Abstract: Methods of controlling the durability of and/or the amount of air in concrete formulations that include combining cement, water, and optionally aggregates, admixtures and/or additives to form a cement mixture; and adding prepuff particles to the cement mixture to form a concrete formulation. The prepuff particles have an average particle diameter of from 0.2 mm to 3 mm, a bulk density of from 0.015 g/cc to 0.35 g/cc, an aspect ratio of from 1 to 3, and a smooth continuous outer surface. The cured and hardened concrete formulation typically has a relative dynamic modulus of at least 70% determined according to Procedure A of ASTM C666 (2003). The amount of air in the concrete typically increases over the amount of air in similar formulations not containing prepuff particles, as determined according to ASTM C231, based on the volume percent of prepuff. The concrete formulations can be used to make articles.

Abstract: Interpolymer resin particles comprised of 20% to 60% by weight of uncross-linked polyolefin e.g. polyethylene, polypropylene, and from 40% to 80% by weight based on the weight of the particles of a vinyl aromatic monomer, e.g. styrene, that is polymerized in a suspension process to form an interpenetrating network of polyolefin with polymerized vinyl aromatic monomer particles and having a gel content of 0 to 1.5% by weight based on the weight of the particles for improved processability in end-use applications and improved ESCR properties. The interpolymer resin particles have a VICAT softening temperature from about 90° C. to about 115° C., and a melt index from 0.2 to 35.0 g/10 minutes (Condition G). The particles can be mixed with a blowing agent to form extruded foam articles, such as foam board, and can be used in extrusion, injection molding, rotomolding, and thermoforming processes to form a layer, e.g.

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: A method of making a cementitious composition that includes combining cement, water and optionally aggregates and optionally additives to form an aqueous cement slurry; adding expanded polymer particles to the aqueous cement slurry; and forming a dispersion of expanded polymer particles in the aqueous cement slurry. The expanded polymer particles have an average particle diameter of from 200 ?m to 5,000 ?m, a bulk density of from 0.02 g/cc to 0.64 g/cc, and an aspect ratio of from 1 to 3.

Abstract: Interpolymer resin particles comprised of 20% to 60% by weight of uncross-linked polyolefin e.g. polyethylene, polypropylene, and from 40% to 80% by weight based on the weight of the particles of a vinyl aromatic monomer, e.g. styrene, that is polymerized in a suspension process to form an interpenetrating network of polyolefin with polymerized vinyl aromatic monomer particles and having a gel content of 0 to 1.5% by weight based on the weight of the particles for improved processability in end-use applications and improved ESCR properties. The interpolymer resin particles have a VICAT softening temperature from about 90° C. to about 115° C., and a melt index from 0.2 to 35.0 g/10 minutes (Condition G). The particles can be mixed with a blowing agent to form extruded foam articles, such as foam board, and can be used in extrusion, injection molding, rotomolding, and thermoforming processes to form a layer, e.g.

Abstract: A method of reducing the odor of a resin that includes the step of adding about 0.1% to about 10% by weight of an absorbent clay to the resin. A resin composition with low odor is provided that includes 60% to 99.9% of a styrenic polymer; optionally 0.1% to 30% of one or more elastomeric polymers; and 0.1% to 10% of an absorbent clay. The styrenic polymer is formed by polymerizing a mixture containing 35% to 100% by weight of one or more styrenic monomers, optionally 1% to 49% by weight of one or more maleate-type monomers, and optionally 1% to 65% by weight of one or more other polymerizable monomers. The resin composition and/or method can be used to make molded articles or a resin foam.

Abstract: Composite materials that include a resin containing a polymer obtained by polymerizing a monomer mixture that contains at least one polymerizable monomer and a magnetic material, where the composite material can be used to make sheet stock and articles, such as storage containers. The composite materials can be made by mechanical milling the magnetic material into the resin or by using bulk, suspension, emulsion, mini-emulsion or micro-emulsion polymerization techniques where the resin is formed in the presence of the magnetic material. Articles made of the composite material can be used in a method of deterring theft of an article which includes providing the above-described container, applying a magnetic field to an interrogation zone, causing movement of the container into the interrogation zone, and detecting a magnetic response resulting from the container moving into the interrogation zone.

