Nucleating agents for thermoplastic resins

Abstract

This invention relates to the use of a special class of sulfonic and phosphonic acids, and salts of the acids, to give improved nucleation for foam extrusion of thermoplastics using either dissolved gas or chemical blowing agents to produce foam.

Description

FIELD OF THE INVENTION

This invention relates to the use of a special class of sulfonic and phosphonic acids, and salts of the acids, to give improved nucleation for foam extrusion of thermoplastics using either dissolved gas or chemical blowing agents to produce foam.

BACKGROUND OF THE INVENTION

Conductive wire is often used to transmit electronic signals. The wire must be protected, or insulated, and thermoplastic coatings are ordinarily used for this. The thermoplastic is extruded from a molten state onto and around the wire. The thermoplastic materials are selected on the basis of having a low dielectric constant and a low dissipation factor. It has previously been found that if the thermoplastic material is foamed as it is applied to the wire, the dielectric constant is desirably lowered, due to the formation of numerous small non-interconnected cells in the foam. In U.S. Pat. No. 3,072,583 is disclosed a nucleated foaming process for extruding perfluorinated polymer foam around transmission wire with a dissolved gas blowing agent. Foamed insulation using other thermoplastic materials, especially polyolefins, is also widely used.

A nucleating agent is needed in the foaming process to achieve uniform, small-diameter cell structure. A preferred art-recognized nucleating agent for fluoropolymer resins is boron nitride, an inert white ceramic powder. A 0.5-2.0 weight % loading of boron nitride, based on polymer, normally provides adequate foam cell nucleation. The lower the specific gravity of the molten resin, the more nucleant is needed, on a weight basis. Thus, an ethylene(E)/tetrafluoroethylene(TFE) copolymer(ETFE copolymer) with a melt specific gravity of about 1.3 requires more nucleant than a tetrafluoroethylene(TFE)/hexafluoropropylene(HFP) copolymer(TFE/HFP copolymer) at a melt specific gravity of 1.6.

U.S. Pat. No. 4,764,538 discloses synergistic combinations of boron nitride and certain inorganic salts which give greatly enhanced foam nucleation in fluoropolymers. This combination not only allows a significant reduction in the amount of boron nitride needed but also gives improved foam in terms of smaller cells. Improved capacitance and diameter uniformity are also attained.

The present invention provides a special class of sulfonic and phosphonic acids, and salts of the acids, which give very efficient nucleation of a wide variety of thermoplastic materials at low concentrations without the use of boron nitride or any other traditional type of nucleating agent.

As used herein the term "thermoplastic" means and is intended to include any organic material that is rendered soft and moldable by application of heat (Hackh's Chemical Dictionary, Julius Grant, 4th edition, McGraw-Hill Book Company, New York, N.Y.). Other terms used synonymously herein with "thermoplastic" and "thermoplastic material" are "thermoplastic resin" and "polymer," it being understood that the resin or polymer must be capable of being rendered soft and moldable by application of heat, that is, it is melt processible. The term "composition" as it is used herein is intended to include the thermoplastic material and other ingredients or additives which, individually, may or may not be melt processible, as will be discussed in greater detail in the Detailed Description of the Invention.

The compositions of this invention are useful in producing foams for other applications as well as for wire coating. Such examples include, but are not intended to be limited to, foamed sheet for electrical insulation, heat insulation and cushioning; foamed pipe and tubing; and injection molded pieces.

SUMMARY OF THE INVENTION

This invention resides in a foamable thermoplastic resin composition containing as a nucleating agent a nucleating-effective amount of at least one compound which is thermally stable at the melt temperature of the extrusion and is selected from sulfonic and phosphonic acids, and salts of the acids, which compositions significantly enhance foam nucleation, as evidenced by smaller foam cells, higher foam void contents, and/or greater uniformity of cell size. These compositions contain 50 to 8000 ppm, preferably 250 to 3000 ppm, by weight, for most compositions, of one or more of the acids and/or salts which are of the formula

Z(CF.sub.2).sub.x (CF.sub.2 CFX).sub.p (R').sub.y (CH.sub.2).sub.z RO.sub.3 ].sub.n M wherein: the bivalent groups, for RO.sub.3, may be present in any sequence; Z is CCl.sub.3, CCl.sub.2 H, H, F, Cl or Br; each X, independently, is selected from H, F, Cl and CF.sub.3; R is sulfur or phosphorus; M is H or a metallic, ammonium, substituted ammonium or quaternary ammonium cation; x is an integer and is 0 to 20; p is an integer and is 0 to 6; y is 0 or 1; z is an integer and is 0 to 20; x+y+z+p is a positive integer or, if x +y+z+p is 0, Z is CCl.sub.3 or CCl.sub.2 H; n is the valence of M; and R' is selected from a C.sub.5-6 perfluorinated alicyclic ring diradical; a C.sub.1-16 perfluorinated aliphatic polyether diradical with repeat units selected from [CF.sub.2 O], [CF.sub.2 CF.sub.2 O], and [CF.sub.2 CF(CF.sub.3)O]; and a substituted or unsubstituted aromatic diradical, in which case, Z is H.

By "foamable, thermoplastic resin composition" is meant any thermoplastic resin composition that is foamable by means of a gas injection process or through use of a chemical blowing agent.

