ENHANCED EXPANDED POLYSTYRENE FOAM INSULATION

• US 20100304075A1
• Filed: 05/28/2009
• Published: 12/02/2010
• Est. Priority Date: 05/28/2009
• Status: Abandoned Application

• Current Assignee: Nova Chemicals Incorporated (Nova Chemicals)
• Original Assignee: Nova Chemicals Incorporated (Nova Chemicals)
• Inventors: Chee, Thomas, Berghmans, Michel, Petela, Grazyna
• Application Number:
  US12/473,527
• Publication Number:
  US 20100304075A1
• Time in Patent Office: Days
• US Class Current: 428/71
• CPC Class Codes: B29C 44/3461 Making or treating expandable particles
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2255/04 on a particulate layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/102 synthetic resin or rubber layer being a foamed layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/0207 Particles made of materials belonging to B32B25/00
• CPC Class Codes: B32B 2264/0235 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2264/0242 Vinyl halide, e.g. PVC, PVDC, PVF or PVDF (co)polymers
• CPC Class Codes: B32B 2264/025 Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers
• CPC Class Codes: B32B 2264/0257 Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
• CPC Class Codes: B32B 2264/101 Glass
• CPC Class Codes: B32B 2264/107 Ceramic
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2266/0207 Materials belonging to B32B25/00
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0235 : Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2266/025 : Polyolefin vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• 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 2307/304 : Insulating
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 29/007 : next to a foam layer
• CPC Class Codes: B32B 29/04 : next to a particulate layer
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: C08J 2325/04 : Homopolymers or copolymers of styrene
• CPC Class Codes: C08J 2409/00 : Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
• CPC Class Codes: C08J 2421/00 : Characterised by the use of unspecified rubbers
• CPC Class Codes: C08J 2425/12 : with unsaturated nitriles
• CPC Class Codes: C08J 2427/06 : Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08J 2453/02 : of vinyl aromatic monomers and conjugated dienes
• CPC Class Codes: C08J 2467/00 : Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08J2477/12; of polyester-imides C08J2479/08; Derivatives of such polymers
• CPC Class Codes: C08J 9/0066 : Use of inorganic compounding ingredients
• CPC Class Codes: C08J 9/224 : Surface treatment
• CPC Class Codes: C08J 9/228 : Forming foamed products
• CPC Class Codes: Y10T 428/233 : Foamed or expanded material encased
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/2998 : including synthetic resin or polymer

Abstract

Partially expanded closed-cell unmatured polystyrene bead with a partial vacuum within the cells inside the bead, which may be coated with an air impervious coating to retain a partial vacuum inside cells for a prolonged period of time. The resulting bead has improved thermal insulating properties and may be used for insulation.

Claims

1. An un-aged or partially aged polymeric bead with internal closed cells which has been expanded from 10 to 50 times the size of the unexpanded bead, having an internal pressure in the cells less than 600 millibars, which has been coated with an air impervious layer having a thickness from 3 to 200 microns.

2. The bead according to claim 1, wherein the polymer in the polymeric bead is selected from the group consisting of:

(i) homopolymers or copolymers of one or more monomers selected from the group consisting of C_6-8 vinyl aromatic monomers which are unsubstituted or may be substituted by one or more members selected from the group consisting of a halogen atom, preferably chlorine and C_1-4 alkyl radicals; and

(ii) copolymers comprising from 95 to 60, weight % of one or more monomers selected from the group consisting of C_6-8 vinyl aromatic monomers which are unsubstituted or may be substituted by one or more members selected from the group consisting of a halogen atom, preferably chlorine and C_1-4 alkyl radicals and from 5 to 40 weight % of one or more monomers selected from the group consisting of C_1-8, preferably C_1-4, alkyl esters of C_3-5 ethylenically unsaturated mono or di-carboxylic acids and C_2-3 alkenyl nitriles which polymers may further comprise from 5 to 40 weight % of one or more elastomers.

3. The polymeric bead according to claim 2 wherein the polymer further comprises from 5 to 40 weight % of one or more elastomers selected from the group consisting of:

(i) co- or homo-polymers of one or more C_4-6 conjugated diolefin monomers which are unsubstituted or substituted by a halogen atom, preferably chlorine;

(ii) random, block or star polymers comprising;

(a) from 30 to 70, preferably 40 to 60 weight % of one or more vinyl aromatic monomers which are unsubstituted or may be substituted by one or more members selected from the group consisting of a halogen atom, preferably chlorine and C_1-4 alkyl radicals;

(b) from 70 to 30, preferably 60 to 40 weight % of one or more C_4-6 conjugated diolefins which may be unsubstituted or substituted by a halogen atom, preferably chlorine; and

(iii) random, block or star polymers comprising;

(a) from 95 to 60, preferably 95 to 75, weight % of one or more C_4-6 conjugated diolefins which may be unsubstituted or substituted by a halogen atom, preferably chlorine; and

(b) from 5 to 40, preferably 5 to 25, weight % of one or more C_2-3 alkenyl nitriles.

