Adding Expanding Agent Subsequent To Solid Polymer Formation Patents (Class 521/60)
  • Patent number: 8592494
    Abstract: A method for producing styrene-modified linear low-density polyethylene-based resin particles, which includes the steps of: dispersing 100 parts by weight of non-crosslinked linear low-density polyethylene-based resin particles which are polymerized using a metallocene compound as a catalyst and contain an inorganic nucleating agent, 50 to 800 parts by weight of a styrene-based monomer and 0.1 to 0.9 parts by weight of a polymerization initiator relative to 100 parts by weight of the styrene-based monomer into an aqueous suspension containing a dispersant; impregnating the polyethylene-based resin particles with the styrene-based monomer under heating the resulting dispersion at such a temperature that the styrene-based monomer does not substantially polymerize; and performing polymerization of the styrene-based monomer at a temperature of (T+10) to (T+35)° C. where T° C. is a crystallization peak temperature of the polyethylene-based resin particles.
    Type: Grant
    Filed: September 12, 2011
    Date of Patent: November 26, 2013
    Assignee: Sekisui Plastics Co., Ltd.
    Inventors: Hideyasu Matsumura, Tatsuya Matsugashita
  • Publication number: 20130267617
    Abstract: Disclosed is a process of fabricating a cast foam product, an intermediate foam product, and a cast foam product. The process includes positioning an expandable component and alloying particles within a die and injecting steam into the die and expanding the expandable component to form an expanded component. The expandable component includes one or more of polystyrene and polymethylmethacrylate. The intermediate foam product includes the alloying particles, the expandable component, and the steam. The cast foam product includes a distribution of the alloying particles and the expanded component, with the alloying particles being physically bound by the expanded component.
    Type: Application
    Filed: April 6, 2012
    Publication date: October 10, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Junyoung PARK, Jason Robert PAROLINI
  • Patent number: 8518540
    Abstract: Multilayer expanded polypropylene resin beads that are heat moldable at low steam pressure and can provide an expanded mold with sufficient rigidity and heat resistance. The beads are formed from a polypropylene resin and a coating layer formed from a different polypropylene resin. The multilayer expanded resin beads can be molded in-mold at a steam pressure lower than the steam pressure for molding single-layer expanded beads made from the polypropylene resin which forms the core layer. The coating layer to core layer resin weight ratio in the multi-layer resin beads is not less than 0.001 and not greater than 0.040 and the expansion ratio of the expanded beads, the average value of the thickness of the coating layer of the expanded beads, calculated based on the coating weight ratio of the multi-layer resin beads, is not less than 0.1 ?m and not greater than 3.0 ?m.
    Type: Grant
    Filed: June 3, 2010
    Date of Patent: August 27, 2013
    Assignee: JSP Corporation
    Inventors: Masakazu Sakaguchi, Kouki Nishijima, Masaharu Oikawa
  • Patent number: 8513317
    Abstract: Provided is a process for producing expanded polyolefin resin particles whose cells are not made nonuniform or extremely smaller as seen in conventional expanded particles, whose cell diameter and expansion ratio can be easily controlled independently, and which, when subjected to in-mold expansion molding, give in-mold expanded molded products satisfactory in fusibility and excellent in surface properties.
    Type: Grant
    Filed: December 3, 2008
    Date of Patent: August 20, 2013
    Assignee: Kaneka Corporation
    Inventors: Jun Fukuzawa, Hiroshi Tsuneishi
  • Publication number: 20130203876
    Abstract: The present invention is a method to start-up a process to make expandable vinyl aromatic polymer pellets comprising, a) providing a pelletizer (S) containing means to introduce the molten vinyl aromatic polymer comprising the expandable agent and optionally additives, a die plate having a plurality of holes of small diameter, typically in the range 0.8 to 1.
    Type: Application
    Filed: January 27, 2011
    Publication date: August 8, 2013
    Applicant: Total Petrochemicals Research Feluy
    Inventors: Michel Cassart, Francis Couget, Elena Prats
  • Patent number: 8501827
    Abstract: A method of using heat-resistant hollow sphere polymers having at least on crosslinked polymer stage, and having a core stage that has been swollen with a volatile base, in applications in which the hollow sphere polymer is exposed to temperatures of from 100° C. to 350° C., is provided. Articles made by the method are also provided.
    Type: Grant
    Filed: August 8, 2006
    Date of Patent: August 6, 2013
    Assignee: Rohm and Haas Company
    Inventors: Chuen-Shyong Chou, John Robert Haigh
  • Patent number: 8476325
    Abstract: A method for producing styrene-modified polyethylene-based resin beads, including the steps of: dispersing 100 parts by weight of polyethylene-based resin beads which contain an inorganic nucleating agent and have a melting point of 95° C. to 115° C., 20 parts by weight or more and less than 300 parts by weight of a styrene-based monomer and a polymerization initiator into an aqueous suspension containing a dispersant; impregnating the polyethylene-based resin beads with the styrene-based monomer under heating the resulting dispersion at such a temperature that the styrene-based monomer does not substantially polymerize; and performing polymerization of the styrene-based monomer at a temperature of (T)° C. to (T+25)° C. (where T° C. is a melting point of the polyethylene-based resin beads.
