Abstract: A process for producing rubber modified polymers having an increased rubber phase volume, including feeding a vinyl aromatic monomer and an elastomer to a polymerization reactor to form a reaction mixture, polymerizing the reaction mixture, combining a copolymer to the polymerized reaction mixture to form a combined mixture, subjecting the combined mixture to further polymerization, and obtaining a rubber modified polymer product from the further polymerization.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: A process for producing a high impact polystyrene having a high swell index including feeding at least one vinyl aromatic monomer and at least one elastomer to at least one polymerization reactor to form a reaction mixture, polymerizing the reaction mixture, combining a chain transfer agent to the reaction mixture leaving the at least one polymerization reactor to form a combined mixture, sending the combined mixture to a devolatilization zone and obtaining a HIPS product having a high swell index.

Abstract: A vessel header comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube. A method of increasing the throughput of a polymerization reaction comprising conducting the polymerization reaction in a reaction vessel comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube wherein the polymerization reaction displays an increase in throughput of 10% and a decrease in volatiles of from 5% to 10% when compared to a polymerization reaction carried out in a reaction vessel lacking a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube.

Abstract: Foamable polystyrene compositions with enhanced blowing agent solubility and methods of making such polystyrene compositions by incorporating a polar additive in styrenic polymer or copolymers.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: A vessel header comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube. A method of increasing the throughput of a polymerization reaction comprising conducting the polymerization reaction in a reaction vessel comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube wherein the polymerization reaction displays an increase in throughput of 10% and a decrease in volatiles of from 5% to 10% when compared to a polymerization reaction carried out in a reaction vessel lacking a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube.

Abstract: A styrenic copolymer composition including at least one alkyl acrylate and/or alkyl methacrylate comonomer, in which the styrenic copolymer composition is optically clear and has at least two times the impact strength compared to general-purpose polystyrene.

Abstract: The present invention is an expandable vinyl aromatic polymer which comprises: a) a matrix of a branched aromatic ionomer, b) 1-10% by weight calculated with respect to the polymer (a), of an expanding agent englobed in the polymeric matrix, c) 0-20% by weight, calculated with respect to the polymer (a), of a filler homogeneously distributed in the polymeric matrix, in which, the branched aromatic ionomer comprises the product of co-polymerizing a first monomer comprising an aromatic moiety and an unsaturated alkyl moiety and a second monomer comprising an ionic moiety and at least two unsaturated moieties, wherein the ionic moiety has at least two ionizable groups, a cationic group that ionizes to form cations and an anionic group that ionizes to form anions, and wherein the cationic group is polyvalent and one capable of forming bridges to other molecules. The present invention also relates to the use of the expandable vinyl aromatic polymer to make expanded articles, in particular insulation boards.

Abstract: A process for producing high impact polystyrene including feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture. Polymerizing the reaction mixture in the first linear flow reactor to a point below the point at which phase inversion occurs to produce a first polymerization mixture and feeding the first polymerization mixture from the first linear flow reactor to a second linear flow reactor. Polymerizing the reaction mixture in the second linear flow reactor to at least a phase inversion point of the mixture to produce a second polymerization mixture and feeding the second polymerization mixture from the second linear flow reactor to at least a third linear flow reactor for post-inversion polymerization of the second polymerization mixture. The product stream can have an ESCR value of at least 10% toughness retained with less than 10 wt % rubber content.

Abstract: Disclosed are high impact polystyrenes prepared using mixed initiators. The mixed initiators include at least one grafting initiator and one non-grafting initiator. The high impact polystyrenes prepared therewith have a continuous polystyrene phase and dispersed therein particles of rubber predominantly having a honeycomb structure of rubber with polystyrene inclusions.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: A method of preparing a high impact polystyrene comprising contacting styrene monomer, a high cis polybutadiene elastomer, and an initiator under high shear within a reaction zone. A high-impact polystyrene comprising a high cis polybutadiene elastomer. A method of preparing a high impact polystyrene comprising contacting styrene monomer, a high cis polybutadiene elastomer, and an initiator under extreme reaction conditions within a reaction zone.

Abstract: A method is provided for perforating a steel plate, forming a devolatilizer nozzle from the steel plate, and heat treating the devolatilizer nozzle. The devolatilizer nozzle may have a yield strength of at least about 110 ksi, and a tensile strength of at least about 140 ksi. The perforations in the steel plate are holes in the nozzle and may be no more than about 0.05 inches in diameter. The thickness of the steel plate may be from about 0 to about 0.75 inches. The nozzle may include at least about 500,000 perforations where the center-to-center hole distance may be at least about 0.08 inches. The capacity of the devolatilizer nozzle may be from about 0 to about 75,000 pounds per hour.

Abstract: A monovinylidene aromatic polymer with a melt flow index of at least 7 g/10 min and a Vicat softening temperature of at least 200° F. may be useful for injection molding with reduced cycle time. The monovinylidene aromatic polymer may be general purpose polystyrene or high impact polystyrene. It may include reduced amounts of mineral oil and increased amounts of an additive such as zinc dimethacrylate to optimize its processability and mechanical characteristics.

Abstract: A method of producing a polymer and layered compound composition having a high degree of exfoliation of the layered compound is disclosed. The layered compound is treated with chemicals having an affinity with the polymer or the monomer of the polymer. The monomer and the layered compound can be combined prior to polymerization. The polymer and layered compound can be combined by solution mixing in a solvent. The layered compound can also be incorporated into the mixture by compounding a polymer product with the layered compound.

Abstract: Peroxide initiators are disclosed that can be used at lower temperatures during HIPS production. Enhanced formation of graft polymers between polystyrene and polybutadiene (rubber) can be accomplished by using these lower temperature peroxide initiators that have a 1 hour half-life period at one or more temperatures from 95° C. to less than 111° C. during the pre-inversion stage. “Higher” temperature initiators are used during and/or after inversion. The use of such “low” temperature initiators improves polymerization rates and grafting values, while reducing the swell index and the amount of rubber used, thereby producing improved HIPS more rapidly and at a lower cost. Also disclosed are HIPS compositions and products produced by such “low” temperature initiators as well as a method of producing improved HIPS.

Abstract: A branched aromatic ionomer is prepared by co-polymerizing a first monomer having an aromatic moiety and an unsaturated alkyl moiety and a second monomer having an ionic moiety and at least one unsaturated moiety. The ionic moiety may have a cationic group having a valence of +1 or greater. Styrene is among the useful first monomers and sodium methacrylate and zinc dimethacrylate are among the useful second monomers. The branched aromatic ionomers may be used to prepare articles including foamed polystyrene and microwave save dishes and utensils.

Abstract: A branched aromatic ionomer is prepared by co-polymerizing a first monomer having an aromatic moiety and an unsaturated alkyl moiety and a second monomer having an ionic moiety and at least one unsaturated moiety. The ionic moiety may have a cationic group having a valence of +1 or greater. Styrene is among the useful first monomers and sodium methacrylate and zinc dimethacrylate are among the useful second monomers. The branched aromatic ionomers may be used to prepare articles including foamed polystyrene and microwave save dishes and utensils.

Abstract: Disclosed are blends of polystyrene and at least one of syndiotactic polypropylene, ethylene propylene copolymers, and styrene-butadiene-styrene triblock copolymers. These blends are prepared using solution polymerization and have unique morphologies and desirable physical properties. The blends can also be prepared with graft-promoting or crosslinking agents and rubbers to prepare modified high impact polystyrene.