PROCESS AND APPARATUS FOR PRODUCTION OF FREE FLOWING POLYTETRAFLUOROETHYLENE MOLDING PELLETS

Abstract: An apparatus and process for the production of agglomerated pellets from a polytetrafluoroethylene (PTFE) resin powder. Such agglomerated pellets are commonly used in moulding apparatus. The pellets of this invention exhibit better and more consistent flowability and higher, more consistent bulk density than those made by previously known apparatus and methods. The apparatus includes a tilted, heated polygonal tube (12) provided at its discharge end with an apertured plate (50) with centrally disposed circular opening (52).

Description: PROCESS AND APPARATUS FOR PRODUCTION OF FREE FLOWING POLYTETRAFLUOROETHYLENE MOLDING PELLETS BACKGROUND OF THE INVENTION T is invention relates to the art of agglomeration and more particularly to the formation of pel lets from a resin in the form of a non-freef lowing powder of po I tetraf I uoroethy I ene (PTFE) and other polymers and copo I ymers . In the moulding of var ious plastics articles, it is customary to feed or stock the mould by pel lets. The pel lets include a base resin, such as po I ytetraf I uoroethy I ene , together with various fi l lers, colorants and the l ike wh i ch are desired in the f inal moulded product. It has been a continuing problem to convert PTFE in the relatively low bulk density and low flow powder forms ava i table from resin manufacturers to a high density free flowing agglomerated pel let that wi I I rapidly and eas i ly feed to modern automatic moulding machines. This is accom l ished by use of a wetting agent (e.g. tr i ch I oroethy I ene , a I ky I alcohols, water soluble alcohols plus water or the I ike) to wet the low bulk density, non free f lowing PTFE polymer, foi l owed by var ious forms of rol l ing or tumb l ing o the wet polymer to promote agglomeration with accompanying bulk density increase. Known agglomerating apparatus and methods include double cone blenders and i nc I ined pans or discs tc convert the powder forms of PTFE to pel lets. The agglomerated pel lets are then dried and/or baked with or without solvent recovery . Another apparatus/method has also been used, prior to this invention, for PTFE resin agglomeration. The polymer from a resin manufacturer (e.g. Tef lon 7A or Teflon 7C from DuPont or G170, former ly G570, from ICI ) is wetted with ethanol containing 5% - 10% water after blending with desired additives (e.g. glass, bronze, various fi l lers, carbon black, SUBSTITUTE SHEET etc. ) and mixed in a blender to thoroughly and uniformly wet the polymer. The wetted polymer is fed through a screen type hammer mi I I to form an initial pel let. These seed pel lets are then fed into a si i ght I y ti I ted, heated octagonal stainless steel tube ( 10 feet long by 14 « -1/2 inches across opposite flats) which is rotating at 10 •- 40 rpm. Agglomeration of the seed pel lets occurs over the 1 •- 2 minute contact time as they pass through the tube. The tube is heated to prevent major sticking of the wet pel lets to the wa I Is of the tube and the tube is incl i ned from 0.1 to 6 degrees to cause essential ly plug flow through the tube. The agglomerated pel lets are then tray dried with sol ent recovery and baked for up to 12 hours at up to 610 F. (321 C. ) to further densify the pel let. In use of this latter apparatus/process over several years, problems have been encountered in making consistent pel let products, particularly with respect to pel let f I owab i I i ty . F I owab i I ity of agglomerated automatic moulding products (pel lets) is measured by a sl it f I ow test , known in this art . Pel letized PTFE (both virgin and f i I led) is placed into a triangular hopper apparatus. When the hopper apparatus is actuated, one side of the hopper gradual ly moves (as in the manner of a sl iding gate) , thus defining a sl it in the bottom of the hopper. This opening increases in size unt i I about 50 grams of pel lets have fa I ien through and into a pan. The same we ight of pel lets, which exhibit better f l owabi l ity, wi l l fal l through a sma I ler si it opening. The si it width is used as an indicator of how we I I the pel let mater i a I wi L I fi l l ou I d ca ities at plastics article fabricators. Variations in pel let f I owab i l ity are typical of most free f I ow products made by this process. A study to determine causes for this variation was conducted. This study included a review of a sma I I scale