Autoclave forming

The use of autoclave technology to produce composite members allows for the manufacturing of sheets with very high mechanical properties compared to the more traditional and cost-effective technologies described herein (Fig. 2.5). 

The use of an autoclave allows for an enhancement of compaction with an increase of pressure during the cycle of up to nearly 7-10 atm and temperatures up 

The most up-to-date autoclaves offer different possibilities to adjust the pressure and temperature during the polymerization cycle in compliance with the most suitable law for each type of resin used. A higher pressure prevents the formation of vacuum between the layers beyond a percentage of 65 %, which is the maximum limit allowed for composite production. This kind of manufacturing process is usually chosen when specific mechanical properties are pursued, such as those required for aeronautics, the space industry, or medical devices. 

The autoclave process (Fig. 2.5) basically represents one of the most up-to-date technologies in the production of composite members. 

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In autoclave forming the main resin flow is normal to the tool surface and Darcy s law is again used but in its one-dimensional form ... 

For hose applications an autoclave forming stage will be performed at 150°C-170°C for 20-60 min. 

Polyamides from diamines and dibasic acids. The polyamides formed from abphatic diamines (ethylene- to decamethylene-diamine) and abphatic dibasic acids (oxabc to sebacic acid) possess the unusual property of forming strong fibres. By suitable treatment, the fibres may be obtained quite elastic and tough, and retain a high wet strength. These prpperties render them important from the commercial point of view polyamides of this type are cabed nylons The Nylon of commerce (a 66 Nylon, named after number of carbon atoms in the two components) is prepared by heating adipic acid and hexamethylenediamine in an autoclave ... 

Mutoclaved lime is a special form of highly hydrated dolomitic lime, used largely for stmctural purposes, that has been hydrated under pressure in an autoclave. 

Silica and Alumina. The manufacture of Pordand cement is predicated on the reaction of lime with siUca and alumina to form tricalcium sihcate [12168-85-3] and aluminate. However, under certain ambient conditions of compaction with sustained optimum moisture content, lime reacts very slowly to form complex mono- and dicalcium siUcates, ie, cementitious compounds (9,10). If such a moist, compact mixture of lime and siUca is subjected to steam and pressure in an autoclave, the lime—silica reaction is greatiy accelerated, and when sand and aggregate is added, materials of concrete-like hardness are produced. Limestone does not react with siUca and alumina under any circumstances, unless it is first calcined to lime, as in the case of hydrauhc lime or cement manufacture. 

Preparation of the polymer can be carried out in glass equipment at atmospheric pressure at temperatures typically above 100°C, but the higher pressures in an autoclave result in much faster reaction rates. Each polymer molecule which used butanol as a starter contains one hydroxyl end group as it comes from the reactor diol-started polymers contain two terminal hydroxyls. Whereas a variety of reactions can be carried out at this remaining hydroxyl to form esters, ethers, or urethanes, this is normally not done and therefore lubricant fluids contain at least one terminal hydroxyl group (36). 

Metals can be precipitated from the Hquid or gas phase. For example, nickel ammonium carbonate gives nickel powder when subjected to hydrogen in an autoclave. Copper, cobalt, molybdenum, and titanium powders can also be formed by precipitation. 

The second type of solution polymerization concept uses mixtures of supercritical ethylene and molten PE as the medium for ethylene polymerization. Some reactors previously used for free-radical ethylene polymerization in supercritical ethylene at high pressure (see Olefin POLYMERS,LOW DENSITY polyethylene) were converted for the catalytic synthesis of LLDPE. Both stirred and tubular autoclaves operating at 30—200 MPa (4,500—30,000 psig) and 170—350°C can also be used for this purpose. Residence times in these reactors are short, from 1 to 5 minutes. Three types of catalysts are used in these processes. The first type includes pseudo-homogeneous Ziegler catalysts. In this case, all catalyst components are introduced into a reactor as hquids or solutions but form soHd catalysts when combined in the reactor. Examples of such catalysts include titanium tetrachloride as well as its mixtures with vanadium oxytrichloride and a trialkyl aluminum compound (53,54). The second type of catalysts are soHd Ziegler catalysts (55). Both of these catalysts produce compositionaHy nonuniform LLDPE resins. Exxon Chemical Company uses a third type of catalysts, metallocene catalysts, in a similar solution process to produce uniformly branched ethylene copolymers with 1-butene and 1-hexene called Exact resins (56). 

