Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and one or more acrylic monomers. The monomers can be polymerized in the presence of polymeric seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: A porous copolymer particle having a particle size of from 0.1 to 2,000 &mgr;m and a permanent pore size of from 2 to 800 nm comprising (i) a monomer containing from 5 to 60 wt % of a monomer (A) selected from N-vinylcarboxylic acid amides represented by formula (I): wherein R1 represents a hydrogen atom or a methyl group, and R2 represents a hydrogen atom, a C1-C8 alkyl group, a phenyl group or a phenyl group substituted with a methyl group or an ethyl group and (ii) from 40 to 95 wt % of a copolymerizable monomer (B) which contains a crosslinking monomer.

Abstract: The invention relates to an optionally foamed sealing composition for preformed seals which can swell when treated with water. The invention also relates to a method for the production thereof out of natural rubber and/or elastomers with a matrix comprised of natural rubber/elastomer components and particle-shaped water absorbing material stored therein. The water absorbing material is a combination of (A) polysaccharide(s) selected from cellulose, starch, starch derivatives removed from grafted starch, amylose, amylopectin, dextran, pectin, inulin, chitin, xanthan, alginic acid, alginates, carrageenan, pustulan, callose, laminarin, guluronic acid, pullulan, lichenin or mixtures of the same with (B) a highly water absorbent synthetic polymer selected from polymers based on (meth)acrylate, poly(meth)acrylic acid and the salts thereof, polyacrylamide, polyalcohols or copolymers of said synthetic polymers.

Abstract: Polypropylene resin pre-expanded particles having a weight of 0.3 to 1.8 mg per particle and a mean cell diameter of at most 250 &mgr;m and exhibiting two fusion peaks on a DSC curve thereof one of which appearing on a higher temperature side has a specific heat of fusion QH, which can be molded in a mold in a shortened molding time to give cellular molded articles having a low density of 25 g/liter or less after being provided with an inorganic gas pressure of at least 1.5 atms when the heat of fusion QH is 2.8 to 6.0 cal/g, or after being provided with an inorganic gas pressure of 1.18 to 1.5 atms when the heat of fusion QH is from 0.3 to less than 2.8 cal/g.

Abstract: Polymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, in the presence of polymeric, emulsion based seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming polystyrene which can then be expanded to form expanded polystyrene. The methods utilize suspending agents, and surfactant can be used in an amount insufficient to form an emulsion.

Abstract: A method of manufacturing a composite article includes applying at least one resin impregnated fiber sheet to an inner surface of a forming mold, applying a predetermined mass of a syntactic foam mixture on at least a portion of the resin impregnated fiber sheets, closing the forming mold and heating the mold, the resin impregnated fiber sheets and the syntactic foam mixture to a predetermined temperature for a time sufficient to fully cure the resin impregnated fiber sheet and the syntactic foam to form the composite article. The syntactic foam mixture is formulated so that during the cure cycle, the syntactic foam gels, expands, and starts to cure before the resin impregnated fiber sheets of the outer shell. The expansion of the inner core of syntactic foam forces the fiber sheets of the shell against the inner surface of the mold to accurately reproduce the mold contours.

Abstract: A procedure for preparing compact and spherical self-activated polymer particles of vinyl monomers having a narrow or monodisperse size distribution in accordance with a special precipitation polymerization process in a polar organic medium, possibly in an organic polar medium mixed with water. The medium is a good solvent for the monomer and a poor solvent for the polymer. All ingredients are initially dissolved in the medium and when polymerization has been initiated, formed polymer precipitates from solution and by the aid of the dispersion stabiliser the polymer particles are kept apart as free spherical beads. The polymerization takes place with a temperature profile which produces a scattered chain length distribution, increases the conversion speed and reduces the particle size distribution. The method for producing the particles also achieves an increased degree of freedom for the production of particles with a certain particle size in a given conversion time.

Abstract: A process prepares styrene polymers comprising water as sole blowing agent by mixing a polystyrene melt with water and with an emulsifying agent in an extruder, extruding the melt into a waterbath and pelletizing the cooled extrudate.

