IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0516482
(2000-03-01)
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발명자
/ 주소 |
- DeSimone, Joseph M.
- Khan, Saad A.
- Royer, Joseph R.
- Spontak, Richard J.
- Walker, Teri Anne
- Gay, Yvon J.
- Siripurapu, Srinivas
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출원인 / 주소 |
- North Carolina State University, The University of North Carolina at Chapel Hill
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대리인 / 주소 |
Myers Bigel Sibley & Sajovet, PA
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인용정보 |
피인용 횟수 :
11 인용 특허 :
53 |
초록
▼
A method of producing a foamed material comprises contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent, wherein the first thermoplastic polymer has a higher percent crystallinity that the second thermoplastic polymer; and subjecting th
A method of producing a foamed material comprises contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent, wherein the first thermoplastic polymer has a higher percent crystallinity that the second thermoplastic polymer; and subjecting the mixture to conditions sufficient to create a thermodynamic instability in the blend foam the mixture, wherein the mixture comprising the first and second thermoplastic polymers has a percent crystallinity lower than the first thermoplastic polymer.
대표청구항
▼
1. A method of producing a foamed material, said method comprising:contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent comprising a surfactant, wherein the surfactant is a copolymer selected from the group consisting of a graft copoly
1. A method of producing a foamed material, said method comprising:contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent comprising a surfactant, wherein the surfactant is a copolymer selected from the group consisting of a graft copolymer, a block copolymer, and a random copolymer, wherein the first thermoplastic polymer has a higher percent crystallinity that the second thermoplastic polymer; andsubjecting the mixture to conditions sufficient to create a thermodynamic instability in the mixture to foam the mixture, the mixture comprising the first and second thermoplastic polymers having a percent crystallinity lower than the first thermoplastic polymer;wherein the foamed material formed by said method has a plurality of distinct void spaces formed therein. 2. The method according to claim 1, wherein the blowing agent is carbon dioxide. 3. The method according to claim 2, wherein the carbon dioxide is liquid carbon dioxide. 4. The method according to claim 2, wherein the carbon dioxide is supercritical carbon dioxide. 5. The method according to claim 2, wherein at least one of the first and second thermoplastic materials is amorphous. 6. The method according to claim 5, wherein the mixture of thermoplastic materials is amorphous. 7. The method according to claim 2, wherein at least one of the first and second thermoplastic materials is semicrystalline. 8. The method according to claim 2, wherein the first thermoplastic polymer is semicrystalline and the second thermoplastic material is amorphous. 9. The method according to claim 8, wherein the mixture of thermoplastic materials is amorphous. 10. The method according to claim 2, wherein the first and second thermoplastic polymers are each independently selected from the group consisting of PVDF, sPS, PTFE, PVC, Nylon (6,6), polyvinylmethylether, PP, PE, HDPE, PS, PMMA, polyisobutylene, PVA, PDMS, PEO, poly(phenylene oxide), PVF, PVDC, PVC, PVOH, PVAc, PC, ethyl acetate, PET, poly(ethylene naphthalate), poly(ε-caprolactone), poly(ether imide), chemical derivatives thereof, and mixtures thereof. 11. The method according to claim 2, wherein the first thermoplastic polymer is selected from the group consisting of PVDF, sPS, PTFE, PVC, Nylon (6,6), polyvinylmethylether, PP, PE, HDPE, PVF, PVDC, PVOH, PVAc, PC, ethyl acetate, PET, poly(ethylene naphthalate), poly(ε-caprolactone), poly(ether imide), chemical derivatives thereof, and mixtures thereof; and the second thermoplastic polymer is selected from the group consisting of PS, PMMA, polyisobutylene, PVA, PDMS, PEO, poly(phenylene oxide), PC, chemical derivatives thereof, and mixtures thereof. 12. The method according to claim 2, wherein the first thermoplastic polymer is PVDF and the second thermoplastic polymer is PMMA. 13. The method according to claim 2, wherein said subjecting step comprises separating the mixture from the blowing agent to foam the mixture. 14. The method according to claim 13 , wherein said step of separating the mixture comprises venting the blowing agent. 15. The method according to claim 2, wherein the blowing agent further includes a co-solvent. 16. The method according to claim 2, wherein the blowing agent is carbon dioxide and the surfactant comprises a CO 2 -philic segment. 17. The method according to claim 16, wherein the CO 2 -philic segment comprises a fluoropolymer. 18. The method according to claim 16, wherein the CO 2 -philic segment comprises a fluoropolymer formed from at least one monomer selected from the group consisting of fluoroacrylate monomers, fluoroolefin monomers, fluorostyrene monomers, fluoroalkylene oxide monomers, fluorinated vinyl alkyl ether monomers, and mixtures thereof. 19. The method according to claim 2, wherein the surfactant comprises a CO 2 -phobic segment. 