    Type: Grant
    Filed: August 19, 2005
    Date of Patent: July 2, 2013
    Assignee: Sekisui Plastics Co., Ltd.
    Inventors: Hideyasu Matsumura, Tatsuya Matsugashita
  • Publication number: 20130158141
    Abstract: A pre-expanded polyolefin particle containing powdered activated carbon (PAC) and a pre-expanded polyolefin particle containing PAC and a sterically hindered amine ether flame retardant, as well as processes for preparing pre-expanded polyolefin particles. A process for producing the pre-expanded polyolefin includes providing polyolefin polymer granules containing powdered activated carbon; impregnating the polyolefin polymer granules with a volatile blowing agent in an aqueous suspension at a pressure of 5 to 50 bar and at temperatures of 100 to 170° C.; and decompression to atmospheric pressure.
    Type: Application
    Filed: August 29, 2011
    Publication date: June 20, 2013
    Applicant: KANEKA BELGIUM N.V.
    Inventors: Pierre Van Ravestyn, Nancy Laeveren
  • Patent number: 8455560
    Abstract: The invention relates to a foam ply based on a biodegradable polyester mixture, comprising i) from 70 to 5% by weight, based on the total weight of components i to ii, of at least one polyester based on aliphatic and aromatic dicarboxylic acids and on aliphatic dihydroxy compounds, and ii) from 30 to 95% by weight, based on the total weight of components i to ii, of poly-lactide, and iii) from 0.1 to 5% by weight, based on the total weight of components i to ii, of a copolymer which comprises epoxy groups and is based on styrene, acrylates, and/or methacrylates, and iv) from 0.5 to 15% by weight of additives; and v) from 0 to 50% by weight of inorganic or organic filler, and also to processes for production of the foam ply mentioned, and to the use of the foam plies for the production of moldings and foils, and also to moldings and foils comprising the foam plies mentioned.
    Type: Grant
    Filed: February 11, 2008
    Date of Patent: June 4, 2013
    Assignee: BASF SE
    Inventors: Björn Dietrich, Daniela Longo-Schedel, Gabriel Skupin, Florian Krückl
  • Patent number: 8455559
    Abstract: The invention provides a process for preparing expandable styrene polymers which comprises the steps of: (a) adding an aqueous phase comprising a suspension stabilizer and an organic phase comprising styrene and an initiator to a reactor, (b) commencing the addition of a blowing agent at a styrene conversion in the range from 40 to 70% and adding the blowing agent over a period ranging from 30 to 60 minutes, (c) adding a stabilizer to stabilize the bead size distribution of the expandable styrene polymer at a styrene conversion in the range from 65 to 99%.
    Type: Grant
    Filed: March 11, 2011
    Date of Patent: June 4, 2013
    Assignee: BASF SE
    Inventors: Wolfgang Ferstl, Jun Gao, Klaus Hahn, Pascal Hesse, Jan Holoch, Klaus-Dieter Hungenberg, Wolfram Husemann, Renata Jovanovic, Wolfgang Kasten, Olaf Kriha, Eckhard Neufeld, Michel Pepers, Birgit Reinhard, Bernhard Schmied, Rudolf Süttinger, Ping Zhang
  • Publication number: 20130116352
    Abstract: Provided is expandable starch beads including a starch-monomer copolymer and a foaming agent impregnated in the starch-monomer copolymer, in which the starch-monomer copolymer is prepared by bonding at least one monomer selected from the group consisting of styrene, ?-methylstyrene, lactide, lactic acid, acrylic acid, methacrylic acid, acrylic ester, methacrylic ester, acrylonitrile, acrylamide, and caprolactone to starch, and the foaming agent includes at least one selected from the group consisting of C2 to C7 aliphatic hydrocarbon, C2 to C7 halogenated hydrocarbon, and carbon dioxide. Since the expandable starch beads have the similar properties to expandable polystyrene beads, and thereby can be foam-molded by equipment for foaming the expandable polystyrene beads, it is possible to produce foams with various sizes and various shapes.
    Type: Application
    Filed: July 14, 2011
    Publication date: May 9, 2013
    Applicant: DAESANG CORPORATION
    Inventors: Young Mo Jo, Ssang Ok Kim, Gun Kyu Lee, Jee Young Yoon, Young Seung Jeon
  • Publication number: 20130059933
    Abstract: A process for producing an expandable pelletized polymeric material which comprises: a) providing a polymer component, consisting of a styrene polymer component having a glass transition temperature of ?130° C., formed from and one or more thermoplastic polymers selected from the group consisting of aromatic polyethers; polyolefins; polyacrylates; polycarbonates; polyesters; polyamides; polyether sulfones; polyether ketones and polyether sulfides, (b) heating the polymer component to form a polymer melt, (c) introducing a blowing agent component into the polymer melt to form a foamable melt, (d) homogenizing the mixture, (f) extruding the blowing agent-containing polymer melt through a die plate, (g) pelletizing the blowing agent-containing melt in a liquid-filled chamber to form a pelletized material.