Abstract: Particulate expandable styrene polymers contain homogeneously distributed graphite particles and can be processed to give self-extinguishing foams having a density of ≦35 g/l.

Abstract: Polymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, in the presence of polymeric, emulsion based seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming polystyrene which can then be expanded to form expanded polystyrene. The methods utilize suspending agents, and surfactant can be used in an amount insufficient to form an emulsion.

Abstract: A composite material with high resistance to impact energy, comprising an expanded polymer selected among polystyrene, polypropylene, copolymer of polyphenylene oxide and polystyrene and mixtures thereof, dispersed in a resin chosen among melaminic resin, phenolic resin and polyurethane resin and mixtures thereof.

Abstract: Propylene resin beads for molding expansion molded articles having improved high temperature resistance include as base resin metallocene-catalyzed copolymers of propylene with at least one or more of ethylene and ∝-olefins of 4 to 20 carbon atoms. The metallocene-catalyzed propylene copolymers are isotactic random copolymers characterized by a melting point higher than 140° C. to 160° C. and a melt flow rate (MFR) of not higher than 12 g/10 minutes, especially, 0.5 to 12 g/10 minutes. Expansion molded articles produced by expansion molding the expanded beads have a high temperature degree of deflection which is lower than that of metallocene-catalyzed propylene homopolymers and lower than that of Ziegler-Natta-catalyzed random propylene copolymers having the same comonomers and melting point.

Abstract: The invention relates to a process for preparing styrene polymers comprising water as sole blowing agent, by polymerizing styrene in aqueous suspension. The polymerization is carried out in the presence of from 5 to 30% by weight of recycled EPS material dissolved in styrene and comprising customary coating agents deriving from production of the EPS.

Abstract: The evaporative casting of molten metals has been shown to produce castings having smooth surfaces with significantly less signs of carbon deposits thereon by using an expandable vinyl aromatic polymer containing a bromine-attached aliphatic or aromatic flame retardant.

Abstract: The invention relates to a process for the preparation of expanded polystyrene particles in which polystyrene beads containing water as the sole expanding agent are expanded. The process involves the following stages: A) the polystyrene beads are pre-expanded at temperatures above 100° C., B) the pre-expanded particles are dried in dry air at temperatures between 20° and 95° C. over a period of from 1 to 10 hours, C) the dried expanded particles are further expanded with steam at temperatures ranging from 100° to 140° C., and D) the stages b and c are repeated as often as is necessary to achieve the desired bulk density.

Abstract: An adhesive coated article comprises a layer of microsphere adhesive onto a portion of at least one major surface of a substrate. The microspheres in the adhesive are obtained as the reaction product of (a) at least one alkyl (meth)acrylate ester wherein the alkyl group contains four to about 14 carbon atoms, preferably four to about 10 carbon atoms and (b) a comonomer(s). The comonomer may be a nonpolar, ionic, polar comonomer or mixtures of such monomers. This microsphere adhesive either contains a (meth)acrylamide comonomer or a polyacrylamide material is post-added to the microsphere adhesive. The adhesive exhibits a lower than expected adhesion to coated papers without sacrificing the adhesion to standard uncoated (bond) papers and preferably, the 90° peel adhesion, as measured on Kromkote® paper (used as an industry standard) is in the range of 20 to 250 grams/inch.

Abstract: A method for manufacturing polyolefin foam beads by a continuous process is disclosed by which the polyolefin foam beads can be produced with increased efficiency and productivity.

Abstract: Process for preparing a flexible polyurethane foam by reacting a polyisocyanate and two different polyols under foam forming conditions so as to prepare a rigid foam and by crushing the rigid foam so obtained in a direction perpendicular to the direction of rise of the foam. Flexible foams are obtained which do not show a major glass transition temperature between −100° C. and +25° C. and which have an anisotropy of 1.80 to 4.00.

Abstract: A biodegradable, water dispersible shaped core product useful in winding or rolling and storage of paper goods is provided by extruding starch which has a particle size of 800 to 1200 microns into an expanded, closed cell starch product.

