WO2006078855A2 - Resin bonded sorbent - Google Patents
Resin bonded sorbent Download PDFInfo
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- WO2006078855A2 WO2006078855A2 PCT/US2006/001957 US2006001957W WO2006078855A2 WO 2006078855 A2 WO2006078855 A2 WO 2006078855A2 US 2006001957 W US2006001957 W US 2006001957W WO 2006078855 A2 WO2006078855 A2 WO 2006078855A2
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- WIPO (PCT)
- Prior art keywords
- resin
- sorbent
- molding composition
- composition according
- multifunctional
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28026—Particles within, immobilised, dispersed, entrapped in or on a matrix, e.g. a resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/26—Drying gases or vapours
- B01D53/28—Selection of materials for use as drying agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/06—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising oxides or hydroxides of metals not provided for in group B01J20/04
- B01J20/08—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising oxides or hydroxides of metals not provided for in group B01J20/04 comprising aluminium oxide or hydroxide; comprising bauxite
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
- B01J20/103—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate comprising silica
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
- B01J20/12—Naturally occurring clays or bleaching earth
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
- B01J20/16—Alumino-silicates
- B01J20/18—Synthetic zeolitic molecular sieves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
- B01J20/16—Alumino-silicates
- B01J20/18—Synthetic zeolitic molecular sieves
- B01J20/183—Physical conditioning without chemical treatment, e.g. drying, granulating, coating, irradiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/2803—Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28042—Shaped bodies; Monolithic structures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B43/00—Arrangements for separating or purifying gases or liquids; Arrangements for vaporising the residuum of liquid refrigerant, e.g. by heat
- F25B43/003—Filters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
- B01D2253/10—Inorganic adsorbents
- B01D2253/102—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
- B01D2253/10—Inorganic adsorbents
- B01D2253/104—Alumina
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
- B01D2253/10—Inorganic adsorbents
- B01D2253/106—Silica or silicates
- B01D2253/108—Zeolites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
- B01D2253/10—Inorganic adsorbents
- B01D2253/106—Silica or silicates
- B01D2253/11—Clays
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2500/00—Problems to be solved
- F25B2500/21—Reduction of parts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B43/00—Arrangements for separating or purifying gases or liquids; Arrangements for vaporising the residuum of liquid refrigerant, e.g. by heat
- F25B43/006—Accumulators
Definitions
- the present invention relates generally to molding compositions, and more particularly, to improved injection molding compositions and articles of manufacture fabricated therefrom comprising water adsorbing additives in a resinous base.
- molding compositions comprising reinforcing additives have not been entirely satisfactory for a number of end-use applications.
- molding composition having relatively high loading levels of reinforcing additives, such as glass fibers and glass beads have the affect of limiting the loading factor of desiccant additives which may be introduced into such molding compositions for optimal moisture adsorption performance.
- desiccant additives which may be introduced into such molding compositions for optimal moisture adsorption performance.
- desirable mechanical properties such as hardness, tensile strength, and other mechanical properties.
- the present invention comprises at least a "resin bonded sorbent" composition comprising a resin and a sufficient amount of sorbent to remove moisture from the environment the molded article will be used in. That is to say, one principal aspect of the invention relates to multifunctional molding compositions having at least a moisture adsorbing amount of a sorbent in combination with a resin. The sorbent-resin combination is present in the composition as a resin bonded sorbent.
- the molding composition is further characterized by enhanced mechanical properties in the absence of an additive having a utility generally recognized for reinforcing articles of manufacture fabricated from resinous molding compositions.
- the invention further relates to multifunctional sorbent-resin molding compositions comprising moisture adsorbing-mechanical property enhancing amounts of adsorbent in combination with reinforcing additives and resin, wherein reduced amounts of reinforcing additives can be employed than otherwise normally required for enhanced mechanical properties.
- these inventors discovered that mechanical properties of molding resins can be enhanced with the introduction of sorbents/desiccants thereby allowing for the introduction of reduced amounts of further additives specifically intended for enhancing mechanical properties of sorbent modified injection molding resins, such as glass fibers and glass beads.