sample preparation unit using an incl i ned unheated rotating disc in place of the heated, octagonal tube in the larger SUBSTITUTE SHEET scale unit. The signif icant observations of this process were : ( 1 ) The product was improved over the large scale process in sl it flow and in bulk density and reproducibi l ity. (2) The type of rol l ing action was different from that in the octagonal rotating tube process. (3) The residence time in the rotating disc unit was 2 - 5 minutes normal ly, wh i le it was much less in the octagonal tube unit. 1 0 Studies were then conducted on a large scale rotating octagonal tube to increase residence time (e.g. lower tube angle, higher tube speeds, lower feed rates, etc. ). No significant improvement in level or reproducibi l ity of sl it f I ow and bulk density was obtained in spite of increased 1 5 residence time to that of a sma I I scale rotating disc unit. An apertured plate or disc at the discharge end of the octagonal tube was then instal led to determine if the disc would improve the ro I I i ng action in the tube, to be more I ike that of the rotating disc agglomerating apparatus. 0 Unexpectedly and surprisingly the disc acted I ike a friction or hydrau I ic clutch to generate a motion essential ly throughout the length of the octagonal tube, analogous to an ocean wave of the pel lets rol I i ng over themselves. _Several sized openings in the disc at the end of the rotating tube 5 were tried and evaluated. With a sma I ler opening, pel let f I owab i l ity increased and bulk density increased, giving this process the capabi l ity of varying both sl it flow and bulk density to suit various end use requirements by changing the size of the end plate opening. For a plate of about 18 inches 0 square, round openings in the plate of 7 , 9, 11 , 11.5 and 13 inches were used. » SUMMARY OF THE INVENTION According to the practi e of this invention, 35 signi f icantly improved results in the formation of plastic SUBSTITUTE SHEET pel lets by agglomeration from PTFE resin powders is real i zed by the addition of an apertured plate at the discharge end of a rotary tube type agglomerating apparatus. The tube may be heated or unheated, although best results have thus far been obtained with heated tubes. The tube is polygonal (octagonal in several tests) although other shapes yield the simi I ar results. It is bel ieved that these improvements (sl it flow and bulk density, as we I I as consistency of both sl it fl ow and bulk density) result from the wavel ike rol l ing action of the pel lets in conjunction with increased dwe I I or residence time of the pel lets in the rotary tube. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side elevational vi ew i l lustrating a typical prior art type rotating drum, the drum being provided with an apertured plate or disc at its discharge end. Figure 2 is an end view taken along section 2-2 of Figure 1. Figure 3 is an enlarged view taken along section 3-3 of Figure 2, of the discharge end of the rotating drum of Figure 1. Figure 4 is a graph showing the variation in si it flow of PTFE pel lets for a heated rotary tube, both with and without the apertured disc or plate of the present invention. Figure 5 is a bar chart showing the improvement in flow of PTFE pel lets formed using the apertured disc of this invention with a heated rotary tube. Figure 6 is a graph showing the changes, in both bulk density and bul density consistency in making agglomerated PTFE pel lets with the apertured plate of this invention, with a heated rotary tube. Figure 7 is a graph showing the improvement in pel let f I owab i l ity, for an unheated tube, enjoyed by the use of the apertured disc or plate of this invention. SUBSTITUTE SHEET DETAILED DESCRIPTION OF THE INVENTION Referring now to Figures 1 >-3 of the drawings, the numeral 10 denotes general ly the pel letizing apparatus of this invention and includes a rotary, octagonal , elongated tube 12 (see Figure 2 ) surrounded by a stationary, annular heating jacket 14, the tube being rotated by a motor 16. There are no baffles within tube 12. Base members designated general ly as 18 and 20 support the assembly. One of the base members may be vertical ly adjustable to vary the ti lt of the tube. A belt and pu I ley arrangement denoted general ly as 22 transmits the rotary motion of the motor to a shaft 24. The shaft is located para I lei and to one side of jacket 14, the shaft carrying dr ive discs 26 at both ends. The