Polyvinyl chloride formulations
View Patent ↗An extrudable polyvinyl chloride composition comprising from 80 to 99.9 percent by weight polyvinyl chloride for use in extruding a first part and a second part, wherein a fusion joint between the first extruded part and the second extruded part is formed by: A) composition at least a portion of a first terminal edge of the first extruded part and a first terminal edge of the second extruded part; B) engaging the melted terminal edges; and C) maintaining pressure between the engaged terminal edges to create a fused joint having a strength that is at least 50% of the tensile strength of the extruded part as measured by ASTM D638-2a. The extruded parts can be pipe sections.
1. A butt fused joint area between a pipe having a terminal edge and a second pipe having a terminal edge, the terminal edge of the first pipe and the terminal edge of the second pipe being butt fused to form a butt fused joint area such that an interior sidewall of the first pipe is free of overlap with an exterior sidewall of the second pipe and an interior sidewall of the second pipe is free of overlap with an exterior sidewall of the first pipe, wherein at least the butt fused joint area is prepared from a pipe composition comprising:
(a) 80 to 99 weight percent polyvinyl chloride;
(b) 0.001 to 1.5 weight percent heat stabilizer;
(c) 0.1 to 5 weight percent of one or more divalent metal salts of one or more C 6 to C 32 linear, branched or cyclic alkyl, alkenyl, aryl, aralkyl or alkaryl carboxylic acids;
(d) 0.1 to 5 weight percent wax;
(e) 0.1 to 5 weight percent UV stabilizer;
(f) 0.1 to 2 weight percent of filler; and
(g) 0.001 to 2 weight percent processing aid,
based upon total weight of the pipe composition.
2. The butt fused joint area according to claim 1 , wherein the polyvinyl chloride is between 90 and 99 weight percent of the total weight of the pipe composition.
3. The butt fused joint area according to claim 1 , wherein the polyvinyl chloride is virgin polyvinyl chloride.
4. The butt fused joint area according to claim 1 , wherein the heat stabilizer is an organotin heat stabilizer.
5. The butt fused joint area according to claim 1 , wherein the divalent metal salts of carboxylic acids comprise calcium stearate.
6. The butt fused joint area according to claim 1 , wherein the pipe composition comprises 0.1 to 2 weight percent calcium stearate.
7. The butt fused joint area according to claim 1 , wherein the wax is paraffin wax.
8. The butt fused joint area according to claim 1 , wherein the wax is oxidized polyethylene wax.
9. The butt fused joint area according to claim 1 , wherein the wax is paraffin wax and oxidized polyethylene wax.
10. The butt fused joint area according to claim 1 , wherein the pipe composition comprises 0.5 to 2 weight percent wax.
11. The butt fused joint area according to claim 1 , wherein the pipe composition comprises 0.001 to 1 weight percent of processing aid.
12. The butt fused joint area according to claim 1 , wherein the processing aid comprises methacrylic ester, acrylic ester, acrylonitrile, and/or styrene.
13. The butt fused joint area according to claim 1 , wherein the processing aid comprises acrylic ester.
14. The butt fused joint area according to claim 1 , wherein the pipe composition further comprises up to 2 weight percent of pigment.
15. The butt fused joint area according to claim 1 , wherein the pipe is a water pipe having a burst strength of at least 200 psi as determined by ASTM D1785 in accordance with ASTM D1599 (Procedure B).
16. The butt fused joint area according to claim 1 , wherein the pipe is a gravity drain pipe, a sanitary pipe, a utility conduit, a water pipe, a sewer pipe, a pressurized pipe, a pipe inserted via horizontal directional drilling, a pipe used in slip lining, a pipe used in a pipe bursting application, a pipe used in guided boring, a pipe used in direct bury applications or any combination thereof.
17. The butt fused joint area according to claim 1 , wherein the first pipe has a diameter of from 0.5 inches (1.27 cm) to 60 inches (153 cm).
18. The butt fused joint area according to claim 1 , wherein the first pipe has a wall thickness of from 0.05 inches (0.125 cm) to 3 inches (7.6 cm).
19. A pipe system comprising a first pipe having a terminal edge, a second pipe having a terminal edge, the terminal edge of the first pipe and the terminal edge of the second pipe being butt fused to form a butt fused joint such that an interior sidewall of the first pipe is free of overlap with an exterior sidewall of the second pipe and an interior sidewall_of the second pipe is free of overlap with an exterior sidewall of the first pipe, wherein at least the butt fused joint is prepared from the pipe composition comprising:
(a) 80 to 99 weight percent polyvinyl chloride;
(b) 0.001 to 1.5 weight percent heat stabilizer;
(c) 0.1 to 5 weight percent of one or more divalent metal salts of one or more C 6 to C 32 linear, branched or cyclic alkyl, alkenyl, aryl, aralkyl or alkaryl carboxylic acids;
(d) 0.1 to 5 weight percent wax;
(e) 0.1 to 5 weight percent UV stabilizer;
(f) 0.1 to 2 weight percent of filler; and
(g) 0.001 to 2 weight percent processing aid,
based upon total weight of the pipe composition.
