement comprises steel.
- Aspect 57 provides the reinforced conduit of any one of Aspects 54-56, wherein the metal reinforcement comprises corrosion-resistant steel.
- Aspect 58 provides the reinforced conduit of any one of Aspects 54-57, wherein the metal reinforcement comprises non-corrosion-resistant steel.
- Aspect 59 provides the reinforced conduit of Aspect 58, wherein the steel comprises carbon steel, stainless steel, austenitic steel, 304, 304L, 316, 316L, or a combination thereof.
- Aspect 60 provides the reinforced conduit of any one of Aspects 54-59, wherein the metal reinforcement is free of protective coatings to protect the metal reinforcement from corrosion.
- Aspect 61 provides the reinforced conduit of Aspect 60, wherein the metal reinforcement directly contacts the extruded conduit.
- Aspect 62 provides the reinforced conduit of any one of Aspects 54-59, wherein the metal reinforcement comprises a protective coating that reduces and/or prevents corrosion to the metal reinforcement.
- Aspect 63 provides the reinforced conduit of Aspect 62, wherein the protective coating has a thickness of 1 micron to 5 mm.
- Aspect 64 provides the reinforced conduit of any one of Aspects 62-63, wherein the protective coating has a thickness of 50 microns to 2 mm.
- Aspect 65 provides the reinforced conduit of any one of Aspects 62-64, wherein the protective coating has a thickness of 100 microns to 1 mm.
- Aspect 66 provides the reinforced conduit of any one of Aspects 62-65, wherein the metal reinforcement and the extruded conduit are free of direct contact and wherein contact between the metal reinforcement and the extruded conduit occurs via the protective coating on the metal reinforcement.
- Aspect 67 provides the reinforced conduit of any one of Aspects 62-66, wherein the protective coating comprises a hydrophobic and/or water-resistant material.
- Aspect 68 provides the reinforced conduit of any one of Aspects 62-67, wherein the protective coating comprises a polyolefin, a polycarbonate, a polyester, or a combination thereof.
- Aspect 69 provides the reinforced conduit of any one of Aspects 62-68, wherein the protective coating comprises polyethylene, polypropylene, a polyacrylate, a bio-derived polyolefin, or a combination thereof.
- Aspect 70 provides the reinforced conduit of any one of Aspects 54-69, wherein the metal reinforcement has a cross-section that is round, oval, square, rectangular, triangular, or a combination thereof.
- Aspect 71 provides the reinforced conduit of any one of Aspects 54-70, wherein the metal reinforcement including any protective coating thereon has a thickness of 0.01 microns to 100 mm.
- Aspect 72 provides the reinforced conduit of any one of Aspects 54-71, wherein the metal reinforcement including any protective coating thereon has a thickness of 0.1 microns to 60 mm.
- Aspect 73 provides the reinforced conduit of any one of Aspects 54-72, wherein the extruded conduit has a wall thickness of 0.1 mm to 100 mm.
- Aspect 74 provides the reinforced conduit of any one of Aspects 54-73, wherein the extruded conduit has a wall thickness of 1 mm to 20 mm.
- Aspect 75 provides the reinforced conduit of any one of Aspects 54-74, wherein the extruded conduit has a wall thickness of 2 mm to 10 mm.
- Aspect 76 provides the reinforced conduit of any one of Aspects 54-75, wherein the extruded conduit has an inside diameter of 1 mm to 1000 mm.
- Aspect 77 provides the reinforced conduit of any one of Aspects 54-76, wherein the extruded conduit has an inside diameter of 5 mm to 700 mm.
- Aspect 78 provides the reinforced conduit of any one of Aspects 54-77, wherein the reinforced conduit has an inside diameter of 10 mm to 1000 mm.
- Aspect 79 provides the reinforced conduit of any one of Aspects 54-78, wherein the reinforced conduit has an inside diameter of 20 mm to 700 mm.
- Aspect 80 provides the reinforced conduit of any one of Aspects 54-79, wherein the reinforced conduit has a total conduit wall thickness of 0.2 mm to 500 mm.
- Aspect 81 provides the reinforced conduit of any one of Aspects 54-80, wherein the reinforced conduit has a total conduit wall thickness of 1 mm to 200 mm.
- Aspect 82 provides the reinforced conduit of any one of Aspects 54-81, wherein the extruded conduit contacts the metal reinforcement on an exterior of the extruded conduit, an interior of the extruded conduit, or a combination thereof.
- Aspect 83 provides the reinforced conduit of any one of Aspects 54-82, wherein the metal reinforcement is partially or fully embedded within the extruded conduit.
- Aspect 84 provides the reinforced conduit of any one of Aspects 54-83, wherein the metal reinforcement comprises a sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof.
- Aspect 85 provides the reinforced conduit of any one of Aspects 54-84, wherein the sleeve comprises an unperforated solid sleeve, a perforated sleeve, a mesh sleeve, a braided sleeve, or a combination thereof.
- Aspect 86 provides the reinforced conduit of any one of Aspects 54-85, wherein the metal reinforcement comprises a pipe, wherein the pipe contacts an exterior of the extruded conduit, wherein the extruded conduit is a liner in the pipe.
- Aspect 87 provides the reinforced conduit of any one of Aspects 54-85, wherein the metal reinforcement comprises a pipe, wherein the pipe contacts an interior of the extruded conduit, wherein the pipe is encased by the extruded conduit.
- Aspect 88 provides the reinforced conduit of any one of Aspects 54-87, wherein the reinforced conduit comprises more than one of the metal reinforcements.
- Aspect 89 provides the reinforced conduit of any one of Aspects 54-88, wherein the reinforced conduit comprises no more than a single one of the metal reinforcement.
- Aspect 90 provides the reinforced conduit of any one of Aspects 54-89, wherein the reinforced conduit comprises no more than a single one of the extruded conduit.
- Aspect 91 provides the reinforced conduit of any one of Aspects 54-88, wherein the reinforced conduit further comprises one or more second extruded conduits, each of the one or more second extruded conduits comprising:
- Aspect 92 provides the reinforced conduit of any one of Aspects 54-88 or 91, wherein the reinforced conduit comprises more than one of the extruded conduits, wherein each extruded conduit has a composition that is independently selected.
- Aspect 93 provides the reinforced conduit of Aspect 92, wherein the extruded conduits are attached to one another end-to-end.
- Aspect 94 provides the reinforced conduit of Aspect 93, wherein the extruded conduits are fused end-to-end.
- Aspect 95 provides the reinforced conduit of Aspect 92, wherein each extruded conduit is a different layer in the reinforced conduit.
- Aspect 96 provides the reinforced conduit of Aspect 95, wherein two or more of the extruded conduits contact one another along their length.
- Aspect 97 provides the reinforced conduit of Aspect 95, wherein the reinforced conduit is substantially free of contact between two or more of the extruded conduits along their length.
- Aspect 98 provides the reinforced conduit of any one of Aspects 95-97, wherein the metal reinforcement is present between two or more of the extruded conduits along their length.
- Aspect 99 provides the reinforced conduit of any one of Aspects 95-98, wherein the metal reinforcement is within interior surfaces of two or more of the extruded conduits along their length.
- Aspect 100 provides the reinforced conduit of any one of Aspects 95-99, wherein the metal reinforcement is outside of two or more of the extruded conduits along their length.
- Aspect 101 provides the reinforced conduit of any one of Aspects 54-100, comprising:
- the middle layer comprising the metal reinforcement
- the outer layer comprising another one of the extruded conduit.
- Aspect 102 provides the reinforced conduit of Aspect 101, wherein the metal reinforcement comprises a metal sleeve, a wound layer of metal fibers, a metal tape, or a combination thereof.
- Aspect 103 provides the reinforced conduit of any one of Aspects 101-102, wherein the metal reinforcement comprises a protective coating.
- Aspect 104 provides the reinforced conduit of any one of Aspects 101-103, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm
- the inner layer has a thickness of 1 mm to 20 mm
- the middle layer has a thickness of 1 mm to 50 mm
- the outer layer has a thickness of 1 mm to 20 mm.
- Aspect 105 provides the reinforced conduit of any one of Aspects 101-104, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm
- the inner layer has a thickness of 3 mm to 15 mm
- the middle layer has a thickness of 5 mm to 35 mm
- the outer layer has a thickness of 3 mm to 15 mm.
- Aspect 106 provides the reinforced conduit of Aspect 54-100, comprising:
- the outer layer comprising the metal reinforcement, the metal reinforcement comprising a metal pipe or metal sleeve.
- Aspect 107 provides the reinforced conduit of Aspect 106, wherein the metal reinforcement comprises a protective coating.
- Aspect 108 provides the reinforced conduit of any one of Aspects 106-107, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm
- the inner layer has a thickness of 1 mm to 50 mm
- the outer layer has a thickness of 1 mm to 50 mm.
- Aspect 109 provides the reinforced conduit of any one of Aspects 106-108, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm
- the inner layer has a thickness of 3 mm to 35 mm
- the outer layer has a thickness of 5 mm to 35 mm.
- Aspect 110 provides the reinforced conduit of any one of Aspects 54-100, comprising:
- an inner layer comprising the metal reinforcement, the metal reinforcement comprising a metal pipe or metal sleeve;
- Aspect 111 provides the reinforced conduit of Aspect 110, wherein the metal reinforcement comprises a protective coating.
- Aspect 112 provides the reinforced conduit of any one of Aspects 110-111, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm
- the inner layer has a thickness of 1 mm to 50 mm
- the outer layer has a thickness of 1 mm to 50 mm.
- Aspect 113 provides the reinforced conduit of any one of Aspects 110-112, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm
- the inner layer has a thickness of 5 mm to 35 mm
- the outer layer has a thickness of 3 mm to 35 mm.
- Aspect 114 provides the article of Aspect 53, wherein the article is a molded article.
- Aspect 115 provides the article of Aspect 114, wherein the molded article is resistant to cold-temperature cracking.
- Aspect 117 provides the article of any one of Aspects 40-52 or 114-115, wherein the article is characterized by superior resistance to at least one selected from:
- Aspect 118 provides the article of Aspect 117, wherein the salt is ZnCl 2 .
- Aspect 119 provides the article of any one of Aspects 116-118, wherein the control is the same composition except that the polyamide in the control has an AEG of ⁇ 60 meq/kg.
- Aspect 120 provides the article of any one of Aspects 116-119, wherein the control is the same composition except that the control contains less than 0.05 wt % maleated polyolefin, and the balance of the composition is the polyamide.
- Aspect 121 provides the article of any one of Aspects 116-120, wherein the article is characterized by superior mechanical strength, as compared to the control.
- Aspect 122 provides the article of any one of Aspects 116-121, wherein the article has a Flame Resistance rating of V-0.
- Aspect 123 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-122, having a tensile strength of at least 30 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 124 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-123, having a tensile strength of 30-200 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 125 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-124, having a tensile strength of 40-150 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 126 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-125, wherein the article has a tensile strength, measured according to ISO 527 on dry-as-molded specimens, of at least 40 MPa, and a notched Charpy impact energy, measured at ⁇ 30° C. and according to ISO 179/1eA on dry-as-molded specimens, of at least 60 kJ/m 2 .
- Aspect 127 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-126, which retains ⁇ 50% of the tensile yield strength, tensile elongation at break, and tensile break strength after undergoing 1:1 (vol/vol) ethylene glycol:water exposure at 120° C.-130° C. for 1000 hrs.
- Aspect 128 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-127, which retains ⁇ 50% of the tensile yield strength, tensile elongation at break, and tensile break strength after undergoing 50 wt % aqueous zinc chloride solution exposure at 23° C. for 200 hours under 3% applied strain to the test specimens.
- Aspect 129 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-128, which, upon heat aging at 140° C. for 1000 hours, has a tensile yield strength, measured according to ISO 527, of at least 40 MPa, a notched Charpy impact energy, measured at 23° C. and according to ISO 179/1eA of at least 45 kJ/m 2 .
- Aspect 130 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-129, which upon heat aging at 140° C. for 1000 hours has a tensile break strength measured according to ISO 527 of at least 30 MPa, and a tensile elongation at break measured according to ISO 527 is at least 5%.
- Aspect 131 provides a method of making the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof comprising:
- Aspect 132 provides the method of Aspect 131, wherein the method is a method of making the reacted composition of any one of Aspects 25-28, further comprising at least partially reacting the condensation polyamide and the maleated polyolefin to form the reacted composition of any one of Aspects 25-28.
- Aspect 133 provides the method of any one of Aspects 131-132, wherein the method is a method of improving glycolysis resistance of the condensation polyamide, wherein the composition of any one of Aspects 1-24 or the reacted composition of any one of Aspects 25-28 has greater glycolysis resistance than the condensation polyamide.
- Aspect 134 provides the method of any one of Aspects 131-133, wherein the method comprises combining the condensation polyamide and the maleated polyolefin to form the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof, in the absence of added glass fibers.
- Aspect 135 provides a method of making the compounded composition of any one of Aspects 31-39 comprising:
- Aspect 136 provides the method of any one of Aspects 131-135, wherein the method comprises combining the condensation polyamide and the maleated polyolefin before adding a chain extender thereto.
- Aspect 137 provides the method of any one of Aspects 135-136, comprising:
- a feed comprising the condensation polyamide and the maleated polyolefin (e.g., at least 30 wt % condensation polyamide, from ⁇ 10 wt % to ⁇ 50 wt % or ⁇ 15 wt % to ⁇ 50 wt % of the maleated polyolefin, and optionally ⁇ 20 wt % to ⁇ 85 wt % of the additional polyamide);
- the maleated polyolefin e.g., at least 30 wt % condensation polyamide, from ⁇ 10 wt % to ⁇ 50 wt % or ⁇ 15 wt % to ⁇ 50 wt % of the maleated polyolefin, and optionally ⁇ 20 wt % to ⁇ 85 wt % of the additional polyamide
- the second compounded polyamide melt is the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or the compounded composition of any one of Aspects 31-39.
- Aspect 138 provides the method of Aspect 137, wherein the first compounder extruder zone is substantially free of the chain extender.
- Aspect 139 provides the method of any one of Aspects 137-138, wherein the first compounder extruder zone is substantially free of chain extenders.
- Aspect 140 provides the method of any one of Aspects 137-139, wherein the chain extender is ⁇ 0.05 to ⁇ 5 wt % of the second compounded polyamide melt.
- Aspect 141 provides the method of any one of Aspects 137-140, wherein a barrel of a screw extruder (e.g., a single screw extruder, a vented twin-screw extruder, or an unvented twin-screw extruder) comprises the first compounder extruder zone and the second compounder extruder zone, wherein the providing of the feed to the first compounder extrusion zone comprises providing the feed to a feed inlet of the barrel, wherein the barrel has a length.
- a screw extruder e.g., a single screw extruder, a vented twin-screw extruder, or an unvented twin-screw extruder
- Aspect 142 provides the method of Aspect 141, wherein the chain extender is introduced to the second compounder extruder zone at least 1 ⁇ 4 of the length of the barrel from the feed inlet of the barrel.
- Aspect 143 provides the method of any one of Aspects 141-142, wherein the chain extender is introduced to the second compounder extruder zone at least 1 ⁇ 2 of the length of the barrel from the feed inlet of the barrel.
- Aspect 144 provides the method of any one of Aspects 141-143, wherein the chain extender is introduced to the second compounder extruder zone at least 3 ⁇ 4 of the length of the barrel from the feed inlet of the barrel.
- Aspect 145 provides the method of any one of Aspects 141-144, wherein the chain extender is introduced to the second compounder extruder zone at least 1 ⁇ 4 of the length of the barrel from the feed inlet of the barrel and sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt.
- Aspect 146 provides the method of any one of Aspects 137-145, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide.
- Aspect 147 provides the method of Aspect 146, wherein the incorporation into the condensation polyamide comprises homogeneous blending (e.g., on a molecular level, or of domains of the maleated polyolefin or a reaction product thereof).
- Aspect 148 provides the method of any one of Aspects 146-147, wherein the incorporation into the condensation polyamide comprises formation of a reaction product of the maleated polyolefin.
- Aspect 149 provides the method of any one of Aspects 146-148, wherein the incorporation into the condensation polyamide comprises reaction of the maleated polyolefin with the condensation polyamide.
- Aspect 150 provides the method of any one of Aspects 146-149, wherein the incorporation into the condensation polyamide comprises formation of domains of the maleated polyolefin or a reaction product thereof in the condensation polyamide.
- Aspect 151 provides the method of any one of Aspects 146-150, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 60 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 152 provides the method of any one of Aspects 146-151, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 70 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 153 provides the method of any one of Aspects 146-152, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 80 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 154 provides the method of any one of Aspects 146-153, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 90 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 155 provides the method of any one of Aspects 146-154, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after about 100 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 156 provides the method of any one of Aspects 137-155, further comprising producing extrudate from the second compounded polyamide melt.
- Aspect 157 provides the method of any one of Aspects 137-156, further comprising producing a molded article from the second compounded polyamide melt.
- Aspect 158 provides a method of extrusion of a polyamide resin, the method comprising:
- Aspect 159 provides a method of molding of a polyamide resin, the method comprising:
- Aspect 160 provides the composition, reacted composition, compounded composition, article, or reinforced conduit of any one or any combination of Embodiments 1-159 optionally configured such that all elements or options recited are available to use or select from.
Abstract
Description
- This application is a continuation-in-part of international Application No. PCT/IB2020/059765 filed Oct. 16, 2020, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/925,524 filed Oct. 24, 2019, U.S. Provisional Patent Application Ser. No. 63/013,884 filed Apr. 22, 2020, U.S. Provisional Patent Application Ser. No. 63/071,715 filed Aug. 28, 2020, and U.S. Provisional Patent Application Ser. No. 63/071,728 filed Aug. 28, 2020, the disclosures of which are incorporated herein in its entirety by reference.
- The present disclosure provides polyamide compositions, methods for making the compositions and polyamide parts extruded or molded from the compositions, and reinforced conduits including an extruded conduit that includes the composition.
- Prior attempts at making pipeline articles from thermoplastic condensation polyamide resins, for example, poly-hexamethyleneadipamide (Nylon-6,6 or N66 or PA66) have shown limited success. Additional thermoplastic resin materials used in production of pipes include polyamide 11 (e.g. coiled N11 high pressure gas pipes at diameters up to 2 inches have been disclosed by Arkema); polyamide 12 (e.g. Evonik Degussa VESTAMID® NRG Polyamide 12 pipe, UBESTA polyamide 12 for burial and rehabilitation of existing cast iron and steel gas mains); polyamide 612 (e.g. DuPont PIPELON® polyamide 612 pipe) and polyvinylidene difluoride (PVDF).
- Thermoplastic condensation polyamide resins that are molded or extruded suffer from insufficient properties for various end uses such as automotive, electronics, chemical processing, and heat transfer applications. Various thermoplastic condensation polyamide resins that are molded or extruded have lower tensile strength, lower chemical resistance, lower stress cracking resistance, or higher melt viscosities (e.g., making extrusion difficult or impossible), than available HDPE, N11, N12, N612 and PVDF materials, especially in pipeline construction.
- International Application Publication No. WO2012/024268A1 relates to a thermoplastic pelletizable polymer composition including: (a) a polyamide; and (b) a polymer polymerized from maleic anhydride and an olefin; wherein the polyamide and the polymer are compounded.
- U.S. Pat. No. 9,353,262 discloses compositions including polyamides with such olefin-maleic anhydride polymers (OMAP).
- International Application Publication No. WO2014/100000A2 relates to polyamide compositions including 60 to 99.9% by weight of a polyamide and 0.5 to 40% by weight of an impact modifier containing maleic anhydride or a functional equivalent thereof. In these compositions, the moisture level is less than the equilibrium moisture content of the polyamide.
- International Application Publication No. WO2016/168306A2 relates to hydrophobic thermoplastic nylon compositions and to pipes and hollow conduits and to methods for making the same.
- European Patent Application Publication No. EP2562219A1 relates to thermoplastic molded substances with increased hydrolysis resistance.
- International Application Publication No. WO2012098063A1 relates to hydrolysis-stable polyamides.
- International Application Publication No. WO2010014791 A1 relates to heat resistant thermoplastic articles including polyhydroxy polymers.
- German Patent Application Publication No. DE102008008098A1 relates to polyamide-elastomer-mixtures having improved resistance to hydrolysis. The polyamide-elastomer blends can be processed to molded articles useful in the automotive sector.
- International Application Publication No. WO2009098305A1 relates to polyamide-elastomer mixtures having improved hydrolysis resistance. The polyamide-elastomer mixtures can be processed into molded parts used in the automotive field.
- International Application Serial No. PCT/US19/42101, filed 17 Jul. 2019 relates fiber including nylon-6,6 and maleated polyolefin exhibiting enhanced stain resistance.
- The present invention provides a composition including a condensation polyamide. The condensation polyamide is at least 30 wt % of the composition. The condensation polyamide is the predominant polyamide in the composition. The condensation polyamide can be one or more polyamides. The composition includes from ≥10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %). The maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone. The maleated polyolefin has a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin. The condensation polyamide can be any one or more suitable condensation polyamides. The maleated polyolefin, or domains thereof, is/are uniformly distributed in the condensation polyamide or in the composition; the condensation polyamide can have an AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., ≥70 meq/kg and ≤125 meq/kg); the condensation polyamide can have an RV of at least 35 (e.g., at least 40, or at least 45, as determined according to ASTM D789); the condensation polyamide can include nylon 66/6T, nylon 66/DI, nylon 66, or a combination thereof; or a combination thereof.
- The present invention provides a composition including a condensation polyamide having an AEG of 265 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., ≤70 meq/kg and ≤125 meq/kg). The condensation polyamide is at least 30 wt % of the composition. The condensation polyamide is the predominant polyamide in the composition. The composition also includes from ≤10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %). The maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin.
