IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0584688
(2006-10-20)
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등록번호 |
US-8557884
(2013-10-15)
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발명자
/ 주소 |
- Miller, Larry M.
- Breindel, Raymond M.
- Weekley, Mitchell Z.
- Cisar, Thomas E.
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출원인 / 주소 |
- Owens Corning Intellectual Capital, LLC
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대리인 / 주소 |
Calfee, Halter & Griswold LLP
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인용정보 |
피인용 횟수 :
0 인용 특허 :
65 |
초록
▼
This invention relates to foam insulating products, particularly extruded polystyrene foam, with increasing the cell orientation and reducing cell anisotropic ratio, as well as the process method for making the products thereof for improving the insulating properties and for reducing the manufacturi
This invention relates to foam insulating products, particularly extruded polystyrene foam, with increasing the cell orientation and reducing cell anisotropic ratio, as well as the process method for making the products thereof for improving the insulating properties and for reducing the manufacturing cost of the foam products. Alternatively, foam insulating products having increased cell compressive strength may be made by decreasing the cell orientation and increasing the cell anisotropic ratio.
대표청구항
▼
1. A method of increasing the cell orientation ratio in the x/z direction of a rigid polymer foam material comprising: providing a device capable of producing a rigid polymer foam material;introducing a thermoplastic polymer resin to said device;heating said thermoplastic polymer resin above its gla
1. A method of increasing the cell orientation ratio in the x/z direction of a rigid polymer foam material comprising: providing a device capable of producing a rigid polymer foam material;introducing a thermoplastic polymer resin to said device;heating said thermoplastic polymer resin above its glass transition temperature and melting point;incorporating one or more blowing agents into said thermoplastic polymer resin at a first pressure to form a gel, said first pressure being sufficient to prevent pre-foaming of said gel;cooling said gel to a die melt temperature; andextruding the gel through a die gap of the device to a region of lower die pressure;wherein said gel is extruded through said die gap onto a conveyor such that the gel grows quicker in the x-direction relative to the z-direction to form the polymer foam material, wherein said x-direction is defined as the extruded direction of the polymer foam material and wherein said z-direction is defined as the vertical thickness direction of the polymer foam materialwherein the polymeric foam material comprises greater than about 95% closed cells. 2. The process of claim 1, wherein said device comprises an extruder, a mixer or a blender. 3. The process of claim 1, wherein the gel grows quicker in the x-direction relative to the z-direction by increasing the line pulling speed of the device through said die gap at a constant die gap thickness while maintaining a constant foam density of the polymeric foam material. 4. The process of claim 1, wherein introducing a thermoplastic polymer material to said device comprises introducing an alkenyl aromatic polymer to said device. 5. The process of claim 1, wherein incorporating one or more blowing agents comprises incorporating one or more blowing agents into said thermoplastic polymer resin at a first pressure to form a gel, said first pressure sufficient to prevent pre-foaming of said gel, said one or more blowing agents comprising partially or fully hydrogenated HCFC's, HFC's, HC's, carbon dioxide, other inert gases, and mixtures thereof. 6. The process of claim 1, wherein introducing a thermoplastic polymer resin to said device comprises introducing a thermoplastic polymer resin to said device, said thermoplastic polymer resin having a weight average molecular weight of between about 30,000 to about 500,000. 7. The method of claim 1, wherein the cell orientation ratio in the x/z direction of the rigid polymer foam materials is between about 1.03 to about 2.0. 8. The process of claim 1, wherein said method produces an insulating board suitable for use in building construction. 9. The process of claim 1, wherein the cooling step further comprises cooling said gel from about 220 degrees C. to about 110 degrees C. 10. The process of claim 1, wherein the first pressure is about 50 bars. 11. The method of claim 1, wherein said polymeric foam material comprises from about 95% to 99.94% closed cells. 12. The method of claim 1, wherein said polymeric foam material has an R-value of between about 5.0 and about 5.81° F.·ft2·hr/BTU. 13. The method of claim 1, wherein said one or more blowing agents comprises an organic blowing agent selected from the group consisting of aliphatic hydrocarbons having from 1 to 9 carbon atoms, aliphatic alcohols having from 1 to 3 carbon atoms and fully or partially halogenated aliphatic hydrocarbons having from 1 to 4 carbon atoms. 14. A method of improving the material properties of a rigid polymeric foam board suitable for use in building construction, comprising the steps of: heating a thermoplastic polymer resin above its glass transition temperature and melting point;incorporating one or more blowing agents into said thermoplastic polymer resin at a first pressure to form a gel, said first pressure sufficient to prevent pre-foaming of said gel;cooling said gel to a die melt temperature;extruding the gel into a region of lower pressure through a die gap onto a conveyor;pre-selecting the size of the die gap and the line speed of the conveyor, thereby controlling the rate at which the gel grows in the x-direction relative to the rate at which the gel grows in the z-direction,wherein said x-direction is defined as the extruded direction of the rigid polymeric foam board and wherein said z-direction is defined as the vertical thickness direction of the rigid polymeric foam board, andwherein the rigid polymeric foam board comprises greater than about 95% closed cells. 15. The method of claim 14, wherein the pre-selecting step further comprises pre-selecting the size of the die gap and the line speed of the conveyor such that the gel grows quicker in the x-direction relative to the z-direction, thereby decreasing the thermal conductivity of the rigid polymeric foam board produced thereby. 16. The method of claim 14, wherein the selecting step further comprises pre-selecting the size of the die gap and the line speed of the conveyor such that the gel grows slower in the x-direction relative to the z-direction, thereby increasing the compressive strength of the rigid polymeric foam board produced thereby. 17. The method of claim 16, wherein the cell orientation ratio in the x/z direction of the rigid polymeric foam board is between about 0.5 to about 0.97. 18. The method of claim 14, wherein said rigid polymeric foam board comprises from about 95% to 99.94% closed cells. 19. The method of claim 14, wherein said polymeric foam board has an R-value of between about 5.0 and about 5.81° F.·ft2·hr/BTU. 20. The method of claim 14, wherein said one or more blowing agents comprises an organic blowing agent selected from the group consisting of aliphatic hydrocarbons having from 1 to 9 carbon atoms, aliphatic alcohols having from 1 to 3 carbon atoms and fully or partially halogenated aliphatic hydrocarbons having from 1 to 4 carbon atoms.
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