Polyolefin foams made with isopentane-based blowing agents
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C08J-009/12
C08J-009/00
C08J-009/14
출원번호
US-0188263
(2002-07-02)
발명자
/ 주소
Handa,Y. Paul
Gu,Jiayan
출원인 / 주소
Pactiv Corporation
대리인 / 주소
Jenkens &
인용정보
피인용 횟수 :
11인용 특허 :
42
초록▼
A blowing agent blend for making polyolefin foams comprising isopentane and at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent having a boiling point less than 28째 C., or a chemical co-blowing agent, or combinations thereof. The blowing agent blend comprises le
A blowing agent blend for making polyolefin foams comprising isopentane and at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent having a boiling point less than 28째 C., or a chemical co-blowing agent, or combinations thereof. The blowing agent blend comprises less than about 99 mol % isopentane.
대표청구항▼
What is claimed is: 1. A blowing agent blend for making polyolefin foams comprising isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and
What is claimed is: 1. A blowing agent blend for making polyolefin foams comprising isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and wherein the blowing agent blend comprises less than about 99 mol % isopentane, and wherein if one of the at least one co-blowing agent is a physical co-blowing agent being isobutane, the blowing agent blend comprises less than 70 mol % isobutane. 2. The blowing agent blend of claim 1, wherein the polyolefin foam is dimensionally stable. 3. The blowing agent blend of claim 1, wherein the co-blowing agent includes at least one physical co-blowing agent, the at least one physical co-blowing agent being methane, ethane, n-propane, n-butane, isobutane, cyclopropane, nitrogen, argon, carbon dioxide, sulfur hexafluoride, nitrous oxide, dimethyl ether, 1,1-difluoroethane (HFC-152a) , 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroet (HFC-134), 1,1,1,3,3-pentafluoropropane (HFC-245fa), or combinations thereof. 4. The blowing agent blend of claim 1, wherein the blowing agent blend includes a chemical co-blowing agent. 5. The blowing agent blend of claim 1, wherein the blowing agent blend comprises from about 10 mol % to about 60 mol % isopentane. 6. The blowing agent blend of claim 5, wherein the blowing agent blend comprises from about 15 mol % to about 40 mol % isopentane. 7. The blowing agent blend of claim 6, wherein the blowing agent blend comprises from about 25 mol % to about 40 mol % isopentane. 8. The blowing agent blend of claim 1, wherein the polyolefin foam comprises polyethylene. 9. The blowing agent blend of claim 1, wherein the polyolefin foam has a density of less than 3 lb/ft3. 10. A polyolefin foam structure prepared by the process comprising the acts of: melting a thermoplastic polyolefin polymer; dissolving an effective amount of a blowing agent blend in the polyolefin polymer, the blowing agent blend comprising isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and wherein the blowing agent blend comprises less than about 99 mol % isopentane, and wherein if one of the at least one co-blowing agent is a physical co-blowing agent being isobutane, the blowing agent blend comprises less than 70 mol % isobutane; forming an extrudate; transferring the extrudate to an expansion zone; and permitting the extrudate to expand in the expansion zone to produce the polyolefin foam structure, the polyolefin foam structure being a substantially closed-cell and dimensionally-stable structure. 11. The polyolefin foam structure of claim 10, wherein the extrudate comprises from about 1 to about 18 wt % blowing agent. 12. The polyolefin foam structure of claim 10, wherein the polyolefin foam structure has at least 20 cells per inch. 13. The polyolefin foam structure of claim 12, wherein the polyolefin foam structure has at least 25 cells per inch. 14. The polyolefin foam structure of claim 13, wherein the polyolefin foam structure has at least 30 cells per inch. 15. The polyolefin foam structure of claim 10, wherein the polyolefin foam structure is a sheet. 16. The polyolefin foam structure of claim 10, wherein the polyolefin foam structure is a plank. 17. The polyolefin foam structure of claim 10 further including mixing a nucleating agent and the thermoplastic polyolefin polymer to form a mixture, and dissolving an effective amount of the blowing agent blend into the mixture. 18. The polyolefin foam structure of claim 10 further including melting a stability control agent, mixing the stability control agent and the thermoplastic polyolefin polymer to form a mixture, and dissolving an effective amount of the blowing agent blend into the mixture. 19. The polyolefin foam structure of claim 10, wherein the polyolefin foam structure comprises polyethylene. 20. The polyolefin foam structure of claim 19, wherein the polyolefin foam structure comprises low density polyethylene. 21. The polyolefin foam structure of claim 10, wherein the polyolefin foam structure has a density of less than 3 lb/ft3. 