Aging Of Foamed Resin Products Patents (Class 264/DIG15)
  • Patent number: 6034144
    Abstract: Disclosed herein is an molded article of foamed and expanded beads of a propylene resin, which is obtained by heating and molding the foamed beads of the propylene resin, wherein the apparent density of the molded article is 0.11 to 0.45 g/cm.sup.3, a value obtained by dividing its maximum bending strength (kgf/cm.sup.2) determined in accordance with JIS K 7221 by the apparent density (g/cm.sup.3) is at least 160 (kgf/cm.sup.2)/(g/cm.sup.3), and the average number of cells at its section is within a range of 5 to 100 cells/mm.sup.2.
    Type: Grant
    Filed: June 10, 1999
    Date of Patent: March 7, 2000
    Assignee: JSP Corporation
    Inventors: Satoru Shioya, Akinobu Hira, Hidehiro Sasaki, Hisao Tokoro
  • Patent number: 5776389
    Abstract: Disclosed is a process for making an extruded alkenyl aromatic polymer foam with a thickness of about 1 inch (2.54 cm) or more and having an enhanced cell size. From about 0.2 to about 2.0 percent by weight of a glycerol monoester of a C.sub.8-24 fatty acid is incorporated to increase cell size about 5 percent or more relative to a corresponding foam without the glycerol monoester. The blowing agent is about 50 percent or more of a blowing agent selected from the group consisting of carbon dioxide, 1,1,1,2-tetrafluoroethane, and 1,1,1-trifluoroethane. Further disclosed is an extruded alkenyl aromatic polymer foam obtainable from the process.
    Type: Grant
    Filed: June 20, 1996
    Date of Patent: July 7, 1998
    Assignee: The Dow Chemical Company
    Inventor: Bharat I. Chaudhary
  • Patent number: 5585058
    Abstract: Disclosed is a method for providing accelerated release of a blowing agent from a solid, non-perforated plastic foam. The method relates (a) providing the solid, non-perforated plastic foam having the blowing agent and a permeability modifier therein and (b) perforating the foam at its surface to form a multiplicity of channels extending from the surface into the foam. The channels are in gaseous communication with the environment outside the foam and provide accelerated release of blowing agent.
    Type: Grant
    Filed: April 25, 1995
    Date of Patent: December 17, 1996
    Assignee: The Dow Chemical Company
    Inventor: Paul A. Kolosowski
  • Patent number: 5411689
    Abstract: A method is disclosed for accelerating the removal of blowing agent from elongate, flexible polyolefin foam bodies, such as polyethylene foam sheeting, in the absence of substantial tension on the foam body so as to avoid breaks in the foam body. The elongate flexible foam body is introduced into a heating zone and draped over a plurality of substantially parallel bars in an endless path. Tension on the foam body is avoided because the foam loops are free hanging between these parallel bars. An endless drive means transports the parallel bars through the heating zone about the endless path, thereby transporting the foam body through the heating zone for removal of blowing agent. Forced heated air is blown over the exposed surface of the foam body at a pre-determined temperature and for a pre-determined time sufficient to remove a substantial portion of the residual blowing agent and to cause sufficient air to diffuse into the foam body so that there is no substantial reduction in the thickness of the foam.
    Type: Grant
    Filed: March 25, 1993
    Date of Patent: May 2, 1995
    Assignee: Sealed Air Corporation
    Inventors: Shau-Tarng Lee, Andrew Oiestad
  • Patent number: 5385698
    Abstract: A method is disclosed for heating pre-expanded foundry pattern molding beads of polystyrene or the like in a stream of hot air to reduce the vapor-forming expansion agent content for the purpose of producing more dimensionally accurate, molded foam bead casting patterns.
    Type: Grant
    Filed: April 23, 1992
    Date of Patent: January 31, 1995
    Assignee: Saturn Corporation
    Inventors: Gary E. Bishop, Patrick J. Van Ryckeghem
  • Patent number: 5254597
    Abstract: A process for the production of chlorofluorocarbon-free, urethane- or urethane- and urea-containing, soft-elastic, semirigid or rigid moldings having a cellular core and a compacted peripheral zone and an essentially pore-free, smooth surface involves reactinga) an organic and/or modified organic polyisocyanate withb) at least one relatively high-molecular-weight compound containing at least two reactive hydrogen atoms, and, if desired,c) a low-molecular-weight chain extender and/or cross-linking agent,in the presence ofd) a blowing agent,e) a catalyst,f) at least one microporous activated charcoal and/or microporous carbon molecular sieve which preferably has a mean pore diameter with a frequency of occurrence of more than 40% in the range from 0.3 to 3 nm, a pore volume of from 0.20 to 1.4 ml/g and a BET surface area of from 500 to 2500 m.sup.2 /g, and, if desired, further additives andg) assistants,in a closed mold with compaction.
