Polymer particles

• US 6,528,570 B1
• Filed: 07/19/2000
• Issued: 03/04/2003
• Est. Priority Date: 07/26/1999
• Status: Expired due to Fees

• Current Assignee: Nova Chemicals
• Original Assignee: Nova Chemicals
• Inventors: Mesters, Carolus Matthias Anna Maria, Berghmans, Michel Florentine Jozef, Pallay, Ján, Neijman, Eric Wilhelmus Johannes Frederik, Metsaars, Alphonsus Catharina Gerardus
• Primary Examiner(s): Cain, Edward J.
• Application Number:
  US09/619,197
• Time in Patent Office: 958 Days
• Field of Search: 523/218, 524/444, 524/445, 524/492, 524/493
• US Class Current: 524/444
• CPC Class Codes: C08F 12/04 containing one ring
• CPC Class Codes: C08F 2/44 Polymerisation in the presence of compounding ingredients, e.g. plasticisers, dyestuffs, fillers
• CPC Class Codes: C08K 7/26 Silicon- containing compounds
• CPC Class Codes: C08L 25/00 Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers

Abstract

Polymer particles containing a polymer of a vinylarene monomer, a porous silicate compound and at least 1.5% by weight of water, based on the weight of vinylarene, water and porous silicate compound, wherein the porous silicate compound is selected from alumino silicates and amorphous silica particles, and a process for the preparation of such polymer particles.

Claims

1. Expandable polymer particles containing a polymer of a vinylarene monomer, a porous silicate compound, and water, wherein the porous silicate compound is selected from the group consisting of alumino silicates and amorphous silica particles and the porous silicate compound is incorporated in said polymer in an amount ranging from about 0.1 to about 10% by weight based on the weight of vinylarene, water and porous silicate compound so as to retain said water in said particles in an amount ranging from 1.5% to about 20% by weight based on the weight of vinylarene, water and porous silicate for use of said water as essentially the sole blowing agent in said expandable particles for the production of pre-expanded polymer particles from said expandable particles.

2. Polymer particles according to claim 1, wherein the porous silicate compound is selected from clays and alumino silicate zeolites.

3. Polymer particles according to claim 2, wherein the porous silicate compound is selected from alumino silicate zeolites having a Si/Al ratio of 1 to 30.

4. Polymer particles according to claim 1, wherein the porous silicate compound is selected from amorphous silica particles that are built from more than 95% by weight of SiO₂.

5. Polymer particles according to claim 4, wherein the average particle size of the porous silicate compound is 50 μ

m or less.

9. Foamed articles obtainable from the polymer particle as defined in claim 1.

10. Polymer particles according to claim 5, wherein the average particle size of the porous silicate compound incorporated in said polymer ranges from about 0.1 μ

m to about 40 μ

m.

11. Polymer particles according to claim 10, wherein the average particle size of the porous silicate compound incorporated in said polymer ranges from about 0.5 μ

m to about 20 μ

m.

6. Process for the preparation of pre-expanded polymer particles from expandable polymer particles containing a polymer of a vinylarene monomer and water as a blowing agent, which process includes:

(a) preparing a viscous mass containing 10-70% by weight, based on the total amount of vinylarene present, of a polymer of a vinylarene monomer, 90-30% by weight, based on the total amount of vinylarene present, of a vinylarene monomer, and including the incorporation of a porous silicate compound in said viscous mass in an amount ranging from about 0.1 to about 10% by weight based on the weight of vinylarene, water, and porous silicate compound;

(b) suspending the viscous mass thus obtained into an aqueous medium to yield suspended particles;

(c) polymerizing the suspended particles to complete monomer conversion to produce said expandable particles containing said vinylarene, said porous silicate compound incorporated therein, and from 1.5% to about 20% by weight of water, based on the weight of vinylarene, porous silicate compound, and water; and

(d) subjecting said expandable particles to a pre-expansion process for said preparation of said pre-expanded polymer particles.

7. Process according to claim 6, wherein the viscous mass of step (a) is obtained by pre-polymerization of vinylarene monomers to a conversion degree of 10 to 70% by weight, based on the weight of the vinylarene monomer present at the start of the polymerization, and adding the porous silicate compound before, during or after the pre-polymerization to the polymerization mixture.

8. Process according to claim 7, wherein potassium persulphate or maleic anhydride is added to the viscous mass.