- the multifunctional molding compositions of the invention may comprise from about 25 to about 55 wt% sorbent, such as a molecular sieve, and from about 45 to about 75 wt% resin, usually a thermoplastic material, either homopolymeric type or copolymer having two or more comonomers.
- sorbent such as a molecular sieve
- resin usually a thermoplastic material, either homopolymeric type or copolymer having two or more comonomers.
- One preferred group of representative resins are the polyamides.
- a preferred amount of sorbent is in the range from about 35 to about 42 wt%, and more preferably, an amount of about 40 wt%.
- One representative preferred molecular sieve is a 4 A molecular type; however, other sieves may be used selected from both natural and artificial zeolites.
- the expression "resin bonded sorbent”, as appearing in the specification and claims, is intended to mean a surface compatibility occurring between the sorbent and the resin through a loss of crystallinity of the resin, whereby the sorbent becomes wetted and miscible with the resin due to a reduction in surface tension.
- the expression "resin bonded sorbent” is intended to include binding between the resin and sorbent, which can occur, for example, through heating the sorbent with the resin, or which can be bound through suitable, non-contaminating coupling, surfactant or compatibilizing agents, discussed in greater detail below.
- sorbent e.g., molecular sieve
- resin e.g., polyamide
- Still another aspect of the present invention comprises methods for making improved articles of manufacture, such as components for vehicular air conditioning systems which can eliminate the usual desiccant bag, including refrigeration systems comprising the steps of forming a composition comprising at least from about 25 to about 55 wt% sorbent, such as a molecular sieve, e.g., both natural and artificial zeolites, and from about 45 to about 75 wt% resin, and then molding a component from the compositions, such as by injection molding processes.
- a composition comprising at least from about 25 to about 55 wt% sorbent, such as a molecular sieve, e.g., both natural and artificial zeolites, and from about 45 to about 75 wt% resin
- Fig. 1 is an end view of an accumulator in accordance with the present invention
- Fig. 2 is a partial cross sectional side view of an accumulator in accordance with the present invention.
- Fig. 3 is an exploded view of a filter/desiccant bag/aluminum fitting component of a refrigeration system in accordance with the prior art
- Fig. 4 is a side view of the component of Fig. 3;
- Fig. 5 is a one-piece filter/fitting made in accordance with the composition of the present invention.
- Fig. 6 is an illustration of the use of the device shown in Fig. 5 along with a desiccant bag;
- Fig. 7 shows a cross sectional view of an embodiment of the part shown in Fig. 5 in use atop a condenser
- Fig. 8 illustrates a mobile refrigeration accumulator baffle portion of a refrigerant vapor/liquid separator, such as is used in the receive of an automobile air conditioning system, made in accordance with the present invention
- Fig. 9 illustrates a cap portion for the separator of Fig. 8. DETAILED DESCRIPTION OF THE INVENTION
- novel molding compositions of the invention and parts fabricated therewith are multi-functional, beneficially combining structural, mechanical and adsorptive capabilities without requiring the usual reinforcing additives. Consequently, with the omission of reinforcing additives the novel molding compositions of the invention are further characterized by higher moisture adsorptive capacities by allowing for higher sorbent loading factors than prior adsorbent-containing molding compositions.
- sorbents of the "resin bonded sorbent" molding compositions have the beneficial effect of imparting reinforcement to the molding compositions of the invention while retaining their moisture adsorptive capacity, but without requiring the usual and customary strengthening additives, such as glass beads, glass fiber, and the like. This allows for higher loading factors of sorbent additives for maximizing adsorptive properties of the molding composition without trade-offs occurring in terms of significantly altered mechanical properties of the molding composition.
- the present invention relates principally to the discovery that the mechanical properties of molding resins comprising sorbent additives are capable of eliminating the usual requirement specifically for reinforcement additives, such as glass beads and glass fibers
- the invention also contemplates multifunctional sorbent- resin molding compositions comprising moisture adsorbing-mechanical property enhancing amounts of adsorbent in combination with reinforcing additives and resin, wherein reduced amounts of reinforcing additives can be employed than otherwise normally required for enhanced mechanical properties. That is, the invention also provides desiccant-containing molding compositions, but with reduced quantities of strength enhancing additives, such as glass fibers and glass beads. This will enhance the mechanical properties of the molding composition without the potential for degrading the strength characteristics of the molded article. More specifically, proportional ranges of sorbent, reinforcing additives and resin can be from about 25 to about 50 Wt% sorbent; from about 5 to about 15 wt% reinforcing additive and from about 45 to about 70 wt% resin.