    Type: Grant
    Filed: November 24, 1992
    Date of Patent: October 19, 1993
    Assignee: BASF A.G.
    Inventors: Peter Horn, Ulrich Mueller, Wolfgang Hoelderich, Rudolf Taddey, Dieter Tintelnot, Ludwig Schuster
  • Patent number: 5114640
    Abstract: A method for making low density (0.8-1.1 lb./cu.ft.) expanded polymeric products uses blowing agent in an amount of any from 2 to 4.4 weight percent and aging periods of from 1 to 80 hours after each expansion step. The process uses 2 to 5 expansion steps and a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.
    Type: Grant
    Filed: October 15, 1991
    Date of Patent: May 19, 1992
    Assignee: BASF Corporation
    Inventors: William H. Harclerode, John C. Knutsen, Barry J. Pekich, John V. Wiman, John C. Voss
  • Patent number: 5115066
    Abstract: A polystyrene polymer as well as an expandable polystyrene formulation comprises a polystyrene polymer having a particular molecular weight distribution. The polymer itself exhibits a polydispersity of from about 1 to less tha 2.0, a weight average molecular weight of greater than about 200,000 to about 300,000, and an M.sub.z :M.sub.n of from about 2 to less than about 3.0. Furthermore, the polystyrene polymer is branched to from 0 to less than 5 weight percent.The expandable polystyrene formulation comprises a polystyrene polymer exhibiting a polydispersity of from about 1.0 to less than 2.5, a weight average molecular weight of from greater than about 180,000 to about 300,000, an M.sub.z :M.sub.n of from about 2 to about 4.5. The polystyrene polymer is present in an amount of from about 94.5 weight percent to about 98 weight percent, based on the total weight of the formulation, and the polystyrene polymer is branched to from 0 to less than 5 weight percent.
    Type: Grant
    Filed: October 15, 1991
    Date of Patent: May 19, 1992
    Assignee: BASF Corporation
    Inventors: Eugene K. Zimmermann, Bernhard Wagner, William E. Volz, William H. Harclerode, John V. Wiman, John C. Voss
  • Patent number: 5110834
    Abstract: Chlorofluorocarbon-free urethane-containing, soft-elastic moldings having a cellular core, a compacted peripheral zone and an essentially pore-free smooth surface are produced by reactinga) an organic and/or modified organic polyisocyanate withb) at least one relatively high-molecular-weight compound containing at least two reactive hydrogen atoms and, if desired,c) a low-molecular-weight chain extender and/or crosslinking agent,in the presence ofd) a blowing agent,e) a catalyst,f) a crystalline, microporous molecular sieve having a cavity diameter of less than 1.3 nm and comprising metal oxides or metal phosphates, and, if desired, further additives andg) assistants,in a closed mold with compaction, expediently by RIM.
    Type: Grant
    Filed: October 3, 1991
    Date of Patent: May 5, 1992
    Assignee: BASF Aktiengesellschaft
    Inventors: Peter Horn, Wolfgang Hoelderich, Rudolf Taddey, Dieter Tintelnot
  • Patent number: 5110524
    Abstract: A method for making low density (0.8-1.1 lb/cu. ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.
    Type: Grant
    Filed: October 15, 1991
    Date of Patent: May 5, 1992
    Assignee: BASF Corporation
    Inventors: William H. Harclerode, William E. Volz, John V. Wiman, John C. Voss, Barry J. Pekich, John C. Knutsen
  • Patent number: 5110836
    Abstract: A method for making low density (0.8-1.1 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent and aging periods of from 1 to 80 hours after each expansion step. The process uses 2 to 5 expansion steps and a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commerically viable processes for making expanded polystyrene products. The process can be used with or without a molding step.
    Type: Grant
    Filed: November 26, 1990
    Date of Patent: May 5, 1992
    Assignee: BASF Corporation
    Inventors: William H. Harclerode, John C. Knutsen, Barry J. Pekich, John V. Wiman, John C. Voss
  • Patent number: 5110837
    Abstract: A method for making low density (0.8-1.1 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.
    Type: Grant
    Filed: November 26, 1990
    Date of Patent: May 5, 1992
    Assignee: BASF Corporation
    Inventors: William H. Harclerode, William E. Volz, John V. Wiman, John C. Voss, Barry J. Pekich, John C. Knutsen
  • Patent number: 5086078
    Abstract: A method for making low density (0.8-2 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent, the process emitting blowing agent during processing in an amount of from only about 0.3 to about 2.5 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commerically viable processes for making expanded polystyrene products. The process can be used with or without a molding step.