drive discs each frictional ly contact annular shrouds 28, the shrouds fixed to the ends of tube 12. Rotary seals 32 at the ends of jacket 14 engage the wide, inner ends of shrouds 28 to inhibit escape of hot air, the hot air being fed from an external source through ducts 37 into jacket 14 to heat tube 12. Exi ducts are designated as 36. However, the direction of air f low within the jacket can be reversed. The particle size of the PTFE powder resin fed into the left, elevated end of tube 12 is typical ly 30 microns (median particle size) , but not usual ly greater than 100 mi crqns wh i I e the final product of agglomerated pel lets is typical ly 20 ^ r -100ϋ microns (median particle size). The discharge end of tube 12, surrounded by one of the shrouds 28, is provided with a plate 50 having a central ly disposed circular opening 52 therein. As shown at Figures 2 and 3, the plate is general ly rectangular and is releasably clamped by a plural ity of spring urged bolts 56 at the plate upper and lower edges. Bolts 56 are mounted in rectangular bars 54, the latter fastened to rim 60 of shroud 28 by threaded fasteners 58. In operation, PTFE resin powder, in the same form as received from a manufacturer, and typical ly mixed with SUBSTITUTE SHEET additives, colorants, f i I I ers of various types, is fed into the left, upper input end of rotating tube 12. Jacket 14 is heated by hot air, the hot air being fed into either end of the jacket. The inlet air temperature is typical ly in the range 250 ,_ 400 F. , and the air outlet temperature is typical ly in the range 200--350 F. Referring now to Figure 4 of the drawings, the decrease in sl it f I ow number (better f l owab i l ity) measured over a period of months for a PTFE compound including glass and graphite, is i I lustrated. The lowermost curve (triangles) i I lustrates the average si it flow number, taken over a period of months, when the agglomerated pel lets are produced using the plate of this invention. The three upper curves represent the si it flow numbers of agglomerated pel lets produced without the apertured plate of this invention. In these three upper curves, the circles represent the minimum si it flow for a single batch from about 5"-15 batches during the particular month indicated. The X's represent the*-P- ' • average sl it f low of al I the batches produced during the particular month indicated. The rectangles represent the maximum si it flow for a single batch during that particular month indicated. Figure 5 also i l lustrates the improvement ( lessening) of si it number achieved with the use of the apertured plate of this invention. The two vertical bars of each touching pair of bars represent ihe average si it flow number for agglomerated PTFE powdered resins produced by agglomeration in a rotating, heated tube without internal baff les. Each pair of bars is designated by a letter, with each letter r-epresent i ng a part icular PTFE composition. The highest bar of each pair of bars represents the si it flow number without the apertured plate 50 at the discharge end of the (heated) rotating tube, wh i le the shortest bar of each pair represents the si it flow number with the plate 50 at the discharge end of the rotating tube . SUBSTITUTE SHEET The compositions A, B, etc. of Figure 5 were s : WT.% (A) Tef Ion 6264 40.0 Molybdenum Sulphide 5.0 Bronze Powder 55.0 (B) Teflon 7C 45.0 Tef Ion L-129 39.0 Orange Pigment Fi I I er 16.0 (C) (D) Tef Ion 7C 45.0 Tef Ion L 29 39.0 PTFE Lubricant 0.5 Fi I ler &. P i g ent 15.5 (E) SUBSTITUTE SHEET ( F ) Tef Ion L-129 76.5 <200 Mesh Sifted G I ass 23.0 B I ack P i gments 0.5 (G) Teflon 7C 20.4 Tef Ion L-129 53.8 Si fted <200 Mesh GI ass F i bres 25.0 Red P i gment 0.8 (H) (J) The Teflon material is obtained from DuPont . The exact nature of the compositions A, B, etc. plays no role in the invention. Figure 5 is given only to demonstrate the improvement in f I owab i I ity of agglomerated PTFE pel lets resulting from the addition of apertured plate or baffle 50 to SUBSTITUTESHEET the end of tube 12 in a rotating tube type of agglomerating apparatus. Figure 6 i I lustrates the improvement in bulk density and bu lk density consistency, for a heated rotary tube, real i zed by the apertured plate of this invention. The left three points represent ( from the top down) the maximum, average, and mini um bulk density values for agglomerated pel lets formed from a PTFE compound containing graphite and carbon