- the resins can be processed and formed by several techniques, including modern high-speed injection molding processes into fully functional component parts, including parts for various sealed systems and assemblies.
- the structural and functional features of the inventive concepts are served while ambient and ingressed moisture are adsorbed to protect sensitive materials or components of systems or assemblies from degradation by moisture; e.g. hydrolysis or corrosion.
- the present invention comprises reinforced structural resin compositions suitable for injection molding with improved mechanical properties, satisfactory melt handling properties, and substantial moisture adsorption properties.
- Most thermoplastic resins are suitable for use in the resin bonded adsorbent compositions of the invention, and include homopolymers and copolymers comprising two or more monomers.
- Representative examples include the polyamides, such as Nylon 6; Nylon 6,6; Nylon 610, and so on.
- Other representative examples include the polyolefins, such as high and low density polyethylenes, polypropylene; copolymers of ethylene-vinyl acetate; polystyrene; polyesters, e.g., PET, to name but a few.
- compositions of the present invention may comprise from about 25 to about 55 wt% sorbent and the balance resin, and more specifically, from about 25 to about 45 wt% sorbent with the balance resin. More preferred compositions may comprise from about 35 to about 42 wt% sorbent, such as a molecular sieve, and the balance resin.
- a most preferred resin bonded sorbent composition may comprise from about 60% nylon molding resin, such as Zytel® 101, commercially available from E.I. duPont, compounded with 40% molecular sieve, such as W. R. Grace 4A molecular sieve powder.
- the molecular sieves of the invention can have a nominal pore size of 4 A, and a particle size range of about 0.4 to about 32 ⁇ . It is to be noted, however, that other molecular sieve pore-sizes can be used as well, such as 3A, 5A, or 1OA, for example.
- sorbents which are useful and functional in this invention are those which bond mechanically to the resin without special additives, such as molecular sieve, as previously discussed. Still others, according to then instant invention, can be induced to bond to the resin through use of a suitable additive, i.e., bind with the aid of a coupling or compatibilizing agent.
- Those sorbents found to perform with coupling or compatibilizing agents include such members as activated carbon and alumina.
- the additives which perform as compatibilizers fall into either of two categories, namely those which bond with the resin or the sorbent, and those having some affinity with both resin and sorbent, and act as solid state surfactants.
- Reactive coupling agents include such classes as maleates, epoxies and silanes.
- reactive coupling agents include such representative examples as maleic anhydride grafted polymers used in amounts ranging from about 2 to about 5 Wt%.
- they can include such representative examples as maleic anhydride grafted to polypropylene or ABS resins, the later being useful as coupling agents with styrenic polymers.
- silanes with various functional groups attached may be used.
- the present invention also contemplates the use of so called non- reactive type compatibilizing agents in binding sorbent and resin.
- metals e.g., zinc or sodium
- acrylates e.g., acrylates
- stearates e.g., block copolymers
- zinc stearate sodium stearate in a range from about 0.01 to about 0.02 wt% based of the sorbent.
- the actual level is driven by the surface area, which is in-turn proportional to the particle size.
- 100 ppm of aluminum stearate would be a typical starting level for compatiblization with a polyamide resin.
- the resin bonded sorbent compositions may be prepared in accordance with the present invention using plastic compounding techniques generally familiar among ordinary skilled artisans.
- Molecular sieve a preferred sorbent, may be incorporated into the resin, e.g., polyamide, polyolefin, or the like, by feeding the sorbent in powdered format along with beads of the chosen resin to a plastics extruder with good mixing characteristics.
- a twin-screw extruder is typically used.
- the resin is melted and the sorbent mixed throughout. It is a necessary condition that the melt blend be heated above the melt point of the resin as determined by DSC (differential scanning calorimetry).
- the temperature should be raised to the point where all crystallinity is lost in order to achieve complete miscibility of the sorbent in the resin melt.