Abstract: The invention relates to expandable olefin bead polymers which comprise a blowing agent with a boiling point of from −5 to 150° C., selected from the group consisting of alkanes, alkanols, ketones, ethers and esters. The particles are unfoamed and have a bulk density above 500 g/l, and can be foamed to a bulk density below 200 g/l after storage for one hour at room temperature in free contact with the atmosphere. They are prepared by impregnating polyolefin pellets in suspension in a pressure vessel with the blowing agent, cooling the batch below 100° C., reducing the pressure and isolating the particles.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and one or more acrylic monomers. The monomers can be polymerized in the presence of polymeric seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: The invention relates to a support provided with super-absorbent material to be manufactured by causing suitable monomers to polymerize in the presence of a catalyst in order to obtain a polymer solution, adding a cross-linking agent to the polymer solution to obtain a pasty composition, subsequently applying the composition on or in a support and allowing the applied composition to dry and cross-link in order to obtain the support with the super-absorbent material, wherein microspheres are added to the paste.

Abstract: The present invention relates to a homogeneous composition of an expandable styrene polymer in the form of beads comprising (a) 100 parts b.w. of a styrene polymer having a weight-average molecular mass of 150,000 to 300,000 and a residual monomer content of less than 2,000 ppm, (b) from 2 to 9 parts by weight of at least one blowing agent comprising n-pentane, (c) from 0.1 to less than 1.0 part by weight of a petroleum wax comprising a mixture of C18 to C80 alkanes, and (d) from 0 to 1.0 part by weight of a nucleating agent chosen from synthetic Fisher-Tropsch or polyolefin waxes. The composition allows the step of pre-expanding the beads to be improved by increasing the rate of expansion of the beads and by improving the productivity of the pre-expansion step, without substantially affecting the final molding step.

Abstract: Process for the preparation of polyvinylarene polymer particles by suspension polymerization, wherein (a) vinylarene monomers are suspended in an aqueous medium to yield a suspension; (b) the temperature of the suspension is adjusted to a temperature above 50° C., at which temperature an initiator is added; (c) subsequently, the reaction temperature is increased by 5 to 30° C. per hour until a temperature of at least 120° C. has been reached; and (d) the temperature is retained at a temperature of at least 120° C. until the polymerization is complete.

Abstract: A foam composition and method of making the same. The foam of the present invention comprises a mixture of glutarate ester plasticizer, adipate ester plasticizer, alcohol carboxylic acid ester, cell stabilizer, barium/zinc activator stabilizer, potassium/zinc activator stabilizer, azodicarbonamide blowing agent, low-fogging vinyl dispersion resin, vinyl blending resin, black acrylic pigment dispersion, and oxazoline viscosity reducer. The foam is made by the process of mixing the ingredients until a homogenous liquid mixture is present, de-airing the homogeneous liquid mixture, casting the liquid mixture on a non-fogging release-coated surface, expanding the cast liquid mixture by exposing it to an elevated temperature for a prescribed duration of time, and then either cooling the expanded mixture and winding it into rolls, or coating the stabilized composition with pressure sensitive adhesive, cooling it, and then winding it into rolls.

Abstract: A closed-cell polymeric foam is provided which is formed using oil-containing furnace black as an insulation enhancer. Other foam properties (for example, cell sizes, densities, limiting oxygen index performance) are similar to those obtained with the use of thermal blacks.

Abstract: Particles of a copolymer of a vinyl arene and a copolymerizable compound containing a polar moiety and a vinyl moiety containing water may be prepared by forming a mixture of monomers and small amounts of water and polymerizing under agitation to 20 to 70% conversion and then suspending the mass in water and finishing the polymerization. The resulting polymer beads contain finely dispersed water which is useful as an environmentally acceptable blowing agent.

Abstract: Urethane molded products for polishing pad comprise two types of cells having different sizes in a urethane molded products formed by mixing and curing an isocyanate-terminated urethane prepolymer and an active hydrogen-containing compound. The molded products may be made by procedure comprising mixing expanded microballoons having a size of 10 to 50 &mgr;m and expanded microballoons having a size of 80 to 100 &mgr;m with the prepolymer and active hydrogen-containing compound and curing the mixture.