    Type: Grant
    Filed: November 26, 1990
    Date of Patent: February 4, 1992
    Assignee: BASF Corporation
    Inventors: William H. Harclerode, Eugene K. Zimmermann, Barry J. Pekich, John C. Knutsen, John V. Wiman, John C. Voss
  • Patent number: 5059376
    Abstract: Objects of thermoplastic polymer foam such as, e.g., sheeting of polyolefins such as polyethylene, are treated at elevated temperatures effective to rapidly purge the foam of a substantial portion of the residual blowing agent. Significant economies are achieved by reducing the amounts of residual blowing agents (such as flammable, toxic or environmentally hazardous gases) to levels presenting no fire hazard or other safety hazards in times substantially less than required in conventional aging under ambient conditions. The processes can be carried out in ovens or other heating zones which form continuations of the basic production line, with the extracted blowing agents recycled or disposed of by combustion.
    Type: Grant
    Filed: April 20, 1989
    Date of Patent: October 22, 1991
    Assignee: Astro-Valcour, Incorporated
    Inventors: Thomas M. Pontiff, Joseph P. Rapp
  • Patent number: 5041465
    Abstract: The evaporative casting of molten metals has been shown to produce casting having smooth surfaces with significantly less sign of carbon deposits thereon by using a polystyrene containing a high temperature peroxide, tert-butyl cumyl peroxide.
    Type: Grant
    Filed: September 17, 1990
    Date of Patent: August 20, 1991
    Assignee: Arco Chemical Technology, Inc.
    Inventor: Fred M. Sonnenerg
  • Patent number: 4925606
    Abstract: The process of enabling foam moldings to expand further than otherwise by impregnating the expanded sheet with inorganic gases such as carbon dioxide, nitrogen, air and other pneumatogens prior to reheating to effect expansion.
    Type: Grant
    Filed: October 10, 1989
    Date of Patent: May 15, 1990
    Assignee: Arco Chemical Technology, Inc.
    Inventors: Peter S. Francis, Thomas M. Chapman
  • Patent number: 4889671
    Abstract: Prefoamed particles of a polyolefin resin are produced by dispersing starting particles of the polyolefin resin, which contains a volatile foaming agent, in a dispersant in a pressure vessel, heating the resultant dispersion to a temperature of at least the softening point of the starting particles in said pressure vessel and then opening the vessel at one end thereof so as to release the starting particles and dispersant into an atmosphere of a pressure lower than the internal pressure of the vessel. The release of the starting particles and dispersant is performed while feeding a heating liquid.
    Type: Grant
    Filed: May 11, 1988
    Date of Patent: December 26, 1989
    Assignee: Japan Styrene Paper Corporation
    Inventors: Hiroyuki Akiyama, Susumu Izawa, Hideki Kuwabara, Toru Yamaguchi
  • Patent number: 4868055
    Abstract: The present invention discloses a vinylidene chloride resin type in-mold foam molding having a broad cross-sectional area and a free shape, which is useful as thermal insulating plate materials or as anti-shock molded vessels, and also to foam particles, which are or expandable particles convenient for the preparation thereof. The present invention is also related to a series of advantageous foaming techniques for completion of such a molding.
    Type: Grant
    Filed: July 25, 1988
    Date of Patent: September 19, 1989
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Norihiko Sakata, Nobuo Miura
  • Patent number: 4861531
    Abstract: The present invention provides a process for production of expansion-molded articles in a mold of a linear low density polyethylene resin which comprises compressing pre-expanded linear low density polyethylene resin beads having two melting points when measured by differential scanning calorimetry and, when the melting point at a low temperature side and the melting point at a high temperature side are designated T.sub.ML and T.sub.MH respectively, between said two melting points and the peak fusion area at said T.sub.ML is designated A.sub.L and the peak fusion area at said T.sub.MH is designated A.sub.H satisfying:5%.ltoreq.A.sub.H /A.sub.L .ltoreq.
    Type: Grant
    Filed: February 16, 1988
    Date of Patent: August 29, 1989
    Assignee: Kanegafuchi Kagaku Kogyo Kabushiki Kaisha
    Inventor: Hirofumi Maeda
  • Patent number: 4822542
    Abstract: This invention relates to a method and apparatus for improving not only the quality of the production of molded foamable thermoplastic resin particles converted into fusion-bonded materials but also the output by protecting the resin from atmospheric pressure by pressurizing the particles and heating the particles to soften the same.