Preferably, M is a metallic cation. When M is H, the resultant sulfonic or phosphonic acid may not be effective in all thermoplastic resin compositions. When M is selected so as to be other than a metallic cation or H, it preferably should be such that the resulting nucleating agent is stable at the foam processing temperature. Failure to provide such consideration in the selection of M may lead to in situ decomposition of the cationic moiety, with resultant conversion of M to H. The significance of this aspect of the invention will be readily understood in view of the significance of M on the foaming process, as described hereinafter in the Detailed Description of the Invention

The stability of the nucleating agent at the foam processing temperature must be considered not only in connection with the selection of M but also in connection with the selection of the other symbols in the above formula. More specifically, it is to be understood that the nucleating agent should be stable at the foam processing temperature which can vary substantially depending on the thermoplastic being foamed. Thus, in the above formula, when each of x, p and y is 0, z is 1 to 10 and Z is CCl.sub.3 or CCl.sub.2 H, the resultant nucleating agent, for example, trichloroethane sulfonic acid or its M salt will be stable at normal polyethylene foam-processing temperatures, such as below about 315.degree. C., but it will not be stable at the temperature needed to foam high-melting thermoplastics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides graphical data which may be used in the selection of M in the formula for the nucleating agent (a TBSA salt, defined hereinafter) in the foaming of TFE/HFP copolymer. FIG. 2 provides graphical data which may be used in the selection of M in the formula for the nucleating agent (a TBSA salt) in the foaming of polyethylene.

DETAILED DESCRIPTION OF THE INVENTION

The thermoplastic resins useful in the present invention include all such resins which can be foamed by a gas injection process and/or by use of a chemical blowing agent. In particular, suitable thermoplastics are those with a dielectric constant of less than 18, preferably less than 12, for example, 10.2 (Example 15 herein). Especially suitable for making foamed electrical insulation by this invention are those resins with a dielectric constant of less than 3. Following is a list of thermoplastic materials, most of which are commercially available, and their dielectric constants relative to air having

______________________________________PTFE or TFE/HFP Copolymer 2.0TFE/PAVE Copolymer 2.1Polypropylene 2.25Polyallomers 2.25Polyethylene 2.3ETFE Copolymer 2.6E/CTFE Copolymer 2.6EVA Copolymer 2.75-2.8Polycarbonate 2.96Polyimide 3.0-3.5Polysulfone 3.13PVC 4.5-5.8Nylon 4.5PVF.sub.2 2.98-8.4Urethanes 6.7-7.5Neoprene @ 1000 KM 16-17______________________________________

Preferred examples of suitable thermoplastics include melt processible fluoropolymers; polyolefins; copolymers of alpha-olefins and alpha, beta-unsaturated carboxylic acids having 3 to 8 carbon atoms, and their metal salts of Groups I to III of the Periodic Chart of the Elements. Examples of other operable thermoplastics include polystyrenes; polyamides; polyesters; vinyl polymers, such as polyvinyl chloride; uncured natural and synthetic rubbers; and the broad class of resins known as thermoplastic elastomers. It is to be further understood that the thermoplastic resins which are useful herein include copolymers such as styrene copolymers, acrylonitrile/butadiene/styrene polymers, and blends thereof, and blends of polymers with non-polymeric materials, for example, pigments, fire retardants, minerals and carbon, that is, any material commonly present in foamed compositions. In other invention is useful with any virgin or blended resin that is capable of being foamed by a gas injection process or by means of a chemical blowing agent.

Foamed fluoropolymer wire insulation, one of the preferred embodiments of this invention, is generally produced in the art by a continuous, gas injection process using chlorodifluoromethane(F-22), nitrogen, carbon dioxide, or other gas or gas mixture which is soluble in the molten resin, using an extruder screw designed for foam operations, and using boron nitride as a nucleating agent. In such processes the gas dissolves in the molten resin inside the extruder. Absorption follows Henry's Gas Law which states that the equilibrium value of the mole fraction of gas dissolved in a liquid is directly proportional to the partial pressure of the gas above the liquid surface. By adjusting the gas pressure in the extruder, the amount of gas dissolved in the melt can be controlled. Generally, the greater the amount of gas dissolved in the melt, the greater the void volume in the resulting foam.

Chlorodifluoromethane(F-22) is especially suited for foaming because it easily dissolves in molten fluoropolymer resins, and its thermal stability is adequate to survive the holdup time in the extruder when mixed with molten resin at temperatures up to 380.degree. C.

As an alternative process, a chemical blowing agent (a chemical which is unstable at the polymer processing temperature and liberates a gas, such as nitrogen, carbon dioxide or hydrogen) can be incorporated into the thermoplastic to provide the dissolved gas which causes bubble formation.

Foam cell formation actually starts shortly after the molten resin containing the blowing agent passes out of the extrusion die. The gas dissolved in the molten resin comes out of solution because of the sudden drop in melt pressure as the extrudate exits the extrusion die. As shown in U.S. Pat. No. 4,764,538, extrusion speed and drawdown influence foaming. The polymer is solidified when the extrudate enters water in a cooling trough, stopping foam cell growth.

A nucleating agent is needed to achieve uniform, small-diameter cell structure. The preferred commonly used nucleating agent for fluoropolymer resins has been boron nitride, an inert white ceramic powder. The present invention covers a special family of sulfonic and phosphonic acids, and salts of the acids, which give very efficient nucleation at low concentrations. The optimum nucleating agent and concentration depend on the specific polymer and conditions employed in the foaming process.

The nucleating agent of this invention can be blended with virgin or blended polymers, as powder or pellets, and extruded to give a homogeneous composition containing the desired amount of the nucleating agent, generally 50-8000 ppm, preferably 250-3000 ppm. Alternatively, the agent can be added to the virgin or blended polymer as a concentrate which may contain 5-20 times the desired amount of nucleating agent, and then the concentrate is mixed with 20-5 parts of virgin or blended polymer before the foaming step.