Abstract: The invention provides a process for the preparation of a particulate polymer having a mode particle size of at least 200 &mgr;m, the improvement comprising the use of substantially monodisperse polymeric particles as polymerization seeds in a suspension polymerization preparation of said particulate polymer.

Abstract: A shaped article composed of an aromatic polyimide has a hollow, essentially spherical structure and a particle size of about 100 to about 1500 &mgr;m, a density of about 1 to about 6 pounds/ft3 and a volume change of 1 to about 20% by a pressure treatment of 30 psi for 10 minutes at room temperature. A syntactic foam, made of a multiplicity of the shaped articles which are bonded together by a matrix resin to form an integral composite structure, has a density of about 3 to about 30 pounds/ft3 and a compression strength of about 100 to about 1400 pounds/in2.

Abstract: The present invention relates to a heat-expandable microcapsule produced from acrylonitrile and N-substituted maleimide as the main polymerizable monomers, or further a monomer giving a hompolymer having a Tg of 50 to 200° C. and polymerizable unsaturated carboxylic acid (including anhydrides), resin foam using this, and a process for producing a foamed resin composite. The present invention can provide a heat-expandable microcapsule that is less apt to color even upon thermal expansion at 200° C. or higher, and a resin foam and a foamed resin composite capable of forming a processed surface, e.g., a matte surface giving a bulky feeling, by using this microcapsule.

Abstract: A process for the preparation of high surface area, low-swelling macroporous polymeric adsorbents is disclosed. The use of organic sulfonic acids to provide postcrosslinking of macroporous copolymers eliminates the need for traditional organic swelling solvents and Lewis-acid catalysts used to provide conventional macronetted polymers. In particular, methanesulfonic acid provides macroporous polymeric adsorbents having high surface area and porosity, low levels of residual vinyl groups, and free of residual contaminants from conventional Lewis-acid/Friedel-Crafts reactions.

Abstract: Foamable modified polystyrene resin particles (E) comprising a particle of a modified polystyrene resin (C) containing a blowing agent (D), wherein the modified polystyrene resin (C) comprises conjugated diene polymer rubber particles (B) dispersed uniformly throughout a polystyrene resin (A) and when the foamable modified polystyrene resin particle (E) is expanded, there is substantially no deformation of the rubber particles (B) before and after the expansion. A foamed article of a modified polystyrene resin which has a cell membrane of the modified polystyrene resin comprising a polystyrene resin and conjugated diene polymer rubber particles dispersed uniformly throughout the polystyrene resin and has a fusion rate of not less than 50%, wherein the rubber particles maintain substantially spherical form in the cell membrane.

Abstract: The present invention relates to a porous crosslinked hydrophilic polymeric material having cavities joined by interconnecting pores wherein at least some of the cavities at the interior of the material communicate with the surface of the material. The present invention also relates to a process for producing the polymeric material. This process involves combining a hydrophilic monomer phase with an oil discontinuous phase to form an emulsion, and polymerizing the emulsion. The emulsion can be a high internal phase emulsion (i.e., a “HIPE”). The polymeric material can be produced in a variety of forms. In one embodiment the emulsion is suspended in an oil suspension medium, and emulsion droplets are polymerized to produce polymeric microbeads.

Abstract: A method for separating poly(vinyl acetate) particles having various particle sizes, which have been prepared by suspension polymerization of vinyl acetate monomers, into respective microspheric poly(vinyl acetate) particles with uniform particle size distribution by the use of inorganic salt as a dispersing and antistatic agent, a method for preparing the microspheric embolic particles of a dual structure consisting of poly(vinyl acetate) core/poly(vinyl alcohol) shell by suspending the separated poly(vinyl acetate) particles into an aqueous alkali solution and subjecting the suspended particles to a heterogeneous surface saponification and the microspheric embolic particles prepared.

