IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
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출원번호 |
US-0016312
(2004-12-17)
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등록번호 |
US-7312253
(2007-12-25)
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발명자
/ 주소 |
- Handa,Yash Paul
- Brackman,Joseph A.
- Castner,Glenn C.
- Zafar,Mohammad
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출원인 / 주소 |
|
대리인 / 주소 |
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인용정보 |
피인용 횟수 :
3 인용 특허 :
39 |
초록
▼
A blowing agent blend for making thermoplastic polymer foams comprises methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocar
A blowing agent blend for making thermoplastic polymer foams comprises methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The thermoplastic polymer foam can be an alkenyl aromatic polymer foam, e.g. a polystyrene foam. The blowing agent blend can comprise any combination of methyl formate and one or more co-blowing agents. The methyl formate-based blowing agent blends produce stable foams for various applications, including containers, packaging systems, as well as insulation boards and building materials. A process for the preparation of such foams is also provided.
대표청구항
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What is claimed is: 1. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend comprising greater th
What is claimed is: 1. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend comprising greater than about 39 weight percent of methyl formate; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater. 2. The process of claim 1, wherein the blowing agent blend further includes at least one co-blowing agent selected from the group consisting of propane, butane, and pentane, or an isomer thereof. 3. The process of claim 1, wherein the blowing agent blend further includes carbon dioxide or water. 4. The process of claim 1, wherein the blowing agent blend further includes a chemical blowing agent. 5. The process of claim 1, wherein the average cell size of the alkenyl aromatic polymer foam board is about 160 to about 285 microns. 6. The process of claim 1, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 7. The process of claim 6, wherein the extrudate comprises from about 4 to about 10 weight percent blowing agent. 8. The process of claim 1, wherein the alkenyl aromatic polymer foam board has a density of about 1.5 to about 3.9 lb/ft3. 9. The process of claim 1, wherein the alkenyl aromatic polymer is polystyrene. 10. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of about 5 to about 85 weight percent of methyl formate and about 15 to about 95 weight percent of at least one co-blowing agent selected from the group consisting of C2 to C5 hydrocarbon, carbon dioxide and water; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 11. The process of claim 10, wherein the average cell size of the alkenyl aromatic polymer foam board is about 160 to about 285 microns. 12. The process of claim 10, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 13. The process of claim 12, wherein the extrudate comprises from about 4 to about 10 weight percent blowing agent. 14. The process of claim 10, wherein the alkenyl aromatic polymer foam board has a density of about 1.5 to about 3.9 lb/ft3. 15. The process of claim 10, further comprising adding at least one additive selected from the group consisting of fillers, colorants, light and heat stabilizers, anti-oxidants, acid scavengers and stability control agents to the polymer. 16. The process of claim 10, further comprising mixing a nucleating agent with the alkenyl aromatic polymer prior to the extrudate forming step. 17. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting essentially of methyl formate and ethane; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, the alkenyl aromatic polymer foam board having a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, wherein the blowing agent blend is the sole blowing agent in the polymer. 18. The process of claim 17, wherein the blowing agent blend consists of methyl formate and ethane. 19. The process of claim 17, wherein the alkenyl aromatic polymer foam board has a density of about 1.5 to about 3.9 lb/ft3. 20. The process of claim 17, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 21. The process of claim 20, wherein the extrudate comprises from about 4 to 10 weight percent blowing agent. 22. The process of claim 17, wherein the average cell size of the alkenyl aromatic polymer foam board is about 160 to about 285 microns. 23. The process of claim 17, wherein the process further comprises mixing a nucleating agent with the alkenyl aromatic polymer prior to the extrudate forming step. 24. The process of claim 17 wherein the alkenyl aromatic polymer foam board is a substantially closed-cell structure. 25. The process of claim 17, wherein the alkenyl aromatic polymer foam board is dimensionally stable. 26. The process of claim 17, further comprising adding at least one additive selected from the group consisting of fillers, colorants, light and heat stabilizers, anti-oxidants, acid scavengers and stability control agents to the polymer. 27. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of methyl formate and 1,1,1,2-tetrafluoroethane (HFC-134a); forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 28. The process of claim 27, the blowing agent blend consisting of about 40 to about 55 percent by weight methyl formate and 45 to 60 percent by weight 1,1,1 ,2-tetrafluoroethane (HFC-134a). 29. The process of claim 26, wherein the average cell size of the alkenyl aromatic polymer foam board is about 180 to about 285 microns. 30. The process of claim 26, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 31. The process of claim 30, wherein the extrudate comprises about 4 to about 10 weight percent blowing agent. 