20. The pipe system according to claim 19 , wherein the pipe composition is a fusion joint composition.
21. The pipe system according to claim 19 , wherein the polyvinyl chloride is between 90 and 99 weight percent of the total weight of the pipe composition.
22. The pipe system according to claim 19 , wherein the polyvinyl chloride is virgin polyvinyl chloride.
23. The pipe system according to claim 19 , wherein the heat stabilizer is an organotin heat stabilizer.
24. The pipe system according to claim 19 , wherein the divalent metal salts of carboxylic acids comprise calcium stearate.
25. The pipe system according to claim 19 , wherein the pipe composition comprises 0.1 to 2 weight percent calcium stearate.
26. The pipe system according to claim 19 , wherein the wax is paraffin wax.
27. The pipe system according to claim 19 , wherein the wax is oxidized polyethylene wax.
28. The pipe system according to claim 19 , wherein the wax is paraffin wax and oxidized polyethylene wax.
29. The pipe system according to claim 19 , wherein the pipe composition comprises 0.5 to 2 weight percent wax.
30. The pipe system according to claim 19 , wherein the pipe composition comprises 0.001 to 1 weight percent of processing aid.
31. The pipe system according to claim 19 , wherein the processing aid comprises methacrylic ester, acrylic ester, acrylonitrile, and/or styrene.
32. The pipe system according to claim 19 , wherein the processing aid comprises acrylic ester.
33. The pipe system according to claim 19 , wherein the pipe composition further comprises up to 2 weight percent of pigment.
34. The pipe system according to claim 19 , wherein the pipe is a water pipe having a burst strength of at least 200 psi as determined by ASTM D1785 in accordance with ASTM D1599 (Procedure B).
35. The pipe system according to claim 19 , wherein the pipe is a gravity drain pipe, a sanitary pipe, a utility conduit, a water pipe, a sewer pipe, a pressurized pipe, a pipe inserted via horizontal directional drilling, a pipe used in slip lining, a pipe used in a pipe bursting application, a pipe used in guided boring, a pipe used in direct bury applications or any combination thereof.
36. The pipe system according to claim 19 , wherein the first pipe has a diameter of from 0.5 inches (1.27 cm) to 60 inches (153 cm).
37. The pipe system according to claim 19 , wherein the first pipe has a wall thickness of from 0.05 inches (0.125 cm) to 3 inches (7.6 cm).
38. A butt fused joint area between a fused first extruded part and second extruded part, the first extruded part and second extruded part being prepared from a composition comprising between 80 to 99.9 percent by weight polyvinyl chloride, wherein an interior sidewall of the first extruded part is free of overlap with an exterior sidewall of the second extruded part, and an interior sidewall of the second extruded part is free of overlap with an exterior sidewall of the first extruded part, the butt fused joint area exhibiting a tensile strength that is at least 50% of the tensile strength of the first extruded part or second extruded part, as measured by ASTM D638-2a.
39. The butt fused joint area according to claim 38 , wherein the butt fused joint area exhibits a tensile strength that is at least 80% of the tensile strength of the first extruded part or second extruded part, as measured by ASTM D638-2a.
40. The butt fused joint area according to claim 38 , wherein the butt fused joint area exhibits a tensile strength that is at least 90% of the tensile strength of the first extruded part or second extruded part, as measured by ASTM D638-2a.
41. The butt fused joint area according to claim 38 , wherein the first extruded pipe section has a diameter of from 0.5 inches (1.27 cm) to 60 inches (153 cm).
42. The butt fused joint area according to claim 38 , wherein the first extruded pipe section has a wall thickness of from 0.05 inches (0.125 cm) to 3 inches (7.6 cm).
43. A fused conduit positioned within an outer pipe, the fused conduit comprising a first extruded conduit and a second extruded conduit, the first extruded conduit and the second extruded conduit being prepared from a composition comprising between 80 to 99.9 percent by weight polyvinyl chloride; wherein the first extruded conduit and the second extruded conduit are butt fused together at a butt fused joint area which exhibits a tensile strength that is at least 80 % of the tensile strength of the first extruded conduit or the second extruded conduit, wherein an interior sidewall of the first extruded conduit is free of overlap with an exterior sidewall of the second extruded conduit, and an interior sidewall of the second extruded conduit is free of overlap with an exterior sidewall of the first extruded conduit.
44. The fused conduit according to claim 43 , wherein the conduit is a pipe.
45. A pipe system, comprising:
a plurality of fused, extruded pipe conduits comprising at least one butt fused joint area, wherein the plurality of pipe conduits are prepared from a composition comprising between 80 to 99.9 percent by weight polyvinyl chloride,
wherein terminal edge areas of the pipe conduits are fused to form the at least one butt fused joint area which exhibits a tensile strength sufficient to permit the pipe system to be pulled without breaking the at least one butt fused joint area and wherein an interior sidewall of a first extruded pipe conduit is free of overlap with an exterior sidewall of a second extruded pipe conduit, and an interior sidewall of the second extruded pipe conduit is free of overlap with an exterior sidewall of the first extruded pipe conduit, and
wherein the at least one butt fused joint area exhibits a tensile strength that is at least 50% of the tensile strength of the first extruded pipe conduit or the second extruded pipe conduit, as measured by ASTM D638-2a.