    Type: Application
    Filed: August 30, 2012
    Publication date: March 7, 2013
    Applicant: BASF SE
    Inventors: Holger Ruckdäschel, Alexandre Terrenoire, Jan Kurt Walter Sandler, Klaus Hahn, Ingo Bellin, Georg Grässel, Martin Weber
  • Publication number: 20130011782
    Abstract: A polymer expanded particle and an expanded toner having small pores, and a production method thereof are provided. A polymer expanded particle comprises micropores having an average pore diameter of less than 50 ?m. An expanded toner comprises micropores having an average pore diameter of 1 ?m to less than 3 ?m, wherein volume average particle diameter is 5 ?m to less than 15 ?m. A method for producing a polymer expanded particle comprises a first step for mixing specific polymer particles with high pressure gas or supercritical fluid, to prepare a mixture, a second step for impregnating with the high pressure gas or the supercritical fluid to the inside of the polymer particles, and a third step for reducing pressure and temperature of the mixture, to form the polymer expanded particle, wherein the pressure and temperature in the third step is reduced for 5 minutes or less from a state of 20 MPa or greater and 60° C. or greater to a state of less than 1 MPa and less than 30° C., respectively.
    Type: Application
    Filed: March 17, 2011
    Publication date: January 10, 2013
    Applicant: TP,PEGAWA CO., LTD
    Inventors: Takayuki Sano, Chang Yi Kong, Tao Zhang, Izumi Okajima, Takeshi Sako
  • Publication number: 20120329892
    Abstract: Expandable thermoplastic polyurethane comprising blowing agent, wherein the Shore hardness of the thermoplastic polyurethane is from A 44 to A 84.
    Type: Application
    Filed: September 6, 2012
    Publication date: December 27, 2012
    Applicant: BASF SE
    Inventors: Frank PRISSOK, Frank Braun
  • Publication number: 20120309859
    Abstract: Interpolymer resin particles that include from about 20% to about 60% by weight based on the weight of the particles of uncross-linked polyolefin resin particles having a VICAT softening temperature greater than 85° C. and from about 40% to about 80% by weight based on the weight of the interpolymer particles of polymerized vinyl aromatic monomer composition particles that have been polymerized in the uncross-linked polyolefin resin particles to form an interpenetrating network of polyolefin resin particles and polystyrene particles. The interpolymer resin particles have a gel content ranging from about 0 to about 1.5% by weight based on the weight of the interpolymer resin particles, a VICAT softening temperature ranging from about 90° C. to about 115° C., and a melt index value ranging from about 0.2 to about 35.0 g/10 minutes (Condition G).
    Type: Application
    Filed: December 1, 2011
    Publication date: December 6, 2012
    Applicant: NOVA CHEMICALS INC.
    Inventor: Steven M. Krupinski
  • Patent number: 8324286
    Abstract: Heat-expandable microspheres include a shell of thermoplastic resin and a blowing agent encapsulated therein having a boiling point not higher than the softening point of the thermoplastic resin, have a maximum expanding ratio not lower than 50 times, and are thermally expanded into hollow particulates having a repeated-compression durability not lower than 75 percent. The method of producing the heat-expandable microspheres includes the steps of dispersing an oily mixture containing a polymerizable component and the blowing agent in an aqueous dispersing medium containing a specific water-soluble compound and polymerizing the polymerizable component contained in the oily mixture.
    Type: Grant
    Filed: November 16, 2006
    Date of Patent: December 4, 2012
    Assignee: Matsumoto Yushi-Seiyaku Co., Ltd.
    Inventors: Toshiaki Masuda, Ichiro Takahara, Kenichi Kitano, Katsushi Miki, Takeshi Inohara, Takeyoshi Fukuda, Takayuki Aoki, Satoshi Kawanami
  • Patent number: 8283389
    Abstract: Method of forming a composition comprising impregnated polylactic acid (PLA) resin beads, by impregnating PLA resin beads with CO2. The method is carried out by contacting the beads with liquid CO2, and holding the impregnated beads at a temperature and pressure that prevents the beads from foaming while allowing the level of impregnated CO2 to reduce to about 4 to 20 weight % relative to the total weight of the beads and CO2.
    Type: Grant
    Filed: January 30, 2008
    Date of Patent: October 9, 2012
    Assignee: Biopolymer Network Limited
    Inventors: Michael Ralph Juergen Witt, Samir Shah
  • Patent number: 8282851
    Abstract: The invention relates to a cellular elastomer which is anisotropic, with anisotropy being defined by the compressive modulus in one of three orthogonal directions being greater than that in the other two directions by a factor of at least 1.5. The invention also relates to a cellular elastomer containing magnetizable particles which have a chain-like alignment along one spatial direction. The invention also relates to a process for producing a cellular elastomer containing magnetiable particles and the use of such elastomers in articles of manufacture.