- The present invention provides a composition including a condensation polyamide. The condensation polyamide is at least 30 wt % of the composition. The condensation polyamide is the predominant polyamide in the composition. The condensation polyamide can be one or more polyamides. The composition includes from ≥10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %). The maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone. The maleated polyolefin has a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin. The condensation polyamide can be any one or more suitable condensation polyamides. The maleated polyolefin, or domains thereof, or a reaction product of the maleated polyolefin, is/are uniformly distributed in the condensation polyamide or in the composition.
- The present invention provides a reacted composition that is a reaction product of the composition including the condensation polyamide and the maleated polyolefin. The reacted composition can include a reaction product of the condensation polyamide and the maleated polyolefin, such as a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin.
- The present invention provides a compounded polyamide composition. The compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin and/or a reaction product of the composition. The compounded polyamide composition also includes one or more other components.
- In various aspects, the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, wherein the maleated polyolefin is ≥10 to ≤50 wt % of the compounded polyamide composition. The compounded polyamide composition includes an additional polyamide that is ≥15 to ≤85 wt % of the compounded polyamide composition (e.g., ≥20 to ≤85 wt %), such as nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof. The compounded polyamide composition also includes a chain extender that is ≥0.05 to ≤5 wt % of the compounded polyamide composition.
- In various aspects, the compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof (e.g., the condensation polyamide and the maleated polyolefin are optionally partially reacted to form a polyamide-polyolefin), wherein the condensation polyamide is 50-80 wt % of the compounded polyamide composition, and wherein the maleated polyolefin is 10-50 wt % of the compounded polyamide composition. The compounded polyamide composition also includes 0 to 20 wt % polyamide 612; 0 to 20 wt % modified polyphenylene ether; 0 to 30 wt % flame retardant; 0 to 10 wt % combined chain extender, heat stabilizer and colorant additives; and 0 to 40 wt % combined filler and/or conductive fiber additives.
- The present invention provides an article that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof.
- In various aspects, the article can be characterized by superior resistance, when compared against a control, to at least one selected from: cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure.
- In various aspects, the article is an extrudate, such as a conduit. In various aspects, the extrudate can be substantially free of glass fibers and/or can be resistant to glycolysis.
- In various aspects, the article is a molded article. In various aspects, the molded article can include glass fibers and/or can be resistant to cold-temperature cracking.
- The present invention provides a reinforced conduit. The reinforced conduit includes an extruded conduit that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof. The reinforced conduit also includes a metal reinforcement.
- The present invention provides a method of making the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same. The method can include combining the condensation polyamide and the maleated polyolefin to form the composition, the reacted composition, the compounded composition, or a combination thereof.
- The present invention provides a method of making the compounded composition, including combining the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, with one or more one or more other components to form the compounded polyamide composition.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes combining the condensation polyamide and the maleated polyolefin before adding a chain extender thereto.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin. The method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone. The method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone. The method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin. The method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone. The method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone. The method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition. A barrel of a screw extruder includes the first compounder extruder zone and the second compounder extruder zone. The providing of the feed to the first compounder extrusion zone includes providing the feed to a feed inlet of the barrel, the barrel having a length. The chain extender is introduced to the second compounder extruder zone at least ¼ of the length of the barrel from the feed inlet of the barrel.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin. The method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone. The method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone. The method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition. The introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone includes introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide.
- The present invention provides a method of extruding a polyamide resin. The method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a feed zone of an extruder. The method includes maintaining extruder barrel conditions sufficiently to obtain the polyamide resin melt inside the extruder. The method includes producing extrudate from the extruder while optionally recovering vapor from the extruder via a vacuum draw.
- The present invention provides a method of molding a polyamide resin. The method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a mold. The method includes producing a molded polyamide resin from the mold.
- Through extensive investigation of condensation polyamides, it has been found that unusual properties arise from combinations of certain condensation polyamides (having relatively high amine end group (AEG) numbers (as measured by titration of polymer solution in solvent such as methanol/phenol) together with certain maleated polyolefins, including those polyolefins having a relatively high degree of maleation. In various aspects, the present invention provides a polyamide composition and method of making the same that can produce high quality extruded conduit, such as having superior properties to extruded conduit made from other polyamide compositions, such as increased resistance to glycolysis and high tensile strength. In various aspects, the present invention provides a polyamide composition that can be molded or extruded to produce an article having suitable properties for various end uses such as automotive, electronics, chemical processing, and heat transfer applications, such as having superior properties as compared to molded or extruded articles formed from other polyamide compositions, such as having higher tensile strength, higher chemical resistance, higher stress cracking resistance, or lower melt viscosities. In some aspects, the properties are equal or better than extruded or molded articles formed from HDPE, N11, N12, N612 and PVDF materials.
- Various embodiments of the reinforced conduit of the present invention can have certain advantages over other conduits and reinforced conduits. For example, in various embodiments, the reinforced conduit of the present invention can have any property or advantage described herein for the extruded conduit including a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, and can further include additional properties and/or advantages due to the metal reinforcement such as described herein below.
- Polyamides such as nylon-6,6 normally contain an equilibrium amount of water. Water can promote the corrosion of certain metals such as certain types of steel (e.g., plain steel). Localized corrosion of a metal pipe can compromise strength and structural integrity of the pipe, and can cause delamination of an adjacent polyamide layer. Therefore, reinforced conduits including polyamides and corrodible metal reinforcements can suffer from degradation and failure. However, in various embodiments of the present invention, the reinforced conduit includes a metal reinforcement that includes a type of metal that is resistant to corrosion from water (e.g., aluminum, or a corrosion-resistant steel) and/or includes a metal reinforcement that has a protective coating thereon that reduces or eliminates corrosion of the metal reinforcement.
- Thermal expansion coefficients differ between certain metals and certain polyamides, such that temperature cycles can trigger delamination between the metal and the polyamide. For example, carbon steel have a coefficient of expansion (COE) of 10.8×10−6 and HDPE has a COE of 100×10−6 to 200×10−6. However, in various embodiments of the present invention, the extruded conduit and the metal reinforcement of the reinforced conduit can have a difference between their respective COEs such that the reinforced conduit is more resistant, or is immune, to delamination under the same conditions as compared to other reinforced conduits, such as compared to reinforced conduits including steel and HDPE. For example, the COE of nylon-6,6 is about 62×10−6 to about 73×10−6, which is closer to the COE of carbon steel than the COE of HDPE.
- In reinforced conduits including a process fluid, any extruded conduit in contact with the process fluid need to be compatible with the process fluid. For example, HDPE is not resistant to hydrocarbons and has a tendency to absorb hydrocarbons and swell. However, in various embodiments, the reinforced conduit of the present invention includes an extruded conduit that includes a polyamide composition with greater compatibility with various process fluids such as hydrocarbons as compared to other extruded conduits, such as compared to extruded conduits including HDPE. As a result, such embodiments of the reinforced conduit can be used for longer times with various process fluids before replacement or repair is required, and a greater variety of process fluids can be compatible with the reinforced conduit.
- Hydrogen gas has a wide variety of applications and is expected to be used in natural gas systems of the future as the market demands clean and efficient energy. Certain polymers such as HDPE has low permeation resistance to hydrogen gas and may experience increased likelihood of embrittlement when used with hydrogen gas. However, in various embodiments, the reinforced conduit of the present invention includes an extruded conduit that includes a polyamide composition (i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof) with higher permeation resistance to hydrogen gas than other polymers, such as compared to HDPE. In various embodiments, the polyamide composition can have a lower likelihood of embrittlement when exposed to hydrogen gas. As a result, such embodiments of the reinforced conduit can have a longer lifetime when used for transport of hydrogen gas.
- Process fluids including slurries and/or solids can erode the inner surface of a pipe. However, in various embodiments of the reinforced conduit including an inner layer of extruded conduit, the extruded conduit of the reinforced conduit can provide enhanced resistance to erosion from process fluids including slurries and/or solids due to the high abrasion resistance of polyamide composition of the extruded conduit (i.e., a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof), such as compared to pipes not including an extruded polymer conduit, or as compared to pipes including extruded polymer conduits formed from other materials.
- Horizontal directional drilling (HDD) is an attractive method of installing pipe, but imparts extreme wear on the outside of the pipeline being installed. However, in various embodiments of the reinforced conduit including an outer layer of extruded conduit, the extruded conduit of the reinforced conduit can provide enhanced resistance to wear on the outside of the reinforced conduit, enabling the reinforced conduit to be installed via HDD or other wear-intensive methods more easily and at lower cost.
- Reference will now be made in detail to certain embodiments of the disclosed subject matter. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.
- Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.
- In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” or “at least one of A or B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.
- In the methods described herein, the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.
- The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range.
- The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%. The term “substantially free of” as used herein can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt/o to about 5 wt % of the composition is the material, or about 0 wt % to about 1 wt %, or about 5 wt % or less, or less than, equal to, or greater than about 4.5 wt %, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt/o or less, or about 0 wt %.
- As used herein, the term “polymer” refers to a molecule having at least one repeating unit and can include copolymers.
- The term “conduit” or “conduit structure”, as used herein, may refer to a hollow channel or duct suitable for conveying a fluid or passage for laying down and enclosing thin electrical wires and cables. The conduit cross-section may have a single hole or multiple holes depending on the application requirement.
- The term “pipe”, as used herein, may embody either right-cylindrical geometry, i.e., having circular cross-sectional shape, and other cross-sectional shapes which may be elongated in one axis perpendicular to the conduit long axis, for example, obround and oval cross-sectional shapes.
- The term “N6” or “Nylon 6”, as used herein, refers to a polymer synthesized by polycondensation of caprolactam. The polymer is also known as polyamide 6, PA6, or poly(caprolactam).
- The term “N66” or “nylon-6,6”, as used herein, refers to a polymer synthesized by polycondensation of hexamethylenediamine (HMD) and adipic acid. The polymer is also known as Polyamide 66 (or PA66), Nylon 66, nylon 6-6, nylon 6/6 or nylon-6,6.
- The term “N12” or “Nylon 12”, as used herein, refers to a polymer synthesized by polycondensation of ω-aminolauric acid or ring-opening polymerization of laurolactam. The polymer is also known as Polyamide 12 (or PA12), Nylon 12, poly(laurolactam), Poly(dodecano-12-lactam), poly(12-aminododecanoic acid lactam).
- The term “N612” or “Nylon 612”, as used herein, refers to a polymer synthesized by polycondensation of hexamethylenediamine (HMD) and α,ω-dodecanedioic acid [or C12 diacid]. The polymer is also known as Polyamide 612 (or PA612), PA 6/12, Nylon 6/12.
- The term “Nylon 66/6T”, as used herein, refers to a co-polymer obtained from N66 and a polymer of N6-terephthalic acid (TPA).
- As used herein, “PA610” or “nylon-6,10” is a semi-crystalline polyamide prepared from hexamethylenediamine (C6 diamine, abbreviated as HMD) and decanedioic acid (C10 diacid). It is commercially available from Arkema, BASF, and such.
- As used herein, “PA66/DI” or “nylon-66/DI” refers to a type of co-polyamide of polyhexamethyleneadipamide (nylon-6,6 or N66 or PA66) and “DI” which is a combination of 2-methyl-pentamethylenediamine (or “MPMD”) and isophthalic acid. MPMD is commercially available as INVISTA Dytek® A amine and industrially known as “D” in the abbreviated formulation labeling. Isophthalic acid is commercially available and industrially known as “I” in the abbreviated formulation labeling.
- The present invention provides a composition including a condensation polyamide. The condensation polyamide is at least 30 wt % of the composition. The condensation polyamide is the predominant polyamide in the composition. The composition includes from ≥10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %). The maleated polyolefin includes maleic anhydride grafted onto a polyolefin backbone. The maleated polyolefin has a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin.
- The maleated polyolefin, or domains thereof, can have a uniform distribution in the condensation polyamide or composition (e.g., uniform molecular distribution of the maleated polyolefin in the condensation polyamide or composition, or uniform distribution of maleated polyolefin domains in the condensation polyamide or composition); the condensation polyamide can have an AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., ≥70 meq/kg and ≤125 meq/kg); the condensation polyamide can have an RV of at least 35 (e.g., at least 40, or at least 45); the condensation polyamide can include nylon 66/6T, nylon 66/DI, nylon 66, or a combination thereof; or a combination thereof.
- The condensation polyamide can be one or more polyamides that can be formed via condensation (e.g., via reaction of an amine and carboxylic acid group to form an amide and release water). The condensation polyamide can include any suitable one or more condensation polyamides. The condensation polyamide can include nylon 66, nylon 66/6T, nylon 66/DI, or a combination thereof. The condensation polyamide can be nylon 66. The condensation polyamide can be substantially free of polyamides (prior to being combined into the composition and combining with any other polyamides therein) other than one or more of nylon 66, nylon 66/6T, and nylon 66/DI. The condensation polyamide can be nylon 66, and the condensation polymer (prior to being combined into the composition) can be substantially free of polyamides other than nylon 66. The condensation polyamide is the predominant polyamide in the composition, such that the condensation polyamide has a higher concentration in the composition than any other polyamide in the composition. The condensation polyamide can have any suitable relative viscosity (RV), such as determined via a formic acid method (e.g., ASTM D789), such as equal to or greater than 35, 40, or 45, or such as equal to or less than 100, 90, or 80, or such as less than or equal to 100 but equal to or greater than 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95, or such as 30-80, 35-75, or 42-50, or such as 35-100, 40-90, or 45-80. The condensation polyamide can be 30-99.9 wt % of the composition, 30-99.9 wt %, 60-99.9 wt %, or 90-99.9 wt %, or equal to or greater than 30 wt %, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, or 99.9 wt % of the composition.
- The condensation polyamide can have any suitable amount of amine end groups (AEG), such as ≥80 meq/kg and ≤125 meq/kg, ≥80 meq/kg and ≤120 meq/kg, or less than or equal to 125 meq/kg but greater than or equal to 80 meq/kg, 85, 90, 95, 100, 105, 110, 115, or 120 meq/kg.
- The composition can further include (in addition to the condensation polyamide) one or more other polyamides, copolymers thereof, or combinations thereof. The one or more other polyamides, copolymers thereof, or combination thereof, can be different than the condensation polyamide (e.g., can be different polyamides having different structures and/or properties than the condensation polyamide). The additional polyamide can be or can include nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof. The one or more additional polyamides can form any suitable proportion of the composition, such as ≥15 to ≤85 wt %, ≥20 to ≤85 wt %, ≥15 to ≤80 wt %, ≥15 to ≤75 wt %, ≥15 to ≤70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %.
- The maleated polyolefin includes a polyolefin or polyacrylate backbone having pendant maleic anhydride groups grafted thereto. The polyolefin component can optionally be an ionomer. The polyolefin can be any suitable polyolefin polymer or copolymer. The polyolefin can include EPDM, ethylene-octene, polyethylene, polypropylene, or a combination thereof. In various aspects, the maleated polyolefin is free of EPDM. The maleated polyolefin can have any suitable grafted maleic anhydride incorporation, such as a grafted maleic anhydride incorporation of less than 10 wt %, or of 0.01 to 10 wt %, based on total weight of the maleated polyolefin, such as ≥0.1 to ≤1.4 wt %, ≥0.15 to ≤1.25 wt %, or less than or equal to 1.25 wt % but equal to or greater than 0.1 wt %, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, or 1.3 wt %. The maleated polyolefin can have any suitable glass transition temperature (Tg), such as ≥−70° C. to ≤0° C., ≥−60° C. to ≤−20° C., ≥−60° C. to ≤−30° C., or less than or equal to 0° C. but greater than or equal to −70° C., −65, −60, −55, −50, −45, −40, −35, −30, −25, −20, −15, −10, or −5° C. The maleated polyolefin can form any suitable proportion of the composition, such as ≥10 wt % to ≤50 wt %, ≥15 wt % to ≤50 wt %, or less than or equal to 50 wt % but greater than or equal to 10 wt %, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 41, 42, 43, 44, 45, 46, 47, 48, or 49%.
- The maleated polyolefin can be any suitable maleic anhydride-grafted polyolefin. A variety of maleated polyolefins are commercially available. These may include, but are not limited to, AMPLIFY® GR Functional Polymers commercially available from Dow Chemical Co. (Amplify™ GR 202, Amplify™ GR 208, Amplify™ GR 216, Amplify™ GR380), Exxelor™ Polymer Resins commercially available from ExxonMobil (Exxelor™ VA 1803, Exxelor™ VA 1840, Exxelor™ VA1202, Exxelor™ PO 1020, Exxelor™ PO 1015), ENGAGE™ 8100 Polyolefin Elastomer commercially available from Dow Elastomer, Bondyram® 7103 Maleic Anhydride-Modified Polyolefin Elastomer commercially available from Ram-On Industries LP, and such. In various embodiments, the maleated polyolefin increases the glycolysis resistance or hydrolysis resistance of the condensation polyamide, improves other properties, or a combination thereof. Table 1 lists non-limiting commercially available modified polyolefins.
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TABLE 1 Commercially available modified polyolefins. Commercial Manuf./ Modification Level Polyolefin Trade Name (wt %) in Polyolefin Polypropylene ExxonMobil/ 0.2-0.5 Exxelor ™ VA1840 Polypropylene Ram-On industries/ <1 Bondyram ® 7103 Very low-density Dow Chemicals/ 0.25-0.5 Polyethylene [vLDPE] Amplify ™ GR208 Polypropylene ExxonMobil/ 0.25-0.5 Exxelor ™ PO1015 Ethylene alpha olefin ExxonMobil/ 0.5-1 Exxelor ™ VA1202 Ethylene octene Dow Chemicals/ 0.5-1 Amplify ™ GR216 Pure Ethylene ExxonMobil/ 0.5-1 Exxelor ™ VA1803 Low-density Dow Chemicals/ >1 Polyethylene [LDPE] Amplify ™ GR202 - In Table 1, the term “Modification Level (wt %) in Polyolefin” means the functionalized level in the polyolefin tested. For example, in the first row of Table 1, polypropylene with 0.2-0.5 wt % modification level means it is a modified polyolefin having 0.2-0.5% grafted maleic anhydride content.
- In various aspects, the composition can include glass fibers or other glass reinforcements, or the composition can be substantially free of glass fibers or other glass reinforcements. The composition can include ≥1 wt % to ≤50 wt % glass fibers, ≥10 wt % to ≤42 wt %, ≥10 wt % to ≤35 wt %, ≥15 wt % to ≤30 wt %, or less than or equal to 50 wt % but equal to or greater than 5 wt %, 10, 15, 20, 25, 30, 35, 40, or 45 wt %. Disclosed compositions containing glass fiber can lend themselves to mixing, extrusion and molding more easily than would be predicted from the performance of more closely balanced (lower AEG) condensation polyamides.
- The present invention provides a reacted composition that is a reaction product of the composition including the condensation polyamide and the maleated polyolefin. The reacted composition can include a reaction product of the condensation polyamide and the maleated polyolefin, such as a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin.
- The reacted composition can include the composition including the condensation polyamide and the maleated polyolefin wherein any suitable proportion of the condensation polyamide has reacted with the maleated polyolefin. For example, the reacted composition can include the polyamide-polyolefin copolymer in a concentration range of ≥50 to ≤7500 ppmw, ≥100 to ≤4900 ppmw, ≥225 to ≤3750 ppmw, or less than or equal to 7500 ppmw but greater than or equal to 50, 100, 250, 500, 750, 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 6,000, 7,000, or 8,000 ppmw. In some aspects, the amount of polyamide-polyolefin copolymer can be calculated by multiplying the concentration of the maleated polyolefin with the modification level of the maleated polyolefin. For example, for a reacted composition made from 80:20 (wt:wt) polyamide:modified polyolefin having 0.5 wt. % grafted (e.g.: maleated) modification, the total reacted polyamide-polyolefin modification functionality in the sample (assuming all grafted maleic anhydride reacts, which may not occur) can be calculated as (0.20)*(0.005)*106=1000 ppmw.
- The reacted composition can include the same components in the same proportions as the composition including the condensation polyamide and the maleated polyolefin, with the exception that the condensation polyamide and the maleated polyolefin are at least partially reacted.
- As described herein, without limiting the scope of the disclosure with a recitation of a theoretical mechanism, the generalized chemical reaction schematically represented in Scheme 1 is one approach to understand the interaction of a maleated olefin copolymer with a polyamide.
- The term “PA”, as used herein, means a polyamide (structure D). Polyamide is a type of synthetic polymer made by the linkage of an amino group of one molecule and a carboxylic acid group of another. Polyamides are also generically referred to as nylons.
- For the chemistry disclosed herein and throughout this disclosure; the olefin copolymer (structure A) may be any copolymer of ethylene, propylene, or butylene. The olefin copolymer may contain a suitable degree of maleation, e.g., maleic content, for example, between 0.05 to 1.5% by weight. This material can be referred to as “modified polyolefin” or “maleated polyolefin” (structure C).
- The term “reacted Polyamide-Polyolefin copolymer” or “modified polyamide” (structure E), as used herein is the reacted portion of the polyolefin and the polyamide matrix. This is dependent upon the original maleation content of the polyolefin additive (structure C).
- The term “degree of maleation” or “modification level”, as used interchangeably herein, means the extent of which the olefin copolymer (structure A) has been reacted with maleic anhydride (structure B).
- The polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin is structure E.