    Type: Grant
    Filed: July 23, 1987
    Date of Patent: April 18, 1989
    Assignee: Japan Styrene Paper Corporation
    Inventors: Hedeki Kuwabara, Atusi Kitagawa, Masato Kanbe
  • Patent number: 4818451
    Abstract: A method of molding pre-foamed synthetic resin particles is described, which comprises increasing the pressure in a mold cavity with a pressurized gas, charging the mold cavity with pre-foamed synthetic resin particles as they are compressed with a gas pressurized to a pressure higher than the pressure in the mold cavity and heating the charged pre-foamed synthetic resin particles with steam so that they are fused together or expanded and fused together to form a foamed molded article, wherein a pressure detector is provided in a conduit for conveying the pre-foamed synthetic resin particles into the mold cavity as they are carried by the pressurized gas or at an inlet portion of a charging port leading to the mold cavity, and the supply of pre-foamed synthetic resin particles into the mold cavity is stopped when the pressure detected by the detector exceeds the pressure in the mold cavity by a predetermined amount.
    Type: Grant
    Filed: April 2, 1987
    Date of Patent: April 4, 1989
    Assignee: Mitsubishi Yuka Badische Co., Ltd.
    Inventors: Masakazu Arai, Masahiro Tanaka
  • Patent number: 4816199
    Abstract: A method is disclosed of making dimensionally stable, expanded polystyrene foam patterns comprising: (a) expanding a supply of beads comprised of polystyrene and a thermally responsive expanding agent, the expansion being accomplished in one or more stages by use of a gaseous heating agent (steam) to define a fused pattern body of the expanded beads, and (b) subjecting the fused pattern body to subatmospheric pressure (in the range of 5-20" of Hg) for a period of about 0.5-6 hours but no more than sufficient to accelerate and complete the migration of the trapped expanding agent out of the pattern body. The expanding agent can be selected from the group consisting of various forms of pentane or butane.
    Type: Grant
    Filed: November 4, 1986
    Date of Patent: March 28, 1989
    Assignee: Ford Motor Company
    Inventors: Bruno Matz, Dolores C. Kearney
  • Patent number: 4804507
    Abstract: Closed-cell foam particles are pressurized to produce particles useful in a process using secondary foaming to achieve a lower density foam. Closed-cell foam particles are initially compressed in a first stage compression tank and then transferred to a main gas pressurization tank. The main gas pressurization tank comprises multi-level shelves, each with a set of compartments. Charges of foam particles pass sequentially through the shelves while becoming fully pressurized. The multi-level shelves with means to move charges of foam particles from shelf to shelf are responsible for the closed cell foam particles becoming pressurized in an efficient manner.
    Type: Grant
    Filed: April 25, 1988
    Date of Patent: February 14, 1989
    Assignee: The Dow Chemical Company
    Inventors: Louis C. Rubens, Stephen P. Chum
  • Patent number: 4777000
    Abstract: An expansion-molded article of a polypropylene resin is produced by filling pre-foamed particles of the polypropylene resin, which have a crystalline structure featuring an inherent peak inherent to the polypropylene resin and a high-temperature peak on the temperature side higher than the temperature corresponding to the inherent peak on a DSC curve obtained by differential scanning calorimetry of the pre-foamed particles and a bulk density of 0.04 g/cm.sup.3 or higher and require melting energy of 8-12 J/g at the high-temperature peak, in a mold without applying any pretreatment to the pre-foamed particles to build up an internal pressure therein, and then heating the pre-foamed particles, whereby the pre-foamed particles are caused to expand into the expansion-molded article conforming with the mold. The pre-foamed particles may alternatively have a bulk density lower than 0.04 g/cm.sup.3 and require melting energy of at least 8 J/g.
    Type: Grant
    Filed: November 25, 1986
    Date of Patent: October 11, 1988
    Assignee: Japan Styrene Paper Corporation
    Inventors: Hideki Kuwabara, Masato Kanbe
  • Patent number: 4721588
    Abstract: A closed circuit process for the production of expanded polystyrene foam is described, comprising the steps of: (a) pre-expanding raw polystyrene beads containing a blowing agent in a pre-expansion vessel; (b) storing the beads in one or more closed storage containers to allow the expanded beads to return to substantially atmospheric pressure; (c) molding the expanded beads to a desired configuration in a closed mold with steam; and (d) removing the thus-formed article from the mold and placing such in an aging room, wherein at each stage the blowing agent released from the beads is recovered, separated from any residual steam by means of a condensing system, and introduced into the burner of a steam generator, thereby serving as fuel for the process.
    Type: Grant
    Filed: June 9, 1986
    Date of Patent: January 26, 1988
    Assignee: Epsilon Holdings, N.V.
    Inventors: Edgar Burchard, Arturo Echeverria, Ignacio G. Sancho, Otto F. Plettner
  • Patent number: 4717518
    Abstract: A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing the products from substantially shrinking or changing dimensionally upon cooling which comprises: exposing the curing product to atmospheric pressure while in contact with the confines of the mold at a time when the cell walls of the curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within the cell walls upon exposure to atmospheric pressure, but before the cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of the crushing force necessary to prevent the products from substantially shrinking or changing dimensionally.