    Type: Grant
    Filed: December 11, 2007
    Date of Patent: October 9, 2012
    Assignee: BASF SE
    Inventors: Joern Duwenhorst, Maximilian Ruellmann, Frank Prissok, Sven Lasai, Steffen Mayer, Michael Harms, Claus Gabriel
  • Patent number: 8268902
    Abstract: Expandable particle composite material suitable for the preparation of expanded materials having a density lower than 40 g/l and a content of closed cells of at least 60%, including heterophase cavities and/or heterophase domains, whose matrix is a synthetic thermoplastic resin having at least 60% by weight of a vinyl aromatic polymer and in which an expanding system is contained, together with a heterogeneously distributed graphite material, having a graphitization degree, calculated by means of the Maire and Mering formula, of at least 0.2.
    Type: Grant
    Filed: May 15, 2008
    Date of Patent: September 18, 2012
    Assignee: Polimeri Europa S.p.A.
    Inventors: Alessandro Casalini, Riccardo Felisari, Dario Ghidoni, Antonio Ponticiello, Alessandra Simonelli
  • Patent number: 8252715
    Abstract: To provide a water absorbing agent which is excellent in balance between absorbency and liquid permeability against pressure and is excellent in flowability at the time of moisture absorption. The water absorbing agent comprises water absorbent resin particles and an organic surface additive, wherein: the organic surface additive having (i) a reactive group for a functional group of a surface of each water absorbent resin particle and (ii) a hydrophobic group exists on the surface of the water absorbent resin particle, and the hydrophobic group has a hydrocarbon group whose carbon number is 8 or more, and a ratio of an oxyalkylene group in a molecular mass of the organic surface additive is 0 or more and 25 mass % or less.
    Type: Grant
    Filed: March 3, 2008
    Date of Patent: August 28, 2012
    Assignee: Nippon Shokubai Co., Ltd.
    Inventors: Kazushi Torii, Yoshifumi Adachi, Taishi Kobayashi, Yusuke Watanabe, Hiroyuki Ikeuchi, Toshimasa Kitayama
  • Publication number: 20120214885
    Abstract: In foamable polystyrene resin particles that are obtained by granulating a polystyrene resin containing a flame retardant and a foaming agent, the flame retardant has a bromine atom in a molecule, contains less than 70% by mass of bromine, has a benzene ring in a molecule, and has a 5% by mass decomposition temperature in a range of from 200° C. to 300° C., and a ratio (B/A) between (A) the amount of the flame retardant contained in the total foamable polystyrene resin particles and (B) the amount of the flame retardant contained in the surface of the resin particles is in a range of from 0.8 to 1.2. By pre-foaming the foamable polystyrene resin particles and then foaming the particles in a mold, a polystyrene resin foam-molded article having flame retardancy is obtained.
    Type: Application
    Filed: October 27, 2010
    Publication date: August 23, 2012
    Inventors: Hiroyuki Tarumoto, Ryosuke Chinomi
  • Patent number: 8236431
    Abstract: A coating for paperboard comprises an aqueous dispersion of a hollow core binder comprising a first polymer that, when dry, has at least one void, the first polymer being substantially encapsulated by at least one second polymer having a glass transition temperature (Tg) ranging from more than ?15° C. and up to and including 30° C., wherein the weight ratio of the said second polymer to the said first polymer ranges from 1:1 to 4:1. One or both of the first polymer and the second polymer may be formed from, as polymerized units, at least one ethylenically unsaturated monomer. The hollow core binder allows for glossy, bright and smooth paperboard coatings while reducing the amount of binder and opacifying pigment necessary to achieve such coating properties. The present invention also provides coated paperboard articles, as well as paper and paperboard that is made from a mixture of pulp with the inventive hollow core binder.
    Type: Grant
    Filed: September 17, 2007
    Date of Patent: August 7, 2012
    Assignee: Rohm and Haas Company
    Inventor: Ravi Mukkamala
  • Patent number: 8222307
    Abstract: Expandable styrene polymers (EPS) comprising, in each case based on the styrene polymer, a) from 0.05 to 5% by weight of an organic bromine compound whose bromine content is at least 50% by weight, as flame retardant, b) from 0.05 to 2% by weight of a flame retardant synergist, c) from 0.1 to 5% by weight of a metal salt as acid scavenger, and process for their production.
    Type: Grant
    Filed: November 20, 2008
    Date of Patent: July 17, 2012
    Assignee: BASF SE
    Inventors: Markus Allmendinger, Bernhard Schmied, Joachim Ruch, Konrad Knoll, Michael Riethues, Klaus Hahn, Carsten Schips, Jessica Rylander
  • Patent number: 8198340
    Abstract: Alkenyl aromatic polymer foam comprising a polymer matrix containing one or more polymer and defining a plurality of cells having an average cell size wherein: (a) the alkenyl aromatic polymer foam has: —(i) an average cell size that is in a range of 0.02 and 5 millimeters; —(ii) a density of 64 kilograms per cubic meter or less; —(iii) an open cell content less than 30 percent; and —(iv) a cell size variation of 30% or less; and wherein the foam further comprises one or more fluorinated alkene blowing agent at a concentration of 0.03 moles or more and 0.3 moles or less per 100 grams of polymer foam.