With chemically blown compositions the blowing agent and nucleating agent can be blended with virgin or blended polymer powder and either compacted into pellets at room temperature to avoid premature decomposition of the blowing agent, or extrusion-compounded at a temperature at which the blowing agent is not decomposed to a substantial extent.

FIG. 1 and Examples 2 and 3 show how routine experimentation can help select the best cation for foaming a particular resin (TFE/HFP copolymer) with a room temperature dielectric constant of 2.05 with CHF2Cl using a salt of Telomer B sulfonic acid(TBSA). Telomer B sulfonic acid is of the formula F(CF.sub.2).sub.n CH.sub.2 CH.sub.2 SO.sub.3 H wherein n is a mixture of 6, 8, 10 and possibly 12, predominantly 8. The results for different cations are plotted on the FIG. 1 graph using the atomic radius of the cation as abscissa and cation valence as ordinate; above the point for each cation is shown the minimum average diameter of the foam cells in micrometers for the optimum concentration tested. It is desirable to have very small cells and high foam void content. It can be seen in FIG. 1 that the cations giving cell diameters equal to or less than about 200 micrometers fall between the two outer lines (the preferred range). The cations giving still smaller cell diameters, equal to or less than about 75 micrometers, fall between the two inner lines (optimum range). As is apparent, for TFE/HFP copolymer the best cations are Zr.sup.++++, Fe.sup.+++, and Ba.sup.++.The preferred nucleating agent concentration for these cations with this copolymer is 500-2000 ppm. Thus, FIG. 1 provides a means for predicting how other salts of TBSA will perform in TFE/HFP copolymers with CHF.sub.2 Cl as blowing agent. Similar performance is observed when the thermoplastic resin is a copolymer of tetrafluoroethylene and a perfluoro(alkyl vinyl ether), such as perfluoro(propyl vinyl ether).

Table 1 which follows shows the great difference in nucleating efficiency of various bivalent salts of TBSA in the experiments depicted in FIG. 1. It also shows that efficient nucleation results in both high void content in the foam and small diameters of the foam cells.

In Table 1 and in all the remaining tables herein, the following abbreviations are used:

SPC: Specific Void Content AFCD: Average Foam Cell Diameter (at mid-wall) M: Micrometers %V: % Voids in Foam as Calculated from the Measured Dielectric Constant cc/cm.sup.3 Cell Count/cm.sup.3 at the Specific Void Content Conc. Concentration Ex St: Extrusion Stability DC: Dielectric Constant FCC: Foam Core Capacitance (lowest value) pF/m: Picofarads/meter C: Capacitance TABLE 1______________________________________TBSA AFCDSalt cc/cm.sup.3 % V (M)______________________________________Barium 2,300,000 55 75Strontium 763,000 59 100Calcium 72,200 41 220Zinc 24,800 20 508______________________________________

FIG. 2 and Example 11 show a similar plot for a polyethylene which has a room temperature dielectric constant of 2.3. Salts of the same TBSA (as in FIG. 1 and Examples 2 and 3) were used, with nitrogen as the blowing agent. FIG. 2 has the same general appearance as FIG. 1, but a narrower optimum range has been chosen (cell diameters equal to or less than about 50 micrometers), and the polymer and blowing agent are different. FIG. 2 shows that with this polyethylene the preferred TBSA salts are those of Cr.sup.+++, Fe.sup.+++, and Ca.sup.++. The preferred nucleating agent concentration for these cations with this polymer is 1000-3000 ppm.

One might expect that fluorine-free salts, such as sodium lauryl sulfate, would be effective nucleating agents for polyethylene, just as the fluorine-containing salts of this invention are for fluoropolymers. Surprisingly, this is not always the case, as shown by Comparative Example B between Examples 11 and 12 herein. Comparative Examples A and B show, also, the inoperability of other compounds as nucleating agents.

Also demonstrated in the examples herein are foamed compositions comprising ethylene/tetrafluoroethylene copolymers. Preferred nucleating agents for such resins include the calcium salt of Telomer B sulfonic acid and the potassium salt of a perfluorinated alkane sulfonic acid of 1-10 carbon atoms. A preferred concentration of such nucleating agents, based on the composition, is 1000 to 3000 ppm.

The broad applicability of the invention is further demonstrated in the examples using polyolefins as the thermoplastic resin. Examples of polyolefins include, but are not limited to, polyethylenes, linear and branched, low density and high density. Blends of polyethylenes, and blends of polyethylene or polyethylenes with other thermoplastic resins are operable herein. Preferred nucleating agents with polyethylene-containing thermoplastic resins are the potassium salt of perfluorooctane sulfonic acid, and the calcium, iron or chromium salt of TBSA, at a preferred concentration of 1000 to 3000 ppm, based on the composition.

In general, polymers having high dielectric constants respond best to TBSA salts with small cation radius and low valence. As the acid strength and/or chain length of the salt anion change in any given polymer, the optimum cation also tends to change. In the polyethylene of Example 11 the optimum cation for a TBSA salt is chromium, whereas with a perfluorooctanesulfonic acid the optimum cation is potassium; with trifluoromethanesulfonic acid, sodium is the best cation of those tested. Thus, as the strength of the sulfonic acid increases and/or chain length decreases, the optimum cation moves down or to the left in a plot, such as in FIG. 2. The phosphonic acids, and their salts, of this invention give results similar to those described above for the sulfonic acids and their salts. It is to be understood that routine experimentation may be required to find the optimum cation and anion for each thermoplastic, with dependence also on variables such as the molecular weight distribution of the thermoplastic, the polarity of the gas used, and the extrusion temperature. However, as demonstrated herein, efficient nucleation is achievable with the nucleating agents of the invention in a wide variety of polymers.

