Polyolefin dispersions, froths, and foams and articles manufactured therefrom are disclosed. Also disclosed is a method for generating a thermoplastic foam from an aqueous dispersion. The aqueous dispersion may include a thermoplastic resin, water, and a stabilizing agent. The method may include add
Polyolefin dispersions, froths, and foams and articles manufactured therefrom are disclosed. Also disclosed is a method for generating a thermoplastic foam from an aqueous dispersion. The aqueous dispersion may include a thermoplastic resin, water, and a stabilizing agent. The method may include adding at least one frothing surfactant to the aqueous dispersion to form a mixture, adding a flame retardant and/or a phase change material, frothing the mixture to create a froth, and removing at least a portion of the water to produce the foam.
대표청구항▼
1. A method for generating an open-cell flame retardant thermoplastic foam from a stabilized aqueous dispersion, the aqueous dispersion comprising a thermoplastic resin, water, and a dispersion-stabilizing agent, the method comprising: adding at least one frothing surfactant to the stabilized aqueou
1. A method for generating an open-cell flame retardant thermoplastic foam from a stabilized aqueous dispersion, the aqueous dispersion comprising a thermoplastic resin, water, and a dispersion-stabilizing agent, the method comprising: adding at least one frothing surfactant to the stabilized aqueous dispersion to form a mixture;adding a flame retardant;frothing the mixture to create a froth; andremoving at least a portion of the water to produce the open-cell foam;wherein the thermoplastic resin comprises an ethylene homopolymer, an ethylene/α-olefin copolymer, or an ethylene/α-olefin multiblock interpolymer, a propylene homopolymer, a propylene/α-olefin copolymer, a propylene/α-olefin multiblock interpolymer, or a combination of two or more thereof. 2. The method of claim 1, further comprising: coating at least a portion of a substrate with a layer of the froth; andremoving a majority of the water from the froth. 3. The method of claim 1, wherein the foam has a fibrillated morphology. 4. The method of claim 1, wherein the flame retardant comprises at least one selected from the group consisting of an inorganic salt, an intumescent, a halogenated compound, a phosphate compound, a borate compound, a melamine compound, and combinations thereof. 5. The method of claim 4, wherein the inorganic salt comprises at least one selected from the group consisting of aluminum hydroxide and magnesium hydroxide. 6. The method of claim 1, wherein the foam comprises from about 5 to about 70% by weight flame retardant. 7. The method of claim 1, wherein the froth has a density ranging from about 0.04 to about 0.45 g/cm3 on a wet basis. 8. The method of claim 2, wherein the coating is performed without an adhesive. 9. The method of claim 2, wherein the foam has a density on a dry basis ranging from about 0.02 to about 0.30 g/cm3 after removing a portion of the water. 10. A foam formed by the method of claim 1. 11. The foam of claim 10, wherein the flame retardant is added after the removal of at least a portion of the water. 12. The foam of claim 10, wherein the flame retardant is added prior to frothing. 13. The foam of claim 10, wherein the foam has an open-cell ratio greater than about 75%. 14. The foam of claim 10, wherein the foam is layered without an adhesive directly to a fabric. 15. A fire barrier, a sound deadening layer, a thermo-regulating material, a thermal insulation layer in clothing, an odor absorber, a padding material, or a perfume carrier comprising the foam of claim 10. 16. The method of claim 1, wherein the foam created comprises 20 weight percent or less residual water. 17. The method of claim 16, wherein the foam created comprises from 0 to about 10 weight percent residual water. 18. The method of claim 16, wherein the foam created comprises from 0 to about 8 weight percent residual water. 19. The method of claim 16, further comprising: coating at least a portion of a substrate with a layer of the froth. 20. The method of claim 16, wherein the flame retardant comprises at least one selected from the group consisting of an inorganic salt, an intumescent, a halogenated compound, a phosphate compound, a borate compound, a melamine compound, and combinations thereof. 21. The method of claim 20, wherein the inorganic salt comprises at least one selected from the group consisting of aluminum hydroxide and magnesium hydroxide. 22. The method of claim 16, wherein the foam comprises from about 5 to about 70% by weight flame retardant. 23. The method of claim 16, wherein the froth has a density ranging from about 0.04 to about 0.45 g/cm3 on a wet basis. 24. The method of claim 19, wherein the coating is performed without an adhesive. 25. The method of claim 16, wherein the foam has a density on a dry basis ranging from about 0.02 to about 0.30 g/cm3 after removing at least a portion of the water. 26. The method of claim 16, wherein the volume of the foam is at least about 60 percent of the volume of the froth. 27. A flame retardant article comprising: a fabric; andthe foam of claim 10 disposed on the fabric. 28. The article of claim 27, wherein the foam layer and the fabric layer are fused without an adhesive. 29. The article of claim 27, wherein the foam is at least partially impregnated in the fabric.
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