    Type: Grant
    Filed: March 10, 2008
    Date of Patent: June 12, 2012
    Assignee: Dow Global Technologies LLC
    Inventors: Van-Chau Vo, Richard T. Fox, Warren H. Griffin
  • Publication number: 20120141772
    Abstract: A process for the production of a light lignocellulose-containing substance having an average density in the range from 200 to 600 kg/m3, in which, in each case based on the lignocellulose-containing substance: A) from 30 to 95% by weight of lignocellulose particles; B) from 1 to 25% by weight of expanded plastics particles having a bulk density in the range from 10 to 100 kg/m3; C) from 3 to 50% by weight of a binder selected from the group consisting of aminoplast resin, phenol-formaldehyde resin and organic isocyanate having at least two isocyanate groups and, if appropriate D) additives are mixed and then pressed at elevated temperature and under elevated pressure, wherein the expanded plastics particles are obtained from expandable plastics particles with a content of blowing agent in the range from 0.01 to 4% by weight, based on the expandable plastics particles.
    Type: Application
    Filed: August 2, 2010
    Publication date: June 7, 2012
    Applicant: BASE SE
    Inventors: Frank Braun, Olaf Kriha, Klaus Hahn, Benjamin Nehls, Maxim Paretolchen, Stephan Weinkötz
  • Patent number: 8173714
    Abstract: Expanded styrene polymers which have a density of less than 25 g/l and a thermal conductivity ?, determined at 10° C. in accordance with DIN 52612, of less than 32 mW/m*K, and also a process for producing them.
    Type: Grant
    Filed: June 9, 2005
    Date of Patent: May 8, 2012
    Assignee: BASF SE
    Inventors: Achim Datko, Klaus Hahn, Markus Allmendinger
  • Patent number: 8142695
    Abstract: The disclosure pertains to foam of polymers, which can be made by a method for making a polymer foam comprising vacuum or gas-filled compartments by making a solution of 1 to 20% by weight of a polymer in a solvent; adding particles to the a polymer solution; solidifying the polymer wherein the particles are contained by heating, cooling, ageing, or coagulating to obtain a polymer foam or matrix comprising the particles, and obtaining from the polymer matrix the polymer foam containing the compartments; and optionally washing, drying, and/or heating the polymer foam.
    Type: Grant
    Filed: March 28, 2008
    Date of Patent: March 27, 2012
    Assignee: Teijin Aramid B.V.
    Inventor: Marinus Johannes Gerardus Journee
  • Publication number: 20120037837
    Abstract: Polyolefin-based resin pre-expanded particles include a polyolefin-based resin composition including a polyolefin-based resin, a sterically hindered amine ether flame retardant expressed by the general formula (1): R1NHCH2CH2CH2NR2CH2CH2NR3CH2CH2CH2NHR4 (1), and a phosphoric ester. The polyolefin-based resin pre-expanded particles are flame retardant polyolefin-based resin pre-expanded particles that can have good in-mold expansion moldability and exhibit excellent flame resistance compared to the conventional pre-expanded particles even when molded into a sample having a higher density or a larger thickness without using a halogen flame retardant, and that do not generate harmful gas during burning.
    Type: Application
    Filed: April 14, 2010
    Publication date: February 16, 2012
    Applicant: KANEKA CORPORATION
    Inventor: Akihiro Itoi
  • Publication number: 20120041086
    Abstract: An expandable pelletized material comprising A) a polymer matrix composed of A1) at least 55% by weight of polyester (based on the entirety of components A1) and A2)) with a total enthalpy of fusion of up to 60 J/g, optionally of one or more melting points in the range from 100 to 300° C. and of one or more glass transition temperatures in the range from 0 to 250° C., and A2) from 0 to 45% by weight (based on the entirety of components A1) and A2)) of one or more thermoplastic polymers different from component A1); B) a physical blowing agent component, and C) optionally further additives is suitable for producing moldable foams for use in the automobile industry, airline industry, construction industry, packaging industry, sports and leisure industry, in transport, in engineering, in lightweight construction, and/or in composite construction.
    Type: Application
    Filed: August 15, 2011
    Publication date: February 16, 2012
    Applicant: BASF SE
    Inventors: Bangaru Dharmapuri Sriramulu Sampath, Olaf Kriha, Holger Ruckdäschel, Philippe Desbois, Freddy Gruber, Klaus Hahn
  • Publication number: 20120022175
    Abstract: [Object] The object of the present invention is to provide a molded foam product in which a flame retardant having no accumulating property in a living body and satisfactory handling property during the production process is dissolved in a plasticizer so that the flame retardant can be uniformly impregnated into resin particles, and which shows excellent heat-fusibility between the particles during molding without resulting in uneven cell density upon expanding, and has excellent flame retardancy and heat resistance.