The present invention provides means for producing foamed thermoplastics having a combination of a uniformly small cell size, less than 400 micrometers, and a very high void content, greater than 50%. For example, using TFE/HFP copolymer thermoplastics, cell sizes of less than 100 micrometers (average) and void contents of greater than 60% can be achieved. Using polyethylene thermoplastics, cell sizes of less than 100 micrometers (average) and void contents of greater than 50% can be achieved. Foams of similar structure (as with polyethylenes) can also be produced using E/TFE copolymers as the thermoplastic.

EXPERIMENTAL DETAILS

In the examples herein the foaming process was carried out by either a continuous gas injection foaming process or by extruding a composition containing a chemical blowing agent in the same extruder, with no gas injection.

The continuous gas injection foaming process was normally carried out using chlorodifluoromethane (F-22) or nitrogen as the blowing agent. Other known blowing agents could be used to give substantially the same results. The foam void level was controlled by the pressure of the blowing agent. The extruder screw design allowed for gas injection and had a mixing torpedo (as disclosed in U.S. Pat. No. 3,006,029) to provide a uniform melt. This mixing torpedo allowed each resin cube blend to become a uniform melt mixture while traversing the length of the screw.

Nucleated compositions for the gas injection process can be prepared by cube blending of the resin (melt cut or strand cut) with a nucleating agent concentrate prepared by blending the sulfonic or phosphonic acid, or its salt, in the form of a powder, with resin powder and/or cubes, and extruding on a 28 mm Werner & Pfleiderer (W&P) twin screw extruder with a strand cutter to pelletize. The resulting cube blends were fed directly to the wire coating extruder hopper.

ETFE copolymer compositions containing chemical blowing agents were prepared by blending the chemical blowing agent and nucleating agent with polymer powder and compacting into cylindrical pellets about 3 mm in diameter and 6 mm in length with a lab model California Pellet Mill. These pellets were fed directly to the wire coating extruder hopper.

Foam cell size was determined at mid-wall of the foam by visual examination with a microscope or by taking a picture of a thin section of foamed wire insulation at 20-30.times. magnification and visually determining average cell size. In some examples the number of cells/cm.sup.3 is also given. This value calculated from the foam void level and the average cell diameter.

Additional abbreviations used in the examples are shown in Table 2. In reciting specific polymer compositions in the table, there is no intent to limit the scope of the polymers operable herein to those specific compositions. Typical conditions used in the examples that follow are shown in Table 3. Regarding Table 3, in Column C a Maillefer extruder was used to produce the foam and an Entwistle extruder was used to produce the skin. In Column H the extruder was a Davis-Standard. In all other columns the extruder was an Entwistle. Further regarding Table 3, in Column A, a B&H 75 crosshead was used; in all other columns the crosshead was a Maillefer 4/6F. Finally, the Column C conditions were carried out to produce a foam-skin construction, using two extruders and a single crosshead.

Foam cell size depends not only on the nucleating agent, but also on other variables, such as wire speed and, in the case of melt draw extrusion, cone length (the distance from the die exit to the point where the molten tubular polymer forms on the wire), as explained in U.S. Pat. No. 4,764,538. Cone length is related to the applied vacuum inside the cone.

