Abstract: Resin beads having an average particle size of from 0.001 mm to 10 mm and containing a continuous phase and a particulate dispersed phase are described. The continuous phase includes elastomeric polymers; the dispersed phase includes homopolymers and/or copolymers containing repeat units resulting from the polymerization of one or more aryl polymerizable monomers. The unexpanded polymer resin beads can be prepared by dispersing an organic phase containing elastomeric polymers and one or more monomers, into droplets and polymerizing the monomers in the organic droplets in a low shear flow pattern. The beads can be impregnated with blowing agents, expanded and can be used to make molded articles. Resin beads having a continuous phase comprising a nitrile rubber, and a dispersed phase comprising one or more homopolymers and/or copolymers containing repeat units resulting form the polymerization of one or more aryl polymerizable show prolonged retention of blowing agents in unexpanded form.

Abstract: Process for preparing polymer, e.g. polystyrene, particles that may not or may contain a water-retaining agent and that require only a one-step process for incorporating the water-retaining agent. The polymer particles may be prepared via an extrusion process, or a bulk polymerization process wherein a water-retaining agent is blended into the polymer melt. Water is incorporated into the particles by soaking them in hot or cold water or treating the particles with steam for a predetermined time depending on the desired water content in the particles. The water-retaining agent may be starch, zeolite, silica dioxide or poly (N-isopropyl acrylamide) ranging from 0.1% to 10.0% by weight. The particles can be expanded via appropriate means to form pre-expanded or expanded particles in a conventional manner.

Abstract: Foamed plastic structures that include one or more foamed plastic bodies containing a polymer matrix that includes one or more polymers formed by polymerizing a monomer mixture formed by polymerizing a monomer mixture containing vinyl aromatic monomers using a polymerization initiator having a structure corresponding to: R(Y)n where R is a C2 to C32 linear, branched, and/or cyclic aliphatic and/or aromatic group that can also include one or more atoms selected from oxygen, nitrogen, halides, silicon and sulfur, Y is a group that can generate a free radical capable of initiating polymerization of the monomers in the monomer mixture; and n is from 2 to 6. The structures formed can include, as non-limiting examples, pallets, containers, stackable containers, produce boxes, seafood shipping containers, geofoam blocks, and insulated concrete forms.

Abstract: Process for preparing polymer, e.g. polystyrene, particles that may not or may contain a water-retaining agent and that require only a one-step process for incorporating the water-retaining agent. The polymer particles may be prepared via an extrusion process, or a bulk polymerization process wherein a water-retaining agent is blended into the polymer melt. Water is incorporated into the particles by soaking them in hot or cold water or treating the particles with steam for a predetermined time depending on the desired water content in the particles. The water-retaining agent may be starch, zeolite, silica dioxide or poly (N-isopropyl acrylamide) ranging from 0.1% to 10.0% by weight. The particles can be expanded via appropriate means to form pre-expanded or expanded particles in a conventional manner.