The use of alkali or alkaline-earth sulfides cataly2es the reaction so that it is complete in a few hours at 150—160°C use of aluminum chloride as the catalyst gives a comparable reaction rate at 115°C. When an excess of sulfur is used, the product can be distilled out of the reactor, and the residue of sulfur forms part of the charge in the following batch reaction. The reaction is carried out in a stainless steel autoclave, and the yield is better than 98% based on either reactant. Phosphoms sulfochloride is used primarily in the manufacture of insecticides (53—55), such as Parathion. 

A hst of polyol producers is shown in Table 6. Each producer has a varied line of PPO and EOPO copolymers for polyurethane use. Polyols are usually produced in a semibatch mode in stainless steel autoclaves using basic catalysis. Autoclaves in use range from one gallon (3.785 L) size in research faciUties to 20,000 gallon (75.7 m ) commercial vessels. In semibatch operation, starter and catalyst are charged to the reactor and the water formed is removed under vacuum. Sometimes an intermediate is made and stored because a 30—100 dilution of starter with PO would require an extraordinary reactor to provide adequate stirring. PO and/or EO are added continuously until the desired OH No. is reached the reaction is stopped and the catalyst is removed. A uniform addition rate and temperature profile is required to keep unsaturation the same from batch to batch. The KOH catalyst can be removed by absorbent treatment (140), extraction into water (141), neutralization and/or crystallization of the salt (142—147), and ion exchange (148—150). 

Sahcyhc acid, upon reaction with amyl alcohol and sodium, reduces to a ring-opened ahphatic dicarboxyhc acid, ie, pimelic acid (eq. 5). The reaction proceeds through the intermediate cyclohexanone-2-carboxyhc acid. This novel reaction involves the fission of the aromatic ring to i j -hexahydrosahcyhc acid when sahcyhc acid is heated to 310°C in an autoclave with strong alkah. Pimelic acid is formed in 35—38% yield and is isolated as the diethyl ester. 

In the absence of a suitable soHd phase for deposition and in supersaturated solutions of pH values from 7 to 10, monosilicic acid polymerizes to form discrete particles. Electrostatic repulsion of the particles prevents aggregation if the concentration of electrolyte is below ca 0.2 N. The particle size that can be attained is dependent on the temperature. Particle size increases significantly with increasing temperature. For example, particles of 4—8 nm in diameter are obtained at 50—100°C, whereas particles of up to 150 nm in diameter are formed at 350°C in an autoclave. However, the size of the particles obtained in an autoclave is limited by the conversion of amorphous siUca to quartz at high temperatures. Particle size influences the stabiUty of the sol because particles <7 nm in diameter tend to grow spontaneously in storage, which may affect the sol properties. However, sols can be stabilized by the addition of sufficient alkaU (1,33). 

Anatase and mtile are produced commercially, whereas brookite has been produced by heating amorphous titanium dioxide, which is prepared from an alkyl titanate or sodium titanate [12034-34-3] with sodium or potassium hydroxide in. an autoclave at 200—600°C for several days. Only mtile has been synthesized from melts in the form of large single crystals. More recentiy (57), a new polymorph of titanium dioxide, Ti02(B), has been demonstrated, which is formed by hydrolysis of K Ti O to form 20, followed by subsequent calcination/dehydration at 500°C. The relatively open stmcture... 

Although hydration under hydrothermal conditions may be rapid, metastable iatermediate phases tend to form, and final equiUbria may not be reached for months at 100—200°C, or weeks at even higher temperatures. Hence, the temperatures of formation given ia Table 6 iadicate the conditions under saturated steam pressure that may be expected to yield appreciable quantities of the compound, although it may not be the most stable phase at the given temperature. The compounds are Hsted ia order of decreasiag basicity, or lime/siHca ratio. Reaction mixtures having ratios C S = 1 yield xonotHte at 150—400°C. Intermediate phases of C—S—H (I), C—S—H (II), and crystalline tobermorite ate formed ia succession. Tobermorite (1.13 nm) appears to persist indefinitely under hydrothermal conditions at 110—140°C it is a principal part of the biader ia many autoclaved cement—silica and lime—silica products. 

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