- The maleated polyolefin, domains thereof, or reaction products thereof with the condensation polyamide, can have any suitable distribution in the condensation polyamide (and in any additional polyamides present) or in the composition. For example, the maleated polyolefin, or domains thereof, can have a uniform or homogeneous distribution in the condensation polyamide (and any additional polyamides present) or in the composition on a molecular level, such that the molecules of the maleated polyolefin are homogeneously distributed therein. The maleated polyolefin or reaction product thereof can forms domains within the condensation polymer (and any other polyamides present) or within the composition; in some aspects, the maleated polyolefin or reaction product thereof can be at least partially immiscible with the condensation polymer. For example, the condensation polymer (and any other polyamides present), or all polymeric components other than the maleated polyolefin, or the remainder of the composition, can form a continuous phase, and the maleated polyolefin can form a discontinuous phase (domains) therein. In various aspects, the compounded polyamide composition described herein can include a uniform or homogeneous distribution of the maleated polyolefin, reaction products thereof, or domains of the maleated polyolefin or reaction products thereof.
- In various aspects, extruded materials described herein, formed from the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, can include a uniform or homogeneous distribution of the maleated polyolefin, reaction products thereof, or domains of the maleated polyolefin or reaction products thereof.
- The present invention provides a compounded polyamide composition. The compounded polyamide composition includes the composition including the condensation polyamide and the maleated polyolefin and/or a reaction product of the composition. The compounded polyamide composition also includes one or more other components.
- The compounded polyamide can be extrudable, such that the compounded polyamide can be extruded to form an extrudate or an extruded article. The compound polyamide can be moldable, such that the polyamide can be placed into a mold and cooled to form a molded article.
- The one or more other components can include any suitable one or more components. The one or more other components can include a modified polyphenylene ether, an impact modifier, a flame retardant, a chain extender, a heat stabilizer (e.g., Zytel® additives [DuPont], Irganox® sterically hindered additives [BASF], and such), a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof. Non-limiting examples of optional additives include adhesion promoters, biocides, anti-fogging agents, anti-static agents, anti-oxidants, bonding, blowing and foaming agents, catalysts, dispersants, extenders, smoke suppressants, impact modifiers, initiators, lubricants, nucleants, pigments, colorants and dyes, optical brighteners, plasticizers, processing aids, release agents, silanes, titanates and zirconates, slip agents, anti-blocking agents, stabilizers, stearates, ultraviolet light absorbers, waxes, catalyst deactivators, and combinations thereof.
- The one or more other components can include a chain extender. The chain extender can be capable of reacting with the amine and/or acid terminal groups of the condensation polyamide and/or of the reaction product thereof with the maleated polyolefin, thereby connecting two polyamide chains. The chain extender can be any suitable chain extender, such as a dialcohol (e.g., ethylene glycol, propanediol, butanediol, hexanediol, or hydroquinone bis(hydroxyethyl)ether), a bis-epoxide (e.g., bisphenol A diglycidyl ether), polymers having epoxide functional groups (e.g., as pendant and/or terminal functional groups), polymers including anhydride functional groups, bis-N-acyl bis-caprolactams (e.g., isophthaloyl bis-caprolactam (IBS), adipoyl bis-caprolactam (ABC), or terephthaloyl bis-caprolactam (TBC)), diphenyl carbonates, bisoxazolines, oxazolinones, diisocyanates, organic phosphites (triphenyl phosphite, caprolactam phosphite), bis-ketenimines, or dianhydrides. The chain extender can be a polymer including anhydride functional groups, such as a maleic anhydride-polyolefin copolymer (e.g., an alternating copolymer of maleic anhydride and ethylene). For end-uses that require hydrolysis resistance, chain extenders that are known to improve hydrolysis resistance are preferred. The chain extender can be any suitable proportion of the compounded polyamide composition, such as ≥0.05 to ≤5 wt % or ≥0.05 to ≤2 wt % of the compounded polyamide composition, or less than or equal to 5 wt % but greater than or equal to 0.05 wt %, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.4, 2.6, 2.8, 3, 3.2, 3.4, 3.6, 3.8, 4, 4.2, 4.4, 4.6, or 4.8 wt %.
- The compounded polyamide composition can include the condensation polyamide and the maleated polyolefin and/or a reaction product thereof, wherein the maleated polyolefin is ≥10 to ≤50 wt % of the compounded polyamide composition. The compounded polyamide composition can include an additional polyamide (different than the condensation polyamide) that is ≥15 to ≤85 wt %, ≥20 to ≤85 wt %, ≥15 to ≤80 wt %, ≥15 to ≥75 wt %, or ≥15 to ≤70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt %, such as nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof. The compounded polyamide composition can include a chain extender that is ≥0.05 to ≤5 wt % of the compounded polyamide composition.
- The compounded polyamide composition can include 50-80 wt % of the condensation polyamide and 10-50 wt % of the maleated polyolefin, and/or a reaction product thereof. The compounded polyamide composition can further include 0 to 20 wt % polyamide 612; 0 to 20 wt % modified polyphenylene ether; 0 to 30 wt % flame retardant; 0 to 10 wt % combined chain extender, heat stabilizer and colorant additives; and 0 to 40 wt % combined filler and/or conductive fiber additives.
- In various aspects, the compounded polyamide composition can include glass fibers or other glass reinforcements, or the compounded composition can be substantially free of glass fibers or other glass reinforcements. The compounded composition can include ≥1 wt % to ≤50 wt % glass fibers, ≥10 wt % to ≤42 wt %, ≥10 wt % to ≤35 wt %, ≥15 wt % to ≤30 wt %, or less than or equal to 50 wt % but equal to or greater than 5 wt %, 10, 15, 20, 25, 30, 35, 40, or 45 wt %. Disclosed compositions containing glass fiber can lend themselves to mixing, extrusion and molding more easily than would be predicted from the performance of more closely balanced (lower AEG) condensation polyamides.
- In various aspects, the composition, reaction product thereof, or compounded polyamide composition, can be provided in a granulate physical form, such as 3 mm diameter 3-5 mm length cylindrical pellets.
- In various aspects, the compounded polyamide composition can include 70-80 wt % of a condensation polyamide that is PA66 having an RV of 35-50 and an AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., equal to or less than 80 wt % and greater than or equal to 70 wt %, 71, 72, 73, 74, 75, 76, 77, 78, or 79 wt %), and 20-30 wt % of the maleated polyolefin (e.g., less than or equal to 30 wt % and greater than or equal to 20 wt %, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 wt %).
- In various aspects, the compounded polyamide composition can include 30-50 wt % of a condensation polyamide that is PA66 having an RV of 35-50 and an AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., less than or equal to 50 wt % and greater than or equal to 30 wt %, 32, 34, 36, 38, 39, 40, 41, 42, 43, 44, 45, 46, 48, or 49%), 20-40 wt % of an additional polyamide that is PA66/DI (e.g., equal to or less than 40 wt % and greater than or equal to 20 wt %, 22, 24, 26, 28, 30, 32, 34, 36, 38, or 239 wt %), 20-30 wt % of the maleated polyolefin (e.g., less than or equal to 30 wt % and greater than or equal to 20 wt %, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 wt), and 1-10 wt % chain extender (e.g., less than or equal to 10 wt % and greater than or equal to 1 wt, 2, 3, 4, 5, 6, 7, 8, or 9 wt %).
- Table 2 gives examples of component ranges for the compounded polyamide composition, given in parts b weight.
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TABLE 2 Examples of component ranges. Using Using High PA66 AEG PA66 Component RV Range RV Range Using PA66/6T ( wt. % ) 35-240 35-240 Copolymer Condensation polyamide 50-75 60-80 60-80 Polyamide 612 (PA612) Up to 20 Up to 20 Up to 20 Modified PPE Up to 20 Up to 20 Up to 20 Maleated-pollyollefinic 18-40 18-40 18-40 component (e.g., GR216, Engage 8401, E-43P, and the like) Chain Extender component Up to 1 Up to 1 Up to 1 (e.g., ZeMac, and the like Colorant component Up to 2.5 Up to 2.5 Up to 2.5 (e.g., BK34, and the like) Heat stabilizer component 0.3-2 0.3-2 0.3-2 (e.g., Irgatiox, Zytel, and the like) Filler component Up to 25 Up to 25 Up to 25 (e.g., GF, and the like) Conductive component Up to 15 Up to 15 Up to 15 (e.g., carbon fiber, carbon black, CNT, graphite powder, and the like) Fire Retardant component Up to 25 Up to 25 Up to 20 TOTAL 100 100 100 - The present invention provides an article that includes the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same.
- In various aspects, the article (or the composition, reaction product thereof, or the compounded composition) can be characterized by superior resistance, when compared against a control, to at least one selected from: cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure. In various aspects, the superior properties can be retained after aging, such as greater than or equal to 50% retention of the superior properties after heat aging at 100-200° C., or 130-160° C., or 140° C., or 150° C. The salt can be any suitable salt, such as ZnCl2. The resistance to cold-temperature cracking can include resistance to cracking when cycled from room temperature, such as 20° C., to extreme low temperatures such as −30° C., −40° C., −50° C. or lower. Advantageously, such cold-temperature cracking resistant compositions are suitable for automotive end-uses in extreme environments such as arctic climates. The control can differ by at least one of AEG, weight percentage of maleated polyolefin, and degree of maleation of the maleated polyolefin. The control can have the same composition as the article, the composition, the reaction product thereof, or the compounded composition, except that the polyamide in the control can have an AEG of <60 meq/kg (or <80 meq/kg, or <70 meq/kg). The control can have the same composition as the article, the composition, the reaction product thereof, or the compounded composition, except that the control can be free of the maleated polyolefin, or, for example, can contain less than 0.05 wt % of maleated polyolefin, with the control having the condensation polyamide in place of the maleated polyolefin (e.g., the balance of the control is the condensation polyamide).
- The article, the composition, the reaction product thereof, or the compounded composition, can be characterized by superior mechanical strength compared to the control. For example, the article, the composition, the reaction product thereof, or the compounded composition, can have a tensile strength of at least 30 MPa, or 30-200 MPa, or 40-150 MPa, or less than or equal to 200 MPa but greater than or equal to 30 MPa, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa.
- The article, the composition, the reaction product thereof, or the compounded composition, can have any suitable melt strength, such as a melt strength of at least 0.1 Newton.
- The article, the composition, the reaction product thereof, or the compounded composition, can have any suitable Flame Resistance rating, such as a Flame Resistance rating of V-0.
- The article, the composition, the reaction product thereof, or the compounded composition, can have any suitable moisture level, such as less than or equal to 0.2 wt %.
- The article, the composition, the reaction product thereof, or the compounded composition, can have a tensile strength, measured according to ISO 527 on dry-as-molded specimens, of at least 40 MPa (e.g., 40 MPa, or 40-200 MPa, or 40-150 MPa, or less than or equal to 200 MPa but greater than or equal to 40 MPa, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa), and a notched Charpy impact energy, measured at −30° C. and according to ISO 179/1eA on dry-as-molded specimens, of at least 60 kJ/m2 (e.g., equal to or greater than 60, 70, 80, 90, or 100 kJ/m2). The “1eA” specifies the sub-method that was used. The sub-method specifies: (a) that the sample was tested edgewise and that the notch was prepare to a specified notch diameter.
- The article, the composition, the reaction product thereof, or the compounded composition, can retain ≥50% (e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%) of the tensile yield strength, tensile elongation at break, and/or tensile break strength after undergoing 1:1 (vol/vol) ethylene glycol:water exposure at 120° C.-130° C. for 1000 hrs. The article, the composition, the reaction product thereof, or the compounded composition, can retain ≥50% (e.g., equal to or greater than 50%, 52, 54, 56, 58, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 98, or 99%) of the tensile yield strength, tensile elongation at break, and/or tensile break strength after undergoing 50 wt % aqueous zinc chloride solution exposure at 23° C. for 200 hours under 3% applied strain to the test specimens.
- The article, the composition, the reaction product thereof, or the compounded composition, upon heat aging at 140° C. for 1000 hours, can have a tensile yield strength, measured according to ISO 527, of at least 40 MPa, and/or a notched Charpy impact energy, measured at 23° C. and according to ISO 179/1eA of at least 45 kJ/m2 (e.g., at least 45, 55, 65, or 75 kJ/m2).
- The article, the composition, the reaction product thereof, or the compounded composition, which upon heat aging at 140° C. for 1000 hours has a tensile break strength measured according to ISO 527 of at least 30 MPa (e.g., 30 MPa, or 30-200 MPa, or 30-150 MPa, or less than or equal to 200 MPa but greater than or equal to 30 MPa, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 MPa), and/or a tensile elongation at break measured according to ISO 527 of at least 5%.
- In various aspects, the article is a molded article. In various aspects, the molded article can include glass fibers (e.g., ≥1 to ≤50% glass fiber, 10 wt. % to 45 wt. %, or 15 wt. % to 42 wt. %) and/or other glass reinforcements and/or can be resistant to cold-temperature cracking.
- The compounded glass-fiber reinforced materials of the present disclosure are also suitable for making Injection Molded (IM) parts for applications in the petrochemical and chemical treatment industry. Enhanced structural and cracking resistance performance of such molded parts and articles are particularly suitable for diesel-operated commercial vehicle filter housing applications, wherein impact resistance and toughness under the standard automotive OEMs temperature cycling protocols (for e.g.: −40° C. to ambient temperatures) are desirable. One specific application is a filter housing molded part used in an aqueous urea solution injection system for selective catalytic reduction (SCR) of NOx emissions from a diesel combustion engine.
- In various aspects, the article is an extrudate, such as a conduit (e.g., a pipe). In various aspects, the extrudate can be substantially free of glass fibers or other glass reinforcements and/or can be resistant to glycolysis. The conduit can be chosen from rigid, flexible, curved, straight, bent (e.g., 90 degree bend or a bend with another angle), serpentine, partially corrugated, fully corrugated, and a combination thereof. The conduit can have a cross-section chosen from round, oval, oblong, square, rectangle, triangle, star, polygonal, and a combination thereof. The conduit can have any suitable dimensions, such as an outside diameter of 3 mm to 100 mm or 8 mm to 50 mm, and such as a wall thickness of 0.2 mm to 10 mm, or 0.5 mm to 3 mm.
- The extruded conduit that is substantially free of glass fibers can be selected from the group consisting of rigid, flexible, curved, bent, serpentine, partially corrugated and fully corrugated. A cross-section of the extruded conduit that is substantially free of glass fibers can be selected from the group consisting of round, oval, oblong, square, rectangle, triangle, star and polygonal. The extruded conduit that is substantially free of glass fibers can be a tube. The extruded conduit that is substantially free of glass fibers can be a pipe.
- A conduit (e.g., tube) may embody either right-cylindrical geometry, i.e., having circular cross-sectional shape, and other cross-sectional shapes which may be elongated in one axis perpendicular to the conduit long axis, for example, obround and oval shapes. A tube is characterized by its aspect ratio [L/D], i.e., a geometric ratio of tube length “L” to tube diameter “D”. As an illustrative example, a tube having a diameter of 1 cm and 10 cm long will have the Aspect Ratio of 10 [10:1 L/D]. The tube Aspect Ratio can have any range depending on the end-use application. The tube diameter “D” can be specified to be inside tube diameter or outside tube diameter.
- In some embodiments, the tube can be straight, curved, bent, serpentine or corrugated along its length. Non-limiting examples of various tube shapes may include short-length and long-length straight tube, angle bent tube [any angle from >0° and <180° ], right angle or 90° bent tube, single-curvature or multiple-curvature tube such as a C-shaped, N-shaped, S-shaped, U-shaped, V-shaped, W-shaped, Z-shaped, etc., partially corrugated tube, fully corrugated tube, and other combinations.
- The conduit can have any suitable shape and any suitable number of layers. The conduit can have a single layer of material. The conduit can have two (e.g., outer and inner) or three (e.g., outer, middle, and inner) layers, or more than three layers. Also, it is possible to co-extrude multi-layered tubes having non-circular cross-sections (for example, oval, oblong, rectangular, polygonal, etc.), depending on the end-use application and cost of manufacture. Further, the individual layer thicknesses may be varied for the desirable mechanical, structural and burst strength performance.
- The industrial utility of the solution presented in this disclosure is apparent in an automotive application as heat exchanging conduit systems. Thin-walled, small-diameter conduits, both straight and corrugated, prepared according to the present disclosure can be effectively assembled for under-the-hood and electric component (e.g.: battery systems) cooling and heat transfer systems. Such conduit systems can be designed and engineered to circulate heat exchange medium (e.g.: water, glycol mixtures, coolants, refrigerants) across the various heat generating components for heat removal in a closed loop manner. Current materials used for such purposes are low-cost EPDM rubber and high-cost PA11/PA12/PA612 specialty polyamides. The EPDM systems are bulky, heavy and require reinforcement wrapping. The specialty polyamides are light-weight and can be flexible but come at a great cost. The present solution addresses the current unmet need in this industrial application space.
- Examples of uses for pipes extruded from the composition, reacted composition, and/or compounded polyamide composition can include, but are not limited to, fluid flow lines, gas gathering, water management, oil and liquified NG (LNG) gathering in the oil and gas industry; municipal, industrial, wastewater, potable and irrigation water systems; hydrogen gas industry; electric cable conduits; and other applications where robust and durable piping is desirable.
- The extruded conduit of the present invention can be used as a component of a reinforced conduit, as described below
- The present invention provides a reinforced conduit. The reinforced conduit includes an extruded conduit including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof. The reinforced conduit also includes a metal reinforcement. The reinforced conduit can correspond to any suitable example of an extruded conduit described herein that includes the extruded conduit including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof, and that also includes a metal reinforcement.
- The extruded conduit can have any suitable wall thickness, such as 0.1 mm to 100 mm, or 1 mm to 20 mm, or 2 mm to 10 mm, or less than or equal to 100 mm and greater than or equal to 0.1 mm, 0.2, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 mm. The extruded conduit can have any suitable diameter, such as an inside or outside diameter of 1 mm to 1000 mm, or 5 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 1 mm, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, or 950 mm.
- The reinforced conduit can have any suitable diameter, such as an inside or outside diameter of 10 mm to 1000 mm, or 20 mm to 700 mm, or less than or equal to 1000 mm and greater than or equal to 10 mm, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, or 650 mm. The reinforced conduit can have any suitable total conduit wall thickness, such as a thickness of 0.2 mm to 500 mm, or 1 mm to 200 mm, or less than or equal to 500 mm and greater than or equal to 0.2 mm, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, 300, 350, 400, or 450 mm.
- The metal reinforcement can include any suitable type of metal or metals that function to reinforce the extruded conduit, and/or that can be reinforced by the extruded conduit. The metal reinforcement can include steel, aluminum, beryllium, copper, an alloy thereof, or a combination thereof. The metal reinforcement can include corrosion-resistant steel, such as stainless steel, austenitic steel, 304, 304L, 316, 316L, or a combination thereof. The metal reinforcement can include non-corrosion-resistant steel, such as carbon steel.
- The metal reinforcement can be free of protective coatings to protect the metal reinforcement from corrosion. In some aspects, the metal reinforcement include a protective coating that reduces and/or prevents corrosion of the metal, such as from water. Polyamides have a tendency to include water and to take up water from the environment, which can corrode metals that are not corrosion-resistant and that lack a protective coating that reduces and/or prevents corrosion of the metal. In aspects lacking a protective coating on the metal reinforcement, the metal reinforcement can directly contact the extruded conduit. In aspects including a protective coating on the metal reinforcement, the reinforced conduit can be substantially free of direct contact between the metal reinforcement and the extruded conduit, and contact that occurs between the metal reinforcement and the extruded conduit can occur via the protective coating.
- The protective coating can be any suitable protective coating, such as a hydrophobic and/or water-resistant material. The protective coating can include a polyolefin, a polycarbonate, a polyester, or a combination thereof. The protective coating can include polyethylene, polypropylene, a polyacrylate, a bio-derived polyolefin, or a combination thereof. The protective coating can include materials prepared from renewable raw materials. The protective coating can be adequately flexible to allow the metal component to be wrapped around the extruded conduit without cracking or damaging the coating. The protective coating can have any suitable thickness, such as a thickness of 1 micron to 5 mm, 50 microns to 2 mm, 100 microns to 1 mm, or less than or equal to 5 mm and greater than or equal to 1 micron, 2, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 250, 300, 400, 500, 600, 800 microns, 1 mm, 1.5, 2, 2.5, 3, 3.5, 4, or 4.5 mm.
- The metal reinforcement including any protective coating thereon can have any suitable thickness, such as a thickness of 0.01 microns to 100 mm, or 0.01 microns to 50 mm, or 0.01 microns to 1 mm, or 0.01 microns to 100 microns, or 0.1 microns to 60 microns, or 5 mm to 50 mm, or 10 mm to 30 mm, or less than or equal to 100 mm and greater than or equal to 0.01 microns, 0.05, 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, 1 mm, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 mm. The metal reinforcement can have any suitable cross-section, such as round, flat (planar), oval, square, rectangular, triangular, or a combination thereof.
- The metal reinforcement can contact the extruded conduit, such as along the length of the extruded conduit. The extruded conduit can contact the metal reinforcement on an exterior of the extruded conduit, an interior of the extruded conduit, or a combination thereof. The metal reinforcement can be partially or fully embedded within the extruded conduit.
- The metal reinforcement can have any suitable shape. The metal reinforcement can include a sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof. The sleeve can include an unperforated solid sleeve, a perforated sleeve, a mesh sleeve, a braided sleeve, or a combination thereof. For fibers and tapes, conventional metal component wrapping/winding techniques can be used and can in some aspects avoid or eliminate gaps in wrapping or wind of the metal reinforcement. The metal reinforcement can include a metal pipe, wherein the pipe can contact an exterior of the extruded conduit. The extruded conduit can be a liner in the pipe. The metal reinforcement can include a metal pipe, wherein the pipe can contact an interior of the extruded conduit. The pipe can be encased by the extruded conduit.