20. The method according to claim 19, wherein the CO 2 -phobic segment is a polymer formed from at least one monomer selected from th e group consisting of styrenics, ∀-olefins, ethylene oxides, dienes, amides, esters, sulfones, sulfonamides, imides, thiols, alcohols, diols, acids, ethers, ketones, cyanos, amines, quaternary ammonium salts, acrylates, methacrylates, thiozoles, and mixtures thereof. 21. The method according to claim 2, wherein the blowing agent further includes a modifier selected from the group consisting of a reactant modifier, water, a plasticizing agent, an anti-bacterial agent, a toughening agent, a processing aid, a colorant, a dye, a flame retardant, and mixtures thereof. 22. The method according to claim 2, wherein the blowing agent is selected from the group consisting of inorganic agents, organic blowing agents, and chemical blowing agents. 23. The method according to claim 22, wherein the blowing agent is an inorganic blowing agent selected from the group consisting of carbon dioxide, nitrogen, argon, water, air nitrogen, and helium. 24. The method according to claim 22, wherein the blowing agent is an organic blowing agent selected from the group consisting of aliphatic hydrocarbons having 1-9 carbon atoms, aliphatic alcohols having 1-3 carbon atoms, and fully and partially halogenated aliphatic hydrocarbons having 1-4 carbon atoms. 25. The method according to claim 22,wherein the blowing agent is a chemical blowing agent selected from the group consisting of azodicarbonaminde, azodiisobutyronitrile, benzenesulfonhydrazide, 4,4-oxybenzene sulfonylsermicarbazide, p-toluene sulfonyl semicarbazide, barium azodicarboxylate, N,N′-dimethyl-N,N′-dinitrosoterephthalamide, and trihydrazino triazine. 26. A method of extrusion processing a mixture of thermoplastic materials, said process comprising:introducing at least two thermoplastic polymers into an extruder barrel, the at least two thermoplastic polymers comprising a first thermoplastic polymer and a second thermoplastic polymer, and wherein the first thermoplastic polymer has a higher percent crystallinity than the second thermoplastic polymer;heating the mixture of thermoplastic materials to provide a molten blend thereof;contacting the molten blend of thermoplastic materials with a blowing agent comprising at least one surfactant, wherein the surfactant is a copolymer selected from the group consisting of a graft copolymer; andsubjecting the blend to conditions sufficient to create a thermodynamic instability in the blend to foam the blend, wherein the foamed blend has a percent crystallinity lower than the first thermoplastic polymer;wherein the foamed material formed by said method has a plurality of distinct void spaces formed therein. 27. The method according to claim 26, wherein said step of contacting the molten blend of thermoplastic materials occurs in a mixing section of the extruder. 28. The method according to claim 26, wherein said subjecting step comprises separating the blowing agent from the molten blend of thermoplastic polymers to form a foamed thermoplastic mixture. 29. The method according to claim 28, wherein said step of separating the blowing agent from the blend comprises venting the blowing agent. 30. The method according to claim 26, wherein the blowing agent is carbon dioxide. 31. The method according to claim 30, wherein the carbon dioxide is liquid carbon dioxide. 32. The method according to claim 30, wherein the carbon dioxide is supercritical carbon dioxide. 33. The method according to claim 26, wherein at least one of the first and second thermoplastic materials is amorphous. 34. The method according to claim 33, wherein the blend of thermoplastic materials is amorphous. 35. The method according to claim 34, wherein at least one of the first and second thermoplastic materials is semicrystalline. 36. The method according to claim 33, wherein the first thermoplastic polymer is semicrystalline and the second thermoplastic material is amorphous. 37. The method according to claim 26, wherein the first thermoplastic polymer and the second thermoplastic polymer are each independently selected from the group consisting of PVDF, sPS, PTFE, PVC, Nylon (6,6), polyvinylmethylether, PP, PE, HDPE, PS, PMMA, polyisobutylene, PVA, PDMS, PEO, poly(phenylene oxide), PVF, PVDC, PVOH, PVAc, PC, poly(ethyl acetate), PET, poly(ethylene naphthalate), poly(ε-ccaprolactone), poly(ether imide), chemical derivatives thereof, and mixtures thereof. 38. The method according to claim 26, wherein the first thermoplastic polymer is selected from the group consisting of PVDF, sPS, PTEE, PVC, Nylon (6,6), polyvinylmethylether, PP, PE, HDPE, PVF, PVDC, PVOH, PVAc, PC, poly(ethyl acetate), PET, poly(ethylene naphthalate), poly(□-caprolactone), poly(ether imide), chemical derivatives thereof, and mixtures thereof; and the second thermoplastic polymer is selected from the group consisting of PS, PMMA, polyisobutylene, PVA, PDMS, PEO, poly(phenylene oxide), PC, chemical derivatives thereof, and mixtures thereof. 39. The method according to claim 26, wherein the first thermoplastic polymer is PVDF and the second thermoplastic polymer is PMMA. 40. The method according to claim 26, wherein the blowing agent further includes a co-solvent. 41. The method according to claim 26, wherein the surfactant comprises a CO 2 -philic segment. 