TABLE 2______________________________________TFE/HFP copolymer a copolymer of 12.3 wt % HFP and the balance TFE with a melt flow rate of 6.6 at 372.degree. C. as measured by ASTM D-2116-83PAVE perfluoro(alkyl vinyl ether)EVA Ethylene/Vinyl AcetatePVF.sub.2 Poly(vinylidene fluoride)boron nitride SHP-325 grade from Carborundum Corp., having a BET surface area of 8.6 m.sup.2 /gpolyarylate aromatic polyester of Bisphenol A and isophthalic acid, with a melt viscosity at 330.degree. C. of 1600 Pa.s at 100 sec.sup.-1 and 2800 Pa.s at 10 sec.sup.-1E/TFE copolymer copolymer of 19.6 wt % ethylene, 2.2 wt % perfluorobutyl ethylene, and the balance TFE, with a melt flow rate of 14 at 297.degree. C. by ASTM D-3159-83Ficel .sup..RTM. Ficel .sup..RTM. AF-100 formulated zinc compound, a chemical blowing agent from Sherex Chemical Co.Expandex .sup..RTM. Expandex .RTM. 175, barium salt of 5-phenyl tetrazole, a chemical blowing agent of Olin Chemicals, Stamford, ConnecticutTFE/PPVE(1) copolymer copolymer of TFE and 3.9 wt. % perfluoro(propyl vinyl ether), with a melt viscosity of 2.2 .times. 10.sup.4 poise at 372.degree. C.TFE/PPVE(2) copolymer copolymer of TFE and 3.9 wt. % perfluoro(propyl vinyl ether), with a melt viscosity of 4.25 .times. 10.sup.4 poise at 372.degree. C.E/CTFE copolymer copolymer of ethylene and chlorotrifluoroethyleneFEP copolymer copolymer of TFE and 12.3 wt. % hexafluoropropylene, with a melt flow rate of 6.6 at 372.degree. C. (ASTM D-2116-83)ZrS-10 zirconium (+4) salt of TBSACrS-10 chromium (+3) salt of TBSACeS-10 cerium (+4) salt of TBSAKS-10 potassium salt of TBSAHS-10 TBSAAS-10 aluminum salt of TBSASrS-10 strontium salt of TBSACaS-10 calcium salt of TBSAZnS-10 zinc salt of TBSABaS-10 barium salt of TBSALS-10 lithium salt of TBSAFS-10 iron (+3) salt of TBSATEAS-10 triethylamine salt of TBSABS-6A barium p-(perfluoro[1,3- dimethylbutyl]) benzene sulfonateBS-9A barium p-(perfluoro[1,3,5- trimethylhexyl]) benzene sulfonateBaS-A1(H) barium p-toluene sulfonateBaP-A barium benzene phosphonateNaP-A sodium benzene phosphonateNaS-A(II) 4,5-dihydroxy-m-benzene disulfonic acid disodium saltBS-8 barium perfluorooctane sulfonateKS-8 potassium perfluorooctane sulfonateKS-8C potassium perfluorocyclo- hexylethane sulfonateNaS-1 sodium trifluoromethane sulfonateKS-1 potassium trifluoromethane sulfonateKS-1(H) potassium methane sulfonateBaS-3(H) barium propane sulfonateNaTCA sodium trichloroacetateBTBP barium salt of F(CF.sub.2).sub.n CH.sub.2 CH.sub.2 PO.sub.3 H wherein n is a mixutre of 6, 8, 10 and possibly 12, predominantly 8NTBP sodium salt of F(CF.sub.2).sub.n CH.sub.2 CH.sub.2 PO.sub.3 H wherein n is a mixture of 6, 8, 10 and possibly 12, predominantly 8LL1121B barium perfluoro(2,5- dimethyl)-3,6-dioxatridecanoateBC14(06) barium perfluoro 3,5,7,9,11,13- hexaoxatetradecanoateBS-12(H) barium lauryl sulfateNS-12(H) sodium lauryl sulfateCC-18(H) calcium stearateBaC-8 barium perfluorooctanoateBaC-9 barium perfluorononanoateAWG-26 Solid copper wire 404 micrometers in diameterAWG-24 Solid copper wire 510 micrometers in diameterAWG-22 Solid copper wire 635 micrometers in diameter______________________________________ TABLE 3__________________________________________________________________________ A B C D E__________________________________________________________________________Type Foaming Gas Injec- Gas Injec- Gas Injection Gas Injec- Chemical tion, F-22 tion, F-22 F-22 tion, F-22 BlowExtruderDiameter (mm) 31.75 31.75 60 mm 25.4 31.75 31.75L/D Ratio 30/1 30/1 30/1 20/1 30/1 30/1Type Melt Draw Pressure Pressure Pressure PressureExtrusionScrew DesignZoneFeed 4.06/10 3.81/10 4.45/10 4.57/12 3.81/10 6.6/13Metering 1.02/4 0.86/3.7 .97/4.0 -- 0.86/3.7 --Gas 3.56/4 3.42/3.25 5.1/3.5 -- 3.42/3.25 --Pumping 1.57/5 1.32/4.25 1.47/6.0 1.9/4 1.32/4.25 2.54/8Mixing 3.81/5.5 5.96/3.5 7.1/4.0 3.6/3.7 5.96/3.5 3.81/5.5Temperatures (.degree.C.)Rear 360 315 329 304 332 250Center Rear 382 315 315 260 285Center 371 315 260 285Center Front 382 315 268 320Front 382 315 321 315 273 330Adaptor 371 315 315 315 223 315X Head 326 325 327 282 320Die 326 330 329 282 320Melt 387 320 343 125 285Screw Speed 80 60 41 72 6Air Gap 4.5 4.6 10 4.6 4.6(meters)Wire Size (mm) 0.643 0.51 0.51 0.58 0.643Wire Speed 18 41 838 22 34(m/min.)Wire Preheat 65 132 223 104 65(.degree.C.)Crosshead Melt 14(FEP) 4.9 13.8 4.9 11.7Pressure(MPa)Gas Pressure 0.7 0.7 0.5 0.7 None(IKPa)Vacuum (mm Hg) 380 None None None NoneDie (mm) 5.05 1.32 0.73 1.32 0.914Guide Tip (mm) 1.91 0.59 0.56 0.59 0.685Foam Core Size 3.30 2.03 0.83 1.45 1.15(mm) to 1.9__________________________________________________________________________ F G H I J__________________________________________________________________________Type Foaming Gas Injec- Chemical Chemical Gas Injec- Gas Injec- tion, N.sub.2 Blow Blow tion, N.sub.2 tion, N.sub.2ExtruderDiameter (mm) 31.75 31.75 50.8 mm 31.75 31.75L/D Ratio 30/1 30/1 28/1 30/1 30/1Type Pressure Pressure Pressure Pressure PressureExtrusionScrew DesignZoneFeed 3.81/10 6.6/13 8.25 3.81/10 4.06/10Metering 0.86/3.7 Note: long 0.86/3.7 1.02/4 transitionGas 3.42/3.25 3.42/4.25 3.56/4Pumping 1.32/4.25 2.54/8 6.6/10 1.32/4.25 1.57/5Mixing 5.96/3.5 3.81/5.5 5.96/3.5 3.81/5.5Temperatures (.degree.C.)Rear 260 160 326 299 165Center Rear 232 188 332 299 177Center 232 201 332 291 165Center Front 254 201 321 288 168Front 273 201 321 282 171Adaptor 273 204 357 279 182X Head 288 204 360 282 177Die 288 204 371 282 177Melt 278 210 343 282 178Screw Speed 80 70 5 40 25Air Gap 4.6 4.6 10 4.6 4.5(meters)Wire Size (mm) 0.508 0.51 0.406 0.508 0.51Wire Speed 48.6 43 30 20 7.6(m/min.)Wire Preheat 99 82 150 93 none(.degree.C.)Crosshead Melt 9.6 23.4 4.8 5.2 5.2Pressure(MPa)Gas Pressure 2.1 None None 2.4 2.1(IKPa)Vacuum (mm Hg) None None None None NoneDie (mm) 1.3 1.3 0.56 1.6 2.1Guide Tip (mm) 0.64 0.56 0.43 0.58 0.56Foam Core Size 2.15 2.3 0.7 2.28 .about.2.5(mm)__________________________________________________________________________ Note: Balance of Extruder screw 1/d lengths are transitions and the screw front tip.