lack, without the apertured plate of this invention. The right points, very nearl coincident, correspond to the bulk density for the same pel letized PTFE compound when the apertured plate of this invention is used. Not onl is the bulk density increased with apertured plate 50, the bulk density is also more consistent in value. Figure 7 i I lustrates f I owab i I i t , as measured by the parameter sl it flow, for an unheated rotary tube, for a PTFE compound containing PTFE resin of about 85 % and about 15 % glass fibres. The left three points (squares) represent sl it flow with no apertured disc in the tube discharge end, the second point from the right (a circle) representing sl it flow with an 11.5 inch opening 52 in plate 50 of Figures 1-3, whi le the right point (an X) represents sl it flow with a smal ler opening 52 (9 inches) in the disc. It wi I I be understood that the particular form of the rotating drum apparatus 10 (without the apertured plate 50) is not critical for the practice of the invention, many of known rotary agglomerating tube constructions being suitable. It wi I I be recognized that the plate or disc 50 may be of various shapes and sizes. A cone-shaped piece has been used and simi lar results have been obtained. It is also obvious that the tube 12 transverse cross sectional shape (circular, octagonal ) , can be varied, as wel l as tube rotary speeds, temperatures, ti lt angles, etc. Prior to the use of an apertured disc in the discharge end of a rotary tube agglomerating apparatus, certain base SUBSTITUTE SHEET PTFE resin powders could not be used to make acceptable free flow pel let products. T is was because some methods employed in grinding the base PTFE resin resulted in very fibrous, low bulk dens it_, po dei which was di ff icult to form into a smooth, free flowing pel let agglomerate. With the use of the disc, it has been possible to make a wide spectrum of free flow products with PTFE powders which are relatively fibrous in nature as we I I as powders which are relatively smooth. SUBSTITUTE SHEET

Claims: CLA 1 MS 1. A method of agglomerating a po I tetraf I uoroethy I ene resin in the form of a powder, either alone or with fi l lers and colorants, into pel lets for moulding machines, the method including the steps of, introducing the powder at one end of a rotating tube, the powder ha ing been treated to increase its wetness, providing the discharge end of the tube with an apertured plate, whereby agglomerated pel lets of improved and more consistent f l owab i l ity and bulk density exit from the rotary tube through the aperture in said plate. 2. The method of claim 1 wherein the rotary tube is heated. 3. The method of claim 1 wherein the rotary tube is polygonal in transverse cross section. 4. The method of claim 3 wherein the rotary tube is octagonal in transverse cross section. 5. The method of claim 1 wherein the plate is apertured by a circular aperture whose centre is located on the longitudinal axis of said rotary tube. 6. The method of claim 1 wherein the resin powder is of a size of about 30 microns and wherein the agglomerated resin pel lets are of a size about 200-1000 microns. 7. The method of claim 1 wherein said rotating tube i s t i I ted . 8. An apparatus for the production of agglomerated PTFE moulding pel lets made from a powder PTFE resin, the apparatus including a rotary tube having an inlet end and an outlet end, the outlet end pro ided with an apertured plate. SUBSTITUTE SHEET 2 - 9. The apparatus of claim 8 wherein at least a portion of the length of the tube is heated. 10. The apparatus of claim 8 wherein the tube is polygonal in transverse cross section. 11. The apparatus of claim 8 wherein the plate is apertured by an opening substantial ly col inear with the axis of the rotary tube. 12. The apparatus of claim 8 wherein the tube is ti I ted to the hor i zonta I . 13. The apparatus of claim 8 wherein said means releasably affixes said apertured plate to said outlet end by releasably clamping at least a periphery of the apertured plate. 14. The apparatus of claim 8 wherein the interior of said rotary tube is free of baffles. 15. The apparatus of claim 8 wherein said plate is mounted so that a plane containing said plate I i es outside of the interior of said rotary tube. SUBSTITUTE SHEET

Inventors: EDENS WILLIAM, EDENS, WILLIAM
Applicants: ICI AMERICA INC, ICI AMERICAS INC.
Application year: 1992
Main classification: B29C67
IPC codes: B29B9, B29C67, B29K27