    Type: Grant
    Filed: September 20, 1985
    Date of Patent: January 5, 1988
    Assignee: Union Carbide Corporation
    Inventor: Keith D. Cavender
  • Patent number: 4704239
    Abstract: A process is disclosed for the production of expanded particles of polymeric material wherein unexpanded particles of the material are contacted with a nitrogen-containing inorganic gas under a first pressure condition to impregnate the particles with the gas. The gas impregnated particles are heated to a temperature higher than the softening point of the material, and dispersed into a liquid medium. The resulting dispersion is subjected to a lower pressure to expand the particles. The expanded particles may be used as prefoamed particles for the molding of foamed articles.
    Type: Grant
    Filed: April 24, 1985
    Date of Patent: November 3, 1987
    Assignee: Japan Styrene Paper Corp.
    Inventors: Shohei Yoshimura, Toru Yamaguchi, Masato Kanbe, Hideki Kuwabara
  • Patent number: 4698191
    Abstract: A method of producing a polypropylene resin molded product from foamed polypropylene particles is disclosed, which comprises introducing a pressurizing gas into foamed polypropylene particles having closed cells so that the particles have an internal gas pressure of from 0.3 to 2.5 Kg/cm.sup.2 G, charging the particles in a mold cavity while compressing the particles with a pressurizing inorganic gas until the initial apparent volume of the particles is reduced to 50 to 99%, removing the gas from the mold cavity while keeping the foamed particles in a compressed state, and introducing steam in the cavity to cause adhesion of the compressed foamed particles. The method produces a molded product having satisfactory appearance and excellent adhesion among particles in a shortened molding cycle.
    Type: Grant
    Filed: January 29, 1986
    Date of Patent: October 6, 1987
    Assignee: Mitsubishi Yuka Badische Co., Ltd.
    Inventors: Hiroshi Endo, Masakazu Arai, Shigeo Nishikawa, Masanori Saito, Masahiro Tanaka, Kunikazu Nagasaki, Shigeki Mathuno
  • Patent number: 4695416
    Abstract: A method of making an expanded plastics foam block section and uniting it with a prior made, or partly made, section comprising the steps of charging a mould space of which one end is defined by a surface of the prior section with expandable plastics beads, initiating the expansion and fusion of the beads to create a cohesive but largely unexpanded mass of beads, obtruding the prior section into the mould space to compress a zone of the cohesive mass adjacent to the said one end, increasing the temperature and pressure in the mould space to complete the expansion and fusion process and to compress the end zone of the prior section to bring its end substantially to its unobtruded position, lowering said pressure and temperature, and ejecting the newly made block section from the mould space.Apparatus for performing the method is also disclosed.
    Type: Grant
    Filed: October 1, 1985
    Date of Patent: September 22, 1987
    Inventors: Peter Treffner, Charles Treffner
  • Patent number: 4692371
    Abstract: Elastomeric materials such as elastomeric nonwoven webs of elastomeric meltblown fibers, elastomeric films or elastomeric molded materials are attained by forming, e.g., extruding or meltblowing, a polystyrenic poly(ethylenebutylene) thermoplastic block copolymer at elevated temperatures of at least about 290 degrees Centigrade, e.g., from about 290 degrees Centigrade to 345 degrees Centigrade. The resulting products retain good elastic elongation and strength properties. In the case of elastomeric nonwoven webs of elastomeric fibers, other fibers such as cellulosic fibers, e.g., cotton fibers, may be combined with the elastomeric fibers by known methods to provide an elastomeric nonwoven web comprising a blend of the elastomeric fibers with other fibers. Such web or film materials are useful generally in applications utilizing webs or sheets of elastic fabrics or the like, for example, in making composite materials in which an elastic layer of material is bonded to a gatherable web.
    Type: Grant
    Filed: July 30, 1985
    Date of Patent: September 8, 1987
    Assignee: Kimberly-Clark Corporation
    Inventors: Michael T. Morman, Tony J. Wisneski
  • Patent number: 4631159
    Abstract: A method for aging an expansion-molded body of polyolefin prepared by heating pre-expanded polyolefin particles within a mold involves cooling the molded body within the mold so that the molded body is not substantially smaller than the volume of the mold cavity and is temporarily expandable after being removed from the mold to not more than 110% relative to the volume in the mold cavity, removing the molded body from the mold, placing the molded body in an atmosphere substantially under atmospheric pressure and having a temperature of 25.degree. to 55.degree. C. lower than the melting point of the polyolefin while the volume of the molded body is 70 to 110% relative to the volume of the mold cavity and holding the molded body in this atmosphere until the temperature of the molded body is at least equal to the temperature of the atmosphere.