    Type: Application
    Filed: March 29, 2010
    Publication date: January 26, 2012
    Inventors: Koji Sakamoto, Kazumi Yamada, Ryosuke Chinomi
  • Publication number: 20120007267
    Abstract: The present invention describes compostable or biobased foams that are useful for fabricating foamed articles. The foams are produced using a compound comprising a compostable or biobased polyester and a blowing agent. Additives including plasticizers and chain extenders are optionally included in the compostable or biobased composition. These foams can be produced using conventional melt processing techniques, such as single and twin-screw extrusion processes. In one embodiment, foamed strand profiles are cooled and cut using conventional strand pelletizing equipment. In another embodiment, foamed beads are produced by cutting the foamed strand at the face of the extrusion die and the foamed bead or strand is subsequently cooled. The resulting compostable or biobased foamed bead has a specific gravity less than 0.15 g/cm3 and the foam is compostable, as determined by ASTM D6400.
    Type: Application
    Filed: July 7, 2011
    Publication date: January 12, 2012
    Applicant: Lifoam Industries
    Inventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske
  • Publication number: 20120010307
    Abstract: The invention provides a composition and process for producing expandable beads from a compostable or biobased thermoplastic polymer. A key aspect of this invention is the ability to incorporate sufficient amounts of hydrocarbon blowing agent into the matrix of the compostable or biobased polymer. The following process may be used. First, the raw materials of compostable or biobased polymers, hydrophobic additive, and other additives are mixed by melt processing techniques. Next, a hydrocarbon blowing agent is added to the admixture, either by addition into the melt or by impregnation into the solid, to produce an expandable bead. Small, lightweight, foamed beads are produced by heating the expandable bead. Then, the expanded beads are subsequently used in conventional operations for molding into foamed articles.
    Type: Application
    Filed: July 7, 2011
    Publication date: January 12, 2012
    Applicant: Lifoam Industries
    Inventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske
  • Publication number: 20120009420
    Abstract: The present invention describes compostable or biobased foams that are useful for fabricating foamed articles. The foams are produced using a compound comprising a compostable or biobased polyester and a blowing agent. Additives including plasticizers and chain extenders are optionally included in the compostable or biobased composition. These foams can be produced using conventional melt processing techniques, such as single and twin-screw extrusion processes. In one embodiment, foamed strand profiles are cooled and cut using conventional strand pelletizing equipment. In another embodiment, foamed beads are produced by cutting the foamed strand at the face of the extrusion die and the foamed bead or strand is subsequently cooled. The resulting compostable or biobased foamed bead has a specific gravity less than 0.15 g/cm3 and the foam is compostable, as determined by ASTM D6400.
    Type: Application
    Filed: July 7, 2011
    Publication date: January 12, 2012
    Applicant: Lifoam Industries
    Inventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske
  • Patent number: 8088482
    Abstract: Hollow thermoexpandable particles or microspheres are provided that contain hydrocarbon blowing agents and have a shell polymer that can be softened at the onset of the expansion temperature and solidified at a higher temperature (thermoset) in an expanded state. Preferably, the microspheres have a shell of thermally expandable and thermally crosslinkable polymer and a hollow interior that contains a hydrocarbon liquid that boils at a temperature below the heat activated crosslinking temperature of the polymer shell. The crosslinking of the shell polymer during or after expansion, which is heat activated at an elevated temperature, can solidify the shell polymer and, then, maintain the expanded volume of the microspheres. The thermoexpandable thermoset polymer particles are useful in insulation, packaging, for making foam materials such as polyurethane or polyisocyanurate rigid foams.
    Type: Grant
    Filed: May 24, 2002
    Date of Patent: January 3, 2012
    Assignee: IP Rights, LLC
    Inventors: Sammie J. (Joey) Glorioso, Jr., James H. Burgess, Jiansheng Tang, Victoria L. Dimonie, Andrew Klein
  • Publication number: 20110319507
    Abstract: Flame-retarded foamable styrene-based resin beads and a process for producing the resin beads are provided in which a combination of two organic bromine-containing compounds is used in order to accomplish a high flame retardancy level with a small amount of addition and decreased level of residual monomer. The flame-retarded foamable resin beads comprises a blowing agent added to resin beads by impregnating with the blowing agent during or after polymerization. The beads are produced by suspension polymerizing a monomer composition containing 0.5 to 5.0 parts by weight per 100 parts by weight of the monomer of a bromine-containing flame retardant comprising (a) an organic bromine-containing compound having 2,3-dibromo-2-alkylpropyl group and (b) an organic bromine-containing compound having a bromine content greater than 50 wt % and free of any bromine atom attached to a tertiary carbon atom.
    Type: Application
    Filed: April 2, 2010
    Publication date: December 29, 2011
    Inventors: Hideaki Onishi, Hisanori Semori, Masashi Asaoka
  • Patent number: 8084509
    Abstract: The present invention provides a pre-expanded particulate polyolefin-based resin capable of easily attaining satisfactory secondary expandability, satisfactory surface appearance, and satisfactory dimensional stability even when it is intended to obtain an in-mold expansion molded article having a thin-wall shape. The present invention provides a pre-expanded particulate polypropylene-based resin including a polypropylene-based resin X as a base resin, where the resin X includes a resin mixture of at least a polypropylene-based resin A having a melting point of 140° C. or lower and a polypropylene-based resin B having a melting point of 145° C. or higher, and the resin mixture is modified by an organic peroxide so as to have a melt index of 5 g/10 min or more and less than 20 g/10 min.