42. The method according to claim 41, wherein the CO 2 -philic segment comprises a fluoropolymer. 43. The method according to claim 41, wherein the CO 2 -philic segment comprises a fluoropolymer formed from at least one monomer selected from the group consisting of fluoroacrylate monomers, fluoroolefin monomers, fluorostyrene monomers, fluoroalkylene oxide monomers, fluorinated vinyl alkyl ether monomers, and mixtures thereof. 44. The method according to claim 26, wherein the surfactant comprises a CO 2 -phobic segment. 45. The method according to claim 44, wherein the CO 2 -phobic segment is a polymer formed from at least one monomer selected from the group consisting of styrenics, ∀-olefins, ethylene oxides, dienes, amides, esters, sulfones, sulfonamides, imides, thiols, alcohols, diols, acids, ethers, ketones, cyanos, amines, quaternary ammonium salts, acrylates, methacrylates, thiozoles, and mixtures thereof. 46. The method according to claim 26, wherein the blowing agent further includes a modifier selected from the group consisting of a reactant modifier, water, a plasticizing agent, an anti-bacterial agent, a toughening agent, a processing aid, a colorant, a dye, a flame retardant, and mixtures thereof. 47. The method according to claim 26, wherein the blowing agent is selected from the group consisting of inorganic agents, organic blowing agents, and chemical blowing agents. 48. The method according to claim 47, wherein the blowing agent is an inorganic blowing agent selected from the group consisting of carbon dioxide, nitrogen, argon, water, air nitrogen, and helium. 49. The method according to claim 47, wherein the blowing agent is an organic blowing agent selected from the group consisting of aliphatic hydrocarbons having 1-9 carbon atoms, aliphatic alcohols having 1-3 carbon atoms, and fully and partially halogenated aliphatic hydrocarbons having 1-4 carbon atoms. 50. The method according to claim 47, wherein the chemical blowing agent is selected from the group consisting of azodicarbonamide, azodiisobutyronitrile, benzenesulfonhydrazide, 4,4-oxybenzene sulfonylsemicarbazide, p-toluene sulfonyl semicarbazide, barium azodicarboxylate, N,N′-dimethyl-N,N′-dinitrosoterephthalamide, and trihydrazino triazine. 51. A method of producing a foamed material, said method comprising:contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent comprising a surfactant, wherein the surfactant is a copolymer selected from the group consisting of a graft copolymer, a block copolymer, and a random copolymer, wherein the first thermoplastic polymer has a higher percent crystallini ty that the second thermoplastic polymer; andsubjecting the mixture to conditions sufficient to create a thermodynamic instability in the mixture to foam the mixture, the mixture comprising the first and second thermoplastic polymers having a percent crystallinity lower than the first thermoplastic polymer;wherein the foamed material formed by said method has a plurality of distinct void spaces formed therein having an average size ranging from about 0 to about 500 microns. 52. The method according to claim 51, wherein the plurality of distinct void spaces formed therein have an average size ranging from about 1 to about 100 microns. 53. The method according to claim 51, wherein the plurality of distinct void spaces formed therein have an average size ranging from about 0.1 to about 50 microns. 54. The method according to claim 53, wherein the mixture of thermoplastic materials is amorphous. 55. The method according to claim 54, wherein the first thermoplastic material is PVDF and the second thermoplastic material is PMMA. 56. A method of extrusion processing a mixture of thermoplastic materials, said process comprising:introducing at least two thermoplastic polymers into an extruder barrel, the at least two thermoplastic polymers comprising a first thermoplastic polymer and a second thermoplastic polymer, and wherein the first thermoplastic polymer has a higher percent crystallinity than the second thermoplastic polymer;heating the mixture of thermoplastic materials to provide a molten blend thereof;contacting the molten blend of thermoplastic materials with a blowing agent comprising at least one surfactant, wherein the surfactant is a copolymer selected from the group consisting of a graft copolymer; andsubjecting the blend to conditions sufficient to create a thermodynamic instability in the blend to foam the blend, wherein the foamed blend has a percent crystallinity lower than the first thermoplastic polymer;wherein the foamed material formed by said method has a plurality of distinct void spaces formed therein having an average size ranging from above about 0 to about 500 microns. 57. The method according to claim 56, wherein the plurality of distinct void spaces formed therein have an average size ranging from about 1 to about 100 microns. 58. The method according to claim 56, wherein the plurality of distinct void spaces formed therein have an average size ranging from about 0.1 to about 50 microns. 59. The method according to claim 58, wherein the blend of thermoplastic materials is armorphous. 60. The method according to claim 59, wherein the first thermoplastic material is PVDF and the second thermoplastic material is PMMA.
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