    Type: Grant
    Filed: November 29, 1984
    Date of Patent: December 23, 1986
    Assignee: Kanegafuchi Kagaku Kogyo Kabushiki Kaisha
    Inventors: Hirofumi Maeda, Kazuyoshi Watanabe, Naruhiko Akamatsu, Kenichi Senda, Shunichi Nishioka
  • Patent number: 4618468
    Abstract: A process for controlling bead size in the production of expandable styrene polymers by suspension polymerization is carried out by adding protective colloids to the aqueous phase before polymerization begins, such protective colloids being used which are homogeneously soluble in water over the entire temperature range from 25.degree. to 125.degree. C. and in which the concentration range being employed shall not lower the boundary surface tension water/styrene below 18 N/mm.sup.2. Lastly, the protective colloids are selected according to their molecular weight and the weight ratio of aqueous to organic phase lies in the range of 0.9:1 to 1:1.25, preferably in the range of 1:1. A grain spectrum is maintained predominantly greater than 0.41 to less than 2.5 mm by varying the molecular weights of the protective colloids.
    Type: Grant
    Filed: August 27, 1984
    Date of Patent: October 21, 1986
    Assignee: Chemische Werke Huls Aktiengesellschaft
    Inventors: Josef K. Rigler, Horst Leithauser
  • Patent number: 4613626
    Abstract: This invention discloses a vinylidene chloride resin type in-mold foam molding having a broad cross-sectional area and a free shape, useful as thermal insulating plate materials or anti-shock molded vessels, and foam particles or expandable particles convenient for preparation thereof, and also a series of advantageous foaming techniques for completion of such a molding. The above foam molding can be prepared by bringing fine particles of a non-crystalline vinylidene chloride type resin obtained generally by suspension polymerization into contact with a volatile organic blowing agent thereby impregnating the resins with the blowing agent to form expandable resin particles, which are in turn subjected to expansion as such, or after forming into pre-expanded foam particles including expandable gas therein, by filling in a mold cavity which can be closed but not sealed, under heating to form a molding through fusion mutually between the expanded particles.
    Type: Grant
    Filed: June 20, 1985
    Date of Patent: September 23, 1986
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Norihiko Sakata, Nobuo Miura
  • Patent number: 4609512
    Abstract: A process for controlling bead size in the manufacture of expandable styrene polymers by suspension polymerization, wherein, referred to the aqueous phase, a concentration of ions of calcium, aluminum, metals of the 1st, 2nd, or 6th through 8th side groups of the period table of elements of 3.times.10.sup.31 5 to 3.times.10.sup.-2 % by mass is established, these metal ions being present as cations in the higher oxidation stage of water-soluble, inorganic salts.
    Type: Grant
    Filed: August 27, 1984
    Date of Patent: September 2, 1986
    Assignee: Chemische Werke Huls AG
    Inventors: Josef K. Rigler, Dirk Reese, Horst Leithauser
  • Patent number: 4585605
    Abstract: The foam of the present invention, which has a multi-cellular structure including many wrinkles having one end in the boundary portion where at least three cells are adjacent to one another and extending toward the central portion of the cell wall, is a rigid thermoplastic resin foam having an ultra-low density, a high sound-insulating property, a high heat-insulating property and a high flexibility, and it is suitable for adaption for building construction. The process of the present invention is to provide the aforesaid foam of the present invention by subjecting the foam of a rigid thermoplastic resin to expansion, contraction and aging.
    Type: Grant
    Filed: September 25, 1985
    Date of Patent: April 29, 1986
    Assignee: Dow Chemical Company
    Inventors: Takao Kadota, Masayuki Hashimoto, Itsuo Hamada
  • Patent number: 4579700
    Abstract: A process for making molded flexible polyurethane cellular products which do not substantially shrink or change dimensionally upon cooling is provided by exposing the curing product to atmospheric pressure while in the confines of the mold. Exposure can be accomplished by unlatching the mold or opening a port at an appropriate time after the reaction mixture was introduced into the mold so as to burst the cell walls of the polyurethane product.
    Type: Grant
    Filed: November 7, 1983
    Date of Patent: April 1, 1986
    Assignee: Union Carbide Corporation
    Inventor: Keith D. Cavender
  • Patent number: 4579701
    Abstract: Low density expanded polystyrene is obtained by extended exposure of particles to atmospheric steam and aging the particles in air. Particles have wrinkled cell walls.