- DuPont's Zytel® 101 polyamide resin would be heated above 262°C. The extruded resin is cooled and then cut or crushed into pellets or granules. Because compounding is performed at elevated temperatures, the sorbent tends not to adsorb moisture during this processing period, but retains its adsorption capacity when molded into a component part and installed in a working environment.
- One further advantage realized with the resin bonded sorbent system of the present invention, wherein the resin and sorbent are intimately bonded, is that gram for gram it is more effective than adsorbent systems employing a bagged adsorbent.
- the sorbent required beading to prevent it from entering the refrigerant stream, for example. This required the sorbent to be bonded within a binder resin, typically 15 wt% binder, such as in the form of a powder.
- a binder resin typically 15 wt% binder, such as in the form of a powder.
- the resin bonded sorbents of the present invention require no additional binder resin because the sorbent is placed directly into the molding resin from which the components are fabricated.
- no intermediary binder resin is required, allowing for higher sorbent loading factors than otherwise achieved with the usual bagged sorbents.
- the compounded resin blend of the invention can then be injection molded in the form of a part.
- An exemplary part is a refrigerant vapor liquid separator, such as is used in the receiver of an automotive air conditioning system. The strength of the silicate-reinforced resin results in a structurally sound molded part.
- Figs. 1 and 2 show an end and partial cross sectional side view, respectively, of aU-Tube assembly 100.
- This embodiment which uses the composition of the present invention to form a liner or sleeve 110 out of the resin bonded sorbent of the present invention, contains a U-tube 120 within accumulator canister 130. This design provides a means of drying against an exposed inner surface of liner 110.
- This embodiment is an alternative to a "baffle" type accumulator of the prior art (not shown).
- the resin formed in accordance with the present invention instead of being melted and injection molded into a functional sorbent part, may be milled or otherwise formed or pelletized into pieces which are then sintered into parts, such as a flow-through monolith structure, or a flow-through dryer component.
- the part is not injection molded, but is molded from the compounded sorbent-loaded resin into a functional part having sufficient porosity for its intended application, such as for use in a receiver dryer assembly.
- Parts fabricated from the resin bonded sorbents of the present invention are particularly well suited to replace multiple-component parts of the prior art.
- many specialized structures have been developed to fit and secure a desiccant material (which was loose) in various parts of a refrigeration system.
- Welded or sewn bags containing beaded or granular molecular sieve or aluminum oxide would be disposed within a flow path.
- beads or granules of desiccant were bonded together in a heated mold with a suitable heat-cured resin or ceramic binder to produce a rigid shape which would serve as a drying block or partial filter.
- Such a structure would be built into a housing.
- the present invention joins the performance of the desiccant with the structural purpose of a part such that a one- piece device serves both functions simultaneously.
- the present invention is contemplated for use with an
- Integrated Receiver Dehydrator Condenser such as those which are starting to find their way into a growing number of vehicles.
- Such mobile refrigeration cycle components basically combine the drying function with the condenser for a number of reasons. It reduces the number of system components, therefore making better use of under-hood space, and concomitantly reduces the number of fittings and connections minimizing the potential for system leaks. It also has some performance gains relative to cooling efficiencies.
- the current technology is illustrated in Figs. 3 and 4 which show aluminum threaded plug 300 with O-rings 305 and 306, an injection molded filter 310, and desiccant bag 320.
- a one piece plug 500 with O-ring 510 can be utilized.
- plug 500 could be assembled with desiccant bag 600 as shown in Fig. 6.
- Fig. 7 illustrates a partial cross section of the device assembled.
- Fig. 7 shows the device 700 disposed adjacent condenser 710.
- Device 700 is comprised of desiccant bag 720 disposed within receiver dryer tube 730.
- filter tube 740 housing integral threaded plug and filter 750.
- 0-rings 705 are also shown.
- Desiccant bag 720 is connected to integral threaded plug and filter 750 at interface 760. This design would eliminate all the separate assembly steps and create a part with fewer separate pieces, as compared to the aluminum threaded plug described above.