32. The process of claim 26, wherein the alkenyl aromatic polymer foam board has a density of about 2.5 to about 3.9 lb/ft3. 33. The process of claim 27, further comprising adding at least one additive selected from the group consisting of fillers, colorants, light and heat stabilizers, anti-oxidants, acid scavengers and stability control agents to the polymer. 34. The process of claim 27, further comprising mixing a nucleating agent with the alkenyl aromatic polymer prior to the extrudate forming step. 35. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of methyl formate and 1,1,1,2-tetrafluoroethane (HFC-134a) and carbon dioxide; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 36. The process of claim 35, the blowing agent blend consisting of about 40 to about 55 percent by weight methyl formate, of about 45 to about 60 percent by weight 1,1,1 ,2-tetrafluoroethane (HFC-134a) and of about 0 to about 4 percent by weight carbon dioxide. 37. The process of claim 35, wherein the alkenyl aromatic polymer foam board has a density of about 2.5 to about 3.9 lb/ft3. 38. The process of claim 35, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 39. The process of claim 38, wherein the extrudate comprises from about 4 to about 10 weight percent blowing agent. 40. The process of claim 35, further comprising adding at least one additive selected from the group consisting of fillers, colorants, light and heat stabilizers, anti-oxidants, acid scavengers and stability control agents to the polymer. 41. The process of claim 35, further comprising mixing a nucleating agent with the alkenyl aromatic polymer prior to the extrudate forming step. 42. An alkenyl aromatic polymer foam board prepared by a process comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend comprising greater than about 39 weight percent of methyl formate; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of 4 per inch or greater. 43. The alkenyl aromatic polymer foam board of claim 42, wherein the blowing agent blend includes a chemical blowing agent. 44. The alkenyl aromatic polymer foam board of claim 42, wherein the blowing agent blend further comprises at least one co-blowing agent selected from the group consisting of propane, butane, and pentane, or an isomer thereof. 45. The alkenyl aromatic polymer foam board of claim 42, wherein the blowing agent blend further includes carbon dioxide or water. 46. The alkenyl aromatic polymer foam board of claim 42, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 47. The alkenyl aromatic polymer foam board of claim 46, wherein the extrudate comprises from about 4 to about 10 weight percent blowing agent. 48. The alkenyl aromatic polymer foam board of claim 42, further comprising mixing a nucleating agent with the thermoplastic alkenyl aromatic polymer prior to the extrudate forming step. 49. The alkenyl aromatic polymer foam board of claim 42, wherein the alkenyl aromatic polymer foam board is a substantially closed-cell structure. 50. The alkenyl aromatic polymer foam board of claim 42, wherein the alkenyl aromatic polymer foam board is dimensionally stable. 51. The alkenyl aromatic polymer foam board of claim 42, wherein the alkenyl aromatic polymer foam board has a density of about 1.5 to about 3.9 lb/ft3. 52. An alkenyl aromatic polymer foam board prepared by a process comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of methyl formate, 1,1,1,2-tetrafluoroethane (HFC-134a) and optionally carbon dioxide; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 53. The alkenyl aromatic polymer foam board of claim 52, the blowing agent blend consisting of about 40 to about 55 percent by weight methyl formate, of about 45 to about 60 percent by weight 1,1,1,2-tetrafluoroethane (HFC-134a) and of about 0 to about 4 percent by weight carbon dioxide. 54. The alkenyl aromatic polymer foam board of claim 52, wherein the alkenyl aromatic polymer foam board has a density of about 2.5 to about 3.9 lb/ft3. 55. The alkenyl aromatic polymer foam board of claim 52, wherein the average cell size of the alkenyl aromatic polymer foam board is about 160 to about 285 microns. 56. The alkenyl aromatic polymer foam board of claim 52, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 57. The alkenyl aromatic polymer foam board of claim 56, wherein the extrudate comprises from about 4 to about 10 weight percent blowing agent. 58. The alkenyl aromatic polymer foam board of claim 52, wherein the alkenyl aromatic polymer foam board is dimensionally stable. 59. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of methyl formate and carbon dioxide, and optionally water; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 60. The alkenyl aromatic polymer foam board of claim 52, further comprising mixing a nucleating agent with the alkenyl aromatic polymer prior to the extrudate forming step. 61. A process for making an alkenyl aromatic polymer foam board comprising: melting a thermoplastic alkenyl aromatic polymer; dissolving an effective amount of a blowing agent blend in the alkenyl aromatic polymer to define a mixture, the blowing agent blend consisting of methyl formate and carbon dioxide, and optionally water; forming an extrudate from the mixture; and expanding the extrudate to produce the alkenyl aromatic polymer foam board, wherein the alkenyl aromatic polymer foam board has a thickness of at least 0.5 inch and an R value of about 4 per inch or greater, and wherein the blowing agent blend is the sole blowing agent in the polymer. 62. The process of claim 61, wherein the average cell size of the alkenyl aromatic polymer foam board is about 160 to about 285 microns. 63. The process of claim 61, wherein the extrudate comprises from about 1 to about 18 weight percent blowing agent. 64. The process of claim 61, wherein the alkenyl aromatic polymer is polystyrene. 65. The process of claim 61, wherein the alkenyl aromatic polymer foam board is dimensionally stable.
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