22. A process for making a polyolefin foam structure comprising the acts of: melting a thermoplastic polyolefin polymer; dissolving an effective amount of a blowing agent blend in the polyolefin polymer, the blowing agent blend comprising isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and wherein the blowing agent blend comprises less than about 99 mol % isopentane, and wherein if one of the at least one co-blowing agent is a physical co-blowing agent being isobutane, the blowing agent blend comprises less than 70 mol % isobutane; forming an extrudate; transferring the extrudate to an expansion zone; and permitting the extrudate to expand in the expansion zone to produce the polyolefin foam structure. 23. The process of claim 22, wherein the polyolefin structure is a substantially closed-cell and dimensionally stable structure. 24. The process of claim 22, wherein the extrudate comprises from about 1 to about 18 wt % blowing agent. 25. The process of claim 22 further including mixing a nucleating agent and the thermoplastic polyolefin polymer to form a mixture, and dissolving an effective amount of the blowing agent blend into the mixture. 26. The process of claim 22 further including melting a stability control agent, mixing the stability control agent and the thermoplastic polyolefin polymer to form a mixture, and dissolving an effective amount of the blowing agent blend into the mixture. 27. The process of claim 22, wherein the co-blowing agent includes at least one physical co-blowing agent, the at least one physical co-blowing agent being methane, ethane, n-propane, n-butane, isobutane, cyclopropane, nitrogen, argon, carbon dioxide, sulfur hexafluoride, nitrous oxide, dimethyl ether, 1,1-difluoroethane (HFC-152a) , 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane (HFC-134), 1,1,1,3,3-pentafluoropropane (HFC-245fa), or combinations thereof. 28. The process of claim 22, wherein the blowing agent blend includes a chemical co-blowing agent. 29. The process of claim 22, wherein the blowing agent blend comprises from about 10 mol % to about 60 mol % isopentane. 30. The process of claim 29, wherein the blowing agent blend comprises from about 15 mol % to about 40 mol % isopentane. 31. The process of claim 30, wherein the blowing agent blend comprises from about 25 mol % to about 40 mol % isopentane. 32. The process of claim 22, wherein the polyolefin foam structure comprises polyethylene. 33. The process of claim 32, wherein the polyolefin foam structure comprises low density polyethylene. 34. The process of claim 22, wherein the polyolefin foam structure has a density of less than 3 lb/ft3. 35. A blowing agent blend for foaming low density polyethylene foam consisting essentially of from about 10 to about 99 mol % isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and wherein if one of the at least one co-blowing agent is a physical co-blowing agent being isobutane, the blowing agent blend comprises less than 70 mol % isobutane. 36. The blowing agent blend of claim 35, wherein the co-blowing agent includes at least one physical co-blowing agent, the at least one physical co-blowing agent being methane, ethane, n-propane, n-butane, isobutane, cyclopropane, nitrogen, argon, carbon dioxide, sulfur hexafluoride, nitrous oxide, dimethyl ether, 1,1-difluoroethane (HFC-152a) , 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane (HFC-134), 1,1,1,3,3-pentafluoropropane (HFC-245fa), or combinations thereof. 37. The blowing agent blend of claim 35, wherein the blowing agent blend comprises from about 10 mol % to about 60 mol % isopentane. 38. The blowing agent blend of claim 37, wherein the blowing agent blend comprises from about 25 mol % to about 40 mol % isopentane. 39. A process for making a low density polyethylene foam structure prepared by the process comprising the acts of: melting a low density polyethylene polymer; dissolving an effective amount of a blowing agent blend in the low density polyethylene polymer, the blowing agent blend comprising from about 10 to about 99 mol % isopentane and at least one co-blowing agent, the co-blowing agent being (i) a physical co-blowing agent having a boiling point less than 28째 C., (ii) a chemical co-blowing agent, or (iii) combinations thereof, and wherein if one of the at least one co-blowing agent is a physical co-blowing agent being isobutane, the blowing agent blend comprises less than 70 mol % isobutane; forming an extrudate; transferring the extrudate to an expansion zone; and permitting the extrudate to expand in the expansion zone to produce the low density polyethylene structure. 40. The process of claim 39 further including melting a stability control agent, mixing a nucleating agent, the stability control agent and the thermoplastic polyolefin polymer to form a mixture, and dissolving an effective amount of the blowing agent blend into the mixture. 41. The process of claim 40, wherein the nucleating agent is talc, and the stability control agent is glycerol monostearate. 42. The process of claim 39, wherein the co-blowing agent includes at least one physical co-blowing agent, the at least one physical co-blowing agent being methane, ethane, n-propane, n-butane, isobutane, cyclopropane, nitrogen, argon, carbon dioxide, sulfur hexafluoride, nitrous oxide, dimethyl ether, 1,1-difluoroethane (HFC-152a) , 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane (HFC-134), 1,1,1,3,3-pentafluoropropane (HFC-245fa), or combinations thereof. 