    Type: Grant
    Filed: September 24, 1984
    Date of Patent: April 1, 1986
    Assignee: The Dow Chemical Company
    Inventors: Chung P. Park, James T. Grimes
  • Patent number: 4552904
    Abstract: The foam of the present invention, which has a multi-cellular structure including many wrinkles having one end in the boundary portion where at least three cells are adjacent to one another and extending toward the central portion of the cell wall, is a rigid thermoplastic resin foam having an ultra-low density, a high sound-insulating property, a high heat-insulating property and a high flexibility, and it is suitable for adaption for building construction. The process of the present invention is to provide the aforesaid foam of the present invention by subjecting the foam of a rigid thermoplastic resin to expansion, contraction and aging.
    Type: Grant
    Filed: March 19, 1985
    Date of Patent: November 12, 1985
    Assignee: The Dow Chemical Company
    Inventors: Takao Kadota, Masayuki Hashimoto, Itsuo Hamada
  • Patent number: 4550003
    Abstract: This invention discloses a vinylidene chloride resin type in-mold foam molding having a broad cross-sectional area and a free shape, useful as thermal insulating plate materials or anti-shock molded vessels, and foam particles or expandable particles convenient for preparation thereof, and also a series of advantageous foaming techniques for completion of such a molding. The above foam molding can be prepared by bringing fine particles of a non-crystalline vinylidene chloride type resin obtained generally by suspension polymerization into contact with a volatile organic blowing agent thereby impregnating the resins with the blowing agent to form expandable resin particles, which are in turn subjected to expansion as such, or after forming into pre-expanded foam particles including expandable gas therein, by filling in a mold cavity which can be closed but not sealed, under heating to form a molding through fusion mutually between the expanded particles.
    Type: Grant
    Filed: December 5, 1984
    Date of Patent: October 29, 1985
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Norihiko Sakata, Nobuo Miura
  • Patent number: 4510106
    Abstract: A process of pre-foaming blowing agent-containing plastic materials, in which the plastic material particles which have been pre-foamed by the addition of heat are transferred without an intermediate resting stage from a sealed pre-foaming chamber into a drying and stabilizing chamber, with a vacuum being maintained during the drying and stabilizing operation.An apparatus for the performance of the process includes a pre-foaming chamber, beneath which there is provided a chamber in which the pre-foamed plastic material is dried and stabilized. The charging opening of the drying and stabilizing chamber is directly under the discharge opening of the pre-foaming chamber and is hermetically sealable by means of a slide valve.
    Type: Grant
    Filed: November 15, 1983
    Date of Patent: April 9, 1985
    Inventor: Kurt Hirsch
  • Patent number: 4510268
    Abstract: Flexibilized, rigid plastic foam sheets with improved properties particularly desirable for low temperature and cryogenic insulation can be prepared by mechanical compression of freshly expanded closed-cell thermoplastic foams. Thus an extruded foam sheet having a density of 20-100 kg/m.sup.3, a y-axial size size of 0.05 to 1.00 mm and a Y-axial compressive strength of at least 1.8 kg/cm.sup.2 is flexibilized with 0.25 to 240 hours of expansion to give a flexibilized foam with improved elongation, workability, crack resistance and water vapor barrier properties.
    Type: Grant
    Filed: April 9, 1982
    Date of Patent: April 9, 1985
    Assignee: The Dow Chemical Company
    Inventors: Hiroshi Tonokawa, Masao Nakamura
  • Patent number: 4504534
    Abstract: A core material for automobile bumpers which is composed of a molded article of foamed particles of a polypropylene-type resin. The molded article has a density of 0.015 to 0.045 g/cm.sup.3 and a compression stress at 50% compression of at least 1 kg/cm.sup.2. The core material simultaneously has excellent energy absorbing property and dimensional recovery and a low density.
    Type: Grant
    Filed: June 13, 1984
    Date of Patent: March 12, 1985
    Assignees: Japan Styrene Paper Corporation, Nissan Motor Company, Limited
    Inventors: Akira Adachi, Takashi Kubota, Yukio Okada, Kenichi Miyazaki, Taro Hagiwara
  • Patent number: 4485193
    Abstract: Resilient foam particles and moldings are obtained employing a lightly crosslinked polymer such as a styrene polymer with volatile fluid foaming agent that has low permeability through the polymer. Multiple expansion will permit low density particles for molding.
    Type: Grant
    Filed: April 16, 1984
    Date of Patent: November 27, 1984
    Assignee: The Dow Chemical Company
    Inventors: Louis C. Rubens, Willard E. Alexander
  • Patent number: 4485059
    Abstract: A method of thermoforming comprising providing a continuous sheet of thermoplastic polymeric foam, transporting said sheet through an atmosphere of at least predominantly steam at a temperature of at least 215.degree. F. maintaining said sheet in said atmosphere for a time sufficient to cause a decrease in the density thereof; thereafter while under the influence of said temperature, deforming at least a portion of said sheet to a predetermined shape and while so deformed, cooling the same to cause retention of said shape and a system for carrying out said method.