EXAMPLE 1

A. TFE/HFP copolymer was cube blended with a 5 weight percent boron nitride concentrate (compounded with TFE/HFP copolymer in a 28 mm W&P twin screw extruder as described earlier) in the ratio needed to give a product with 0.25% boron nitride.

B. A second composition was prepared from TFE/HFP copolymer by blending a 5 weight % boron nitride concentrate plus a 0.3 weight % KS-10 concentrate to give 0.25% boron nitride and 330 ppm KS-10.

C. A third composition was prepared from TFE/HFP copolymer by blending with a 5 weight percent boron nitride concentrate plus a concentrate containing 0.3% calcium tetraborate to give 0.25% boron nitride and 125 ppm calcium tetraborate.

D. A fourth composition was prepared from TFE/HFP copolymer by blending with a 5 weight % boron nitride concentrate plus a concentrate containing 0.3% calcium tetraborate and a 0.3 weight % TBSA concentrate to give 0.25% boron nitride and 125 ppm calcium tetraborate plus 330 ppm of TBSA.

These four compositions were extruded onto wire under the conditions of Table 3, Column A with the following results:

TABLE 4______________________________________ AFCDComposition % V (M) cc/cm.sup.3______________________________________A. 55 381 18,000B. 60 152 312,000C. 55 100 2,800,000D. 58 76 12,000,000______________________________________ As seen from these results, the KS-10 can be used with boron nitride, and it gives enhanced foam nucleation. Similarly, TBSA can be used in conjunction with boron nitride and calcium tetraborate, and it gives enhanced nucleation.

EXAMPLE 2

TFE/HFP copolymer was blended with a 5% boron nitride concentrate and with a 0.3% BaS-1 concentrate to give the compositions shown in Table 5. Each composition was foamed onto wire using the conditions of Table 3, Column A.

TABLE 5______________________________________ Conc. AFCDAdditive (ppm) (M)______________________________________None -- 635Boron nitride 5000 125BaS-10 125 760BaS-10 500 100BaS-10 1000 75BaS-10 1500 255______________________________________ As shown above, BaS-10 is a very effective nucleant at low concentrations compared with boron nitride, a traditional nucleating agent used with TFE/HFP copolymers. It should also be noted that there is an optimum concentration for the BaS-10 nucleating agent.

EXAMPLE 3

Samples of TFE/HFP copolymer containing several concentrations of various salts of TBSA were prepared by blending virgin resin with the appropriate ratio of concentrate containing 0.3% of the fluorosulfonic acid salt. These compositions were foamed onto wire as described in Table 3, Column A, with the results shown in Table 6. The last column shows the deviation from the average diameter (3300 micrometers) of the foam insulated wire.

TABLE 6______________________________________ Conc. AFCD DeviationAdditive (ppm) (M) % V (M)______________________________________Boron 5500 127 58 .+-.76nitride(control)ZrS-10 75 685 61 .+-.127 300 387 58 .+-.127 500 76 67 .+-.76 1000 76 65 .+-.76 2000 203 65 .+-.127 3000 203 56 .+-.127CrS-10 75 635 52 .+-.50 300 431 59 .+-.76 500 101 62 .+-.50 1500 127 62 .+-.50 2000 89(a) 37 -- 3000 (b) (b) --CeS-10 63 559 63 .+-.127 250 635 65 .+-.127 500 762 72 .+-.127 1000 381 66 .+-.76 2000 178 67 .+-.76 3000 127 62 .+-.50KS-10 63 762 78 .+-.127 250 304 65 .+-.76 500 241 66 .+-.76 1000 228 64 .+-.76 2000 (b) (b) --HS-10 63 762 61 .+-.76 250 203 65 .+-.76 500 127 64 .+-.76 1000 127 61 .+-.76AS-10 500 889 60 .+-.100 1000 127 58 .+-.50 2000 139 60 (b)SrS-10 500 139 58 .+-.100 2000 127 59 .+-.75 3000 228 57 .+-.127CaS-10 500 203 41 .+-.76 1000 228 41 .+-.100 1500 406 41 .+-.127Zn-10 1000 508 20 .+-.127 2000 381 20 .+-.127 3000 381 20 .+-.127BaS-10 125 762 20 (c) 500 101 55 .+-.50 1000 76 55 .+-.50 1500 254 40 .+-.150LS-10 500 178* 55 .+-.75 1000 178* 56 .+-.75FS-10 75 406 52 .+-.250 150 101 55 .+-.50 300 101 58 .+-.50 500 76 55 .+-.50 1000 76 55 .+-.59______________________________________ *Cells collapsed to ellipses to the indicated minor diameter. If these cells were spherical cells, they would be 280 micrometers in diameter. (a)open cells (b)gas injector probe plugged (c)no record As seen above, all of these fluorosulfonic acid salts (and the HS-10 itself) function as nucleating agents. Some are much better than others and the performance of each one varies with concentration. In addition to cell size and void content variation, there are significant fluctuations in diameter and capacitance.

EXAMPLE 4

A series of samples containing various levels of salts of three other types of sulfonic acids and a phosphonic acid were also prepared, extended in TFE/HFP copolymer and foamed onto wire, as described in EXample 3, with the results shown in Table 7. The last column shows the deviation from the average diameter (3300 micrometers) of the foam insulated wire.