Abstract: It is desirable to reduce the amount of volatile organic blowing agent in expandable polystyrene. This may be accomplished by partially polymerizing a mass of styrene and incorporating therein water together with an emulsifier. The partially polymerized mass is then polymerized to a high conversion using conventional suspension techniques. The polymer beads containing water which acts as a blowing agent are recovered.

Abstract: A process for the preparation of expandable polymer particles containing a polymer of a vinylarene monomer and a foaming agent, which process comprises:1) polymerizing, by suspension polymerization, 100 parts by weight of a vinylarene monomer, in the presence of 1 to 20 parts by weight of a radical initiator having a half life of 1 hour in benzene at 70 to 110.degree. C., until at least 60% of the vinylarene monomer is polymerized;400 to 4,900 parts by weight additional vinylarene monomer as well as 0.05 to 1% wt, based on the amount of vinylarene monomer added in step 2, of a radical initiator having a half life of 1 hour in benzene at 70 to 110.degree. C. and polymerizing to completion, in which process the blowing agent can be added before, during or after the polymerization process.

Abstract: Provided are a foaming propylene-ethylene random copolymer which is characterized in that (1) its ethylene unit content [x (wt. %)] falls between 0.2 and 10% by weight, (2) its MI falls between 1 and 16 g/10 min, (3) its boiling diethyl ether extraction [E (wt. %)] and x satisfy the relation of a formula (I):E.ltoreq.0.25x+1.1 (I),(4) its melting point [Tm (.degree. C.)] and x satisfy the relation of a formula (II):Tm.ltoreq.165-5x (II),(5) its isotactic triad fraction in the PPP chain moiety as measured through .sup.13 C.ltoreq.NMR is not smaller than 98 mol %, and preferably, (6) the relation between the time of relaxation .tau. (sec) of the copolymer and MI of the copolymer satisfies a formula (III):.tau..ltoreq.0.80-0.42.times.log MI (III),and also its foaming beads and cellular articles. The copolymer and its foaming beads have improved primary and secondary foamability, and the cellular articles of the copolymer have excellent mechanical properties including rigidity.

Abstract: A process for the preparation of high surface area, low-swelling macroporous polymeric adsorbents is disclosed. The use of organic sulfonic acids to provide postcrosslinking of macroporous copolymers eliminates the need for traditional organic swelling solvents and Lewis-acid catalysts used to provide conventional macronetted polymers. In particular, methanesulfonic acid provides macroporous polymeric adsorbents having high surface area and porosity, low levels of residual vinyl groups, and free of residual contaminants from conventional Lewis-acid/Friedel-Crafts reactions.

Abstract: A hollow sphere organic pigment in which a core containing a void is encapsulated by a first shell polymer having a glass transition temperature greater than 50.degree. C., the first shell having polymerized thereon a second shell polymer having a glass transition temperature of -15.degree. C. to -50.degree. C. is provided. Also provided is a paper or paperboard coating composition containing the hollow sphere organic pigment, a method for improving the strength and opacity of a paper or paperboard coating by using the coating composition dried, a coated paper or paperboard bearing the dried coating composition, and a method for improving the strength and opacity of paper or paperboard by incorporating a particular hollow sphere organic pigment into the formed wet sheet.

Abstract: Polyolefinic particle foams containing additives may be produced by a process, which comprises(a) initially charging a pressure-resistant reactor with a dispersion consisting essentially of polyolefin particles and a liquid dispersion medium, and also a mixture of a volatile organic blowing agent and the additive to be introduced;(b) carrying out a heat treatment in which the polyolefin particles are impregnated with the mixture; and subsequently(c) discharging the dispersion through an orifice into a low-pressure space, thus foaming the polymer particles.The process achieves efficient incorporation of the additives into the polyolefin particles. The particle foams thus-obtained are useful for the production of moldings.

Abstract: When it is intended to obtain foamed particles having a high expansion ratio upon the production of foamed particles of a polyolefin resin, there has been a problem that foamed particles uneven in cell diameter are produced. Any molded article produced with such foamed particles has involved a drawback that it is poor in dimensional stability, and its surface profile becomes uneven.The invention relates to foamed particles comprising a polyolefin resin as a base resin, wherein the base resin contains a metal salt (excluding alkali metal salts) of boric acid in such a manner that the content of the metal salt of boric acid in the raw resin amounts to 50-50,000 ppm. Zinc borate, magnesium borate or the like is used as the metal salt of boric acid.

