Highly abrasion-resistant grafted polyolefin pipe

Abstract

A pipe or tube article comprising an innermost comprising a grafted polyolefin composition made from a grafted polyolefin composition is disclosed which can provide long lifetime, highly abrasion-resistant pipes for mining and other transportation uses. Methods for preparing the article and transporting abrasive materials through the article are also described.

1 . A pipe- or tube-shaped article having an innermost layer wherein
 the innermost layer has a thickness of about 0.001 to about 102 mm and comprises a grafted polyolefin composition;   the grafted polyolefin is made from a parent polyolefin comprising ethylene and an α-olefin with 3 to 20 carbons having a density of about 0.92 g/cc (ASTM D-792) or less, grafted with about 0.005 to about 10 wt % of an α,β-ethylenically unsaturated carboxylic acid or anhydride; and has a Shore A hardness of about 96 or less (ASTM D2240, ISO 868).   
   
   
       2 . The article of  claim 1  wherein the parent polyolefin has a density of about 0.90 g/cc or less; the parent polyolefin is grafted with about 0.03 to about 5 wt % of an α,β-ethylenically unsaturated carboxylic acid or anhydride; and the grafted polyolefin has a Shore hardness of about 80 or less. 
   
   
       3 . The article of  claim 1  wherein
 the parent polyolefin comprises from about 5 wt % to about 50 wt % of the α-olefin comonomer based on the total weight of the parent polyolefin copolymer;   the α-olefin contains from 3 to 10 carbons; and   the α,β-ethylenically unsaturated carboxylic acid or anhydride is selected from the group consisting of maleic anhydride, maleic acid, fumaric acid, acrylic acid, methacrylic acid, itaconic anhydride, itaconic acid, citraconic acid, citraconic anhydride, crotonic acid, crotonic anhydride, methyl crotonic acid, cinnamic acid, endo-bicyclo-[2.2.1]-5-heptene-2,3-dicarboxylic acid, endo-bicyclo-[2.2.1]-5-heptene-2,3-dicarboxylic anhydride, cis-4-cyclohexene-1,2-dicarboxylic acid, cis-4-cyclohexene-1,2-dicarboxylic anhydride and mixtures thereof.   
   
   
       4 . The article of  claim 3  wherein the α,β-ethylenically unsaturated carboxylic acid or anhydride is maleic anhydride. 
   
   
       5 . The article of  claim 4  further comprising from about 0.1 wt % to about 80 wt %, based on the total weight of the grafted polyolefin composition of abrasion-resistant filler. 
   
   
       6 . The article of  claim 3  further comprising an outer layer having a thickness of about 0.1 to about 102 mm and comprising rubber, elastomer, thermoplastic elastomer, acid terpolymer, ionomer terpolymer, or mixtures of two or more thereof. 
   
   
       7 . The article of  claim 3  further comprising an outer layer comprising a fiber reinforcement material; the fiber reinforcement material comprises a high strength fiber and optionally a thermoset resin; and the high strength fiber is produced from fiberglass, continuous glass fiber, polyaramide fiber, aramid fiber, graphite, carbon fiber, silica, quartz, ceramic, silicon carbide, boron, alumina, alumina-silica, polyethylene, ultrahigh molecular weight polyethylene, polyimide, liquid crystal polymers, polypropylene, polyester, or polyamide. 
   
   
       8 . The article of  claim 7  further comprising an intermediate layer between the innermost layer and the outer layer and the intermediate layer comprises rubber, elastomer, thermoplastic elastomer, acid terpolymer, ionomer terpolymer, or mixtures of two or more thereof. 
   
   
       9 . The article of  claim 8  wherein the high strength fiber is filament, warp yarn, unidirectional sheet, mat, cloth, knitted cloth, paper, non-woven fabric, woven fabric, or mixtures of two or more thereof. 
   
   
       10 . The article of  claim 3  comprising an outermost layer. 
   
   
       11 . The article of  claim 4  comprising an outermost layer which comprises carbon steel, steel, stainless steel, cast iron, galvanized steel, aluminum, or copper, or alloys of two or more thereof. 
   
   
       12 . The article of  claim 11  wherein the innermost layer is in contact with the outermost layer and the outermost layer comprises carbon steel. 
   
   
       13 . The article of  claim 7  comprising a metal outermost layer, in contact with the innermost layer, comprising carbon steel, steel, stainless steel, cast iron, galvanized steel, aluminum, or copper, or alloys of two or more thereof. 
   
   
       14 . The article of  claim 13  wherein the outermost layer comprises carbon steel. 
   
   
       15 . The article of  claim 5  comprising a metal outermost layer, in contact with the innermost layer, comprising carbon steel, steel, stainless steel, cast iron, galvanized steel, aluminum, or copper, or alloys of two or more thereof. 
   
   
       16 . The article of  claim 15  wherein the outermost layer comprises carbon steel. 
   
   
       17 . A method comprising laying up a pre-formed film or sheet into a preformed metal or plastic pipe to produce a grafted polyolefin-lined metal or plastic pipe wherein the film or sheet is monolayer or multilayer film or sheet and is produced from a grafted polyolefin; and the pre-formed film or sheet is as recited in  claim 3 . 
   
   
       18 . The method of  claim 17  further comprising heating the metal or plastic pipe above the softening point of the grafted polyolefin and allowing the metal or plastic pipe to cool to produce the grafted polyolefin-lined metal or plastic pipe. 
   
   
       19 . A method comprising pulling or inserting an article into the interior surface of a metal pipe to produce a pipe- or tube-shaped article comprising a grafted polyolefin; wherein the pipe is the article characterized in  claim 1 . 
   
   
       20 . The method of  claim 19  further comprising producing an abrasive material; flowing the abrasive material into one end of the pipe- or tube-shaped article; receiving the abrasive material out of the other end of pipe- or tube-shaped article for transporting the abrasive material thereby transporting the abrasive material.