Thermoset desiccant product and method for making same
View Patent ↗A method of forming a desiccating part including the steps of: (a) blending a composition comprising: at least 60 wt % desiccant, up to 10 wt % wetting agent, up to 5 wt % processing aid, and 10-30 wt % thermosetting resin; (b) forming the composition blended in step (a) into a part or shape; and (c) heating the part or shape of step (b) to crosslink the resin. Also included is a desiccating part comprising at least 70 wt % desiccant and a thermosetting binder resin.
1. A method of forming a desiccating part comprising the steps of:
(a) blending a composition comprising:
at least 60 wt % desiccant particles,
a wetting agent,
a processing aid, and
5-30 wt % thermosetting resin selected from the group consisting of: alkyd resins, amino resins, polyester resins, urea-formaldehyde resins, and silicone resins, wherein the wetting agent is present in an amount up to 10 wt % and the processing aid is present in an amount up to 5 wt %, said composition being formable into an uncured dimensionally stable part; (b) forming the composition blended in step (a) into the uncured dimensionally stable part without curing the part; and, (c) curing the part outside of a press or a mold.
2. The method of claim 1 wherein the curing step (c) comprises heating the part for a time sufficient to activate the desiccant.
3. The method of claim 1 wherein the blending step (a) comprises adding a molecular sieve as the desiccant.
4. The method of claim 3 wherein adding a molecular sieve comprises adding a molecular sieve powder having a size selected from the group consisting of 3 A, 4 A, 5 A, and 10 A molecular sieve powders, and combinations thereof.
5. The method of claim 1 wherein the wetting agent is isopropyl alcohol.
6. The method of claim 1 wherein the thermosetting resin is not self-curing, and step (a) further comprises blending a composition comprising a curing agent.
7. The method of claim 1 further comprising the step of:
(d) activating the desiccant by heating the crosslinked part.
8. The method of claim 1 further comprising the step of:
(d) activating the desiccant by exposing the crosslinked part to a vacuum.
9. The method of claim 1 wherein the desiccant is reactivated by heating the crosslinked part after the desiccant has adsorbed water.
10. The method of claim 1 wherein the step of curing comprises heating the part to a temperature between 99° C. and 193° C.
11. The method of claim 1 wherein the thermosetting resin is a solid thermosetting resin.
12. A method of forming a desiccating part comprising the steps of:
(a) blending a composition comprising:
at least 60 wt % desiccant particles,
a wetting agent,
a processing aid, and
5-30 wt % thermosetting resin selected from the group consisting of:
phenolic resins, alkyd resins, amino resins, polyester resins, urea-formaldehyde resins, epoxide resins, melamine resins, phenol-formaldehyde resins, polyurethane resins and silicone resins, wherein the wetting agent is present in an amount up to 10 wt % and the processing aid is present in an amount up to 5 wt %, said composition being formable into an uncured dimensionally stable part or shape;
(b) forming the composition blended in step (a) into the uncured dimensionally stable part without curing the part;
(c) curing the part outside of a press or a mold.
13. The method of claim 12 wherein said thermosetting resin is a phenolic resin.
14. The method of claim 12 wherein the thermosetting resin is a solid thermosetting resin.
15. The method of claim 13 wherein said phenolic resin is a solid pulverized thermosetting resin.
16. The method of claim 1 wherein the step of forming the composition blended in step (a) into the uncured dimensionally stable part is performed by a rotary press.
17. The method of claim 16 wherein the rotary press presses the composition blended in step (a) at pressures ranging from 3 tons to 9 tons.
18. The method of claim 12 wherein the step of forming the composition blended in step (a) into the uncured dimensionally stable part is performed by a rotary press.
19. The method of claim 18 wherein the rotary press presses the composition blended in step (a) at pressures ranging from 3 tons to 9 tons.
20. A method of forming a desiccating part comprising the steps of:
(a) blending a composition comprising:
at least 60 wt % desiccant,
up to 10 wt % wetting agent,
up to 5 wt % lubricant, and
10-30 wt % of a dry thermosetting resin selected from the group consisting of: phenolic resins, amino resins, polyester resins, polyurethane resins, and silicone resins;
(b) pressing the composition blended in step (a) into a part; followed by
(c) heating the part of step (b) outside of a press or a mold to crosslink the resin.
21. The method of claim 20 wherein said thermosetting resin is selected from the group consisting of phenol-formaldehyde resins, alkyd resins, melamine resins, and urea-formaldehyde resins.
22. The method of claim 20 wherein the heating step (c) comprises heating the part for a time sufficient to both crosslink the resin and activate the desiccant.
23. The method of claim 20 wherein the blending step (a) comprises adding a molecular sieve as the desiccant.
24. The method of claim 20 wherein the blending step (a) comprises adding a desiccant which is a molecular sieve powder having a size selected from the group consisting of 3 A, 4 A, 5 A, and 10 A molecular sieve powders, and combinations thereof.
25. The method of claim 20 wherein the wetting agent is isopropyl alcohol.
26. The method of claim 20 comprising the further step of machining the crosslinked part from step (c).