- FIG. 8 illustrates a mobile refrigeration accumulator upper portion 800 of a refrigerant vapor/liquid separator, such as is used in the receiver of an automobile air conditioning system.
- accumulator upper portion 800 contains J-Tube 810 which is mounted within it. In this case, one or both of these pieces are molded from the resin bonded sorbent composition of the present invention.
- Fig. 9 illustrates cap 900 which would be placed over top accumulator upper portion 800. In a preferred embodiment of such an accumulator apparatus, both upper portion 800 and cap 900 would be injection molded and then welded, or possibly injection blow-molded in halves.
- Test samples of resin bonded sorbents were prepared according to the claimed invention employing the following protocols.
- the resins are procured from a supplier in pellet form (most common is cylindrical (.03-.12 inch diameter x .06-.25 inch long), other forms included tear drop format (.06-.19 inch).
- the ratio of molecular sieve to the resin is determined by weight of the components.
- the resin was premixed in a poly bag by hand (5-15 min).
- the pre-blend was emptied into the hopper of a Brabender single screw extruder. Action from the screw further blends and melts the resin and molecular sieve as it travels through the extruder barrel.
- the resin bonded sorbent then exits through the single strand die (1 circular hole) at the end of the extruder forming one strand of molten material.
- the nylon based resin was heated above 262 0 C.
- the strand was then cooled by air.
- the strands were broken into pieces.
- the pieces were placed in a hopper of an injection molding machine and parts molded. The parts were broken into pieces and re-introduced back into the injection molding machine where the tensile specimens (dog bones) were injection molded for testing.
- the resin chosen was one known to be compatible with refrigerants used in modern air conditioning systems, specifically R-134a and R-152a.
- the resin was also compatible with compressor lubricants entrained in the refrigerant stream.
- the desiccant was the same as that most commonly used in conventional systems, namely a 3 A or 4A molecular sieve.
- compositions comprising polypropylene, namely Huntsman Polypropylene 6106.
- This resin was also compatible with refrigerants, as well as with compressor lubricant. It was compounded in a similar fashion as nylon in Example 1, namely: 60% polypropylene resin and 40% molecular sieve Type 4A. The resin was heated above 174°C. The compounded resin had similar advantageous mechanical properties compared to the pure resin, and performs, structurally, close to that of a glass reinforced resin. Its properties are summarized in Table II. The values were determined by the same ASTM standards as provided in Table I.
- melt flow was reduced with sorbent reinforced nylon compared with nylon neat (pure polymer) or glass bead reinforced nylon. Nevertheless it was in a workable range and was higher than polypropylene. Melt flow of sorbent reinforced polypropylene was improved relative to polypropylene neat or glass reinforced polypropylene.
- Polypropylene is hydrophobic and is thus much slower to adsorb moisture. But it is fully functional as a sorbent while being fully functional as a molding resin.
- Additional applications of this invention are numerous. Such applications would include any resin bonded component or structure used in an air conditioning or refrigeration system. As discussed above, examples include J-tubes that are injection molded in halves and welded or possibly injection blow-molded, sleeve liners, coatings for an interior part or shell, co-injection molded composite structures, and insert molded filter-dryer assemblies. Diagnostic applications would include test strip substrates, case or supports for E-trans cases, containers or components of containers for diagnostic products.
- Pharmaceutical applications would include parts of a tablet container, such as a base, or closure, or the body of the container itself, an insert into a tablet container such as a bottom support or a neck insert to aid in dispensing, a thermoformed sheet or as a layer of a multilayer thermoformable sheet suitable for one-at-a-time or two-at-a-time dose dispensing from a blister or other compartmented package.
- Electronics and electro-optical device applications would include complete breather filter bodies, inserts for night vision sensor units, or inserts for rear view camera bodies.
Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MX2007009603A MX2007009603A (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent. |
BRPI0606430A BRPI0606430B1 (en) | 2005-01-21 | 2006-01-20 | molding composition and method of making molded article |
AU2006206378A AU2006206378A1 (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent |
EP06718955A EP1838434A4 (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent |
CA002594618A CA2594618A1 (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent |
KR1020077016277A KR101356455B1 (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent |
JP2007552274A JP2008545809A (en) | 2005-01-21 | 2006-01-20 | Resin bonded adsorbent |
IL184596A IL184596A (en) | 2005-01-21 | 2007-07-12 | Multifunctional molding compositions including a sorbent in combination with a resin |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/040,471 | 2005-01-21 | ||
US11/040,471 US20060166818A1 (en) | 2005-01-21 | 2005-01-21 | Resin bonded sorbent |
US11/335,108 | 2006-01-19 | ||
US11/335,108 US7595278B2 (en) | 2005-01-21 | 2006-01-19 | Resin bonded sorbent |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2006078855A2 true WO2006078855A2 (en) | 2006-07-27 |
WO2006078855A3 WO2006078855A3 (en) | 2006-09-28 |
Family
ID=36692886
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2006/001957 WO2006078855A2 (en) | 2005-01-21 | 2006-01-20 | Resin bonded sorbent |
Country Status (10)
Country | Link |
---|---|
US (1) | US7595278B2 (en) |
EP (1) | EP1838434A4 (en) |
JP (2) | JP2008545809A (en) |
KR (1) | KR101356455B1 (en) |
AU (1) | AU2006206378A1 (en) |
BR (1) | BRPI0606430B1 (en) |
CA (1) | CA2594618A1 (en) |
IL (1) | IL184596A (en) |
MX (1) | MX2007009603A (en) |
WO (1) | WO2006078855A2 (en) |
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EP1930369A2 (en) | 2006-12-07 | 2008-06-11 | Multisorb Technologies, Inc. | Resign bonded sorbent |
JP2010527308A (en) * | 2007-03-29 | 2010-08-12 | マルチソーブ テクノロジーズ インコーポレイティド | Adsorbent composite barrier selection method for packaging applications. |
CN102016404A (en) * | 2008-04-21 | 2011-04-13 | 穆尔蒂索伯技术有限公司 | Lamp assembly |
US8853124B2 (en) | 2005-01-21 | 2014-10-07 | Multisorb Technologies, Inc. | Resin bonded sorbent |
DE102013217072A1 (en) * | 2013-08-27 | 2015-03-05 | Behr Gmbh & Co. Kg | capacitor |
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US9339789B2 (en) * | 2004-10-12 | 2016-05-17 | Multisorb Technologies, Inc. | Thermoset desiccant product and method for making same |
US7595278B2 (en) * | 2005-01-21 | 2009-09-29 | Multisorb Technologies, Inc. | Resin bonded sorbent |
AU2013203787C1 (en) * | 2007-03-29 | 2015-07-23 | Multisorb Technologies, Inc. | Method for selecting adsorptive composite barriers for packaging applications |
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EP2370181A4 (en) | 2008-12-18 | 2012-12-26 | 3M Innovative Properties Co | Filter element utilizing shaped particle-containing nonwoven web |
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US8853124B2 (en) | 2005-01-21 | 2014-10-07 | Multisorb Technologies, Inc. | Resin bonded sorbent |
EP1930369A2 (en) | 2006-12-07 | 2008-06-11 | Multisorb Technologies, Inc. | Resign bonded sorbent |
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DE102013217072A1 (en) * | 2013-08-27 | 2015-03-05 | Behr Gmbh & Co. Kg | capacitor |
Also Published As
Publication number | Publication date |
---|---|
MX2007009603A (en) | 2007-09-25 |
JP2008545809A (en) | 2008-12-18 |
CA2594618A1 (en) | 2006-07-27 |
JP2013100537A (en) | 2013-05-23 |
EP1838434A2 (en) | 2007-10-03 |
US20060166819A1 (en) | 2006-07-27 |
KR20070100742A (en) | 2007-10-11 |
IL184596A (en) | 2012-02-29 |
US7595278B2 (en) | 2009-09-29 |
BRPI0606430B1 (en) | 2016-03-15 |
BRPI0606430A2 (en) | 2010-01-19 |
WO2006078855A3 (en) | 2006-09-28 |
AU2006206378A1 (en) | 2006-07-27 |
KR101356455B1 (en) | 2014-02-03 |
EP1838434A4 (en) | 2010-05-05 |
IL184596A0 (en) | 2007-10-31 |
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