4. The bead according to claim 2, wherein the air impervious layer is selected from the group consisting of:

(i) polyvinylidene chloride;

(ii) polymers comprising from 80 to 95 weight % of vinylidene chloride and 20 to 5 weight % of one or more monomers selected from the group consisting of one or more C_1-6, preferably esters of a C_3-6 carboxylic acid, acrylonitrile and optionally from 0 to 15 weight % of vinyl chloride;

(iii) poly (p-xylylene);

(iv) a latex of synthetic or natural rubber; and

(v) crosslinked aliphatic polyesters.

5. The bead according to claim 4, further comprising from 100 to 10,000 parts per million (ppm) based on the total weight of the coated bead of an insecticide selected from the group consisting of borates, 1-[(6-chloro-3-pyridinyl)methyl]-4,5-dihydro-N-nitro-1H-imidazol-2-amine;

3-(2,2-dichloroethenyl)-2,2-di-methylcyclopropanecarboxylic acid;

cyano(3-phenoxyphenyl)-methyl ester;

3-(2,2-dichloroethenyl)-2,2-dimethylcyclopropanecarboxylic acid (3-phenoxyphenyl)methyl ester; and

1-[(6-chloro-3-pyridinyl)methyl]-4,5-dihydro-N-nitro-1H-imidazol-2-amine(imidacloprid).

6. The bead according to claim 4, further comprising a flame retardant in an amount from 5,000 ppm to 50,000 ppm based on the weight of the polymer of a flame retardant selected from the group consisting of hexabromocyclododecane, dibromoethyldibromocyclohexane, tetrabromocyclooctane, tribromophenol alkyl ether, tetrabromobisphenol A-bis(2,3-dibromopropyl ether) and mixtures thereof.

7. The bead according to claim 4, further comprising from about 1 to 25 weight % of an infrared attenuating agent selected from the group consisting of carbon black, furnace black, acetylene black, channel black, graphite and ceramic microspheres having a vacuum therein.

8. A molded sheet, slab or block comprising the beads of claim 2.

9. A molded sheet, slab or block according to claim 8, further comprising on at least a major surface one or more of a vapor barrier and metallic foil having reflective surface facing external to said sheet.

10. The molded sheet, slab or block according to claim 9, wherein the vapor barrier comprises a sheet of a polyolefin.

11. The molded sheet, slab or block according to claim 9, wherein the metallic foil is selected from the group consisting of aluminum foil and a polyester foil having a metallic surface.

12. The molded sheet, slab or block according to claim 9, wherein the matrix further comprises one or more members selected from the group consisting of glass microspheres, expanded vermiculite and long glass fibers.

18. A process to make a bead according to claim 2 comprising preparing a suspension polymerized expandable polymer bead and expanding it to 20 to 50 times its size, and before it is matured coating the surface of the bead with an air impervious layer having a thickness from 3 to 200 microns.

19. The process according to claim 18, wherein the polymer is selected from the group consisting of:

(i) homopolymers or copolymers of one or more monomers selected from the group consisting of C_6-8 vinyl aromatic monomers which are unsubstituted or may be substituted by one or more members selected from the group consisting of a halogen atom, preferably chlorine and C_1-4 alkyl radicals; and

(ii) copolymers comprising from 95 to 60 weight % of one or monomers selected from the group consisting of C_6-8 vinyl aromatic monomers which are unsubstituted or may be substituted by one or more members selected from the group consisting of a halogen atom, preferably chlorine and C_1-4 alkyl radicals and from 5 to 40 weight % of one or more monomers selected from the group consisting of C_1-8, preferably C_1-4, alkyl esters of C_3-5 ethylenically unsaturated mono or di-carboxylic acids and C_2-3 alkenyl nitrites which polymers may further comprise from 5 to 40 weight % of one or more elastomers.

20. The process according to claim 19 wherein the air impervious layer is elected from the group consisting of:

(i) polyvinylidene chloride;

(ii) polymers comprising from 80 to 95 weight % of vinylidene chloride and 20 to 5 weight % of one or more monomers selected from the group consisting of one or more C_1-6, preferably esters of a C_3-6 carboxylic acid, acrylonitrile and optionally from 0 to 15 weight % of vinyl chloride;

(iii) poly (p-xylylene);

(iv) a latex of synthetic or natural rubber; and

(v) crosslinked aliphatic polyesters.

21. The process according to claim 20, wherein the polymer beads are spray coated with a solution or dispersion of material forming said impervious layer.

22. The process according to claim 20, wherein said beads are immersed in a solution or dispersion of material forming said impervious layer.

13. A sheet, slab or block molded of un-aged or partially aged polymeric beads which have been expanded from 10 to 50 times the size of the unexpanded bead, having internal closed cells and internal pressure in the cells less than 600 millibars and the said sheet, slab or block has been coated on all surfaces with an air impervious layer having a thickness from 3 to 200 microns.

14. A molded sheet, slab or block according to claim 13, further comprising on at least a major surface one or more of a vapor barrier and metallic foil having reflective surface facing external to said sheet.

15. The molded sheet, slab or block according to claim 14, wherein the vapor barrier comprises a sheet of a polyolefin.

16. The molded sheet, slab or block according to claim 14, wherein the metallic foil is selected from the group consisting of aluminum foil and a polyester foil having a metallic surface.

17. The molded sheet, slab or block according to claim 14 wherein the matrix further comprises one or more members selected from the group consisting of glass microspheres, ceramic microspheres, expanded vermiculite and glass fibers.