    Type: Grant
    Filed: November 18, 2005
    Date of Patent: December 27, 2011
    Assignee: Kaneka Corporation
    Inventors: Tetsuya Shibata, Tomonori Iwamoto
  • Patent number: 8063177
    Abstract: A pre-expanded polypropylene resin particle can be produced in the following manner: a polypropylene resin particle produced by an under water cut method, water, a dispersing agent, and a foaming agent are charged in a pressure-resistant container, the resulting mixture is heated to a temperature equal to or higher than the softening temperature of the polypropylene resin particle to allow the polypropylene resin particle to be impregnated with the foaming agent under pressure, and the resulting product is released into the atmosphere having a pressure lower than the pressure of the inside of the pressure-resistant container. As the polypropylene resin composition, a composition is used which comprises 100 parts by weight of a polypropylene resin and 1 to 20 parts by weight of a polyethylene resin having a melt viscosity of 10 to 2000 mPa·s at 140° C.
    Type: Grant
    Filed: September 29, 2008
    Date of Patent: November 22, 2011
    Assignee: Kaneka Corporation
    Inventors: Tetsuya Minami, Tetsuya Shibata, Hidekazu Oohara
  • Publication number: 20110281964
    Abstract: The invention relates to a process for preparing a foamed polymer composition using expandable hollow microbeads, wherein, in a first process strand, first starting materials, which include at least the predominant portion of the polymer or polymers to be used, are mixed and degassed to give a premix, whereafter this premix is subjected to a pressure such that the pairing of this pressure with the temperature of the premix is below the pressure and temperature pairing that is critical for triggering the expansion of the hollow microbeads to be used, wherein, in a second process strand, second starting materials, including the hollow microbeads to be used, are degassed, whereafter the second starting materials treated in the second process strand are added to the premix prepared in the first process strand, whereafter the second starting materials are mixed with the premix.
    Type: Application
    Filed: January 28, 2011
    Publication date: November 17, 2011
    Applicant: tesa SE
    Inventors: Franziska ZMARSLY, Klaus Kleinhoff, Axel Burmeister
  • Patent number: 8058320
    Abstract: A thermally foamable microsphere having a structure that a foaming agent is encapsulated in an outer shell formed from a polymer, wherein the foaming agent contains isododecane, and a production process of the thermally foamable microsphere by a suspension polymerization process using a polymerizable monomer and a foaming agent containing dodecane.
    Type: Grant
    Filed: September 13, 2005
    Date of Patent: November 15, 2011
    Assignee: Kureha Corporation
    Inventors: Tetsuo Ejiri, Mitsuhiro Matsuzaki, Shunzo Endo
  • Publication number: 20110251296
    Abstract: A process for producing pre-expanded particles, comprising the steps of: impregnating 100 parts by weight of polystyrene type resin particles with a volatile blowing agent in the presence of 0.1 to 2.0 parts by weight of a first antistatic agent to obtain expandable resin particles; and bringing 100 parts by weight of the expandable resin particles into contact with 0.1 to 2.0 parts by weight of a second antistatic agent in the presence of an antifoaming agent, and then pre-expanding the particles, thereby obtaining pre-expanded particles, wherein the second antistatic agent and the antifoaming agent are used in a ratio by weight of 1:0.04 to 1.50.
    Type: Application
    Filed: December 25, 2009
    Publication date: October 13, 2011
    Applicant: SEKISUI PLASTICS CO., LTD.
    Inventors: Yuichi Gondo, Hideyasu Matsumura
  • Patent number: 8026291
    Abstract: Expanded and extruded polyolefin foams are obtained using environmentally benign non-VOC methyl formate as a blowing agent. The blowing agent can be a blend further including at least one co-blowing agent, preferably an environmentally friendly species (e.g., non-VOC), which is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s) or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The blowing agent blend can include any combination of methyl formate and one or more co-blowing agents. The polymer foam can include polyethylene, polypropylene or a combination thereof. The methyl formate-based blowing agent blends produce stable foams for various applications, including containers, packaging systems, as well as for insulation and protective cushioning. Processes for the preparation of such foams are also provided.
    Type: Grant
    Filed: February 21, 2007
    Date of Patent: September 27, 2011
    Assignee: Pactiv Corporation
    Inventors: Y. Paul Handa, Gary A. Francis
  • Publication number: 20110218257
    Abstract: The present invention relates to a particulate, expandable polymer, for example polystyrene (EPS) or polylactic acid (PLA) or a combination thereof, which can be processed to form a foam having a fine cell structure and a low density, and which contains a thermal insulation value-increasing material so as to increase the thermal insulation value thereof The present invention further relates to a method for producing such particulate, expandable polymer, as well as to a foam material based on such a polymer.
    Type: Application
    Filed: October 5, 2009
    Publication date: September 8, 2011
    Inventors: Jan Noordegraaf, Franciscus Petrus Antonius Kuijstermans, Josephus Petrus Maria De Jong
  • Patent number: 8013031
    Abstract: This invention provides a process for extruding a PLA resin using high levels of CO2. Excellent quality, low density foam is produced easily and reproducibly. The foams arc capable of being heat-annealed to induce significant crystallinity, even when an ordinarily amorphous PLA resin is used.