- The reinforced conduit can include a single one of the extruded conduits and a single one of the metal reinforcements, or the reinforced conduit can include more than one of the extruded conduits, the metal reinforcements, or more than one of both. The reinforced conduit can include one and not more than one of the metal reinforcements, or can include more than one of the metal reinforcements. The reinforced conduit can include one and not more than one of the extruded conduits, or can include more than one of the extruded conduits. In aspects including more than one of the extruded conduits, each of the extruded conduits can have a composition that is independently selected, and each of the extruded conduits can have a composition that is the same or different. In aspects including more than one of the metal reinforcements, each of the metal reinforcements can be the same or different type and/or composition of metal reinforcement (e.g., sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof).
- The reinforced conduit can further include one or more second extruded conduits. Each of the one or more second extruded conduits can be the same as the extruded conduit of the present invention (e.g., including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same, or a combination thereof), or can include a different extruded composition including one or more polymers.
- The reinforced conduit can include more than one of the extruded conduits, wherein each extruded conduit has a composition that is independently selected. In some aspects, the extruded conduits can be attached to one another end-to-end (e.g., the extruded conduits can be fused end-to-end and/or attached end-to-end via a fitting). In some aspects, each extruded conduit can be a different layer in the reinforced conduit.
- In aspects of the reinforced conduit including multiple extruded conduits that form different layers in the reinforced conduit, two or more of the extruded conduits can contact one another along their length (e.g., free of intervening layers), or two or more of the extruded conduits can be substantially free of contact between two or more of the extruded conduits along their length (e.g., includes one or more intervening layers between the extruded conduits, such as the metal reinforcement). The metal reinforcement can be present between two or more of the extruded conduits along their length. The metal reinforcement can be within inside surfaces of two or more of the extruded conduits along their length. The metal reinforcement can be outside of two of more of the extruded conduits along their length. The radial placement of the metal reinforcement layer between the inner and outer extruded conduit layers can depend on the processing conditions, the type of intended use of the reinforced conduit, and the operating environment of the reinforced conduit. For example, the metal reinforcement layer can be closer to the outer surface than the inner surface when the external operating pressure will be higher than the internal operating pressure. In another example, the metal replacement layer can be closer to the inner surface than the outer surface when the internal operating pressure will be higher than the external operating pressure. In some examples, the metal replacement layer can be approximately midway between the inner surface and the outer surface. Reinforced conduits for applications such as high pressure or vacuum can include multiple metal components and/or thicker metal components. In some aspects, two or more of the extruded conduits in the reinforced conduit have approximately the same thickness. In some aspects, two or more of the extruded conduits in the reinforced conduit can have different thicknesses.
- In various aspects, the reinforced conduit can include an inner layer including the extruded conduit; a middle layer contacting the inner layer, the middle layer including the metal reinforcement, and an outer layer contacting the middle layer, the outer layer including another one of the extruded conduits. The metal reinforcement can include any suitable metal reinforcement, such as a metal sleeve, a wound layer of metal fibers, a metal tape, or a combination thereof. The metal reinforcement can include a protective coating, or can be free of a protective coating that reduces and/or prevents corrosion. The reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm. The inner layer can have a thickness (i.e., wall thickness) of 1 mm to 20 mm, or 3 mm to 15 mm. The middle layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm. The outer layer can have a thickness of 1 mm to 20 mm, or 3 mm to 15 mm.
- The reinforced conduit can include an inner layer including the extruded conduit; and an outer layer contacting the inner layer, the outer layer including the metal reinforcement, wherein the metal reinforcement includes a metal pipe or metal sleeve. The metal reinforcement can include a protective coating, or the metal reinforcement can be free of a protective coating that reduces and/or prevents corrosion. The reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm. The inner layer can have a thickness of 1 mm to 50 mm, or 3 mm to 35 mm. The outer layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm.
- The reinforced conduit can include an inner layer including the metal reinforcement, wherein the metal reinforcement includes a metal pipe or metal sleeve. The reinforced conduit can also include an outer layer contacting the inner layer, wherein the outer layer includes the extruded conduit. The metal reinforcement can include a protective coating, or the metal reinforcement can be free of a protective coating that reduces and/or prevents corrosion. The reinforced conduit can have an outside diameter of 10 mm to 600 mm, or 20 mm to 310 mm. The inner layer can have a thickness of 1 mm to 50 mm, or 5 mm to 35 mm. The outer layer can have a thickness of 1 mm to 50 mm, or 3 mm to 35 mm.
- The reinforced conduit can have any suitable length. For example, shorter segments can be up to the length of a flatbed truck, and longer segments can be coiled. Metal and/or mechanical fittings can be used to fuse the reinforced conduit into a continuous pipeline.
- The reinforced conduit can be useful for a wide variety of applications. The reinforced conduit can be used underground, above-ground, sub-sea. The reinforced conduit can be used for aerospace applications such as atmospheric applications and space applications. The reinforced conduit can be used for transporting fluids, irrigation, agricultural infrastructure, oilfield fluids, sub-sea drilling, off-shore platforms, and the like. The reinforced conduit can be used for conveying/transporting light hydrocarbons such as natural gas (NG or LNG), propane (LPG), C1-C2 hydrocarbons and hydrogen mixtures; various liquids of industrial use such as irrigation water, waste water, salt water, and cooling water; chemically compatible solvents/reagents, acids, and bases; slurries that may be abrasive to the contact surfaces, for example, coal liquids/slurries, cement slurries, on-shore/off-shore oilfield liquids; intermediate process streams in industrial manufacturing plant facilities, brine, fire water retention and transport, natural gas and/or hydrogen mixtures, and sour gas (H2S-containing); and combinations thereof.
- The article, the composition, the reaction product thereof, or the compounded composition, can have any suitable Flame Resistance rating, such as a Flame Resistance rating of V-0 or V-1. There are a variety of tests and standards that may be used to rate the flame retardant nature of a polymeric resin system. Underwriters' Laboratories Test No. UL 94 serves as one Industry Standard test for flame retardant thermoplastic compounds. “UL 94 Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances” gives details of the testing method and criteria for rating. The test method ASTM D635 is Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position; The test method ASTM D3801 is Standard Test Method for Measuring the Comparative Burning Characteristics of Solid Plastics in a Vertical Position. Vertical burning test ratings (e.g.: V-0, V-1, V-2) are more stringent and difficult to achieve than Horizontal burning ratings (HB-1, HB-2, HB-3). As seen in Table 3, the V-0 rating is distinguished from V-1 and V-2 ratings, which are less acceptable if one is seeking the best flame retardance rating. For certain uses, V-1 is acceptable. Even with the variety of functional additives commercially available, it is not a predictable pathway for a person having ordinary skill in the art to find a particular combination of ingredients which, together, can achieve a V-1 or a V-0 rating in a UL 94 Flammability test.
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TABLE 3 V-0, V-1, and V-2 ratings. Criteria Conditions V-0 V-1 V-2 After-flame time for each 10 s 30 s 30 s individual specimen t1 or t2 Total after-flame time 50 s 250 s 250 s for any condition set (t1 plus t2 for the 5 specimens) After-flame plus afterglow time 30 s 60 s 60 s for each individual specimen after the second flame application (t2 + t3) After-flame or afterglow of any No No No specimen up to the holding clamp Cotton indicator ignited by No No Yes flaming particles or drops - The UL 94 Flammability test performance rating may be assessed at various thicknesses, for instance and without limitation, 3.18 mm, 3.0 mm, 1.5 mm, 0.71 mm, 0.4 mm. By achieving a UL 94 V-0 rating at a thickness as thin as 3.18 mm, it is known that a plastic article having any larger thickness will also achieve a UL 94 V-0 rating. Obtaining a V-0 rating is more difficult to achieve in thinner test specimens, such as for 0.4 mm or 0.71 mm thicknesses, than thicker ones.
- Other tests and instruments exist to rate flammability, such as but not limited to, the Limiting Oxygen Index (LOI) test (ASTM 2863); the cone calorimetry instrument (which measures amount and rate of heat release during combustion) ASTM E 1354 and ISO 5660-1 Standards are both based upon this instrument; Glow Wire Flammability (IEC 60695-2-12); Glow Wire Ignition (IEC 60695-2-13). Other tests which exist to rate flame retardancy include, and are not limited to, those where the rate of smoke generation, smoke obscuration, the toxicity of smoke and combustion gases, are determined. Other tests exist to rate flame retardancy which are application specific, these include but are not limited to applications such as; apparel fabrics, upholstery fabrics, airbag fabrics, carpets, rugs.
- There exist flame retardant additives and flame retardant additive systems well known in the art. There exist broad classes of flame retardant additives and flame retardant additive systems, for instance and without limitation: halogen-containing flame retardants, halogen-containing flame retardants with synergists, phosphorus-containing flame retardants, inorganic flame retardants, nitrogen-containing flame retardants, nitrogen-containing flame retardants with synergists, these may be used alone or in combination. Plastics Additive Handbook, 5th Ed., Ed Hans Zweifel, Hanser, 2000, ISBN 1-56990-295-X, Chapter 12 speaks to the general topic and in Table 12.1 p 688 exemplifies typical flame retardant additive system and the levels of flame retardant additives used in polyamides. Plastic Additives, 4th Ed., ed R Gächter and H Müller, Hanser, 1993, ISBN 3-446-17571-7, Chapter 12 speaks to the general topic and in Table 7 p 739 exemplifies flame retardant additives and the levels of flame retardant additives used in polyamides. Flame Retardants for Plastics and Textiles Practical Applications, Ed Edward D. Weil, Sergei V. Levchik. 2nd Edition, Hanser 2016, ISBN: 978-1-56990-578-4, Chapter 5, p 117 speaks to the topic of flame retardant additives and flame retardant additive systems for polyamides and exemplifies flame retardant additives and the levels of flame retardant additives used in polyamides throughout. Manufacturers and providers of flame retardant additives will often supply guidance on effective formulations, for instance, ICL Industrial Products Ltd produce such a guidance sheet for polyamides: Flame Retardants for Polyamides (General Application Data on Flame-Retardants for Polyamides 6 and 6,6), historically available at http://icl-ip.com/wp-content/uploads/2012/02/Polyamide-gnl-130729.pdf.
- Halogen-containing flame retardant additives include, but not limited to: brominated polystyrene; poly(dibromostyrene); poly(pentabromobenzylacrylate); brominated polyacrylate; brominated epoxy polymer; epoxy polymers derived from tetrabromobisphenol A and epichlorohydrin; ethylene-1,2-bis(pentabromophenyl); Dechlorane Plus; chlorinated polyethylene; and mixtures thereof. Halogen-containing flame retardant additives with synergists include, but are not limited to: the halogen-containing flame retardant additive together with a synergist, such as but not limited to: antimony (III) oxide, antimony (V) oxide, sodium antimonate; iron (II) oxide, iron (II/III) oxide, iron (III) oxide, zinc borate, zinc phosphate, zinc stannate, and mixtures thereof. Phosphorus-containing flame retardant additives include, but are not limited to: red phosphorus, ammonium polyphosphate, melamine polyphosphate, melamine pyrophosphate, metal dialkylphosphinates (such as but not limited to aluminum methylethylphosphinate, and aluminum diethylphosphinate), aluminum hypophosphite, and mixtures thereof. Inorganic flame retardant additives include, but are not limited to: magnesium hydroxide, alumina monohydrate, alumina trihydrate, aluminum hydroxide, and mixtures thereof. Nitrogen-containing flame retardant additives include, but not limited to: melamine cyanurate, melamine polyphosphate, melamine pyrophosphate, melamine, melan, and mixtures thereof. Nitrogen-containing flame retardant additives with synergists include, but not limited to: nitrogen-containing flame retardant additives together with a synergist, such as but not limited to, Novalac resins. Small amounts of polytetrafluoroethylene are often incorporated into a flame retardant additive system to retard dripping.
- The literature of flame retardant additive systems also speaks to the different mechanisms by which the flame retardant additive imparts its flame retardant properties which may be active in the condensed phase, the gas phase or both. In the condensed phase the flame retardant additive may act as a heat sink or may participate in the formation of char (called an intumescent system) limiting heat and mass transportation, or provide conduction of heat away by evaporation, or mass dilution. In the gas phase flame retardants may act by interrupting the combustion chemistry by providing volatile species that form radicals in the gas phase which quench the radical chain reactions that would otherwise initiate or propagate the fire. Without limiting the scope of the disclosed subject matter, the composition, reacted composition, compounded polyamide composition, or article formed therefrom, may aid the effectiveness by which these flame retardant mechanisms may work.
- The present invention provides a method of making the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, or the compounded polyamide composition including one or both of the same. The method can include combining the condensation polyamide and the maleated polyolefin to form the composition, the reacted composition, the compounded composition, or a combination thereof. A method of forming the article can include making the composition, reaction product thereof, or compounded polyamide composition; alternatively, the composition, reaction product thereof, or compounded polyamide composition can be pre-formed before the onset of a method of forming the article.
- The present invention provides a method of making the compounded composition, including combining the composition including the condensation polyamide and the maleated polyolefin, or the reaction product thereof, with one or more one or more other components to form the compounded polyamide composition.
- The method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, can be a method of improving glycolysis resistance of the condensation polyamide, wherein the composition, reaction product thereof, or compounded composition including one or both of the same, has greater glycolysis resistance than the condensation polyamide.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, can include combining the condensation polyamide and the maleated polyolefin, or compounding the composition or reaction product thereof, in the absence of added glass fibers.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes combining the condensation polyamide and the maleated polyolefin (e.g., and allowing the two to at least partially react to form a reaction product thereof) before adding a chain extender thereto. In other aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes combining the condensation polyamide, the maleated polyolein, and the chain extender at once without allowing any extra time for the condensation polyamide and the maleated polyolefin to react.
- In various aspects, the method of making the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, includes providing to a first compounder extruder zone a feed including the condensation polyamide and the maleated polyolefin. The method includes maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone. The method includes introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone. The method includes maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition including the condensation polyamide and the maleated polyolefin, the reaction product thereof, or the compounded composition. The second compounder extruder zone is downstream of the first compounder extruder zone and can be any suitable distance from the first compounder extruder zone; the chain extender can be added at any suitable location along the length of the screw extruder barrel.
- The first compounder extruder zone can be substantially free of the chain extender, and/or of any chain extender. The chain extender can be ≥0.05 to ≤5 wt % of the second compounded polyamide melt. The method can further include producing an article from the second compounded polyamide melt; for example, the method can include producing extrudate from the second compounded polyamide melt, or producing a molded article from the second compounded polyamide melt.
- The extruder used to make the composition including the condensation polyamide and the maleated polyolefin or the reaction product thereof, or the method of making the compounded composition, can be a screw extruder (e.g., a single screw extruder, a vented twin-screw extruder, or an unvented twin-screw extruder). A barrel of the screw extruder can include the first compounder extruder zone and the second compounder extruder zone. Providing the feed to the first compounder extrusion zone can include providing the feed to a feed inlet of the barrel.
- In various aspects, the chain extender can be introduced to the second compounder extruder zone in the barrel a suitable distance away from the feed inlet. For example, the chain extender can be introduced to the second compounder extruder zone at least ¼ of the length of the barrel from the feed inlet of the barrel. The chain extender can be introduced to the second compounder extruder zone at least ½ of the length of the barrel from the feed inlet of the barrel. The chain extender can be introduced to the second compounder extruder zone at least ¾ of the length of the barrel from the feed inlet of the barrel. The chain extender can be introduced to the second compounder extruder zone sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt, and equal to or greater than ¼ of the length of the barrel from the feed inlet of the barrel, or ½, ¾, or more. The chain extender can be introduced to the second compounder extruder zone sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt, and equal to or greater than 20% of the length of the barrel from the feed inlet of the barrel, or 30%, 40, 50, 60, 70, 80, 90, or 95% or more of the length of the barrel from the feed inlet of the barrel.
- In various aspects, the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone can include introducing the chain extender to the first compounded polyamide melt after a certain weight percentage of the maleated polyolefin has incorporated into the condensation polyamide or into the composition. Incorporation into the condensation polyamide or into the composition can include homogeneous blending of the chain extender with the condensation polyamide or the composition (e.g., on a molecular level, or of domains of the maleated polyolefin or a reaction product thereof), formation of a reaction product of the maleated polyolefin (e.g., with the condensation polyamide), formation of domains of the maleated polyolefin or a reaction product thereof in the condensation polyamide or the composition, or a combination thereof. The introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone can include introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide, or greater than or equal to 50%, 60%, 70%, 80%, 90%, greater than or equal to 95%, or after about 100% of the maleated polyolefin has incorporated into the condensation polyamide.
- Without undue experimentation but with such references as “Extrusion, The Definitive Processing Guide and Handbook”; “Handbook of Molded Part Shrinkage and Warpage”; “Specialized Molding Techniques”; “Rotational Molding Technology”; and “Handbook of Mold, Tool and Die Repair Welding”, all published by Plastics Design Library (elsevier.com website), one can make articles of any conceivable shape and appearance using the composition, reacted composition, and/or compounded polyamide composition of the present disclosure, such as from the second compounded polyamide melt.
- The present invention provides a method of extruding a polyamide resin (e.g., a method of forming an extruded article). The method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a feed zone of an extruder. The method includes maintaining extruder barrel conditions sufficiently to obtain the polyamide resin melt inside the extruder. The method includes producing extrudate (e.g., a conduit) from the extruder while optionally recovering vapor from the extruder via a vacuum draw.
- In some aspects, compounded polyamide resin pellets can be added to an extrusion apparatus and the polyamide resin can be melted.
- Various methods and apparatuses for extruding thermoplastic resins into conduits or tubes of desired shapes and forms can be used for production of tubes of the disclosed invention. For example, in one embodiment, melting may be done in an extruder with single screw or twin-screw to produce a homogeneous melt. Tube head temperature can be maintained within 280-300° C. of the melt temperature of polymer. The extrudate can be cooled in air or using coolant. For coolant method, a calibrator with a coolant, such as water in the temperature range of 40-70° C., can also be used. The flow rate of water in the cooling tank is maintained such that outside skin freezes instantaneously upon contact, and the outside tube temperature is within 5-10° C. of the glass transition temperature of polymer.
- In one embodiment, the extrusion apparatus includes a static mixer and a rotating screw design configured to melt the polyamide containing thermoplastic resin. In alternative embodiments, a single screw extruder, a twin-screw extruder, a vented single screw extruder, or a vented twin screw extruder is used.
- Use of the static mixer in the process of the present invention was found to significantly improve the surface quality of the inside surface of the tube. When a static mixer was used in the process, the inside surface of the tube was observed to have a glossy finish. Other advantages of using a static mixer include thermal homogenization, minimization of melt memory, uniform viscosity and density, enhanced mixing of colors and minor additives, efficient use of all raw materials, elimination of streaks or clouds in the pipe, consistent quality and higher yield (less rejects).
- In one embodiment, the polyamide thermoplastic resin can be melted at temperature ranging from 240 to 320° C., or from 250 to 310° C.
- The melted polyamide thermoplastic resin is then extruded and passed through a tube forming zone of the extrusion apparatus to form the thermoplastic tube. Positive pressure may be applied to the internal cavity of the formed tube through mandrel or pin. In one aspect of this embodiment, the process further includes the step of passing the portion of a thermoplastic tube through a dryer.
- In one embodiment of this process of the present invention, the residence time from extrusion to tube forming is less than 60 minutes, for example, less than 50 minutes, for example, less than 40 minutes. Examples of tube forming zones include, but are not limited to, spiral or basket shaped die head, transition zone, a heated mandrel with or without a heated pin which forms at least a portion of a thermoplastic tube. When using a heated mandrel or pin, positive pressure may be applied to the internal cavity of the formed tube through mandrel or pin.
- In one embodiment, the process of the present invention further includes passing the melted polyamide thermoplastic resin through a screen to remove any contaminants or un-melted portions prior to extrusion. In this embodiment, the screen may be reinforced by a breaker plate to create pressure in the extruding apparatus.
- An extruded conduit can be a multi-layer conduit including one or more layers formed from the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, or a monolayer conduit formed from the composition. Monolayer conduits can optionally include up to 2 wt % (actives) UV-grade colorant. Multi-layered conduits can include inside/outside surface skin layers and can include up to 1 wt % (actives) non-UV grade colorant. The extruded conduit the article can be characterized, when compared against a control, by superior resistance to at least one selected from cold-temperature cracking, urea exposure, fuel exposure, oil exposure, high-temperature exposure, hydrolysis, glycolysis, and salt exposure.
- The present invention provides a method of molding a polyamide resin (e.g., a method of forming a molded article). The method includes providing a polyamide resin including the composition that includes the condensation polyamide and the maleated polyolefin, the reaction product thereof, the compounded polyamide composition, or a combination thereof, to a mold. The method includes producing a molded polyamide resin from the mold.
- Various embodiments of the present invention can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.
- A twin-screw vented extruder having 18-mm diameter co-rotating screw with a 40-56 L/D (i.e., L/D ratio of 40-56) was used for compounding. The unit had one main feeder and at least three side feeders. A feed rate of at least 1 kg/hr was used. The twin-screw co-rotating/turning at least 1000 RPM was sufficient to provide high shear for effective compounding. The total compounder throughput was at least 15 kg/hr.
- The compounding unit had at least three vent ports: one atmospheric port and two vacuum ports. A knock-out pot was provided in this operation. The rotating twin screws imparted forward momentum to the heated mass inside the barrel. The barrel was heated along its length to melt the polymer. Typically, 240-320° C. was used for nylon 66.