    Type: Grant
    Filed: April 28, 1983
    Date of Patent: November 27, 1984
    Assignee: Mobil Oil Corporation
    Inventors: Charles M. Krutchen, Wen-Pao Wu
  • Patent number: 4483809
    Abstract: The present invention relates to a process for preparing a polyolefin foam by heat-molding pre-expanded beads of an expandable polyolefin resin containing a foaming agent in a mold, said process being improved in preparing beads having a peak expansion rate at pre-expansion equal to 1.3 to 3 times the expansion rate of beads to be packed into the mold, adjusting the beads to a pre-expansion rate depending on an expansion rate of the desired foam, and packing and molding the pre-expanded beads in a mold without any further addition of expandability thereto. The polyolefin foam prepared by the process of the present invention is evenly fused to the interior and is less liable to shrink or deform.
    Type: Grant
    Filed: January 14, 1983
    Date of Patent: November 20, 1984
    Assignee: Kanegafuchi Kagaku Kogyo Kabushiki Kaisha
    Inventors: Masao Ando, Kenkichi Tanaka, Kiroku Sato
  • Patent number: 4464484
    Abstract: Prefoamed polymer particles having excellent moldability are produced by a process comprising a step (impregnating step) of impregnating carbon dioxide or carbon dioxide and a volatile blowing agent in polymer particles, a step (dispersing step) of dispersing the polymer particles into a dispersion medium in a sealed vessel, a step (heating step) of heating the polymer particles to a temperature higher than the softening point of said polymer particles, and a step (releasing step) of opening one end of said vessel and simultaneously releasing the polymer particles and dispersion medium from inside the vessel to an atmosphere held at a pressure lower than that of the vessel. In this process, the impregnating step, dispersing step and heating step need not be altogether effected separately. These steps can be performed simultaneously in one and the same vessel.
    Type: Grant
    Filed: December 13, 1983
    Date of Patent: August 7, 1984
    Assignee: Japan Styrene Paper Corporation
    Inventors: Shohei Yoshimura, Hideki Kuwabara
  • Patent number: 4456573
    Abstract: A process for manufacturing expanded polystyrene panels includes the following stages:(a) Preparation of pre-expanded panels of polystyrene by extrusion and simultaneous injection of propellent agent into an extruder fitted with an extrusion die of suitable type and in particular fitted with means allowing for good mixing of the molten polymer with the propellent agent and means allowing for uniform cooling to the best value of the temperature of the expandable plastic mass before exit from the die.(b) Conditioning of said panels at room temperature or at whatever temperature higher than room temperature, provided it is such to prevent the panels from undergoing either dimensional variation or deformation due to internal stress or true expansion.
    Type: Grant
    Filed: July 2, 1982
    Date of Patent: June 26, 1984
    Assignee: Lavorazione Materie Plastiche L.M.P. S.p.A.
    Inventors: Franco Ragazzini, Roberto Colombo
  • Patent number: 4448737
    Abstract: A system and a method for the production of thermoformable plastic foam material from a mix of plastic foam selvage and a foamable virgin plastic resin. Accordingly, the present invention provides for a selvage formed during the production of thermoformed foam material articles from a plastic foam sheet stock is recycled and admixed with the virgin foamable plastic resin, in that the material components are admixed in a feed hopper and then conducted from the feed hopper into a twin-screw compressor which will impart a positive forward feed to the compressible plastic materials conveyed therethrough.
    Type: Grant
    Filed: December 30, 1982
    Date of Patent: May 15, 1984
    Assignee: Mobil Oil Corporation
    Inventor: David E. Johnson
  • Patent number: 4443393
    Abstract: A method for pressurizing pre-foamed particles of a polyolefin resin by maintaining the pre-foamed particles in an atmosphere of a pressurized gas to impart a predetermined internal pressure thereto, which comprises first maintaining the particles under a pressure which does not cause shrinkage to the particles, and then increasing the applied pressure gradually under conditions which do not cause shrinkage to the particles.
    Type: Grant
    Filed: December 7, 1982
    Date of Patent: April 17, 1984
    Assignee: Japan Styrene Paper Corporation
    Inventors: Hiroyuki Akiyama, Hideki Kuwabara, Toru Yamaguchi, Masahiko Kishida
  • Patent number: RE34123
    Abstract: The process of enabling foam moldings to expand further than otherwise by impregnating the expanded sheet with inorganic gases such as carbon dioxide, nitrogen, air and other pneumatogens prior to reheating to effect expansion.
    Type: Grant
    Filed: August 21, 1991
    Date of Patent: November 10, 1992
    Assignee: Arco Chemical Technology, L.P.
    Inventors: Peter S. Francis, Thomas M. Chapman