43. The process of claim 39, wherein the blowing agent blend includes a chemical co-blowing agent. 44. The process of claim 39, wherein the blowing agent blend comprises from about 10 mol % to about 60 mol % isopentane. 45. The process of claim 44, wherein the blowing agent blend comprises from about 25 mol % to about 40 mol % isopentane. 46. The process of claim 39, wherein the low density polyethylene foam has a density of less than 3 lb/ft3. 47. The blowing agent blend of claim 1, wherein the blowing agent blend comprises isopentane and isobutane, the blowing agent comprises less than 70 mol % isobutane. 48. The blowing agent blend of claim 47, wherein the blowing agent blend further includes at least one additional co-blowing agent selected from the group consisting of methane, ethane, n-propane, cyclopropane, and n-butane. 49. The blowing agent blend of claim 1, wherein the blowing agent blend comprises less than 99 mol % isopentane and (i) at least one physical co-blowing hydrocarbon agent having a boiling point less than 28째 C. and the at least one physical co-blowing hydrocarbon agent not being isobutane, (ii) at least one physical non-hydrocarbon co-blowing agent having a boiling point less than 28째 C., (iii) at least one chemical co-blowing agent, or (iv) combinations thereof. 50. The blowing agent blend of claim 49, wherein the blowing agent blend comprises less than 99 mol % isopentane and at least one physical hydrocarbon co-blowing agent selected from the group consisting of methane, ethane, n-propane, cyclopropane, and n-butane. 51. The blowing agent blend of claim 1, wherein the blowing agent blend comprises less than 99 mol % isopentane and at least one physical non-hydrocarbon co-blowing agent having a boiling point less than 28째 C. 52. The process of claim 22, wherein the blowing agent blend comprises isopentane and isobutane, the blowing agent comprises less than 70 mol % isobutane. 53. The process of claim 52, wherein the blowing agent blend further includes at least one additional co-blowing agent selected from the group consisting of methane, ethane, n-propane, cyclopropane, and n-butane. 54. The process of claim 22, wherein the blowing agent blend comprises less than 99 mol % isopentane and (i) at least one physical co-blowing hydrocarbon agent having a boiling point less than 28째 C. and the at least one physical co-blowing hydrocarbon agent not being isobutane, (ii) at least one physical non-hydrocarbon co-blowing agent having a boiling point less than 28째 C., (iii) at least one chemical co-blowing agent, or (iv) combinations thereof. 55. The process of claim 54, wherein the blowing agent blend comprises less than 99 mol % isopentane and at least one physical hydrocarbon co-blowing agent selected from the group consisting of methane, ethane, n-propane, cyclopropane, and n-butane. 56. The process of claim 22, wherein the blowing agent blend comprises less than 99 mol % isopentane and at least one physical non-hydrocarbon co-blowing agent having a boiling point less than 28째 C. 57. A blowing agent blend for making polyolefin foams comprising (i) isopentane, (ii) isobutane, and (iii) at least one of the co-blowing agents selected from the group consisting of n-propane, 1,1,1, 2-tetrafluoroethane (HFC-134a), dimethyl ether, ethane, butane, and combinations thereof, and wherein the blowing agent blend comprises less than 70 mol % isobutane. 58. The blowing agent blend of claim 57, wherein the blowing agent blend consists essentially of (i) isopentane, (ii) isobutane, and (iii) at least one of the co-blowing agents selected from the group consisting of n-propane, 1,1,1,2-tetrafluoroethane (HFC-134a), dimethyl ether, and combinations thereof. 59. The blowing agent blend of claim 57, wherein the blowing agent blend comprises at least 10 mol % isopentane. 60. A process for making a polyolefin foam structure comprising the acts of: melting a thermoplastic polyolefin polymer; dissolving an effective amount of a blowing agent blend in the polyolefin polymer, the blowing agent blend comprising (i) isopentane, (ii) isobutane, and (iii) at least one of the co-blowing agents selected from the group consisting of n-propane, 1,1,1,2-tetrafluoroethane (HFC-134a), dimethyl ether, ethane, butane, and combinations thereof, and wherein the blowing agent blend comprises less than 70 mol % isobutane; forming an extrudate; transferring the extrudate to an expansion zone; and permitting the extrudate to expand in the expansion zone to produce the polyolefin foam structure. 61. The process of claim 60, wherein the blowing agent blend consists essentially of (i) isopentane, (ii) isobutane, and (iii) at least one of the co-blowing agents selected from the group consisting of n-propane, 1,1,1,2-tetrafluoroethane (HFC-134a), dimethyl ether, and combinations thereof. 62. The process of claim 60, wherein the blowing agent blend comprises at least 10 mol % isopentane.
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