TABLE 7______________________________________ Conc. AFCD DeviationAdditive (ppm) (M) % V (M)______________________________________BS-9A 500 762 75 (b) 1000 762 62 (b) 2000 381 60 .+-. 75 3000 253 54 .+-. 75BS-8 500 254 56 .+-. 100 1000 228 57 .+-. 75 2000 101 59 .+-. 50KS-8C 1500 635 40 .+-. 200 3000 400 40 .+-. 200BTBP 1500 64 80 .+-. 200 3000 25-67 .about.70(a) (c)______________________________________ (a)open cells (b)unstable; diameter control was poor (c)unstable; foaming in crosshead As seen from the above results, the three barium salts are effective as nucleating agents for TFE/HFP copolymers, whereas the potassium salt is not.

COMPARATIVE EXAMPLE A

In contrast to Examples 3 and 4, samples containing various levels of other types of salts (not within the invention) in TFE/HFP copolymers were prepared in the same manner-from concentrates containing 0.3% of the salt. These compositions were also foamed onto wire as described in Table 3, Column A with the results shown in Table 8.

TABLE 8______________________________________ Conc. AFCDAdditives (ppm) (M) % V______________________________________LL1121B 500 1016 65 1000 558 46 2000 1016 45 3000 1016 63BC14(06) 500 890 52 1000 762 55 2000 890 55 3000 1016 62BS-12(H) 500 431 57 1000 711 52 2000 889 57 3000 889 57CC-18(H) 500 685 60 1000 1270 62 2000 1524* 63BaC-8 500 635 46 1000 635 45BaC-9 500 1016 42 1000 762 53 1500 889 53______________________________________ *Foam cells blistered outside the insulation surface. All of the compositions gave large cell size (i.e., greater than 400 micrometers) an produced unstable capacitance and diameter in extrusion.

EXAMPLE 5

Compositions with tetrafluoroethylene(TFE)/perfluoro(propyl vinyl ether) (PPVE) copolymers (TFE/PPVE copolymers) were made up using a 0.3% concentrate of BaS-10 as described in Example 2. These compositions were foamed onto wire according to the conditions of Table 3, Column A. The results are shown in Table 9. The capacitance and diameter stability during extrusion are shown in the last column.

TABLE 9______________________________________ Conc. AFCDAdditive (ppm) (M) % V Remarks______________________________________TFE/PPVE(1)Boron nitride 5000 300 55 (a)(control)BaS-10 63 406 51 (b) 125 330 57 (b) 250 304 55 (b) 500 304 55 (b) 1000 102 55 (b) 2000 89 57 (b) 3000 127 54 (b)TFE/PPVE(2)Boron nitride 5000 255 55 (a)(control)BaS-10 500 286 57 (c) 1000 191 58 (c) 2500 51 60 (a) 3000 76 62 (a)______________________________________ (a)Steady extrusion (b)Head pressure very low in extrusion and some foaming in the crosshead occurred to make stability of the process borderline. This occurred because the extruder screw design was not optimized for TFE/PPVE(1). (c)Extrusion not steady As seen from these results, BaS-10 is an effective nucleating agent for TFE/PPVE copolymer resins. Note that there is an optimum concentration range to achieve th smallest cell size.

EXAMPLE 6

ETFE copolymer containing 2 wt. % boron nitride or varying amounts of fluorosulfonic acid salts as indicated in Table 10 was foamed onto wire at about 40 meters/minute according to the conditions of Table 3, Column B. This produced a 0.7 mm thick foamed insulation on AWG-24 solid copper wire having capacitance values near 60 pF/m at a foam void level of about 60% (Table 10 except for KS-8 and KS-8C). For KS-8 and KS-8C this produced a 0.28 mm thick foamed insulation on AWG-24 wire having capacitance values near 136 pF/m (a foam void level of about 42%). Relative foaming performance, as indicated by insulation diameter and capacitance variability and by foam cell size, is shown in Table 10. The last column shows the deviation from the average core diameter of 1900 micrometers and the deviation from the average capacitance of 62-69 pF/m, except for KS-8 and KS-8C wherein the deviations are from an average core diameter of 1068 micrometers and an average capacitance of 138 pF/m.

TABLE 10______________________________________ Conc. AFCD DeviationAdditive (ppm) (M) (M; pF/m)______________________________________None None 432 (b)LS-10 750 -- (a) 1500 -- (a) 3000 -- (a)CaS-10 750 76 1500 51 (c) .+-. 13; .+-. 0.3* 3000 51BaS-10 750 178 1500 178 (c) .+-. 38; .+-. 1.5 3000 178ZnS-10 750 432 1500 432 (d) .+-. 40; - 15 3000 432AS-10 750 500 1500 432 (d) .+-. 50; - 15 3000 483FS-10 750 635 1500 635 (c) .+-. 10; .+-. 0.3KS-8 250 127 500 114 1000 76 (c) .+-. 10; .+-. 0.3 2000 50 3000 89KS-8C 250 178 500 152 (c) .+-. 10; .+-. 0.3 2000 64 3000 38-76______________________________________ (a) gas injector probe plugged (b) low void content, 32% unstable extrusion (c) extrusion foaming stable (d) extrusion foaming unsteady *capacitance average of 57 pF/m

EXAMPLE 7

BaS-10 was evaluated as a nucleating agent for ETFE copolymer in a high speed extrusion (625 m/min.) of thin wall foam-skin insulation on AWG-24 solid copper wire. Conditions used are given in Table 3, Column C and the results are given in Table 11. A dielectric constant of 1.7 corresponds to a foam void level of 48%.