Abstract: In a process for preparing expandable styrene polymers containing graphite particles, styrene is polymerized in aqueous suspension in the presence of graphite particles.

Abstract: Poly(vinylamine)-based superabsorbent gels are disclosed. The superabsorbent gels either comprise a mixture of a poly(vinylamine) polymer and an acidic water-absorbing polymer, like polyacrylic acid, or comprise a salt of a poly(vinylamine) polymer. An improved method of preparing poly(vinylamine) also is disclosed.

Abstract: Foamed and expanded beads of a crosslinked aliphatic polyester resin having a gel fraction of at least 5% by weight. The expanded beads may be obtained by crosslinking beads of a non-crosslinked aliphatic polyester resin with a crosslinking agent including an organic peroxide to obtain crosslinked resin beads having a gel fraction of at least 5% by weight, and then expanding the crosslinked resin beads. A biodegradable foamed article may be obtained by thermally foaming the crosslinked, expanded aliphatic polyester resin beads in a mold.

Abstract: An improved process for manufacture of expandable polymer particles is provided. The continuous process disclosed produces expandable polymer pellets in a single step while eliminating many of the dangers inherent in processes of prior art employed for the same. The polymers produced herein are of uniform size, and may be molded into various articles of manufacture using existing equipment and techniques known to those skilled in the art.

Abstract: The present invention relates to a foamed article comprising a modified polypropylene resin which is a graft copolymer of a polypropylene resin and an aromatic vinyl monomer and has an average number of the grafted aromatic vinyl chains of not less than 1 in one molecule of the graft copolymer and a weight average molecular weight of the grafted aromatic vinyl chains of not less than 200, and relates to a process for preparation thereof. According to the present invention, the foamed article comprising the polypropylene resin and having a high closed cell content, a high expansion ratio and good external appearance can be provided.

Abstract: Disclosed herein are foamed and expanded beads of a polypropylene resin for molding, which comprise an uncrosslinked propylene random copolymer having a melting point of at least 140.degree. C. as a base resin, wherein the time required to attenuate an air pressure within the foamed beads applied by a pressurizing treatment with air from 1.2 kgf/cm.sup.2 (G) to 0.8 kgf/cm.sup.2 (G) under atmospheric pressure at 23.degree. C. is at least 80 minutes, and the CNI value of the foamed beads, which is defined by the following equation (1):CNI=log.sub.10 [Pw.times.Er.div.(2.24.times.D.sup.3 .times.B)](1)wherein Pw is an average weight (mg) per foamed bead, Er is a bulk expansion ratio (time) of the foamed beads, D is a cell diameter (mm) of the foamed beads, and B is a density of the base resin, is smaller than 3.80.

Abstract: A high-speed agitation type mixer of a continuous extruding method including a plurality of agitating members provided around a rotational shaft inside a fixed casing is used to mix and react a water absorbing resin containing a carboxyl group with an aqueous liquid containing, for example, a crosslinking agent that can react with the carboxyl group. The agitating members of the mixer of a continuous extruding method are provided so as to form in the ejection side a second area whose thrusting force is weaker than the thrusting force in a first area in which the water absorbing resin supplied into the casing is dispersed. A device for manufacturing a water absorbing agent is thus offered which boasts good absorbency under pressure and always maintain its excellent performance with end products.

Abstract: Stable high internal phase water-in-oil emulsions containing polymerizable vinyl monomers, crosslinking monomers and initiators are obtained, useful in producing low density porous crosslinked polymeric materials by using a surfactant system containing (a) an anionic surfactant, the anionic surfactant having an oil soluble tail and an anionic functional group and (b) one or more quatemary salts having one or more hydrocarbon groups having greater than or equal to 8 carbon atoms. A water-in-oil emulsion can be formed with lower surfactant concentration than sorbitan fatty acid ester alone and improved surfactant performance at elevated temperatures is obtained.