Extruded closed cell thermoplastic foam

• US 4,656,074 A
• Filed: 04/09/1985
• Issued: 04/07/1987
• Est. Priority Date: 04/09/1985
• Status: Expired due to Fees

• Current Assignee: Collins & Aikman Holdings SA de CV
• Original Assignee: Collins & Aikman Holdings SA de CV
• Inventors: Conley, Kenneth E., Stull, Thomas E.
• Primary Examiner(s): Foelak, Morton
• Application Number:
  US06/721,203
• Time in Patent Office: 728 Days
• Field of Search: 521/134, 521/81, 521/139, 521/137, 521/143, 428/85, 428/95, 264/54, 264/DIG. 18
• US Class Current: 428/95
• CPC Class Codes: B32B 2266/08 Closed cell foam
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2471/02 Carpets
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: C08J 2423/00 Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
• CPC Class Codes: C08J 9/0061 characterized by the use of several polymeric components
• CPC Class Codes: D06N 2203/042 Polyolefin (co)polymers
• CPC Class Codes: D06N 2203/045 Vinyl (co)polymers
• CPC Class Codes: D06N 2203/047 Arromatic vinyl (co)polymers, e.g. styrene
• CPC Class Codes: D06N 2203/065 Polyamides
• CPC Class Codes: D06N 2203/068 Polyurethanes
• CPC Class Codes: D06N 2205/04 Foam
• CPC Class Codes: D06N 7/0076 the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
• CPC Class Codes: D06N 7/0086 characterised by the cushion backing, e.g. foamed polyurethane
• CPC Class Codes: Y10S 264/18 Cross-linking a thermoplastic linear foam during molding
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/249976 : Voids specified as closed
• CPC Class Codes: Y10T 428/249988 : Of about the same composition as, and adjacent to, the void-containing component
• CPC Class Codes: Y10T 428/249989 : Integrally formed skin

Abstract

Useful resilient extruded closed cell foam compositions are produced by the present invention by forming an extrudable blend comprising a heat activatible chemical blowing agent and a polymer component consisting essentially of chlorinated polyethylene and at least one other thermoplastic polymer. The amount of chlorinated polyethylene is from 0.025 to 0.5 parts per part of the thermoplastic polymer. The blend is extruded at a temperature below the activation temperature of the blowing agent to form an unfoamed thermoplastic sheet, and the sheet is thereafter heated to a temperature sufficient to activate the blowing agent and expand the sheet and produce a non-crosslinked closed cell thermoplastic foam.

Claims

1. An extruded chemically post-blown resilient non-crosslinked closed cell thermoplastic foam comprising a blend of chlorinated polyethylene and at least one other thermoplastic polymer selected from the group consisting of polyurethane, polyamide, styrenic and olefin resins, the amount of chlorinated polyethylene, by weight, being from 0.025 to 0.5 parts per part of said at least one thermoplastic polymer, and said foam having a substantially uniform size closed cell structure.

2. A foam according to claim 1 in the form of a sheet having opposed, substantially parallel outer surfaces, and wherein the outer surfaces include an integrally formed, substantially moisture impermeable skin.

3. A foam according to claim 1 additionally including a particulate inorganic filler material dispersed throughout the foam.

4. A foam according to claim 1 wherein said at least one other thermoplastic polymer is selected from the group consisting of styrenic and olefinic polymers.

5. A foam according to claim 1 wherein said at least one other thermoplastic polymer is an ethylene polymer.

6. A foam according to claim 5 wherein said ethylene polymer is a copolymer of ethylene with at least one ethylenically unsaturated monomer.

7. A foam according to claim 6 wherein said ethylenically unsaturated monomer is selected from the group consisting of vinyl acetate and methyl acrylate.

8. An extruded chemically post-blown resilient non-crosslinked closed cell thermoplastic foam comprised of a thermoplastic polymer component consisting essentially of a blend of chlorinated polyethylene and a copolymer of ethylene with methyl acrylate, the amount of chlorinated polyethylene, by weight, being from 0.025 to 0.5 parts per part of said ethylene copolymer, and said foam having a substantially uniform size closed cell structure.

9. An extruded chemically post-blown resilient non-crosslinked closed cell thermoplastic foam comprised of a thermoplastic polymer component consisting essentially of a blend of chlorinated polyethylene and a copolymer of ethylene with vinyl acetate, the amount of chlorinated polyethylene, by weight, being from 0.025 to 0.5 parts per part of said ethylene copolymer, and said foam having a substantially uniform size closed cell structure.

10. A foam backed carpet article comprising a carpet layer including a backing and pile yarns secured to said backing and extending from one side thereof to form a pile surface, and a resilient foam underlay secured to the opposite side of said backing, said foam underlay comprising an extruded chemically post-blown resilient non-crosslinked closed cell thermoplastic foam comprising a blend of chlorinated polyethylene and at least one other thermoplastic polymer, the amount of chlorinated polyethylene, by weight, being from 0.025 to 0.5 parts per part of said ethylene copolymer, and said foam having a substantially uniform size closed cell structure.