- The processing section of the twin-screw compounder was set up to suit various process needs and to allow a wide variety of processes, such as compounding processes. Polymer, fillers, and additives (as desired), were continuously fed into the first barrel section of the twin screw using a metering feeder. The products were conveyed along the screw and were melted and mixed by kneading elements in the plastification section of the barrel. The polymer then traveled along to a side port where fillers (if desired), such as but not limited to glass fiber, could be added. The polymer then traveled on to degassing zones and from there to a pressure build zone where it then exited the die via an at least 3-mm hole as a lace. The cast lace was fed into a water bath to cool and to enable it to be cut into chips via a pelletizer. The unit was able to withstand at least 70 bar die pressure. A die with a minimum of four holes, each at least 3 mm diameter, was used for pelletizing.
- The compounded pellet having a diameter of 3 mm and a length of 3-5 mm was produced using the above equipment. The moisture content of the pelletized material was <0.2 wt. %.
- Flammability testing was established by performing a test functionally equivalent to the UL 94 Standard.
- General Procedure for Volatile Extraction Method. Extrusion Step.
- The compounded polyamide resin pellets were added to an extrusion apparatus and the polyamide resin was melted.
- Various methods and apparatuses for extruding thermoplastic resins into conduits or tubes of desired shapes and forms were used for production of tubes. Melting was done in a vented twin-screw extruder in 26 mm or 45 mm sizes to produce a homogeneous melt. Tube head temperature was maintained within 280-300° C. of the melt temperature of polymer. The extrudate was cooled in air or using coolant. For coolant method, a calibrator with a coolant, such as water in the temperature range of 40-70° C., was also used. The flow rate of water in the cooling tank was maintained such that outside skin freezes instantaneously upon contact, and the outside tube temperature was within 5-10° C. of the glass transition temperature of polymer.
- The extrusion apparatus included a static mixer and a rotating screw design configured to melt the polyamide-containing thermoplastic resin, generally at a temperature between 260 and 310° C. Use of the static mixer in the was found to significantly improve the surface quality of the inside surface of the tube. When a static mixer was used in the process, the inside surface of the tube was observed to have a glossy finish. Other advantages of using a static mixer included thermal homogenization, minimization of melt memory, uniform viscosity and density, enhanced mixing of colors and minor additives, efficient use of all raw materials, elimination of streaks or clouds in the pipe, consistent quality, and higher yield (e.g., less rejects).
- The melted polyamide containing thermoplastic resin was then extruded and passed through a tube forming zone of the extrusion apparatus to form the thermoplastic tube. Positive pressure was applied to the internal cavity of the formed tube through mandrel or pin. In one aspect of this embodiment, the process further includes the step of passing the portion of a thermoplastic tube through a dryer.
- Feedstock PA66 polyamide, as used herein, is a commercially available INVISTA nylon 66 (or N66) grade under the Tradename INVISTA™ U4800 polyamide resin. The PA66 has standard RV range of 42-50. The feedstock PA66 may also have RV ranging from 80 to 240.
- As used herein, “High-AEG polyamide 66” or “High AEG N66” is commercially available from INVISTA. High-AEG polyamide 66 is characterized by its RV range of 30-80, for example 35-75 RV, for example, 35-70 RV, and AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg of the polyamide resin, for example 270 meq/kg and ≤125 meq/kg, ≥75 meq/kg and ≤125 meq/kg, ≥80 meq/kg and ≤125 meq/kg, 290 meq/kg and ≤120 meq/kg of the polyamide resin.
- As used herein, “PA 66/6T” refers to a type of partially aromatic polyamide that is commercially available from manufacturers including Arkema, BASF, DuPont, DSM and EMS. PA 66/6T is a type of co-polyamide prepared from PA66 and “6T”. The 6T part is a combination of hexamethylene diamine and terephthalic acid “T”.
- As used herein, “PPE” is commercially available from Asahi Kasei, SABIC, Mitsubishi and LG Chem.
- As used herein, “Amplify® GR216” is a maleic anhydride grafted and is commercially available from Dow Chemical.
- As used herein, “PA612” is commercially available from DuPont, EMS, Shakespeare, Nexis. PA612 is a semi-crystalline polyamide prepared from hexamethylenediamine (C6 diamine, abbreviated as HMD) and dodecanedioic acid (C12 diacid, abbreviated as DDDA).
- As used herein, “Engage 8401” is commercially available from Dow Chemical.
- As used herein, “Epolene E-43P” is commercially available from Westlake Chemical.
- As used herein, “ZeMac E60” is a chain extender that is a copolymer of maleic anhydride and ethylene and is commercially available from Vertellus.
- As used herein, “BK34” is a colorant additive and is commercially available from AmeriChem, Clariant.
- As used herein, “Zytel FE7108” is commercially available from DuPont, AmeriChem.
- Diethylphosphinic Acid Aluminum salt (CAS No. 225789-38-8) belongs to a family of dialkyl phosphinic acid salts. It is commercially available for use as flame retardant in engineering plastics such as polyamides, polyesters, thermosets and elastomers.
- As used herein, Rianox® U-Pack B1171, a commercial polymer additive product of Rianlon, is a blend of hindered phenolic antioxidant and a phosphite for processing and long-term thermal stabilization.
- The formulation “PA66/DI” used in the examples of the present disclosure had an RV of 45, and a composition of 92:8 PA66:DI (wt/wt), with the “DI” part being about 40:60 D:I (wt/wt). Other non-limiting co-polyamides suitable for use in place of the PA66/DI used in the present examples include 66/D6, 66/DT, 6T/DT, 66/610, 66/612, and such.
- As used herein, “Stabaxol® P100” is a type of hydrolysis stabilizer commercially available from Lanxess.
- ASTM D789: Relative viscosity (RV) measurement method. ASTM D638-14: Tensile strength (MPa) measurement method. ISO 75: Heat Deflection Temperature [HDT] measurement method. ISO 178: Flexural Stress and Flexural Modulus measurement method. ISO 180: Izod Notched Impact Strength (23° C., kJ/m2) measurement method. ISO 188: Method of heat aging used for test samples. ISO 307: Viscosity Number (VN) method using sulfuric acid. ISO 527: Tensile Modulus and % Elongation-at-Break measurement method. UL 94 Std.: Flammability [V-0/V-1/V-2] Rating Determination method. ISO 179/2-1eU: Notched and Un-Notched Charpy Impact. ISO 11357: Melting point via DSC.
- To simulate Environmental Stress Cracking (ESC), injection molded tensile bars were placed onto multiple sustained strain fixtures, with strain rates of 0%, 1% and 3%. Four samples were tested per exposure and strain conditions. The exposure medium was 50% zinc chloride aqueous solution. Exposure temperature and time were 23° C. and 200 hours, respectively. The resistance to ZnCl2 testing was performed according to the standard SAE J2260 (1996) Section 7.5. The strained tensile bars were examined for crazing after 24 hours, 72 hours, 120 hours, 168 hours, and 200 hours of exposure time. During this period, pH of the zinc chloride solution was monitored and adjusted if needed to achieve a constant pH. At the completion of exposure time, the tensile stress and elongation at break were measured via ASTM D638 or ISO 527 at 23° C.
- Injection molded tensile and impact bars were used for testing. A mixture of glycol/water at 1:1 volume ratio was prepared and cast into a pressure vessel. Then, the bars were fully immersed in the glycol/water mixture and the pressure vessel was sealed. Pressure and temperature were both slowly increased to achieve the desired level. The exposure temperature and time were 100-130° C. and 1000-3000 hours, respectively. Test bars were removed for tensile and impact testing at the interval of 500 hours.
- Injection molded tensile and impact bars were used for testing. Bars were heat-aged according to ISO 188. After heat-aging, the bars were cooled to room temperature in the lab, and tensile stress, elongation at break, and impact properties were measured using the appropriate methods listed above.
- Tables 4A and 4B give compositional ranges for the several polyamide samples that were compounded using the general procedure detailed above.
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TABLE 4A Polyamide samples 1A-1H. A B C D E F G H Component wt. % wt. % wt. % wt. % wt. % wt. % wt. % wt. % 48 RV PA66 (U4800) 73.5 73.5 70.5 73 58.5 58.5 High AEG PA66 (45 RV) 73.5 PA 66/6T Copolymer 73.5 Modified PPE 15 Maleated Polyolefin 25 20 25 25 25 25 25 25 (Amplify ™ GR216 or ExxonMobil VA1840) PA612 15 Engage 8401 5 Epolene E-43P 3 Chain Extender (ZeMac E60) 0.5 Colorant (BK34 CB&N) 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Irganox B1171 HS Zytel FE7108 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 TOTAL 100 100 100 100 100 100 100 100 -
TABLE 4B Samples 1I-1M, I J K L M Component wt. % wt. % wt % wt. % wt. % 48 RV PA66 (U4800) 52 47 37 High AEG PA66 (45 RV) 52 PA 66/6T Copolymer 59 Modified PPE 15 Maleated polyolefin (Amplify ™ 25 25 25 25 25 GR216 or ExxonMobil VA1840) PA612 15 Diethylphosphinic Acid Aluminum 22 22 15 12 22 salt Rianox ® U-Pack B1171 0.4 0.4 0.4 0.4 0.4 Colorant (e.g., BK34 (CB&N)) 0.6 0.6 0.6 0.6 0.6 Zytel FE7108 TOTAL 100 100 100 100 100 - The compounded polyamide specimens A through M in Tables 4A-B were obtained as cylindrical pellets of dimension 3 mm diameter and 3-5 mm length.
- A conduit was extruded from melted compounded polyamide resins of Examples 1 (A-M) using a vented twin-screw extruder. The molten polymer was passed through a screen into a heated spiral or basket-type die head where the polymer came in contact with a mandrel. The melted polymer then flowed into the gap between the pin of the mandrel and the sleeve, referred to as the die-gap, where the polymer was cooled down. The conduit wall thickness was controlled by the die-gap, swell ratio, and orientation ratio. Typical extrusion conditions are as follows: Screw RPM 40-200; Grooved bush temp 40-200° F.; Barrel Temps. (5 barrels) 505-580° F.; Die Temp. (5 die heads) 500-550° F.
- Once the compounded resin composition was passed through the die-gap, it was then passed through a calibrator ring, which was used to size the conduit to the correct outer diameter. Water may or may not be used in the calibrator ring as a lubricant to minimize sticking. The calibrator ring also has the ability to pull a vacuum for correctly sizing the outer diameter of the conduit. The conduit was then moved through two or more cooling tanks with either water spray of atomized droplets or a water bath to cool the conduit to less than 150° C. The extruded conduit (or tube) used in most Examples herein has standard Aspect Ratio (L/D) of between 5 and 100 with 0.8-5 cm outside diameter and wall thickness in the range of up to 3 mm. The extruded conduit (tube) was produced in a continuous fashion to either make continuous coils or cut into straight section of desired length using a saw. However, the same or similar conditions can be utilized to manufacture bigger or smaller tube sizes with standard L/D ranging from 5 to 1000.
- Using the extrusion process described above, Examples A-H compounded resins were extruded in the form of a cylindrical conduit of dimension 8-50 mm outside diameter×variable linear length, with a wall thickness in the range 0.5-3 mm.
- The extruded cylindrical conduits included straight and corrugated designs. These conduit specimens were tested for flexibility, mechanical strength, chemical resistance (particularly, salt resistance), glycolysis resistance, hydrolysis resistance, heat aging, and flame resistance.
- The extruded conduits according to the present Example showed improved performance with respect to their mechanical strength, chemical resistance (ZnCl2 salt resistance), glycolysis resistance, hydrolysis resistance, heat aging, and flame resistance.
- Surprisingly, the extruded conduits according to the present Example showed improved flexibility without causing any stress cracking for a long in-use duration.
- In Table 5A, the mechanical and structural performance properties are listed for several of the test specimens prepared according to the Example 1 formulations.
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TABLE 5A Mechanical and structural performance properties for test specimens from Example 1 formulations. Example Example Example Performance Property 1A 1E 1F Moisture Absorption, at 50% RH (%) 2.1 1.9 2.2 Tensile Strength, DAM (MPa) 47 43 46 Tensile Strength, at 50%RH (MPa) 45 41 44 Elongation @ Break, DAM (%) 122 128 149 Elongation @ Break, at 50%RH (%) 207 203 225 23° C. Notched Charpy Impact, DAM 102 101 107 (kJ/m2) 23° C. Notched Charpy Impact, at 130 128 132 50%RH (kJ/m2) −30° C. Notched Charpy Impact, DAM 47 61 90 (kJ/m2) −30° C. Notched Charpy Impact at 71 67 85 50%RH (kJ/m2) 23° C. Un-Notched Charpy Impact, DAM NB NB NB −30° C. Un-Notched Charpy Impact, DAM NB NB NB Flexural Modulus, DAM (MPa) 1530 1500 1430 Melt Temperature (° C.) 262 255 262 RH—Relative Humidity; DAM—Dry as Molded; NB—No Break - In Table 5B, the mechanical and structural performance properties are listed for several of the commercially available PA66, PA12 and PA612 materials.
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TABLE 5B Mechanical and structural performance properties for several commercially available PA66, PA12, and PA612 materials. Com- Com- Com- mercial mercial mercial High PA12 PA612 Tough (Extrusion (Extrusion Performance Propery PA66 Grade) Grade) Moisture Absorption, at 50% 2.0 0.6 1.2 RH (%) Tensile Strength, DAM (MPa) 50 41 54 Tensile Strength, COND (MPa) 46 39 41 Elongation @ Break, DAM (%) 45 163 20 Elongation @ Break, COND (%) 218 171 76 23° C. Notched Charpy Impact, 72 88 43 DAM (kJ/m2) 23° C. Notched Charpy Impact, 122 100 96 COND (kJ/m2) −30° C.Notched Charpy Impact 33 87 15 DAM (kJ/m2) −30° C. Notched Charpy Impact, 38 92 21 COND (kJ/m2) 23° C. Un-Notched Charpy NB/NB NB/NB NB/NB Impact, DAM/COND −30° C. Un-Notched Charpy NB/NB NB/NB NIINF3 Impact, DAM/COND Tensile Modulus, DAM (MPa) 1176 960 1970 Tensile Modulus, COND (MPa) 612 542 1158 Flexural Modulus, DAM (MPa) 1500 — — Melt Temperature (° C.) 260-263 180 220 RH—Relative Humidity; DAM—Dry as Molded: COND—Conditioned specimen at 50% RH; NB—No Break - The inventive test specimens according to the present Example have the following properties: Tensile strength >40 MPa (DAM) and >30 MPa (at 50% RH). Elongation @ Break >100% (DAM) and >200% (at 50% RH). Notched Charpy Impact @ 23° C.>100 kJ/m2 and @−30° C.>20 kJ/m2. Un-Notched Charpy Impact @ 23° C. and @ −30° C. “No Break”. Moisture uptake <2.5% at 50% RH conditioned specimens. Low water vapor permeation of <30 mg/h/m2. Low conductivity of >1012 Ohm·cm. Extruded or molded articles sustain 1.5-2.5 bars (5 bars maximum) operating pressure. Chemical exposure or aging performance: Retained ≥50% mechanical properties after 50:50 (vol/vol) glycol:water exposure at 100° C. for 2000 hours or at 130° C. for 1000 hours; Retained ≥50% mechanical properties after 50% zinc chloride solution exposure at 23° C. for 200 hours; Retained ≥50% mechanical properties after heat aging at 110° C. or 140° C. for 1000 hours.
- Some of the test bar specimens prepared from the Example 1 formulations, were exposed to 50% aqueous zinc chloride (ZnCl2) solution. The exposure time was 200 hours at 23° C. and under 3% sustained strain to simulate the tube bending condition. The salt resistance test was performed according to the SAE J2260 (1996) Test Method Section 7.5.
- Table 6 provides the measured Break Strength (in MPa), Tensile Elongation of Break (%), and Tensile Modulus (in MPa) for the tested specimens exposed to salt solution at 23° C. and under 3% strain. The test results labeled “Before” are for test specimens that were not exposed to the salt solution. The test results labeled “After 3%” are for test specimens that had been exposed to salt solution for 200 hours with 3% sustained strain applied.
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TABLE 6 Properties of test bar specimens prepared from 1A, 1E, and 1F. Example 1A Example 1E Example 1F Before After 3% Before After 3% Before After 3% Break strength (MPa) 42 41 41 40 44 42 Tensile Elongation at break (%) 99 162 56 237 133 180 Tensile Modulus (MPa) 2065 1717 2144 1924 1903 1662 - Upon test completion, there was no significant material degradation and as evidenced in changes in tensile yield strength. Visual inspection showed no observable surface cracking or crazing, further indicating resistance to salt exposure for the test specimens.
- Using the above-described Volatile Extraction Method during the extrusion process, the surface porosity of the extruded articles is controlled to a desired distribution.
- When the extruded tube specimen is cut to visually inspect the cross-section, no visible porosity is observed. Furthermore, the absence of volatiles also provides smooth internal tube surface finish and regular inner tube diameter.
- Three multi-layer tubes were prepared. The multi-layer tubes have a round cross-sectional profile, with a wall that includes an inner layer and an outer layer, with a middle layer sandwiched between and in contact with the inner layer and the outer layer. Table 7A provides the details for the three co-extruded multi-layered tubes.
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TABLE 7A Details for co-extruded multi-layered tubes. Multi- layered Tube Tube Cross- Tube Cross- Tube Cross- Construction section 6A section 6B section 6C Nutnber of 3 3 3 layers co- extruded Type Non-reinforced Reinforced Reinforced Materials Various All PA66 Various Inner Layer Thickness 0.1-0.3 mm 0.5-2 mm 0.1-2 mm Material Tefzel HT2202, Tefzel HT2202, Modified PA66, Daikin EP- Daikin EP- Tefzel HT2202, 7000, maleated- 7000, maleated- Daikin EP- polypropylene, polypropylene, 7000, maleated- Dow Engage ™ Dow Engage ™ polypropylene, series, HDPE, series, HDPE, Dow Engage ™ PA12, PA11, PA12, PA11, series, HDPE, PPA PPA PA12, PA11, Middle Layer PPA Thickness 0.7-2.5 mm 0.4-1 mm 0.4-1 mm Material Modified PA66 10-50% glass/ 10-50% glass/ carbon fiber/ carbon fiber/ carbon black carbon black filled PA66 filled PA66 Outer Layer Thickness 0.1-0.3 mm 0.5-2 mm 0.5-2 mm Material same as inner same as inner same as inner layer layer layer Total Tube 0.9-3.1 mm 1.4-5 mm 1-5 mm Thickness Inside Tube 1.8-48.2 mm 5-47.2 mm 5-48 mm Dia. Outside Tube 8-50 mm 15-50 mm 15-50 mm Dia. Tube Length Varies as per end-use application - Table 7B provides the details for co-extruded multi-layered pipes according to the present Examples. It will be understood that there no limit on the number of co-extruded layers and their combinations will depend on the end-use application.
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TABLE 7B Details for co-extruded multi-layered pipes 6D-6F. Multi- Pipe Cross- Pipe Cross- Pipe Cross- layered section section section having Pipe having having both, inner Construction an inner layer an outer layer and outer layers (or skin) 6D (or skin) 6E (or skins) 6F Number of 2 2 3 layers co-extruded Total Pipe 5-80 mm 5-80 mm 5-80 mm Thickness Pipe diameter 2″ to 24″ 2″ to 24″ 2″ to 24″ Pipe Length Up to 2000-ft (can be coiled) for <6″ dia. pipe Up to 400-ft for >6″ dia. pipe Varies depending on end-use application Inner Layer Thickness 0.5-5 mm [No inner 0.5-5 mm Material Any of the layer] Any of the modified PP, modified PP, modified modified HDPE, PA12, HDPE, PA12, PA6, 12, PPS, PA6, 12, PPS, PPA, ETFE PPA, ETFE Middle Layer Thickness 4.5-75 mm 4.5-75 mm 4-70 mm Material Modified 10-50% 10-50% PA66 glass/carbon glass/carbon fiber/carbon fiber/carbon black filled black filled PA66 PA66 Outer Layer Thickness [No outer 0.5-5 mm 0.5-5 mm Material layer] Any of the Any of the modified modified PP, modified PP, modified HDPE, PA12, HDPE, PA12, PA6, 12, PPS, PA6, 12, PPS, PPA, ETFE PPA, ETFE - The co-extruded multi-layer pipes shown in Table 7B are useful in oil and gas processing, water management systems, and in other such applications as conduits for electrical and fiber optic cabling, hydrogen gas processing, and the like. The inner and/or outer layer (or conduit skin) materials may be appropriately selected to be chemically compatible in end-use fluid flow applications where the fluid is in direct contact.
- Some of the test bar specimens, prepared from the Example 1 formulations, were exposed to 50% aqueous glycol solution. The exposure time was maintained for 504 hours and 1008 hours at the constant test temperature of 120° C. Table 8 provides the measured Break Strength (in MPa), Tensile Elongation of Break (%), and Tensile Modulus (in MPa) for the tested specimens exposed to glycol at 120° C. The test results labeled “Before” are for test specimens that have not been exposed to glycol solution. Surprisingly, the elongation at break was observed to be >100% for Example 1 (F) even after 1008 hrs of glycol exposure at 120° C.
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TABLE 8 Glycolysis resistance of test bars prepared from 1A, 1E, and 1F. Example 1A Example 1E Example 1F 504 1008 504 1008 504 1008 Before hr hr Before hr hr Before hr hr Break strength (MPa) 42 27 23 41 26 25 44 28 26 Tensile Elongation at break 99 101 55 56 97 43 133 112 105 (%) Tensile Modulus (MPa) 2065 356 414 2144 458 458 1903 372 310 - Heat aging performance testing was performed at 140° C. for some of the test bar specimens prepared from the Example 1 formulations. Table 9 provides the measured Break Strength (in MPa), Tensile Modulus (in MPa), and Notched Charpy 23° C. (kJ/m2) for the tested specimens. The property measurements were conducted at 200 hr, 400 hr, 600 hr and 1000 hr heat aging increments. The test results labeled “Before” are for test specimens before the heat aging test.