46. The pipe system according to claim 45 , wherein the butt fused joint area exhibits a tensile strength that is at least 80% of the tensile strength of the first extruded pipe conduit or the second extruded pipe conduit, as measured by ASTM D638-2a.
47. The pipe system according to claim 45 , wherein the butt fused joint area exhibits a tensile strength that is at least 90% of the tensile strength of the first extruded pipe conduit or the second extruded pipe conduit, as measured by ASTM D638-2a.
48. The pipe system according to claim 45 , wherein the first extruded pipe section has a diameter of from 0.5 inches (1.27 cm) to 60 inches (153 cm).
49. The pipe system according to claim 45 , wherein the first extruded pipe section has a wall thickness of from 0.05 inches (0.125 cm) to 3 inches (7.6 cm).
50. A method of butt fusing a first extruded part and a second extruded part, the first extruded part and the second extruded part prepared from a composition comprising from 80to 99.9 percent by weight polyvinyl chloride, the method comprising:
heating and melting at least a portion of at least one of a first terminal edge of the first extruded part and a second terminal edge of the second extruded part; and
butt fusing the first terminal edge of the first extruded part and the second terminal edge of the second extruded part by engaging the melted first terminal edge with the melted second terminal edge to form a butt fused joint area, wherein an interior sidewall of the first extruded part is free of overlap with an exterior sidewall of the second extruded part, and an interior sidewall of the second extruded part is free of overlap with an exterior sidewall of the first extruded part;
wherein the butt fused joint area exhibits a tensile strength that is at least 80% of the tensile strength of the first extruded part or second extruded part, as measured by ASTM D638-2a.
51. The method according to claim 50 , wherein the at least one butt fused joint area exhibits a tensile strength that is at least 90% of the tensile strength of the first extruded part or the second extruded part, as measured by ASTM D638-2a.
52. A method of expanding a fused pipe formed from a first extruded pipe section and a second extruded pipe section, the first and second extruded sections prepared from a composition comprising from 80 to 99.9 percent by weight polyvinyl chloride, the method comprising:
heating and melting at least a portion of at least one of a first terminal edge of the first extruded pipe section and a second terminal edge of the second extruded pipe section;
butt fusing the first terminal edge of the first extruded pipe section and the second terminal edge of the second extruded pipe section by engaging the melted first terminal edge with the melted second terminal edge, thereby creating a butt fused joint area wherein an interior sidewall of the first extruded conduit is free of overlap with an exterior sidewall of the second extruded conduit and an interior sidewall of the second extruded conduit is free of overlap with an exterior sidewall of the first extruded conduit; and
expanding the fused pipe in an expansion operation, thereby forming an expanded, fused conduit.
53. A method of lining a host pipe with a plurality of fused, extruded liner pipe portions, at least a portion of the plurality of the fused, extruded liner pipe portions being prepared from a composition comprising between 80 to 99.9 percent by weight polyvinyl chloride, the method comprising:
heating and melting at least a portion of at least one of a first terminal edge of a first liner pipe portion and a second terminal edge of at least one subsequent liner pipe portion; and
butt fusing the first liner pipe portion and the at least one subsequent liner pipe portion by engaging the melted first terminal edge with the melted second terminal edge thereby providing a fused liner pipe with at least one butt fused joint area, wherein an interior sidewall of the first liner pipe portion is free of overlap with an exterior sidewall of the second liner pipe portion and an interior sidewall of the second liner pipe portion is free of overlap with an exterior sidewall of the first liner pipe portion; and
inserting the fused liner pipe into the host pipe,
wherein the at least one butt fused joint area exhibits a tensile strength that is at least 50% of the tensile strength of first liner pipe portion or second liner pipe portion, as measured by ASTM D638-2a.
54. A butt fused joint area between a first pipe having a terminal edge, and a second pipe having a terminal edge, the terminal edge of the first pipe and the terminal edge of the second pipe being butt fused to form a butt fused joint area such that an interior sidewall of the first pipe is free of overlap with an exterior sidewall of the second pipe and an interior sidewall of the second pipe is free of overlap with an exterior sidewall of the first pipe, wherein at least the butt fused joint area is prepared from a pipe composition comprising:
(a) 80 to 99 weight percent polyvinyl chloride;
(b) 0.001 to 1.5 weight percent heat stabilizer;
(c) 0.1 to 5 weight percent of one or more divalent metal salts of one or more C 6 to C 32 linear, branched or cyclic alkyl, alkenyl, aryl, aralkyl or alkaryl carboxylic acids;
(d) 0.1 to 5 weight percent wax;
(e) 0.1 to 5 weight percent UV stabilizer;
(f) 0.1 to 2 weight percent of filler; and
(g) 0.001 to 2 weight percent of processing aid comprising methacrylic ester, acrylic ester, acrylonitrile, and/or styrene,
based upon total weight of the pipe composition, wherein the pipe composition is free of chlorinated polyethylene.