Abstract: A foamed sheet containing a polymer composition including a polymer formed by polymerizing a mixture including 40% to 90% of styrenic monomers; 5% to 45% of maleate-type monomers; 0.1% to 25% by weight of elastomeric polymers with Mn greater than 6,000; and 0.1% to 10% by weight of low molecular weight polymers that include one or more monomers according to the formula CH2?CR3R2, where R3 is H or a C1-C3 alkyl group and R2 is a C1-C22 linear, branched or cyclic alkyl or alkenyl groups. The low molecular weight polymer has Mn of from 400 to 6,000 and can optionally include functional groups. The foamed sheet is made by injecting blowing agents into the polymer melt composition; mixing the blowing agent with the polymer composition; and extruding the mixture to provide a foamed sheet. The foamed sheets can be thermoformed into containers suitable for use in microwave heating of food.

Abstract: A business method for constructing a building that includes providing a catalog of building components from suppliers in an established network of suppliers. Construction specifications for a building are inputted into a computer containing the database and components are selected from the building component database that correspond with the construction specifications. A database of compatiblized components that correspond with the construction specifications is produced and used to provide technical drawings of the components and construction drawings for the building. The individual component specifications and drawings are communicated to the building component suppliers who produce or obtain individual components conforming to the individual component specifications. A sequence for assembling the individual components to construct the building is determined and the components are transported to a construction site according to the sequence, where the building is then constructed.

Abstract: A polymer blend composition having improved physical properties comprises (i) 70% to 95% by weight of a blend of a styrene maleic anhydride (SMA) copolymer, e.g., rubber modified styrene maleic anhydride copolymer and a styrene polymer e.g., polystyrene or high impact polystyrene (HIPS) and (ii) from 30% to 5% by weight of an acrylic copolymer, e.g., a rubber modified styrene methyl methacrylate (SMMA) copolymer which acts as a compatibilizer for the SMA copolymer, which may be a regrind, and the styrene polymer. This polymer blend composition has good impact strength and elongation properties. The weight percent ratio of the SMA copolymer to styrene polymer in component (i) may be 95:5 or 5:95 based on the total weight of component (i). The polymer blend composition may be extruded into sheet and thermoformed into an article, e.g., a container for packaged foods or may be co-extruded to produce a laminated article.

Abstract: A styrenic copolymer composition comprising 55% to 94% by weight of one or more styrenic monomers; 2% to 25% by weight of one or more maleate-type monomers; and 4% to 20% by weight of an elastomer composition comprising a first a first high molecular weight elastomer polymer having a number average molecular weight of greater than 12,000, a particle size ranging from about 0.05 micron to about 1.0 micron, and ranging from 50 to 99% by weight based on the weight of the elastomer composition, and a second high molecular weight elastomer polymer having a number average molecular weight of greater than 12,000, a particle size ranging from about 0.50 to about 3.0 microns, and ranging from 1.0% to 50% by weight based on the weight of the elastomer composition. The styrenic copolymer composition optionally further comprises from about 0.1 to about 8.0% by weight. The styrenic copolymer composition is formed via polymerizing methods.

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: A lightweight ready-mix concrete composition that contains 8-20 volume percent cement, 11-50 volume percent sand, 10-31 volume percent prepuff particles, 9-40 volume percent coarse aggregate, and 10-22 volume percent water, where the sum of components used does not exceed 100 volume percent. The prepuff particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3. The slump value of the composition measured according to ASTM C 143 is from 2 to 8 inches. After the lightweight ready-mix concrete composition is set for 28 days, it has a compressive strength of at least 1400 psi as tested according to ASTM C39.

Abstract: A lightweight cementitious composition containing from 22 to 90 volume percent of a cement composition and from 10 to 78 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles and can be included as a layer on wall panels and floor panels and can be used in insulated concrete forms. Aspects of the lightweight cementitious composition can be used to make lightweight structural units.