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TABLE 9 Heat aging performance testing of test bar specimens prepared from 1A, 1E, and 1F. Example 1A Example 1E Example 1F 200 400 600 1000 200 400 600 1000 200 600 1000 Before h h h h Before h h h h Before h 400 h h Break 47 48 48 48 46 43 46 45 46 43 46 47 46 46 41 strength (MPa) Tensile 1560 1742 1726 1702 1504 1537 1692 1728 1812 1552 1467 1526 1578 1576 1410 Modulus (MN) Notched 102 85 72 64 49 101 80 65 57 47 107 88 74 68 53 Charpy, 23° C. (kJ/m2) - Formulations 1A and 1F were compounded with chopped E-glass fiber (ChopVantage® HP 3610 chopped strands) to obtain reinforced materials that are suitable for injection molded applications, as shown in Table 10 (all values are on the weight basis).
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TABLE 10 Glass fiber-compounded materials. Example General Example General Component 9A Range 9B Range Example 1A Formulation 65% 50-85% — — Example 1F Formulation — — 65% 50-85% Chopped E-glass Fiber 35% 15-50% 35% 15-50% Zn Stearate/EBS Lubricant ≤0.5% ≤0.5% - Surprisingly, in these embodiments, very high levels of glass fibers were incorporated for the illustrative specimens of Example 1A and 1F. In some aspect, the compounded polyamide formulation in the present disclosure may include from 1 wt. % up to 50 wt. % glass fiber, of the total weight, for example, from 10 wt. % up to 45 wt. % glass fiber, for example from 15 wt. % up to 42 wt. % glass fiber.
- The test specimens of Table 10 had unexpected mechanical, chemical resistance, hydrolysis resistance, salt resistance, and fuel/oil resistance properties, as listed below.
- Mechanical performance properties. Tensile modulus: 8000-10000 MPa. Elongation at break: 4%-5%. Un-Notched Charpy at 23° C.: 90-100 kJ/m2. Un-Notched Charpy at −40° C.: 80-90 kJ/m2. Notched Charpy at 23° C.: 20-30 kJ/m2. Notched Charpy at −40° C.: 15-20 kJ/m2.
- Hydrolysis Resistance Properties: Hydrolysis resistance after exposed to glycol/water 50/50 at 130° C. for 1008 hrs. Tensile strength: 70-90 MPa. Elongation at break: >5%. Un-Notched Charpy at 23° C.: 40-50 kJ/m2.
- Salt Resistance Properties: Zinc Chloride resistance after exposed to 50% aqueous solution at 23° C. for 300 hrs. Tensile strength: 100 MPa. Elongation at break: >5%. Un-Notched Charpy at 23° C.: 70-90 kJ/m2.
- Urea Resistance Properties: Urea resistance after exposed to aqueous urea solution at 60-80° C. for 3000 hrs. Tensile strength: 70-90 MPa. Elongation at break: >5%. Un-Notched Charpy at 23° C.: 50-70 kJ/m2.
- Fuel/Oil Resistance Properties: Motor oil resistance after exposure at 150 ZC for 5000 hrs. Tensile strength: 90-110 MPa. Elongation at break: 3-5%. Un-Notched Charpy at 23° C.: 40-70 kJ/m2.
- The glass-fiber reinforced materials from Examples 9A-B were injection molded into suitable shaped parts depending on the end-use application. These IM parts were subjected to the standard temperature cycling protocols practiced in the automotive OEM industry.
- It was observed that the tested IM parts showed superior impact resistance and toughness during repeated temperature cycling testing.
- Table 11 lists compositional ranges and some embodiments of several polyamide samples that were compounded using the general procedure detailed above.
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TABLE 11 Samples Q-Z. Component Range [basis: wt. %] Wt. % Q R S T U V W X Y Z Fed at the main throat (or hopoer) of the compounding exinider High AEG PA66 20-75 49.8 74 49.3 38.8 24.5 27.8 37.8 — 69 69 (45 RV) PA66/DI (45 RV) 20-85 — — — 29 43.3 22 30 67.75 — — PA610 5-50 18 18 18 Impact modifier 1040 25 25 25 25 25 25 25 25 75 75 (e.g., Amplify ™ GR216) Black MB Colorant 0.5-2.5 1.0 — 1.0 1.0 1.0 1.0 1.0 1.0 — — (e.g.: carbon black or Nigrosine black dye) Heat Stabilizer 0.5-2 1.2 1.0 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.0 (e.g.: Cu-based or organic based such as Irganox ® B1171) Fed at mid-way (side feed) of compounding extruder High AEG PA66 <10 4.75 — 4.75 4.75 4.75 4.75 4.5 4.25 4.75 4.5 (45 RV) Chain Extender 0.1-1 0.25 — 0.25 0.25 0.25 0.25 — 0.25 0.25 0.5 (e.g.: ZeMac E60) Hydrolysis 0.1-3 — — 0.5 — — — 0.5 0.5 — — Stabilizer (e.g.: Stabaxol P100) TOTAL 100 110 110 100 100 100 100 101 110 110 - The compounding for the Table 11 compositions was performed using a conventional screw type extruder and in the 240-265° C. temperature range.
- In the Formulation labeled “R” in Table 11, all the listed ingredients were fed at the main throat (or hopper) of the compounding extruder. In other Table 11 formulations, as described therein, a majority of the total polyamide quantity and modified polyolefin along with colorant and heat stabilizer additives were fed at the main throat (or hopper) of the compounding extruder. The remaining quantity of the polyamide was mixed with the chain extender and/or hydrolysis stabilizer additives and fed mid-way (via side feed) of the compounding extruder.
- It was surprisingly observed that the above split-feed compounding method improved the compounding performance when compared against feeding all ingredients at the main throat (or hopper) of the compounding extruder. Although not bound by the theory, this observation led to a belief that late introduction of chain extender additive (as done mid-way during compounding) affects the initial interaction between polyamide component(s) and modified polyolefin in the front section. It is also presumed that the presence of chain extender introduced early-on in the front section of the compounder may be prone to instantly interacting with the polyamide component(s) before any modified polyolefin is able to do so. This instant interaction between the chain extension additive and the polyamide component(s) may lead to a rapid rise in the molecular weight build and viscosity, both being detrimental for compounding process operability. The interaction can be controlled by adding the chain extender a suitable distance away from the polyamide and modified polyolefin addition point (e.g., the main throat of the compounding extruder) to allow suitable time for the polyamide and modified polyolefin to react, by avoiding adding chain extender until a suitable percentage of the modified polyolefin has incorporated and/or reacted with the polyamide, or a combination thereof.
- The above-compounded polyamide specimens Q through Z in Table 11 are obtained as cylindrical extruded pellets of dimension 2-4 mm diameter and 3-5 mm length.
- A round cross-section pipe was extruded from melted compounded polyamide resins of Examples 11Q-Z using a vented twin-screw extruder, as described in Example 2.
- The extruded pipe herein has standard Aspect Ratio (L/D) of up to 15,000 with 5.08-61 cm (2″ to 24″) outside diameter “D” and wall thickness in the range of 5 to 80 mm. The extruded pipe is produced in a continuous fashion to either make continuous long section that can be loosely coiled or cut into straight short sections of desired lengths.
- In one example, a 7.62 cm (3″) outside diameter pipe having 10 mm thickness wall and about 1500 cm (50 ft) length straight section is continuously extruded (200 Aspect Ratio). In another example, a 10.16 cm (4″) outside diameter pipe having 20 mm thickness wall and about 2000 cm (˜100-ft) length straight section is continuously extruded (300 Aspect Ratio).
- In one embodiment and by way of continuous extrusion of the present disclosure, it is possible to obtain a long-coiled pipe section having up to 15.24 cm (6″) diameter and 2000 ft length. In another embodiment of the present disclosure, it is possible to obtain a straight pipe section having 20.32 cm (8″) diameter and up to 400 ft length.
- According to the present disclosure, it is possible to obtain a multi-layered conduit. Such multi-layered conduits may include annular layers or a surface skin or a jacket. Materials suitable for layering may include modified polypropylene, modified HDPE, PA12, PA612, PPS, PPA, ETFE, and such. In one example, the extruded pipe section may contain an inner layer (or skin) having a thickness of between 0.5-4 mm. In another example, the extruded pipe section may contain an outer layer (or skin) having a thickness of between 0.5-4 mm.
- The extruded pipes may include straight designs for mono- as well as multi-layered piped of desired diameters, wall thicknesses, and linear lengths.
- The test specimens of Table 11 have the mechanical and structural performance described in Table 12A-F. Table 12A-F data is measured for dry as molded (DAM) test specimens unless otherwise indicated. The measured heat deflection temperature (HDT) ranges for Table 12 formulations (DAM specimens) were 50-60° C. at 1.8 MPa and 75-90° C. at 0.45 MPa. The moisture absorption for the below test specimens was <2.1 wt % at equilibrium conditions.
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TABLE 12A Mechanical and structural strength of test specimens of Table 11. Specimen [R] of Specimen [W] of Table 11 Table 11 DAM COND DAM COND Yield strength (MPa) 40 30 41 30 Yield elongation (%) 5 40 6 50 Break strength (MPa) 46 44 45 42 Tensile elongation at break (%) 149 215 123 205 Tensile modulus (MPa) 1360 530 1200 450 Notched Charpy, 23° C., kJ/m2 107 132 111 134 Notched Charpy, −30° C., 90 85 85 89 kJ/m2 Un-Notched Charpy, 23° C., NB NB NB NB kJ/m2 Un-Notched Charpy, −30° C., NB NB NB NB kJ/m2 HDT @ 1.8 MPa (° C.) 55 — Not available — HDT @ 0.45 MPa (° C.) 81 — Not available — Moisture absorption, equi (%) 2.2 2.0 DAM—Dry as molded; COND—Conditioned specimen at 50% RH; NB—No Break -
TABLE 12B Mechanical and structural strength of test specimens of Table 11. Measured property Q R S T U V W X Y Z MFI @ 290° C. and 1.75 22.55 1.38 6.45 1.93 3.45 3.09 1.01 1.5 0.73 15 kg (g/10 min) Melting Point 258 262 259 254 239 256 259 242 260 258 (° C.) Crystallization 205 219 209 208 197 204 209 192 214 216 Temperature (° C.) Break Strength 43 47 44 47 45 43 45 45 47 48 (MPa) Yield Strength 38 39 38 45 41 39 41 42 41 43 (MPa) Elongation 5 5 5 5 6 5 6 6 5 6 at Yield (%) Elongation 89 149 113 130 103 127 123 103 56 103 at Break (%) Tensile Modulus 1312 1466 1290 1552 1274 1342 1168 1276 1474 1586 (MPa) Notched Charpy, 108 107 111 102 107 109 111 109 103 106 23° C. (kJ/m2) Notched Charpy, 68 90 45 39 47 47 86 51 50 48 −30° C. (kJ/m2) Un-Notched Charpy, NB NB NB NB NB NB NB NB NB NB 23° C. (kJ/m2) Un-Notched Charpy, NB NB NB NB NB NB NB NB NB NB −30° C. (kJ/m2) All specimens are Dry-as-molded [DAM]; “NB”—No Break -
TABLE 12C Glycolysis resistance of test bars prepared from Table 11 Specimens. Specimen [R] of Table 11 Specimen [W] of Table 11 Before 500 hr 1000 hr Before 500 hr 1000 hr Yield Strength (MPa) 40 23 22 41 22 22 Yield Elongation (%) 5 40 30 6 40 40 Break strength (MPa) 46 27 25 45 26 24 Tensile Elongation 110 136 96 123 143 107 at break (%) Tensile Modulus (MPa) 1360 266 290 1200 238 262 -
TABLE 12D Heat aging performance testing of test bars prepared from Table 11 Specimens. The heat aging test was performed at 140° C. Specimen [R] of Table 11 Specimen [W] of Table 11 Before 250 h 500 h 1000 h Before 250 h 500 h 1000 h Yield Strength (MPa) 40 41 41 N/A 41 42 42 N/A Yield Elongation (%) 5 5 5 N/A 6 6 6 N/A Break strength (MPa) 46 46 46 43 45 46 46 46 Tensile Elongation at 110 97 64 7 123 114 105 42 break (%) Tensile Modulus 1360 1274 1224 1276 1200 1336 1410 1438 (MPa) Notched Charpy, 107 83 72 52 111 106 102 82 23° C. (kJ/m2) -
TABLE 12E Heat aging performance testing of test bars prepared from several commercially available PA66, PA12, and PA612 materials shown in Table 5B. Commercial High Commercial PA12 Commercial PA612 Tough PA66 (Extrusion Grade) (Extrusion Grade) Before 250 h 500 h 1000 h Before 250 h 500 h 1000 h Before 250 h 500 h 1000 h Break strength (MPa) 50 46 41 24 41 37 37 38 54 53 55 53 Tensile Elongation 45 5 3 2 163 134 47 24 20 24 20 5 at break (%) Tensile Modulus 1776 1686 1704 1736 960 840 998 1142 1970 2008 2074 2108 (MPa) Notched Charpy, 72 30.6 28.5 22.1 88 63.9 35.0 5.3 43 28.5 8.0 1.7 23° C. (kJ/m2) -
TABLE 12F Salt Resistance (ZnCl2) of test bars prepared from Table 11 Specimens. Specimen [R] of Table 11 Specimen [W] of Table 11 Before After 0% After 3% Before After 0% After 3% Yield Strength (MPa) 39 38 38 Not Measured Yield Elongation (%) 4 40 40 Break strength (MPa) 44 43 42 46 42 45 Tensile Elongation 133 156 180 154 145 171 at break (%) Tensile Modulus (MPa) 1903 1782 1662 731 552 517 - Formulation 1F was compounded with chopped E-glass fiber (e.g.: ChopVantage® HP 3610 chopped strands) and polyamide (e.g., nylon-6,6 such as 45 RV High AEG PA66) to obtain reinforced materials having glass fiber reinforcement in the 35-45 wt. % range. Such reinforced compounded materials are suitable for injection molded applications. Tables 13A-C (weight basis) show these compounded materials.
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TABLE 13A Formulation 1F with 35 wt. % glass fiber reinforcement. Component Example Example Example Example Example (Basis: wt. %) 14A 14B 14C 14D 14E Example 1F 57.5 49.5 42 34 65 Formulation Nylon-6,6 (e.g., 45 7.5 15.5 23 31 — RV High AEG PA66) Chopped E-glass 35 35 35 35 35 Fiber Heat Stabilizer (e.g.: <1 <1 <1 <1 <1 Cu-based or organic based such as Irganox ® B1171) TOTAL 100 100 100 100 100 -
TABLE 13B Formulation 1F with 40 wt. % glass fiber reinforcement. Component Example Example Example Example Example (Basis: wt. %) 14F 14G 14H 14I 14J Example 1F 53 46 38.5 31.5 60 Fomnilation Nylon-6,6 (e.g., 45 7 14 21.5 28.5 — RV High AEG PA66) Chopped E-glass 40 40 40 40 40 Fiber Heat Stabilizer <1 <1 <1 <1 <1 (e.g.: (Cu-based or organic based such as Irganox ® B1171) TOTAL 100 100 100 100 100 -
TABLE 13C Formulation 1F with 45 wt. % glass fiber reinforcement. Component Example Example Example Example Example (Basis: wt. %) 14K 14L 14M 14N 14O Example 1F 48.5 42 35.5 29 55 Formulation Nylon-6,6 (e.g., 45 6.5 13 19.5 26 — RV High AEG PA66) Chopped E-glass 35 35 35 35 45 Fiber Heat Stabilizer <1 <1 <1 <1 <1 (e.g.: Cu-based or organic based such as Irganox ® B1171) TOTAL 100 100 100 100 100 - In Examples 14A-O, the polyamide used was poly(hexamethylene adipamide) or nylon-6,6.
- It was observed that the toughness performance of injection-molded parts obtained from the above compounded materials could be varied depending on the level of polyamide and glass fiber reinforcement used in the material. Tables 14A-L list the measured mechanical strength properties characteristics of some of the Table 13A-C compounded materials prepared and tested according to the present disclosure. All specimens were tested under a dry-as-molded (DAM) condition unless otherwise indicated.
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TABLE 14A Mechanical strength properties of compounded materials. Performance Property [measured for Example DAM specimen] 14B 14D 14E 14G 14I 14J Tensile Strength (MPa) 140 147 124 150 164 135 Elongation at Break (%) 5.9 5.2 6.3 5.3 4.7 5.9 Tensile Modulus (GPa) 9.2 9.2 8.5 10.5 11.2 9.5 Un-Notched Charpy, 112 108 108 115 113 115 −40° C. (KJ/m2) Un-Notched Charpy, 108 104 110 109 106 100 −23° C. (KJ/m2) Notched Charpy, 15 13 16 15 14 17 −40° C. (KJ/m2) Notched Charpy, 24 17 29 23 18 30 −23° C. (KJ/m2) -
TABLE 14B Mechanical strength properties of compounded materials. Example ID: 14B 14D 14E Dry Cond Dry Cond Dry Cond Tensile Strength (MPa) 140 106 147 107 124 95 Tensile Modulus (MPa) 9199 5798 9232 5740 8506 5226 Elongation at Break (%) 5.9 10.7 5.2 10.1 6.3 11.3 Un-Notched Charpy, 108 117 104 115 110 117 23° C. (KJ/m2) Un-Notched Charpy, 112 110 108 103 108 104 −30° C. (KJ/m2) Notched Charpy, 24 32 17 26 29 40 23° C. (KJ/m2) Notched Charpy, 15 16 13 14 16 17 −30° C. (KJ/m2) Moisture Absorption (%) 1.4 1.7 1.3 -
TABLE 14C Mechanical strength properties of compounded materials. Example ID: 14G 14I 14J Dry Cond Dry Cond Dry Cond Tensile Strength (MPa) 150.0 112.0 164.0 121.0 135 103 Tensile Modulus (MPa) 10460 6622 11183 7176 9530 6158 Elongation at Break (%) 5.3 9.6 4.7 8.4 5.9 10.4 Un-Notched Charpy, 109 120 106 117 100 123 23° C. (KJ/m2) Un-Notched Charpy, 115 108 113 108 115 110 −30° C. (KJ/m2) Notched Charpy, 15 33 18 27 30 38 23° C. (KJ/m2) Notched Charpy, 23 16 14 14 17 19 −30° C. (KJ/m2) Density (g/cc) 1.33 1.37 Moisture Absorption (%) 1.3 -
TABLE 14D Mechanical strength properties of compounded materials after 250 h of Heat Aging at 150° C. Example Performance Property 14B 14D 14E 14G 14I 14J Tensile Strength (MPa) 146.0 153.2 126.8 155.5 171.8 135.2 Elongation at Break (%) 5.1 4.8 5.2 4.8 4.2 4.7 Tensile Modulus (GPa) 9.118 8.870 8.226 10.248 11.132 9.730 Un-Notched Charpy 77.38 58.91 68.58 68.05 66.24 66.98 (KJ/m2)-15 J hammer at room temperature Notched Charpy 26.17 20.54 29.41 25.8 21.86 28.8 (KJ/m2)-2 J hammer at room temperature -
TABLE 14E Mechanical strength properties of compounded materials after 500 h of Heat Aging at 150° C. Example Performance Property 14B 14D 14E 14G 14I 14J Tensile Strength (MPa) 145.3 154.2 128.2 153.4 168.5 133.6 Elongation at Break (%) 4.6 4.3 5.0 4.3 3.8 4.3 Tensile Modulus (GPa) 8.960 9.218 8.194 10.258 10.954 9.316 Un-Notched Charpy 57.48 47.63 61.91 54.0 46.21 55.19 (KJ/m2)-15 J hammer at room temperature Notched Charpy 24.46 19.10 27.69 24.25 21.22 27.37 (KJ/m2)-2 J hammer at room temperature -
TABLE 14F Mechanical strength properties of compounded materials after 1000 h of Heat Aging at 150° C. Example Performance Property 14B 14D 14E 14G 14I 14J Tensile Strength (MPa) 140.1 146.9 122.4 147.2 158.0 128.3 Elongation at Break (%) 3.3 3.0 3.4 2.9 2.7 2.9 Tensile Modulus (GPa) 9.070 9.558 8.196 10.642 11.062 9.204 Un-Notched Charpy 38.75 39.58 35.98 42.88 41.62 34.11 (KJ/m2)-15 J hammer at room temperature Notched Charpy 22.60 18.17 25.61 23.27 20.30 25.28 (KJ/m2)-2 J hammer at room temperature -
TABLE 14G Glycolysis resistance of test bars prepared from Example 14 Specimens. Example ID: 14B 14D 14E 0 hr 500 hr 0 hr 500 hr 0 hr 500 hr Tensile strength (MPa) 139.7 64.7 147.0 68.9 124.1 61.9 Elongation @ break (%) 5.9 7.3 5.2 7.4 6.3 8.2 Chord Modulus (GPa) 9.2 3.826 9.2 3.860 8.5 3.340 -
TABLE 14H Glycolysis resistance of test bars prepared from Example 14 Specimens. Example ID: 14G 14I 14J 0 hr 500 hr 0 hr 500 hr 0 hr 500 hr Tensile strength (MPa) 149.9 71.3 164.2 76.8 135.0 71.3 Elongation @ break (%) 5.3 6.7 4.7 5.9 5.9 6.7 Chord Modulus (GPa) 10.5 3.788 11.2 4.660 9.5 4.220 -
TABLE 14I Salt [ZnCl2] resistance of test bars prepared from Example 14 Specimens. Conditions: 50% ZnCl2 solution, 23° C., 200 hrs, 0% sustained strain (ASTM test bars) 14G 14I Example ID: Before After Before After Tensile strength (MPa) 150 136 167 152 Elongation @ break (%) 5.3 5.8 4.8 5 -
TABLE 14J Tensile Stress versus Strain Performance of compounded materials at 23° C. Tensile Stress (MPa) At Tensile Strain (%) 14B 14D 14E 14G 14I 14J 0 0 0 0 0 0 0 0.5 43 45 40 50 53 43 1 78 80 69 88 96 78 1.5 98 103 85 108 120 95 2 113 120 97 123 138 108 2.5 124 132 106 134 149 117 3 131 141 112 141 158 123 3.5 135 144 116 145 161 127 4 138 145 119 148 163 130 4.5 139 146 121 149 132 4.7 164 5 122 134 5.2 147 5.3 150 5.5 123 5.9 140 135 6.3 124 -
TABLE 14K Published Mechanical strength properties of some commercially available materials. Ref: https://www.campusplastics.com/campus/en/datasheet Grade 1-33% Grade 2-35% Grade 3-33% 30% glass fiber glass fiber glass glass reinforced heat 33% glass fiber reinforced heat reinforced, heat reinforced heat stabilized, reinforced heat stabilized, impact stabilized, impact stabilized, impact impact stabilized, impact modified PA66 modified PA66 modified PA66 modified PA6 modified PA6 Dry Cond Dry Cond Dry Cond Dry Cond Dry Cond Tensile Strength 146 108 137 107 147 107 138 78 125 70 (MPa) Tensile Modulus 8900 6200 8480 6750 9300 5400 8650 4850 9000 4500 (MPa) Elongation at Break 3.7 7 4.5 8.4 3.2 6.8 3.6 5.1 3.5 8 (%) Un-Notched Charpy, 97 98 98 97 87 99 95 110 105 100 23° C. (KJ/m2) Un-Notched Charpy, 106 100 106 104 94 94 90 101 115 95 −30° C. (KJ/m2) Notched Charpy, 20 28 21 27 23 28 20 35 35 40 23° C. (KJ/m2) Notched Charpy, 18 17 16 15 15 8 15 9.7 20 17 −30° C. (KJ/m2) HDT at 0.45 MPa 261 260 260 220 215 (° C.) HDT at 1.8 MPa 246 242 245 200 200 (° C.) Shrinkage, 0.3 0.3 0.3 0.2 Parallel (%) Shrinkage, 0.7 1 0.7 0.9 Normal (%) Moisture 1.5 2 1.7 absorption (%) Density (g/cc) 1.33 1.33 1.33 1.34 -
TABLE 14L Tensile Stress versus Strain Performance of commercially available material shown in Table 14K and at 23° C. Tensile Stress (MPa) Grade 1 - 33% glass fiber reinforced heat stabilized impact At Tensile modified polyamide 66 resin Strain (%) Dry Cond 0 0 0 0.5 44.99 31.01 0.6 53.03 0.7 61.1 40.46 0.8 68.34 0.9 75.28 48.68 1 81.76 1.1 87.89 55.35 1.3 98.72 62.17 1.4 103.83 1.5 68.02 1.6 112.62 1.7 73.23 1.8 119.99 1.9 77.95 2 125.92 2.1 82.24 2.2 131.08 2.3 85.89 2.4 135.25 2.5 89.48 2.6 138.93 2.7 92.55 2.8 141.91 2.9 95.36 3 144.21 3.1 97.82 3.2 145.85 3.3 99.91 3.4 146.5 3.5 101.6 3.8 103.8 4.1 105.55 4.8 107.31 - A round cross-section monolayer pipe was extruded from melted compounded polyamide resin formulation “T” of Example 11 (Table 11) except that the black MB colorant additive used was a UV-grade carbon black at about 2.0 wt. % active concentration level in the total formulation. Pipe extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section pipe sections can be extruded using any of the formulations described in Table 11 of Example 11.
- A round cross-section multi-layer pipe was extruded from melted compounded polyamide resin formulation “W” of Example 11 (Table 11) that contains about 1.0 wt. % (active in total) non-UV grade black MB colorant. Pipe extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section pipe sections can be extruded using any of the formulations described in Table 11 of Example 11.
- The multilayer wall pipe section included a 20-mm thickness annular core section of formulation “W” of Table 11 (Example 11) having an inside 3-mm thick as well as outside 3-mm thick surface skin of HDPE. The multilayer wall pipe section was about 4.5″ O.D. and 50-ft long. Such durable pipe is industrially useful for conveying flowable materials that are compatible with direct HDPE surface contact.
- About 3,000 kgs of each, 18A, 18B and 18D formulations, and about 1,000 kgs of 18C formulation, as represented in Table 15, are prepared by compounding the listed ingredients in their respective amounts.
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TABLE 15 Example 17A-D formulations. Component [basis: wt. %] 17A 17B 17C 17D Fed at the main throat (or hopper) of compounding extruder 48 RV PA66 (U4800) — — 75.1 — High AEG PA66 (45 RV) 68 38.8 — 37.8 PA66/DI (45 RV) — 29 — 29 Impact Modifier (e.g.: Dow 25 25 22 25 Amplify ™ GR216 or ExxonMobil VA1840) Black Colorant (e.g.: carbon 1-3 % loading black (CB), or Nigrosine For example - 1% active loading black dye) of non-UV grade carbon black or 2% active loading of UV grade Heat Stabilizer (e.g.: Cu- 0.5-2.0 based or organic based such as Irganox ® B1171) Fed at mid-way (side feed) of compounding extruder High AEG PA66 (45 RV) 4.75 4.75 — 4.5 Chain Extender (e.g.: ZeMac 0.25 0.25 — — E60) Hydrolysis Stabilize (e.g.: — — — 0.5 Stabaxol ® P100) TOTAL 100 100 100 100 CB—Carbon Black. - For 17A and 17B compounding, the High AEG PA66 feed was split with a major portion fed at the main throat (or hopper) of the compounding extruder with other listed ingredients. The remaining portion was blended with the chain extender additive and the blend is fed at mid-way (side feed) of the compounding extruder. Homogeneous dispersion and mixing of the ingredients were observed in each case.
- The compounding extruder was a vented twin-screw extruder, as described in Example 2. The screw speed is 450 RPM with 70-80% torque. The compounded resin, in each case, was pelletized into 3 mm diameter and 3-4 mm extrudates with a moisture level of below 0.15 wt %.
- The extrudates obtained as above were suitable for extruding conduits and pipes of the desired dimensions.
- As a non-limiting illustration, round cross-section, 2.54 cm (1″) outside diameter (×3 mm wall thickness) monolayer conduits were extruded from each of the melted compounded polyamide resin formulations “Q” and “W” of Example 11 (Table 11) that contained about 1.0 wt. % (active in total) non-UV grade black MB colorant. Extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section conduits can be extruded using any of the formulations described in Table 11 of Example 11. The extruded conduit lengths can be varied to as short as inches to continuous large coilable sections, for example, 10-ft, 100-ft, 200-ft, 500-ft, and such.
- As a non-limiting illustration, round cross-section, 10.16 cm (4″) outside diameter [×3 mm wall thickness] monolayer conduits are extruded from each, melted compounded polyamide resin formulations “Q” and “W” of Example 11 (Table 11) except that the black MB colorant additive used is a UV-grade carbon black at about 2.0 wt. % active concentration level in the total formulation. Extrusion was performed using a vented twin-screw extruder, as described in Example 2. Similar round cross-section conduits can be extruded using any of the formulations described in Table 11 of Example 11. The extruded conduit lengths can be varied to as short as inches to continuous large coilable sections, for example, 10-ft, 50-ft, 100-ft, 500-ft, and such.
- The compositions of Example 1 and Example 11 are extruded into conduits as described in Examples 2 and 12, respectively, to fabricate a 6″-outside diameter cylindrical-shaped flow conduit. The polyamide pellets are fed to a pipe extrusion equipment. A 0.5 mm to 20 mm thick metal sleeve layer is designed to be embedded in the polyamide matrix. The overall flow conduit thickness is 12 to 15 mm and the longitudinal length of the section is 5.4 meters (for a “stick”) to 152 meters (for a coiled product).
- A metal reinforced modified PA66 flow conduit is prepared according to Example 20 except the metal layer is wrapped around polymer liner (used for chemical and temperature resistance) and an external polymer shell/sleeve is used for abrasion (parallel) and impact (perpendicular) resistances to allow for faster and easier installation. The flow conduit also allows for the metal to be protected from corrosion thus removing the need for cathodic protection.
- Several 6″-outside diameter×152-meter-long coiled metal-reinforced modified PA66 flow conduit section ends, prepared according to Example 20, are melt-fused together to assemble a long flow conduit line and for use in the fluid transport service. The long line can be installed underground, above-ground or the combination of the two. The metal reinforcement of the modified PA66 flow line is beneficial for structural strength, integrity, and durability/life.
- Table 16 shows examples of various 3-layer reinforced conduits, which have modified PA66 layers that are prepared according to Example 20.
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TABLE 16 3-Layer reinforced conduits. Conduit Conduit Conduit Metal- Cross-section Cross-section cross-section reinforced having having having Conduit continuous wound wound Construction metal layer metal fiber metal tape Number of 3 3 3 layers Total conduit 20-50 min 20-50 mm 20-50 mm wall thickness Conduit 1″ to 12″ 1″ to 12″ 1″ to 12″ outside diameter Conduit Inside 142 for PA66 via 142 for PA66 via 142 for PA66 via Surface Williams-Hazen Williams-Hazen Williams-Hazen Roughness Coefficient Coefficient Coefficient Conduit length Vanes depending on end-use application Short segments suitable for handling on a flatbed truck to long coilable segment (up to 2000 feet) Conduit segments joined by fittings and fusing for a continuous flow path Inner Layer Total Thickness 5-10 mm 5-10 mm 5a-10 mm Material modified PA66 modified PA66 modified PA66 having chemical having chemical having chemical compatibility, compatibility, compatibility, hydrolysis hydrolysis hydrolysis resistance, salt resistance, salt resistance, salt cracking cracking cracking resistance resistance resistance Middle Layer Total Thickness 10-30 mm 10-30 mm 10-30 mm Material metal sleeve of hydrophobic metal tape 5-30 min wall material of 5-30 mm thickness coated wall thickness having a metal fiber encased in a hydrophobic [ggg micron hydrophobic skin [500 dia.] strands skin [500 micron] on wound micron] on both sides layer both sides Outer Layer Total Thickness 5-10 mm 5-10 mm 5-10 mm Material modified modified modified PA66 [either PA66 [either PA66 [either unreinforced unreinforced unreinforced or glass-fiber or glass-fiber or glass-fiber reinforced]; reinforced]; reinforced]; may include may include may include additive additive additive package package package for UV for UV for UV resistance, resistance, resistance, color color color - Table 17 shows examples of various 2-layer reinforced conduits, which have modified PA66 layers that are prepared according to Example 20.
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TABLE 17 2-Layer reinforced conduits. Conduit Cross- Conduit Cross- Metal-reinforced section having section having Conduit continuous wound Construction metal layer metal fiber Number of layers 2 2 Total conduit wall 15-60 mm 15-60 mm thickness Conduit outside 1″ to 12″ 1″ to 12″ diameter Conduit Inside 142 for PA66 via About 135 to Surface Williams-Hazen about 145 via Roughness Coefficient Williams-Hazen Coefficient Conduit length Varies depending on end-use application Short segments suitable for handling on a flatbed truck to long coilable segment (up to 2000 feet) Conduit segments joined by fittings and fusing for a continuous flow path Inner Layer Total Thickness 5-30 mm 10-30 mm Material modified PA66 metal sleeve having chemical optionally compatibility, having a hydrolysis hydrophobic resistance, salt skin cracking [500 micron] resistance on both sides Outer Layer Total Thickness 10-30 mm 5-30 mm Material metal sleeve modified PA66 optionally having a having chemical hydrophobic skin compatibility, [500 micron] hydrolysis on both sides resistance, salt cracking resistance - The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the embodiments of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of embodiments of the present invention.
- The following exemplary Aspects are provided, the numbering of which is not to be construed as designating levels of importance:
- Aspect 1 provides a composition comprising
- a condensation polyamide, wherein the condensation polyamide is at least 30 wt % of the composition, wherein the condensation polyamide is the predominant polyamide in the composition; and
- from ≥10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %), wherein the maleated polyolefin comprises omaleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin;
- wherein, optionally,
- the maleated polyolefin, or domains thereof, is/are uniformly distributed in the condensation polyamide or in the composition (e.g., with domains having a largest dimension of less than 1 micron, or 5 nm to less than 1,000 nm, or from 9 to 400 nm), or
- the condensation polyamide has an AEG of 65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., ≥70 meq/kg and ≤125 meq/kg), or
- the condensation polyamide has an RV of at least 35 (e.g., at least 40, or at least 45), or
- the condensation polyamide comprises nylon 66, nylon 66/6T, nylon 66/DI, or a combination thereof, or
- a combination thereof.
- Aspect 2 provides the composition of Aspect 1, wherein the condensation polyamide is chosen from nylon 66, nylon 66/6T, nylon 66/DI, and a combination thereof.
- Aspect 3 provides the composition of any one of Aspects 1-2, wherein the condensation polyamide is nylon 66.
- Aspect 4 provides the composition of any one of Aspects 1-3, wherein the condensation polyamide is 30-99.9 wt % of the composition.
- Aspect 5 provides the composition of any one of Aspects 1-4, wherein the condensation polyamide is 60-99.9 wt % of the composition.
- Aspect 6 provides the composition of any one of Aspects 1-5, wherein the condensation polyamide is 90-99.9 wt % of the composition.
- Aspect 7 provides the composition of any one of Aspects 1-6, wherein the composition further comprises one or more other polyamides, copolymers thereof, or combinations thereof, in addition to the condensation polyamide.
- Aspect 8 provides the composition of any one of Aspects 1-7, wherein the composition further comprises an additional polyamide comprising nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof.
- Aspect 9 provides the composition of Aspect 8, wherein the additional polyamide comprises nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, or a combination thereof.
- Aspect 10 provides the composition of any one of Aspects 8-9, wherein the additional polyamide is ≥15 to ≤85 wt % of the composition.
- Aspect 11 provides the composition of any one of Aspects 8-10, wherein the additional polyamide is ≥20 to ≤70 wt % of the composition.
- Aspect 12 provides the composition of any one of Aspects 1-11, wherein the condensation polyamide has an AEG of ≥80 meq/kg and ≤125 meq/kg.
- Aspect 13 provides the composition of any one of Aspects 1-12, wherein the condensation polyamide has an AEG of ≥80 meq/kg and ≤120 meq/kg.
- Aspect 14 provides the composition of any one of Aspects 1-13, comprising ≥1 wt % to ≤50 wt % glass fibers.
- Aspect 15 provides the composition of any one of Aspects 1-14, comprising ≥10 wt % to ≤42 wt % glass fibers.
- Aspect 16 provides the composition of any one of Aspects 1-15, comprising ≥10 wt % to ≤35 wt % glass fibers.
- Aspect 17 provides the composition of any one of Aspects 1-16, comprising ≥15 wt % to ≤30 wt % glass fibers.
- Aspect 18 provides the composition of any one of Aspects 1-17, wherein the maleated polyolefin comprises a polyolefin backbone that comprises EPDM, ethylene-octene, polyethylene, polypropylene, or a combination thereof.
- Aspect 19 provides the composition of any one of Aspects 1-18, wherein the maleated polyolefin is free of EPDM.
- Aspect 20 provides the composition of any one of Aspects 1-19, wherein the maleated polyolefin has a grafted maleic anhydride incorporation of ≥0.1 to ≤1.4 wt % based on total weight of the maleated polyolefin.
- Aspect 21 provides the composition of any one of Aspects 1-20, wherein the maleated polyolefin has a grafted maleic anhydride incorporation of ≥0.15 to ≤1.25 wt % based on total weight of the maleated polyolefin.
- Aspect 22 provides the composition of any one of Aspects 1-21, wherein the maleated polyolefin has a glass transition temperature (Tg) of ≥−70° C. to ≤0° C.
- Aspect 23 provides the composition of any one of Aspects 1-22, wherein the maleated polyolefin has a glass transition temperature (Tg) of ≥−60° C. to ≤−20° C.
- Aspect 24 provides the composition of any one of Aspects 1-23, wherein the maleated polyolefin has a glass transition temperature (Tg) of ≥−60° C. to ≤−30° C.
- Aspect 25 provides a reacted composition that is a reaction product of the composition of any one of Aspects 1-24, wherein the reacted composition comprises a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin of the composition of any one of Aspects 1-24.
- Aspect 26 provides the reacted composition of Aspect 25, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ≥50 to ≤7500 ppmw, based on the total weight of the reacted composition.
- Aspect 27 provides the reacted composition of any one of Aspects 25-26, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ≥100 to ≤4900 ppmw, based on the total weight of the reacted composition.
- Aspect 28 provides the reacted composition of any one of Aspects 25-27, wherein the reacted composition comprises the polyamide-polyolefin copolymer in a concentration range of ≥225 to ≤3750 ppmw, based on the total weight of the reacted composition.
- Aspect 29 provides a composition comprising:
- a condensation polyamide having an AEG of ≥65 milliequivalents per kg (meq/kg) and ≤130 meq/kg (e.g., ≥70 meq/kg and ≤125 meq/kg), wherein the condensation polyamide is nylon 66 and is at least 30 wt % of the composition, wherein the nylon 66 is the predominant polyamide in the composition; and
- from ≥10 wt % to ≤50 wt % of a maleated polyolefin (e.g., ≥15 wt % to ≤50 wt %), wherein the maleated polyolefin comprises maleic anhydride grafted onto a polyolefin backbone, the maleated polyolefin having a grafted maleic anhydride incorporation of ≥0.05 to ≤1.5 wt % based on total weight of the maleated polyolefin.
- Aspect 30 provides a reacted composition that is a reaction product of the composition of Aspect 29, wherein the reacted composition comprises a polyamide-polyolefin copolymer formed from at least partial reaction of the condensation polyamide and the maleated polyolefin of the composition of Aspect 29.
- Aspect 31 provides a compounded polyamide composition comprising:
- the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof; and
- one or more other components.
- Aspect 32 provides the compounded polyamide composition of Aspect 31, wherein the compounded polyamide composition is extrudable.
- Aspect 33 provides the compounded polyamide composition of any one of Aspects 31-32, wherein the one or more other components comprise a modified polyphenylene ether, an impact modifier, a flame retardant, a chain extender, a heat stabilizer, a colorant additive, a filler, a conductive fiber, glass fibers, another polyamide other than the condensation polyamide, or a combination thereof.
- Aspect 34 provides the compounded polyamide composition of any one of Aspects 31-33, wherein the one or more other components comprise a chain extender, wherein the chain extender is ≥0.05 to ≤5 wt % of the compounded polyamide composition.
- Aspect 35 provides the compounded polyamide composition of any one of Aspects 31-34, wherein the chain extender comprises a dialcohol, a bis-epoxide, a polymer comprising epoxide functional groups, a polymer comprising anhydride functional groups, a bis-N-acyl bis-caprolactam, a diphenyl carbonate, a bisoxazoline, an oxazolinone, a diisocyanate, an organic phosphite, a bis-ketenimine, a dianhydride, a carbodiimide, a polymer comprising carbodiimide functionality, or a combination thereof.
- Aspect 36 provides the compounded polyamide composition of any one of Aspects 31-35, wherein the chain extender comprises a maleic anhydride-polyolefin copolymer, such as an alternating copolymer of maleic anhydride and ethylene.
- Aspect 37 provides the compounded polyamide composition of any one of Aspects 31-36 comprising:
- the condensation polyamide;
- the maleated polyolefin that is ≥10 to ≤50 wt % of the compounded polyamide composition;
- an additional polyamide that is ≥15 to ≤85 wt % of the compounded polyamide composition; and
- a chain extender that is ≥0.05 to ≤5 wt % of the compounded polyamide composition.
- Aspect 38 provides the compounded polyamide composition of any one of Aspects 31-37 comprising:
- 50-80 wt % of the condensation polyamide;
- 0 to 20 wt % polyamide 612;
- 0 to 20 wt % modified polyphenylene ether;
- 10-50 wt % of the maleated polyolefin;
- 0 to 30 wt % flame retardant;
- 0 to 10 wt % combined chain extender, heat stabilizer and colorant additives; and
- 0 to 40 wt % combined filler and/or conductive fiber additives;
- wherein nylon 66 and the maleated polyolefin are optionally partially reacted to form a polyamide-polyolefin.
- Aspect 39 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or the compounded polyamide composition of any one of Aspects 31-38, comprising an additional polyamide comprising nylon 66, nylon 612, nylon 610, nylon 12, nylon 6, nylon 66/6T, nylon 66/DI, nylon 66/D6, nylon 66/DT, nylon 66/610, nylon 66/612, a polyamide copolymer, or a combination thereof, wherein the additional polyamide is ≥15 to ≤85 wt % of the composition, or ≥20 to ≤85 wt %, ≥15 to ≤80 wt %, ≥15 to ≤75 wt %, ≥15 to ≤70 wt % of the composition, or less than or equal to 85 wt % but equal to or greater than 15 wt %, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 wt % of the composition.
- Aspect 40 provides an article comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof.
- Aspect 41 provides the article of Aspect 40, wherein the article is an extrudate.
- Aspect 42 provides the article of any one of Aspects 40, wherein the article is a molded article.
- Aspect 43 provides the article of any one of Aspects 40-41, wherein the article is a conduit.
- Aspect 44 provides the article of Aspect 43, wherein the article is an extruded conduit, such as a monolayer or multi-layer conduit. Monolayer conduits can optionally include up to 2 wt % (actives) UV-grade colorant. Multi-layered conduits can include inside/outside surface skin layers and can include up to 1 wt % (actives) non-UV grade colorant.
- Aspect 45 provides the article of Aspect 44, wherein the extruded conduit is substantially free of glass fibers.
- Aspect 46 provides the article of Aspect 45, wherein the extruded conduit is selected from the group consisting of rigid, flexible, curved, bent, serpentine, partially corrugated and fully corrugated.
- Aspect 47 provides the article of Aspects 45-46, wherein a cross-section of the extruded conduit that is substantially free of glass fibers is selected from the group consisting of round, oval, oblong, square, rectangle, triangle, star and polygonal.
- Aspect 48 provides the article of Aspects 45-47, wherein the extruded conduit that is substantially free of glass fibers is a tube.
- Aspect 49 provides the article of Aspects 45-48, wherein the extruded conduit that is substantially free of glass fibers is a pipe.
- Aspect 50 provides the article of any one of Aspects 44-49, wherein the extruded conduit is resistant to glycolysis.
- Aspect 51 provides the article of any one of Aspects 43-50, wherein the conduit is chosen from rigid, flexible, curved, bent, serpentine, partially corrugated, fully corrugated, and a combination thereof.
- Aspect 52 provides the article of any one of Aspects 43-51, wherein the conduit has a cross-section chosen from round, oval, oblong, square, rectangle, triangle, star, polygonal, and a combination thereof.
- Aspect 53 provides the article of any one of Aspects 40-44 or 50-52, wherein the article comprises from ≥15 to ≤50% glass fiber and exhibits superior resistance to at least one of chemical, fuel/oil, hydrolysis, glycolysis, and salt exposure, as compared to a control, wherein the control differs by at least one of AEG, weight percentage of maleated polyolefin, and degree of maleation of the maleated polyolefin.
- Aspect 54 provides a reinforced conduit comprising:
- an extruded conduit comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof; and
- a metal reinforcement.
- Aspect 55 provides the reinforced conduit of Aspect 54, wherein the metal reinforcement comprises steel, aluminum, beryllium, copper, an alloy thereof, or a combination thereof.
- Aspect 56 provides the reinforced conduit of any one of Aspects 54-55, wherein the metal reinforcement comprises steel.
- Aspect 57 provides the reinforced conduit of any one of Aspects 54-56, wherein the metal reinforcement comprises corrosion-resistant steel.
- Aspect 58 provides the reinforced conduit of any one of Aspects 54-57, wherein the metal reinforcement comprises non-corrosion-resistant steel.
- Aspect 59 provides the reinforced conduit of Aspect 58, wherein the steel comprises carbon steel, stainless steel, austenitic steel, 304, 304L, 316, 316L, or a combination thereof.
- Aspect 60 provides the reinforced conduit of any one of Aspects 54-59, wherein the metal reinforcement is free of protective coatings to protect the metal reinforcement from corrosion.
- Aspect 61 provides the reinforced conduit of Aspect 60, wherein the metal reinforcement directly contacts the extruded conduit.
- Aspect 62 provides the reinforced conduit of any one of Aspects 54-59, wherein the metal reinforcement comprises a protective coating that reduces and/or prevents corrosion to the metal reinforcement.
- Aspect 63 provides the reinforced conduit of Aspect 62, wherein the protective coating has a thickness of 1 micron to 5 mm.
- Aspect 64 provides the reinforced conduit of any one of Aspects 62-63, wherein the protective coating has a thickness of 50 microns to 2 mm.
- Aspect 65 provides the reinforced conduit of any one of Aspects 62-64, wherein the protective coating has a thickness of 100 microns to 1 mm.
- Aspect 66 provides the reinforced conduit of any one of Aspects 62-65, wherein the metal reinforcement and the extruded conduit are free of direct contact and wherein contact between the metal reinforcement and the extruded conduit occurs via the protective coating on the metal reinforcement.
- Aspect 67 provides the reinforced conduit of any one of Aspects 62-66, wherein the protective coating comprises a hydrophobic and/or water-resistant material.
- Aspect 68 provides the reinforced conduit of any one of Aspects 62-67, wherein the protective coating comprises a polyolefin, a polycarbonate, a polyester, or a combination thereof.
- Aspect 69 provides the reinforced conduit of any one of Aspects 62-68, wherein the protective coating comprises polyethylene, polypropylene, a polyacrylate, a bio-derived polyolefin, or a combination thereof.
- Aspect 70 provides the reinforced conduit of any one of Aspects 54-69, wherein the metal reinforcement has a cross-section that is round, oval, square, rectangular, triangular, or a combination thereof.
- Aspect 71 provides the reinforced conduit of any one of Aspects 54-70, wherein the metal reinforcement including any protective coating thereon has a thickness of 0.01 microns to 100 mm.
- Aspect 72 provides the reinforced conduit of any one of Aspects 54-71, wherein the metal reinforcement including any protective coating thereon has a thickness of 0.1 microns to 60 mm.
- Aspect 73 provides the reinforced conduit of any one of Aspects 54-72, wherein the extruded conduit has a wall thickness of 0.1 mm to 100 mm.
- Aspect 74 provides the reinforced conduit of any one of Aspects 54-73, wherein the extruded conduit has a wall thickness of 1 mm to 20 mm.
- Aspect 75 provides the reinforced conduit of any one of Aspects 54-74, wherein the extruded conduit has a wall thickness of 2 mm to 10 mm.
- Aspect 76 provides the reinforced conduit of any one of Aspects 54-75, wherein the extruded conduit has an inside diameter of 1 mm to 1000 mm.
- Aspect 77 provides the reinforced conduit of any one of Aspects 54-76, wherein the extruded conduit has an inside diameter of 5 mm to 700 mm.
- Aspect 78 provides the reinforced conduit of any one of Aspects 54-77, wherein the reinforced conduit has an inside diameter of 10 mm to 1000 mm.
- Aspect 79 provides the reinforced conduit of any one of Aspects 54-78, wherein the reinforced conduit has an inside diameter of 20 mm to 700 mm.
- Aspect 80 provides the reinforced conduit of any one of Aspects 54-79, wherein the reinforced conduit has a total conduit wall thickness of 0.2 mm to 500 mm.
- Aspect 81 provides the reinforced conduit of any one of Aspects 54-80, wherein the reinforced conduit has a total conduit wall thickness of 1 mm to 200 mm.
- Aspect 82 provides the reinforced conduit of any one of Aspects 54-81, wherein the extruded conduit contacts the metal reinforcement on an exterior of the extruded conduit, an interior of the extruded conduit, or a combination thereof.
- Aspect 83 provides the reinforced conduit of any one of Aspects 54-82, wherein the metal reinforcement is partially or fully embedded within the extruded conduit.
- Aspect 84 provides the reinforced conduit of any one of Aspects 54-83, wherein the metal reinforcement comprises a sleeve, a pipe, a ring, a mesh, a braid, a fiber strand, or a combination thereof.
- Aspect 85 provides the reinforced conduit of any one of Aspects 54-84, wherein the sleeve comprises an unperforated solid sleeve, a perforated sleeve, a mesh sleeve, a braided sleeve, or a combination thereof.
- Aspect 86 provides the reinforced conduit of any one of Aspects 54-85, wherein the metal reinforcement comprises a pipe, wherein the pipe contacts an exterior of the extruded conduit, wherein the extruded conduit is a liner in the pipe.
- Aspect 87 provides the reinforced conduit of any one of Aspects 54-85, wherein the metal reinforcement comprises a pipe, wherein the pipe contacts an interior of the extruded conduit, wherein the pipe is encased by the extruded conduit.
- Aspect 88 provides the reinforced conduit of any one of Aspects 54-87, wherein the reinforced conduit comprises more than one of the metal reinforcements.
- Aspect 89 provides the reinforced conduit of any one of Aspects 54-88, wherein the reinforced conduit comprises no more than a single one of the metal reinforcement.
- Aspect 90 provides the reinforced conduit of any one of Aspects 54-89, wherein the reinforced conduit comprises no more than a single one of the extruded conduit.
- Aspect 91 provides the reinforced conduit of any one of Aspects 54-88, wherein the reinforced conduit further comprises one or more second extruded conduits, each of the one or more second extruded conduits comprising:
- the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof, or
- a different extruded composition comprising one or more polymers.
- Aspect 92 provides the reinforced conduit of any one of Aspects 54-88 or 91, wherein the reinforced conduit comprises more than one of the extruded conduits, wherein each extruded conduit has a composition that is independently selected.
- Aspect 93 provides the reinforced conduit of Aspect 92, wherein the extruded conduits are attached to one another end-to-end.
- Aspect 94 provides the reinforced conduit of Aspect 93, wherein the extruded conduits are fused end-to-end.
- Aspect 95 provides the reinforced conduit of Aspect 92, wherein each extruded conduit is a different layer in the reinforced conduit.
- Aspect 96 provides the reinforced conduit of Aspect 95, wherein two or more of the extruded conduits contact one another along their length.
- Aspect 97 provides the reinforced conduit of Aspect 95, wherein the reinforced conduit is substantially free of contact between two or more of the extruded conduits along their length.
- Aspect 98 provides the reinforced conduit of any one of Aspects 95-97, wherein the metal reinforcement is present between two or more of the extruded conduits along their length.
- Aspect 99 provides the reinforced conduit of any one of Aspects 95-98, wherein the metal reinforcement is within interior surfaces of two or more of the extruded conduits along their length.
- Aspect 100 provides the reinforced conduit of any one of Aspects 95-99, wherein the metal reinforcement is outside of two or more of the extruded conduits along their length.
- Aspect 101 provides the reinforced conduit of any one of Aspects 54-100, comprising:
- an inner layer comprising the extruded conduit;
- a middle layer contacting the inner layer, the middle layer comprising the metal reinforcement; and
- an outer layer contacting the middle layer, the outer layer comprising another one of the extruded conduit.
- Aspect 102 provides the reinforced conduit of Aspect 101, wherein the metal reinforcement comprises a metal sleeve, a wound layer of metal fibers, a metal tape, or a combination thereof.
- Aspect 103 provides the reinforced conduit of any one of Aspects 101-102, wherein the metal reinforcement comprises a protective coating.
- Aspect 104 provides the reinforced conduit of any one of Aspects 101-103, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm,
- the inner layer has a thickness of 1 mm to 20 mm,
- the middle layer has a thickness of 1 mm to 50 mm, and
- the outer layer has a thickness of 1 mm to 20 mm.
- Aspect 105 provides the reinforced conduit of any one of Aspects 101-104, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm,
- the inner layer has a thickness of 3 mm to 15 mm,
- the middle layer has a thickness of 5 mm to 35 mm, and
- the outer layer has a thickness of 3 mm to 15 mm.
- Aspect 106 provides the reinforced conduit of Aspect 54-100, comprising:
- an inner layer comprising the extruded conduit; and
- an outer layer contacting the inner layer, the outer layer comprising the metal reinforcement, the metal reinforcement comprising a metal pipe or metal sleeve.
- Aspect 107 provides the reinforced conduit of Aspect 106, wherein the metal reinforcement comprises a protective coating.
- Aspect 108 provides the reinforced conduit of any one of Aspects 106-107, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm,
- the inner layer has a thickness of 1 mm to 50 mm, and
- the outer layer has a thickness of 1 mm to 50 mm.
- Aspect 109 provides the reinforced conduit of any one of Aspects 106-108, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm,
- the inner layer has a thickness of 3 mm to 35 mm, and
- the outer layer has a thickness of 5 mm to 35 mm.
- Aspect 110 provides the reinforced conduit of any one of Aspects 54-100, comprising:
- an inner layer comprising the metal reinforcement, the metal reinforcement comprising a metal pipe or metal sleeve; and
- an outer layer contacting the inner layer, the outer layer comprising the extruded conduit.
- Aspect 111 provides the reinforced conduit of Aspect 110, wherein the metal reinforcement comprises a protective coating.
- Aspect 112 provides the reinforced conduit of any one of Aspects 110-111, wherein:
- the reinforced conduit has an outside diameter of 10 mm to 600 mm,
- the inner layer has a thickness of 1 mm to 50 mm, and
- the outer layer has a thickness of 1 mm to 50 mm.
- Aspect 113 provides the reinforced conduit of any one of Aspects 110-112, wherein:
- the reinforced conduit has an outside diameter of 20 mm to 310 mm,
- the inner layer has a thickness of 5 mm to 35 mm, and
- the outer layer has a thickness of 3 mm to 35 mm.
- Aspect 114 provides the article of Aspect 53, wherein the article is a molded article.
- Aspect 115 provides the article of Aspect 114, wherein the molded article is resistant to cold-temperature cracking.
- Aspect 116 provides the article of any one of Aspects 40-52 or 114-115, wherein the article is characterized by one or more superior properties as compared to a control.
- Aspect 117 provides the article of any one of Aspects 40-52 or 114-115, wherein the article is characterized by superior resistance to at least one selected from:
- cold-temperature cracking,
- urea exposure,
- fuel exposure,
- oil exposure,
- high-temperature exposure,
- hydrolysis,
- glycolysis, and
- salt exposure,
- when compared against a control.
- Aspect 118 provides the article of Aspect 117, wherein the salt is ZnCl2.
- Aspect 119 provides the article of any one of Aspects 116-118, wherein the control is the same composition except that the polyamide in the control has an AEG of <60 meq/kg.
- Aspect 120 provides the article of any one of Aspects 116-119, wherein the control is the same composition except that the control contains less than 0.05 wt % maleated polyolefin, and the balance of the composition is the polyamide.
- Aspect 121 provides the article of any one of Aspects 116-120, wherein the article is characterized by superior mechanical strength, as compared to the control.
- Aspect 122 provides the article of any one of Aspects 116-121, wherein the article has a Flame Resistance rating of V-0.
- Aspect 123 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-122, having a tensile strength of at least 30 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 124 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-123, having a tensile strength of 30-200 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 125 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-124, having a tensile strength of 40-150 MPa, or having a melt strength of at least 0.1 Newton, or a combination thereof.
- Aspect 126 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-125, wherein the article has a tensile strength, measured according to ISO 527 on dry-as-molded specimens, of at least 40 MPa, and a notched Charpy impact energy, measured at −30° C. and according to ISO 179/1eA on dry-as-molded specimens, of at least 60 kJ/m2.
- Aspect 127 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-126, which retains ≥50% of the tensile yield strength, tensile elongation at break, and tensile break strength after undergoing 1:1 (vol/vol) ethylene glycol:water exposure at 120° C.-130° C. for 1000 hrs.
- Aspect 128 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-127, which retains ≥50% of the tensile yield strength, tensile elongation at break, and tensile break strength after undergoing 50 wt % aqueous zinc chloride solution exposure at 23° C. for 200 hours under 3% applied strain to the test specimens.
- Aspect 129 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-128, which, upon heat aging at 140° C. for 1000 hours, has a tensile yield strength, measured according to ISO 527, of at least 40 MPa, a notched Charpy impact energy, measured at 23° C. and according to ISO 179/1eA of at least 45 kJ/m2.
- Aspect 130 provides the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or the article of any one of Aspects 40-53 or 114-129, which upon heat aging at 140° C. for 1000 hours has a tensile break strength measured according to ISO 527 of at least 30 MPa, and a tensile elongation at break measured according to ISO 527 is at least 5%.
- Aspect 131 provides a method of making the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof comprising:
- combining the condensation polyamide and the maleated polyolefin to form the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof.
- Aspect 132 provides the method of Aspect 131, wherein the method is a method of making the reacted composition of any one of Aspects 25-28, further comprising at least partially reacting the condensation polyamide and the maleated polyolefin to form the reacted composition of any one of Aspects 25-28.
- Aspect 133 provides the method of any one of Aspects 131-132, wherein the method is a method of improving glycolysis resistance of the condensation polyamide, wherein the composition of any one of Aspects 1-24 or the reacted composition of any one of Aspects 25-28 has greater glycolysis resistance than the condensation polyamide.
- Aspect 134 provides the method of any one of Aspects 131-133, wherein the method comprises combining the condensation polyamide and the maleated polyolefin to form the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof, in the absence of added glass fibers.
- Aspect 135 provides a method of making the compounded composition of any one of Aspects 31-39 comprising:
- combining the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or a combination thereof, with one or more other components to form the compounded polyamide composition of any one of Aspects 31-39.
- Aspect 136 provides the method of any one of Aspects 131-135, wherein the method comprises combining the condensation polyamide and the maleated polyolefin before adding a chain extender thereto.
- Aspect 137 provides the method of any one of Aspects 135-136, comprising:
- providing to a first compounder extruder zone a feed comprising the condensation polyamide and the maleated polyolefin (e.g., at least 30 wt % condensation polyamide, from ≥10 wt % to ≤50 wt % or ≥15 wt % to ≤50 wt % of the maleated polyolefin, and optionally ≥20 wt % to ≤85 wt % of the additional polyamide);
- maintaining the first compounder extruder zone conditions sufficient to obtain a first compounded polyamide melt inside the first compounder extruder zone;
- introducing a chain extender to the first compounded polyamide melt in a second compounder extruder zone; and
- maintaining the second compounder extruder zone conditions sufficient to obtain a second compounded polyamide melt inside the second compounder extruder zone, wherein the second compounded polyamide melt is the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, or the compounded composition of any one of Aspects 31-39.
- Aspect 138 provides the method of Aspect 137, wherein the first compounder extruder zone is substantially free of the chain extender.
- Aspect 139 provides the method of any one of Aspects 137-138, wherein the first compounder extruder zone is substantially free of chain extenders.
- Aspect 140 provides the method of any one of Aspects 137-139, wherein the chain extender is ≥0.05 to ≤5 wt % of the second compounded polyamide melt.
- Aspect 141 provides the method of any one of Aspects 137-140, wherein a barrel of a screw extruder (e.g., a single screw extruder, a vented twin-screw extruder, or an unvented twin-screw extruder) comprises the first compounder extruder zone and the second compounder extruder zone, wherein the providing of the feed to the first compounder extrusion zone comprises providing the feed to a feed inlet of the barrel, wherein the barrel has a length.
- Aspect 142 provides the method of Aspect 141, wherein the chain extender is introduced to the second compounder extruder zone at least ¼ of the length of the barrel from the feed inlet of the barrel.
- Aspect 143 provides the method of any one of Aspects 141-142, wherein the chain extender is introduced to the second compounder extruder zone at least ½ of the length of the barrel from the feed inlet of the barrel.
- Aspect 144 provides the method of any one of Aspects 141-143, wherein the chain extender is introduced to the second compounder extruder zone at least ¾ of the length of the barrel from the feed inlet of the barrel.
- Aspect 145 provides the method of any one of Aspects 141-144, wherein the chain extender is introduced to the second compounder extruder zone at least ¼ of the length of the barrel from the feed inlet of the barrel and sufficiently far from an outlet of the barrel to provide mixing of the chain extender with the first compounded polyamide melt to form the second compounded polyamide melt.
- Aspect 146 provides the method of any one of Aspects 137-145, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 50 wt % of the maleated polyolefin fed has incorporated into the condensation polyamide.
- Aspect 147 provides the method of Aspect 146, wherein the incorporation into the condensation polyamide comprises homogeneous blending (e.g., on a molecular level, or of domains of the maleated polyolefin or a reaction product thereof).
- Aspect 148 provides the method of any one of Aspects 146-147, wherein the incorporation into the condensation polyamide comprises formation of a reaction product of the maleated polyolefin.
- Aspect 149 provides the method of any one of Aspects 146-148, wherein the incorporation into the condensation polyamide comprises reaction of the maleated polyolefin with the condensation polyamide.
- Aspect 150 provides the method of any one of Aspects 146-149, wherein the incorporation into the condensation polyamide comprises formation of domains of the maleated polyolefin or a reaction product thereof in the condensation polyamide.
- Aspect 151 provides the method of any one of Aspects 146-150, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 60 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 152 provides the method of any one of Aspects 146-151, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 70 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 153 provides the method of any one of Aspects 146-152, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 80 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 154 provides the method of any one of Aspects 146-153, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after at least 90 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 155 provides the method of any one of Aspects 146-154, wherein the introducing of the chain extender to the first compounded polyamide melt in the second compounder extruder zone comprises introducing the chain extender to the first compounded polyamide melt after about 100 wt % of the maleated polyolefin has incorporated into the condensation polyamide.
- Aspect 156 provides the method of any one of Aspects 137-155, further comprising producing extrudate from the second compounded polyamide melt.
- Aspect 157 provides the method of any one of Aspects 137-156, further comprising producing a molded article from the second compounded polyamide melt.
- Aspect 158 provides a method of extrusion of a polyamide resin, the method comprising:
- providing a polyamide resin comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof, to a feed zone of an extruder;
- maintaining extruder barrel conditions sufficiently to obtain the polyamide resin melt inside the extruder; and
- producing extrudate from the extruder while optionally recovering vapor from the extruder via a vacuum draw.
- Aspect 159 provides a method of molding of a polyamide resin, the method comprising:
- providing a polyamide resin comprising the composition of any one of Aspects 1-24, the reacted composition of any one of Aspects 25-28, the compounded polyamide composition of any one of Aspects 31-39, or a combination thereof, to a mold; and
- producing a molded polyamide resin from the mold.
- Aspect 160 provides the composition, reacted composition, compounded composition, article, or reinforced conduit of any one or any combination of Embodiments 1-159 optionally configured such that all elements or options recited are available to use or select from.
Claims (20)
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WO2021079244A1 (en) | 2021-04-29 |
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