Expandable styrene polymers containing graphite particles

• US 6,340,713 B1
• Filed: 11/15/1999
• Issued: 01/22/2002
• Est. Priority Date: 05/14/1997
• Status: Expired due to Term

• Current Assignee: BASF AG (BASF SE)
• Original Assignee: BASF AG (BASF SE)
• Inventors: Naegele, Dieter, Kaempfer, Knut, Braun, Frank, Hahn, Klaus, Glück, Guiscard
• Primary Examiner(s): Foelak, Morton
• Application Number:
  US09/423,613
• Time in Patent Office: 799 Days
• Field of Search: 521/56, 521/59, 521/60, 521/79, 521/82, 521/98, 521/146, 521/907
• US Class Current: 521/60
• CPC Class Codes: C04B 14/024 Graphite
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 18/027 Lightweight materials
• CPC Class Codes: C04B 2103/63 Flame-proofing agents
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C08J 2325/04 Homopolymers or copolymers of styrene
• CPC Class Codes: C08J 9/0023 containing oxygen
• CPC Class Codes: C08J 9/0066 Use of inorganic compounding ingredients
• CPC Class Codes: C08J 9/141 Hydrocarbons
• CPC Class Codes: C08J 9/16 Making expandable particles
• CPC Class Codes: Y10S 521/907 Nonurethane flameproofed cellular product

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.

Claims

1. A particulate expandable styrene polymer which can be processed to give foams having a density of ≦

35 g/l and contains from 0.05 to 8% by weight of homogeneously distributed graphite particles having a mean particle size of from 1 to 50 μ

m.

2. A particulate expandable styrene polymer as claimed in claim 1 which contains an organic bromine compound having a bromine content of ≧

70% by weight as flame retardant and can be processed to give self-extinguishing foams which pass the burning test B2 (in accordance with DIN

     4102).

3. A particulate expandable styrene polymer as claimed in claim 1 which contains from 0.6 to 5% by weight, based on the polymer, of an organic bromine compound having a bromine content of ≧

70% by weight as flame retardant and from 0.1 to 1.0% by weight, based on the polymer, of a C—

C- or O—

O-labile organic compound as flame retardant synergist.

4. A particulate expandable styrene polymer as claimed in claim 3, wherein the organic bromine compound is selected from the group consisting of brominated aliphatic, cycloaliphatic and aromatic compounds.

5. A particulate expandable styrene polymer as claimed in claim 3, wherein the flame retardant synergist is bicumyl or dicumyl peroxide.

6. A particulate expandable styrene polymer as claimed in claim 1 which contains from 3 to 10% by weight of a hydrocarbon having from 3 to 10 carbon atoms as blowing agent.

7. A process for producing an expandable styrene polymer as claimed in claim 1, which comprises mixing graphite particles and blowing agent with molten polystyrene in an extruder and then extruding the melt and cooling and granulating it.

8. A process for producing an expandable styrene polymer as claimed in claim 1, which comprises mixing graphite particles with molten polystyrene containing blowing agent in an extruder and then extruding the melt and cooling and granulating it.

9. A process for producing an expandable styrene polymer as claimed in claim 1, which comprises mixing graphite particles with molten polystyrene in an extruder, then extruding the melt and cooling and granulating it and subsequently impregnating the granules in aqueous suspension with blowing agents.

10. A process for producing polystyrene foams, which comprises foaming expandable styrene polymers as claimed in claim 1 containing graphite particles to a density of ≦

35 g/l.

13. A particulate expandable styrene polymer as claimed in claim 1, wherein the graphite particles have a size of 2.5 to 12 μ

m.

14. A particulate expandable styrene polymer as claimed in claim 4, wherein the organic bromine compound is hexabromocyclododecane, pentabromomonochlorocyclohexane or pentabromophenyl allyl ether.

11. An expanded polystyrene foam having a density of ≦

35 g/l, containing from 0.05 to 8% by weight of homogeneously distributed graphite particles having a mean particle size of from 1 to 50 μ

m and having a thermal conductivity which is reduced sufficiently for the foam to meet the requirements of thermal conductivity class 035 (in accordance with DIN 18164, Part 1, Table

     4).

12. An expanded polystyrene foam as claimed in claim 11 having a density of ≦

35 g/l and containing, in each case based on the polymer,

15. A method of providing buildings with thermal insulation, comprising:

insulating said buildings with the expanded styrene polymer of claim 11.

16. A method of constructing buildings, comprising:

in the construction of said buildings, employing structural materials fabricated from the expanded styrene polymer of claim 11.

17. A method of providing machines with thermal insulation, comprising:

insulating said machines with the expanded styrene polymer of claim 11.

18. A method of fabricating domestic appliances, comprising:

assembling said domestic appliances from parts made from the expanded styrene polymer of claim 11.

19. A method of manufacturing packaging materials, comprising:

manufacturing said packaging materials with the expanded styrene polymer of claim 11.