Abstract: A labeled expanded resin container that includes pre-expanded resin beads molded in a shape having a sidewall with an outer surface and a base; and a label formed from a label material capable of maintaining an electrostatic charge disposed over at least a portion of the outer surface of the sidewall of the container. The container has a rim strength that is at least 50% greater than the rim strength of a container that does not contain a label, where the containers are otherwise made using the same equipment. After a liquid at 50° F. (10° C.) is placed in the container and the container is exposed to conditions of 86° F. (30° C.) and 60% relative humidity for 30 minutes, less than 2 ml of moisture condenses on the outer surface of the container.

Abstract: Expandable or pre-expanded thermoplastic particles, e.g. polystyrene particles, used to form foam containers e.g. cups, bowls, are coated with a coating composition comprising a liquid part consisting of a) liquid polyethylene glycol with an average molecular weight of 200 to 800; and a solid part comprising components selected from the group consisting of b) polyolefin wax, e.g. polyethylene wax, c) a metal salt of higher fatty acids, e.g. zinc stearate or calcium stearate; d) polyethylene glycol with an average molecular weight of 900 to 10,000; and e) a fatty bisamide or fatty amide, e.g. ethylene bis-stearamide; and combinations of b) through e). The coating composition prevents or resists leakage of liquids and foods with oil and/or fatty components and improves the rim strength and ATF properties of foam containers.

Abstract: Styrenic resin composition comprising a rubber modified styrene maleic anhydride copolymer and polybutene. The resin is prepared by several methods including adding polybutene into the reactor, or adding polybutene to the syrup exiting the reactor and prior to entering the devolatilizer, or compounding polybutene into the polymer in an extruder after the polymer exits the devolatilizer. The polybutene ranges from 0.1 to 8% by weight and has a number average molecular weight from 900 to 2500. The rubber ranges from 4% to 20% by weight and has a particle size from 0.1 micron to 11 microns. The resin can be extruded into sheet and thermoformed into an article or can be coextruded to produce a laminated article, which may be a container for packaged foods that can be heated in microwave ovens and which container has improved toughness, elongation, and heat distortion resistance properties.

Abstract: A foam thermoplastic container e.g. cup, bowl molded from expandable thermoplastic particles e.g. expandable polystyrene, has a film made of a thermoplastic resin e.g. solid polystyrene, rubber-modified polystyrene, PET, polyethylene, polypropylene, fused to its inner sidewall surface by heat and pressure to create a barrier to resist the leakage of liquid and food with oil and/or fatty components and to increase the rim strength of the container. The thermoplastic resin film can be fused to the outer surface of the container for printing purposes and/or to create a barrier and/or can be fused to the base surfaces of the container. The molding machine used to form the foam container is used to fuse the film to the container.

Abstract: A thermoplastic sheet that includes a continuous phase and a dispersed phase, where A) the continuous phase contains a polymer composition resulting from the polymerization of a monomer mixture containing a styrenic monomer and an alkyl (meth)acrylate monomer in the presence of the dispersed phase; and B) the dispersed phase contains one or more block copolymer selected from diblock and triblock copolymers of styrene-butadiene, styrene-butadiene-styrene, styrene-isoprene, styrene-isoprene-styrene, partially hydrogenated styrene-isoprene-styrene. The thermoplastic sheet is formed by extruding a thermoplastic composition that is cut to desired dimensions to form thermoplastic items, e.g. identification cards, credit cards, bank cards, key cards, gift cards, phone cards, playing cards, menus, and the like. Indicia and/or printing can be applied to the items to provide for commercial applications. The sheet may be opaque or may be relatively clear to transparent with a Haze value of 0.01% up to 10%.

Abstract: A lightweight cementitious composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 10 to 50 volume percent of sand and/or other fine aggregate, where at least a portion of the sand and/or fine aggregate has a fineness modulus of less than 2; where the sum of components used does not exceed 100 volume percent, and where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles.