Claims
- 1. A blowing agent for foaming polystyrene consisting essentially of:
- at least one low permeability compound, said low permeability compound having a permeability in said polystyrene lower than about 1.times.10.sup.-12 cc(STP)(cm)/{(sec)(cm.sup.2)(cmHg)};
- at least one low volatility compound, said low volatility compound having a boiling point higher than about 23.degree. C. and selected from the group consisting of acetone, acetone/water, methyl acetate, and mixtures thereof; and
- optionally, at least one high volatility compound, said high volatility compound having a boiling point lower than about 0.degree. C.;
- wherein said blowing agent comprises less than about 70 wt % of said low permeability compound.
- 2. The blowing agent of claim 1, including said at least one high volatility compound.
- 3. The blowing agent of claim 2, wherein said at least one low permeability compound is selected from the group consisting of isopentane, isobutane, and mixtures thereof, at least one of said low volatility compound is acetone and at least one of said high volatility compound being carbon dioxide.
- 4. The blowing agent of claim 2, wherein said at least one high volatility compound is selected from the group consisting of carbon dioxide, nitrogen, hydrofluorocarbons, ethane, and mixtures thereof.
- 5. The blowing agent of claim 1, wherein said at least one low permeability compound is selected from the group consisting of cyclopentane, isopentane, isobutane, 2-2 dimethyl butane, cyclohexane, and mixtures thereof.
- 6. The blowing agent of claim 1, wherein said blowing agent comprises less than 60 wt % of said low permeability compound.
- 7. The blowing agent of claim 6, wherein said blowing agent comprises less than 50 wt % of said low permeability compound.
- 8. The blowing agent of claim 1, wherein said low permeability compound is classified as a volatile organic compound (VOC) by the Environmental Protection Agency (EPA).
- 9. The blowing agent of claim 1, including said at least one high volatility compound, at least one of said high volatility compound is not classified as a volatile organic compound (VOC) by the Environmental Protection Agency (EPA).
- 10. The blowing agent of claim 1, wherein said blowing agent comprises at least about 10 wt % of said low volatility compound.
- 11. The blowing agent of claim 10, wherein said blowing agent comprises at least about 20 wt % of said low volatility compound.
- 12. A polystyrene foam structure prepared by the process comprising the steps of:
- (a) melting a mixture comprising a thermoplastic polymer;
- (b) dissolving an effective amount of blowing agent in the mixture of step (a), said blowing agent consisting essentially of at least one low permeability compound and at least one low volatility compound, said low permeability compound having a permeability in said polystyrene foam structure lower than about 1.times.10.sup.-12 cc(STP)(cm)/{(sec)(cm.sup.2)(cmHg)}, said low volatility compound having a boiling point higher than about 23.degree. C. and selected from the group consisting of acetone, acetone/water, methyl acetate, and mixtures thereof and, optionally, at least one high volatility compound, said high volatility compound having a boiling point lower than about 0.degree. C.;
- (c) forming an extrudate, said extrudate comprising from about 0.5 to about 3 wt % low permeability compound;
- (d) transferring the extrudate to an expansion zone; and
- (e) permitting the extrudate to expand in said expansion zone to produce said polystyrene foam structure, said polystyrene foam structure has a density from about 1 to about 15 lb/ft.sup.3.
- 13. The polystyrene foam structure of claim 12, including said at least one high volatility compound.
- 14. The polystyrene foam structure of claim 13, wherein at least one of said low permeability compound is selected from the group consisting of isopentane, isobutane, and mixtures thereof, at least one of said low volatility compound is acetone and including said at least one high volatility compound, said at least one of said high volatility compound being carbon dioxide.
- 15. The polystyrene foam structure of claim 12, wherein said extrudate comprises from about 2 to about 10 wt % blowing agent.
- 16. The polystyrene foam structure of claim 15, wherein said extrudate comprises from about 3 to about 8 wt % blowing agent.
- 17. The polystyrene foam structure of claim 16, wherein said extrudate comprises from about 4 to about 6 wt % blowing agent.
- 18. The polystyrene foam structure of claim 12, wherein said extrudate comprises from about 0.5 to about 1.88 wt % of said low permeability compound.
- 19. The polystyrene foam structure of claim 12, wherein said extrudate comprises from about 1 to about 3 wt % of said low permeability compound.
- 20. The polystyrene foam structure of claim 12, wherein said extrudate comprises from about 0.25 to about 5 wt % said low volatility compound.
- 21. The polystyrene foam structure of claim 20, wherein said extrudate comprises from about 0.5 to about 3 wt % said low volatility compound.
- 22. The polystyrene foam structure of claim 13, wherein said extrudate comprises from about 0.25 to about 5 wt % said high volatility compound.
- 23. The polystyrene foam structure of claim 22, wherein said extrudate comprises from about 0.5 to about 3 wt % said high volatility compound.
- 24. The polystyrene foam structure of claim 12, wherein said at least one low permeability compound is selected from the group consisting of cyclopentane, isopentane, isobutane, 2-2 dimethyl butane, cyclohexane, and mixtures thereof.
- 25. The polystyrene foam structure of claim 13, wherein said at least one high volatility compound is selected from the group consisting of carbon dioxide, nitrogen, hydrofluorocarbons, ethane, and mixtures thereof.
- 26. A process for producing a polystyrene foam structure comprising the steps of:
- (a) melting a mixture comprising a thermoplastic polymer;
- (b) dissolving an effective amount of blowing agent in the mixture of step (a), said blowing agent consisting essentially of at least one low permeability compound and at least one low volatility compound, said low permeability compound having a permeability in said polystyrene foam structure lower than about 1.times.10.sup.-12 cc(STP)(cm)/{ (sec)(cm.sup.2)(cmHg)}, said low volatility compound being selected from the group consisting of acetone, acetone/water, methyl acetate, and mixtures thereof and, optionally, at least one high volatility compound, said high volatility compound having a boiling point lower than about 0.degree. C.;
- (c) forming an extrudate, said extrudate comprising from about 0.5 to about 3 wt % low permeability compound;
- (d) transferring the extrudate to an expansion zone; and
- (e) permitting the extrudate to expand in said expansion zone to produce said polystyrene foam structure, said polystyrene foam structure having a density from about 1 to about 15 lb/ft.sup.3.
- 27. The process of claim 26, including said at least one high volatility compound.
- 28. The process of claim 27, wherein said at least one low permeability compound is selected from the group consisting of isopentane, isobutane, and mixtures thereof, said at least one low volatility compound is acetone and said at least one high volatility compound is carbon dioxide.
- 29. The process of claim 26, wherein said at least one low permeability compound is selected from the group consisting of cyclopentane, isopentane, isobutane, 2-2 dimethyl butane, cyclohexane, and mixtures thereof.
- 30. The process of claim 27, wherein said at least one high volatility compound is selected from the group consisting of carbon dioxide, nitrogen, hydrofluorocarbons, ethane, and mixtures thereof.
- 31. The process of claim 26, wherein said extrudate comprises from about 0.5 to about 1.88 wt % low permeability compound.
- 32. The process of claim 26, wherein said extrudate comprises from about 0.25 to about 5 wt % low volatility compound.
- 33. The process of claim 32, wherein said extrudate comprises from about 0.5 to about 3 wt % low volatility compound.
- 34. The process of claim 27, wherein said extrudate comprises from about 0.25 to about 5 wt % high volatility compound.
- 35. The process of claim 34, wherein said extrudate comprises from about 0.5 to about 3 wt % high volatility compound.
- 36. The process of claim 26, wherein said extrudate comprises from about 2 to about 10 wt % blowing agent.
- 37. The process of claim 36, wherein said extrudate comprises from about 3 to about 8 wt % blowing agent.
- 38. The process of claim 37, wherein said extrudate comprises from about 4 to about 6 wt % blowing agent.
- 39. A blowing agent for foaming polystyrene consisting essentially of:
- at least one low permeability compound being selected from the group consisting cyclopentane, isopentane, isobutane, 2-2 dimethyl butane, cyclohexane, and mixtures thereof;
- at least one low volatility compound being selected from the group consisting of acetone, an acetone/water mixture, methyl acetate, and mixtures thereof; and
- optionally, at least one high volatility compound, said high volatility compound having a boiling point lower than about 0.degree. C.;
- wherein said blowing agent comprises less than about 70 wt % low permeability compound.
- 40. The blowing agent of claim 39, including said at least one high volatility compound, said at least one high volatility compound being selected from the group consisting of carbon dioxide, nitrogen, hydrofluorocarbons, ethane, and mixtures thereof.
- 41. The blowing agent of claim 39, wherein said at least one low permeability compound is selected from a group consisting of isopentane, isobutane, and mixtures thereof, said at least one low volatility compound is acetone and includes said at least one high volatility compound, said at least one high volatility compound being carbon dioxide.
- 42. The blowing agent of claim 39, where in said blowing agent comprises less than about 60 wt % low permeability compound.
- 43. The blowing agent of claim 42, wherein said blowing agent comprises less than about 50 wt % low permeability compound.
- 44. The blowing agent of claim 39, wherein said blowing agent comprises greater than 15 wt % of said low volatility compound.
- 45. The blowing agent of claim 39, wherein said blowing agent comprises greater than 30 wt % of said low volatility compound.
- 46. A blowing agent for foaming polystyrene consisting essentially of:
- at least one low permeability compound, said low permeability compound having a permeability in said polystyrene lower than about 1.times.10.sup.-12 cc(STP)(cm)/{(sec)(cm.sup.2 )(cmHg)};
- at least one low volatility compound, said low volatility compound having a boiling point higher than about 23.degree. C. and selected from the group consisting of acetone, acetone/water, methyl acetate, and mixtures thereof; and
- optionally, at least one high volatility compound, said high volatility compound having a boiling point lower than about 0.degree. C.;
- wherein said blowing agent comprises at least about 15 wt % of said low volatility compound.
- 47. The blowing agent of claim 46, wherein said blowing agent comprises greater than about 20 wt % of said low volatility compound.
- 48. The blowing agent of claim 47, wherein said blowing agent comprises greater than about 30 wt % of said low volatility compound.
- 49. The blowing agent of claim 46, including said at least one high volatility compound.
- 50. The blowing agent of claim 49, wherein said at least one low permeability compound is selected from the group consisting of isopentane, isobutane, and mixtures thereof, at least one of said low volatility compound is acetone and at least one of said high volatility compound being carbon dioxide.
- 51. The blowing agent of claim 49, wherein said at least one high volatility compound is selected from the group consisting of carbon dioxide, nitrogen, hydrofluorocarbons, ethane, and mixtures thereof.
- 52. The blowing agent of claim 46, wherein said at least one low permeability compound is selected from the group consisting of cyclopentane, isopentane, isobutane, 2-2 dimethyl butane, cyclohexane, and mixtures thereof.
- 53. The blowing agent of claim 46, wherein said blowing agent comprises less than about 70 wt % of said low permeability compound.
- 54. The blowing agent of claim 53, wherein said blowing agent comprises less than about 60 wt % of said low permeability compound.
RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 08/941,960, filed Oct. 1, 1997, now allowed U.S. Pat. No. 5,939,463.
US Referenced Citations (15)
Foreign Referenced Citations (1)
Number |
Date |
Country |
5272479 |
May 1980 |
AUX |
Non-Patent Literature Citations (3)
Entry |
"General Purpose Polystyrene," Encyclopedia of Polymer Science and Engineering, J. Wiley & Sons, 2nd Edition, vol. 16, pp. 62-71 (1989). |
Krutchen et al., "Gas Chromatographic Determination Of Residual Blowing Agents In Polystyrene Foams," Proceeding SPE ANTEC '88, pp. 704-706 (1988). |
Zwolinski et al., Extruded Polystyrene Foam With CFC/Carbon Dioxide Blowing Agents, ANTEC 1986, pp. 30-33 (1986). |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
941960 |
Oct 1997 |
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