    Type: Grant
    Filed: March 24, 2005
    Date of Patent: September 6, 2011
    Assignee: NatureWorks LLC
    Inventors: Kevin Cink, Jeffrey C. Smith, James F. Nangeroni, Jed Richard Randall
  • Publication number: 20110196053
    Abstract: A polymer foam with density in the range from 5 to 120 kg/m3, comprising a) a polymer component, comprising at least one styrene polymer, b) from 0.
    Type: Application
    Filed: February 7, 2011
    Publication date: August 11, 2011
    Applicant: BASF SE
    Inventors: Klaus Hahn, Olaf Kriha, Ingo Bellin, Patrick Spies, Sabine Fuchs, Peter Deglmann, Klemens Massonne, Hartmut Denecke, Christoph Fleckenstein, Geert Janssens, Maximilian Hofmann, Manfred Döring, Ciesielski Michael, Jochen Wagner
  • Patent number: 7964652
    Abstract: Disclosed is a method for production of an expandable polyethylene resin particle having a foaming agent impregnated therein, which comprises polymerizing a styrene monomer or a monomer mixture containing a styrene monomer onto a nuclear particle comprising an ethylene-vinyl acetate copolymer and a linear low-density polyethylene.
    Type: Grant
    Filed: May 22, 2007
    Date of Patent: June 21, 2011
    Assignee: JSP Corporation
    Inventors: Kazuki Okamura, Hiroshi Nakaguki
  • Patent number: 7943676
    Abstract: A method of recycling waste plastic foam materials firstly is to smash a waste material including polyurethane foam into fine particles so as to obtain a first starting material. The first starting material is then crisped and followingly milled into powder so as to obtain a second starting material. The second starting material is then placed into a mixer to mix with a first foaming reaction solution including polyol, catalyst and additives injected into the mixer so as to form a semi-treated foaming material. And then, the semi-treated foaming material is mixed with a second foaming reaction solution including diisocyanate injected into the mixer so as to obtain a completed-treated foaming material. Lastly, the completed-treated foaming material is poured into a mold and then water vapor is uniformly introduced into the mold so as to induce the completed-treated foaming material to proceed foaming reaction.
    Type: Grant
    Filed: February 7, 2008
    Date of Patent: May 17, 2011
    Inventor: Kun-Huang Chang
  • Publication number: 20110046249
    Abstract: Expandable vinyl aromatic polymers which comprise: a matrix obtained by polymerizing 50-100% by weight of one or more vinyl aromatic monomers and 0-50% by weight of at least one copolymer izable monomer; 1-10% by weight, calculated with respect to the polymer (a), of an expanding agent englobed in the polymeric matrix; 0.05-25% by weight, calculated with respect to the polymer (a), of a filler comprising coke with a surface area, measured according to ASTM D-3037/89, ranging from 5 to 50 m2/g.
    Type: Application
    Filed: May 1, 2009
    Publication date: February 24, 2011
    Applicant: Polimeri Europa S.P.A.
    Inventors: Antonio Ponticiello, Dario Ghidoni, Riccardo Felisari
  • Publication number: 20110039089
    Abstract: The invention relates to a polymer-based cellular structure comprising carbon nanotubes. To a method for its production and uses thereof.
    Type: Application
    Filed: April 14, 2006
    Publication date: February 17, 2011
    Applicant: Toyota Jidosha Kabushiki Kaisha
    Inventors: Nour-Eddine El Bounia, Thomas Roussel
  • Publication number: 20110009508
    Abstract: There are provided expandable polystyrene resin particles formed by granulating a polystyrene resin containing an expanding agent, wherein the weight-average molecular weight Mw of the polystyrene resin is in the range of 120,000 to 270,000, and the expanding agent contains, as an essential component, pentane at a proportion of 3 to 8 parts by mass based on 100 parts by mass of the polystyrene resin, while the composition of the pentane is in the range of isopentane:normal pentane=10:90 to 80:20 by mass ratio. These expandable polystyrene resin particles can utilize a recycled raw material, and can produce a molded foam product having sufficient mechanical strength, while the expandable polystyrene resin particles have a long bead life and excellent low pressure moldability.
    Type: Application
    Filed: January 23, 2009
    Publication date: January 13, 2011
    Inventors: Ryosuke Chinomi, Hiroyuki Tarumoto, Yoshifumi Saitou
  • Patent number: 7868053
    Abstract: Expandable pelletized styrene polymer materials with at least bi- or multimodal molecular weight distribution, to a process for their preparation, and to use for producing moldable-foam moldings.
    Type: Grant
    Filed: December 10, 2004
    Date of Patent: January 11, 2011
    Assignee: BASF SE
    Inventors: Klaus Hahn, Gerd Ehrmann, Joachim Ruch, Markus Allmendinger, Bernhard Schmied, Jan Holoch, Franz-Josef Dietzen