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 method for the production of a vinyl aromatic polymer through the use of a supported light-induced photoreductant. A reactor is provided which contains a catalyst bed comprising a light-induced photoreductant component supported on a particulate substrate forming a permeable catalyst bed. A reaction stream comprising a vinyl aromatic monomer, a soluble reductant, and a transition metal salt is introduced into the reactor and passed through the catalyst bed. In addition, a gaseous oxidizing agent is introduced into the reactor and flowed through the catalyst bed and into contact with the reaction stream. The catalyst bed is irradiated with electromagnetic radiation in the ultraviolet or visible light range at an intensity sufficient to activate the photoreductant component and produce a free radical to initiate polymerization of the vinyl aromatic monomer to form a corresponding vinyl aromatic polymer. The vinyl aromatic polymer is then recovered from the reactor.

Abstract: A process for the preparation of a hydroperoxide functionalized rubber compound by the conversion of triplet state oxygen to singlet state oxygen in the presence of oxygen and a light-induced photoreductant. A dispersion of an unsaturated rubber component in a carrier solvent is introduced into a reactor containing a permeable catalyst bed comprising a light-induced photoreductant component supported on a particulate substrate component and passed through the catalyst bed. A gaseous oxidizing agent is passed through the catalyst bed in contact with the rubber-containing dispersion. The catalyst bed is irradiated with electromagnetic light radiation in the ultraviolet or visible light range at an intensity sufficient to convert triplet oxygen in the oxygenated rubber component to singlet oxygen. The oxygenated rubber component is then recovered from the reactor.

Abstract: A plug flow reactor having an inner shell 27 surrounded by outer shell 21 and having at least one annular flow passage 35 therebetween can be used to prepare compositions, including polymers. The plug flow reactor also includes inlet port 36, an outlet port 37 and a plurality of exchanger tubes 26 wherein the exchanger tubes are in fluid communication to the at least one annular flow passage. Polystyrene and high impact polystyrene can be prepared using the reactor.

Abstract: Disclosed is a reactor or sparging vessel suitable for use for reaction mixtures containing vapor and/or gas bubbles. It comprises a mechanical agitation means suitable to redistribute flow radially and at least one perforated plate suitable to provide resistance to axial flow. In desirable embodiments it may include at least one electrically or hydraulically-stimulated rotatable shaft upon which at least one blade impeller is mounted, and at least one perforated plate oriented such that it provides resistance to axial flow. The perforated plate may have channels therethrough whose cross-sectional dimension is smaller than the projected average diameter of the vapor and/or gas bubbles. The reactor or sparging vessel offers improved flow dynamics, including reduced back mixing and narrowed residence time distribution. A method of employing the reactor for a reaction mixture containing vapor and/or gas bubbles is also disclosed. An impeller blade having two curvatures is also disclosed.

Abstract: Residual monomer in a polymer matrix may be reduced by a method including admixing a polymer matrix comprising an amount of residual monomer and a conjugated diene. This method can be carried out under reaction conditions such that the amount of residual monomer is reduced. The monomer comprises at least one electron withdrawing substituent and the conjugated diene comprises at least one electron donating substituent. This method is particularly useful for reducing the amount of residual styrene monomer in polystyrene homopolymer and copolymer compositions.

Abstract: A method of homogeneously polymerizing styrene comprising admixing an ethylenically unsaturated monomer and an initiation system that is soluble in the monomer. This system includes a metal; a peroxide, hydroperoxide or mixture thereof; and a reductant. Under appropriate reaction conditions, the cyclic oxidation and reduction of the metal produces free radicals which initiate homogeneous polymerization of the ethylenically unsaturated monomer. The invention beneficially enables relatively low temperature processing with inexpensive initiation.

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: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: Disclosed are novel non-linear vinyl polymers comprised of a multifunctional peroxide, and a cross-linking agent and/or a chain transfer agent, and methods of making such polymers having: at least 0.03 branches/1000 backbone carbons; linear portions with a molecular weight (Mw) of 350,000 or less; 0.2 to 3.0 branches/molecule; or, a Mz/Mw of from 1.7 to 5.7. Methods of quantifying branching are disclosed using a linear reference having 0.0 to 0.06 branches/1000 backbone carbons along with SEC techniques and measurements of molecular weight, molecular size, and concentration. Also discovered is a vinyl polymer resin comprised of from 0.1 to 50 weight percent of non-linear polymers having at least 0.06 branches/1000 backbone carbons, where branching is measured using a heat polymerized polystyrene having from 0.0 to 0.06 branches/1000 backbone carbons as a linear reference.

Abstract: It has been discovered that improved polystyrene products may be obtained by polymerizing styrene in the presence of at least one multifunctional initiator, at least one chain transfer agent, and at least one cross-linking agent. The presence of the multifunctional initiator tends to cause more branched structures in the polystyrene. A mathematical model that helps optimize the levels of these additives for given molecular weights, melt flow indices (MFIs) and zero shear viscosities (?0) has also been discovered.

Abstract: It has been discovered that improved polystyrene products may be obtained by polymerizing styrene in the presence of at least one multifunctional initiator that is trifunctional or tetrafunctional and at least one lower functionality initiator that is difunctional or monofunctional. These polymers may have increased Mz, increased MFI, and increased MWD. Optionally the resin may include at least one chain transfer agent, at least one cross-linking agent and/or a styrene-conjugated diene-styrene block copolymer. The presence of the multifunctional initiator tends to cause more branched structures in the polystyrene.

Abstract: A process for preparing a polymer may be monitored, controlled, or monitored and controlled using the turbidity of a process stream. The process stream is a dispersed phase fluid including polymer particles. The interaction of the process stream and light passing through the senor probe is measured and used to define a value for the turbidity of the process stream. The value for the turbidity of the process stream is a component of an algorithm used to determine in real time the polymer particle size or the concentration of polymer particles in the process stream and is used to monitor, control, or monitor and control the process for preparing a polymer. Polystyrene and Polyethylene are among the polymers that may be prepared using this process.

Abstract: Disclosed is a process for preparing a polymer. The process includes at least one process stream and the process stream has at least one characteristic of interest. The process further includes passing the process stream past a sensor probe connected to a near-IR spectrophotometer and passing light from a light source through the probe and into the spectrometer wherein the light source, spectrometer and sensor probe are connected by a fiber optic cable. The effect of the interaction of the process stream and the light passing through the senor probe is measured and used to define a value for the characteristic of interest. The value for the characteristic of interest is a component of an algorithm and the algorithm is used, in real time, to monitor, control, or monitor and control the process for preparing a polymer.

Abstract: Disclosed is a process for devolatilizing a polymer comprising passing the polymer through a devolatizer comprising a plate heat exchanger wherein the plates of the plate heat exchanger are heated by a plurality of heating tubes and wherein the heating tube comprises a return tube nested inside of a supply tube. The use of the disclosed invention allows for a comparatively small heat profile across heating plates as compared to prior art plate heat exchangers.

Abstract: It has been discovered that improved polystyrene products may be obtained by polymerizing styrene in the presence of at least one multifunctional initiator, at least one chain transfer agent, and at least one cross-linking agent. The presence of the multifunctional initiator tends to cause more branched structures in the polystyrene. A mathematical model that helps optimize the levels of these additives for given molecular weights, melt flow indices (MFIs) and zero shear viscosities (&eegr;0) has also been discovered.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.