METHOD FOR FORMING A LAYERED TUBE AND LAYER THEREIN

• US 20140251532A1
• Filed: 05/12/2014
• Published: 09/11/2014
• Est. Priority Date: 12/28/2012
• Status: Active Grant

• Current Assignee: AGC Chemicals Americas, Inc. (AGC, Inc.), Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: AGC Chemicals Americas, Inc. (AGC, Inc.), Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Sarkar, Soumayajit, Mapkar, Javed, Hummelt, Edward, Phaneuf, Kenneth, Lefere, Robert Michael, Proof, Joseph David, Chapman, Gregory James
• Granted Patent: US 9,694,528 B2
• Time in Patent Office: Days
• US Class Current: 156/244.13
• CPC Class Codes: B29C 48/0021 combined with joining, lining or laminating
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/10 flexible, e.g. blown foils
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 53/562 spirally
• CPC Class Codes: B29D 23/001 Pipes; Pipe joints pleated hoses B29D23/18
• CPC Class Codes: B29K 2027/12 containing fluorine
• CPC Class Codes: B29L 2007/00 Flat articles, e.g. films or sheets B29L2024/00 takes precedence
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2023/005 Hoses, i.e. flexible
• CPC Class Codes: F16L 11/081 comprising one or more layers of a helically wound cord or wire in combination with braided layers F16L11/088
• CPC Class Codes: F16L 11/082 two layers
• CPC Class Codes: F16L 11/085 comprising one or more braided layers in combination with layers of a helically wound core or wire F16L11/088
• CPC Class Codes: F16L 11/086 two layers

Abstract

A method includes premixing an anti-static additive and a first crosslinker to form an anti-static intermediate mixture where the anti-static additive is dispersed in the first crosslinker. The method also includes compounding the anti-static intermediate mixture and at least a portion of the first fluoropolymer to form a first compounded mixture. The method further includes extruding the first compounded mixture to form a layer.

Claims

1. A method comprising:

premixing an anti-static additive and a first crosslinker to form an anti-static intermediate mixture where the anti-static additive is dispersed in the first crosslinker;

compounding the anti-static intermediate mixture and at least a portion of a first fluoropolymer to form a first compounded mixture; and

extruding the first compounded mixture to form a layer.

2. The method as set forth in claim 1 wherein the anti-static additive comprises carbon nanotubes.

3. The method as set forth in claim 1 further comprising mixing the anti-static intermediate mixture and a second portion of the first fluoropolymer prior to compounding the anti-static intermediate mixture and the first fluoropolymer, wherein the second portion of the first fluoropolymer is powder in form.

4. The method as set forth in claim 1 wherein the first compounded mixture consists essentially of the first fluoropolymer, the first crosslinker, and the anti-static additive.

5. The method as set forth in claim 1 wherein compounding the anti-static intermediate mixture and at least the portion of the first fluoropolymer is further defined as compounding under high-shear.

6. The method as set forth in claim 5 wherein compounding under high-shear comprises compounding in an extruder with a high-shear extrusion screw having an L:

D ratio of about 30;

1 at a revolution per minute of at least 100.

7. The method as set forth in claim 1 further comprising;

compounding a second fluoropolymer and a second crosslinker to form a second compounded mixture; and

extruding the second compounded mixture to form an outer layer surrounding the layer thereby forming a layered tube including the layer and the outer layer;

wherein the second fluoropolymer is the same as or different than the first fluoropolymer; and

wherein the second crosslinker is the same as or different than the first crosslinker.

8. The method as set forth in claim 7 wherein a third fluoropolymer is compounded with the second crosslinker and the second fluoropolymer to form the second compounded mixture, and wherein the third fluoropolymer is different than the second fluoropolymer.

9. The method as set forth in claim 1 wherein compounding the anti-static intermediate mixture and the first fluoropolymer comprises compounding the anti-static intermediate mixture, the first fluoropolymer, and a fourth fluoropolymer to form the first compounded mixture, and wherein the fourth fluoropolymer is different than the first fluoropolymer.

10. The method as set forth in claim 9 wherein compounding the anti-static intermediate mixture and at least the portion of the first fluoropolymer is further defined as a high-shear compounding step using a high-shear extrusion screw and a low-shear compounding step using a low-shear extrusion screw where, in the high-shear compounding step, the anti-static intermediate mixture and at least the portion of the first fluoropolymer are compounded under high-shear with the high-shear extrusion screw at a revolution per minute of 100 to 400 to form the first compounded mixture and, in the low-shear compounding step, the first compounded mixture and the fourth fluoropolymer are compounded under low-shear with the low-shear extrusion screw at a revolution per minute of 100 to 300.

11. The method as set forth in claim 9 wherein compounding the anti-static intermediate mixture and at least the portion of the first fluoropolymer is further defined as a high-shear compounding step and a low-shear compounding step with each compounding step using the same extrusion screw where, in the high-shear compounding step, the anti-static intermediate mixture and at least the portion of the first fluoropolymer are compounded under high-shear with the extrusion screw at a revolution per minute of greater than 200 to 400 to form the first compounded mixture and, in the low-shear compounding step, the first compounded mixture and the fourth fluoropolymer are compounded under low-shear with the extrusion screw at a revolution per minute of 200 or less.

12. The method as set forth in claim 1 further comprising compounding the first compounded mixture and a second portion of the first fluoropolymer to form a third compounded mixture.

13. The method as set forth in claim 12 wherein compounding the first compounded mixture and the second portion of the first fluoropolymer comprises compounding the first compounded mixture, the second portion of the first fluoropolymer, and a fourth fluoropolymer to form the third compounded mixture, wherein the fourth fluoropolymer is different than the first fluoropolymer.

14. The method as set forth claim 13 wherein the second portion of the first fluoropolymer and the fourth fluoropolymer are powder in form.

15. The method as set forth in claim 1 further comprising applying radiation to the layer to cure the layer.

16. The method as set forth in claim 15 wherein the radiation is applied to the layer via an electron beam.

17. The method as set forth in claim 1 further comprising maintaining a void volume in an extruder as the first compounded mixture is extruded.

18. The method as set forth in claim 7 wherein the first compounded mixture and the second compounded mixture are co-extruded to form the layer and the outer layer, respectively, thereby forming the layered tube.

19. The method as set forth in claim 7 further comprising applying radiation to the outer layer to cure the layered tube.

20. The method as set forth in claim 19 wherein the radiation is applied via an electron beam.

21. The method as set forth in claim 1 further comprising applying heat to the anti-static additive to remove moisture from the anti-static additive prior to premixing the anti-static additive and the first crosslinker.

22. The method as set forth in claim 1 wherein the first fluoropolymer comprises poly(ethylene-tetrafluoroethylene).

23. The method as set forth in claim 1 wherein the first crosslinker is a triallyl derivative of cyanuric acid.

24. The method as set forth in claim 7 wherein the second fluoropolymer comprises poly(ethylene-tetrafluoroethylene).

25. The method as set forth in claim 8 wherein the third fluoropolymer comprises poly(propylene-tetrafluoroethylene).

26. The method as set forth in claim 9 wherein the fourth fluoropolymer comprises poly(propylene-tetrafluoroethylene).

27. The method as set forth in claim 7 further comprising forming a hose assembly comprising the layered tube and a reinforcement layer constructed of para-aramid synthetic fibers.

28. The method as set forth in claim 27 wherein forming the hose assembly comprises providing an outer cover.

29. The method as set forth in claims 28 wherein forming the hose assembly comprises providing an adhesive layer between the reinforcement layer and the outer cover.