TABLE 11______________________________________ C Diameter Foam AFCD ExAdditive (pF/m) (M) DC (M) St______________________________________2% BN 121.4 .+-. 1.0 1092 .+-. 50 1.68 50 (a)(Control Resin) 500 ppm 132.2 .+-. 0.3 1049 .+-. 13 1.71 50 (b)BaS-101000 ppm 125.3 .+-. 0.3 1054 .+-. 13 1.63 38 (c)BaS-102000 ppm 131.2 .+-. 0.3 1049 .+-. 13 1.70 25 (b)BaS-103000 ppm 128.9 .+-. 1.6 1049 .+-. 25 1.68 50 (b)BaS-10______________________________________ (a) Good, steady (b) A few capacitance spikes. These positive spikes in the capacitance chart record occurred every 5-8 minutes. (c) Excellent, very steady As seen from the above results, BaS-10 not only gives small cell size but it also improves both diameter and capacitance control in this miniature foam.

EXAMPLE 8

An E/CTFE copolymer (Halar.RTM. 500 available from Ausimont Chemical Co.) was foamed with CHF.sub.2 Cl gas injection using a start-stop extrusion procedure. This technique was necessary to avoid immediate plugging of the gas injection probe (improper screw design). The foaming process was carried out according to the conditions given in Table 3, Column D. Nucleated compositions were prepared using a 0.3% concentrate of the salt in the copolymer. The results are given in Table 12.

TABLE 12______________________________________ Conc. FCC Foam % AFCDAdditive (ppm) (pF/m) DC V (M) cc/cm.sup.3______________________________________None 0 98.4 2.01 28 304 336,000CaS-10 1500 96.8 2.20 20 203 800,000CaS-10 3000 75.5 1.78 43 102 15,000,000______________________________________ As seen from the results, CaS-10 is a very effective foam nucleant.

EXAMPLE 9

HAP-E/TFE, a chemical-blown ETFE copolymer foam resin commercially available from Chromatics, Inc. (Bethel, Conn.) was foamed onto wire with and without added BaS-10 using the extrusion setup shown in Tab)e 3, Column E. In each case, the HAP-E/TFE (210 grade) was blended into a 50/50 mix with ETFE copolymer (one virgin and one containing 0.3% BaS-10). The results are shown in Table 13.

TABLE 13______________________________________ No Added Added Nucleant Nucleant 1500 ppm BS-10______________________________________Solid AWG-22 Dia (mm) 0.635 0.635C (pF/m) 91.9 74.2Stability of C (pF/m) .+-.3.3 .+-.0.7Foam Diameter (mm) 2.39 2.54D C 2.0 1.85% V 30 35AFCD (M) 230 38cc/cm.sup.3 at 33% voids 38,000 13,000,000______________________________________ As seen from the results, this nucleating agent is very effective in this system.

EXAMPLE 10

Chemical-blown ETFE copolymer compositions were prepared by dry blending powdered ETFE copolymer with Ficel.RTM. and the sulfonic acid salt indicated in Table 14. The blends were pelletized in a lab scale California Pellet Mill before evaluation. The compositions were foamed onto wire according to conditions given in Table 3, Column E. The results are given in Table 14. In each case the amount of blowing agent was 0.38 wt. %.

TABLE 14______________________________________Additive BaS-10 CaS-10 KS-8 KS-8Conc. 1000 ppm 1000 ppm 1000 ppm 3000 ppm______________________________________C (pF/m) 170.6 175.5 198.4 183.7Foam Diameter 1.17 1.15 1.10 1.08(mm)DC 1.9 1.9 1.9 1.75% V 36 36 36 45AFCD (M) 76 51 51 38cc/cm.sup.3 1,500,000 6,500,000 6,500,000 18,000,000______________________________________ As seen from the results, these compositions give good quality foam with small cell size.

EXAMPLE 11

Blends of 98% of a broad molecular weight distribution linear high density polyethylene (0.964 g/cm.sup.3) having a melt index of 1.9 (standard method 190.degree. C./2.16 kg) and 2% of a high pressure branched polyethylene with a 0.929 g/cm.sup.3 density and a melt index of 1.9, containing various levels of sulfonic acid and phosphonic acid salts, were prepared from 0.3% concentrates and foamed as an approximately 60% void insulation onto wire using conditions given in Table 3, Column F. The results are given in Table 15. The last column shows the capacitance in pF/m and the deviation from the average diameter (2150 micrometers) of the foam insulated wire.

TABLE 15______________________________________ Conc. AFCDAdditive (ppm) (M) Remarks______________________________________None 0 360 (a) 55-88 pF/m; .+-. 150 MFS-10 60 229 150 165 750 63 (b) 52 .+-. 0.3 pF/m; .+-. 50 M 1500 51 3000 51CrS-10 60 203 150 152 750 102 (b) 52 .+-. 0.3 pF/m; .+-. 50 M 1500 51 3000 38KS-10 60 254 (a) 55-88 pF/m; .+-. 100 M 150 254 750 203 (a) 55-88 pF/m; .+-. 75 M 1500 127 (b) 52 .+-. 0.3 pF/m; .+-. 50 M 3000 237BaS-10 63 102 125 89 250 76 (b) 52 .+-. 0.3 pF/m; .+-. 25 M 500 68 1000 64 3000 64CaS-10 63 76 125 76 (b) 52 .+-. 0.3 pF/m; .+-. 25 M 250 64 1000 51KS-8 500 51 1000 43 (b) 52 .+-. 0.3 pF/m; .+-. 25 M 2000 33 3000 33KS-6A 500 89 1000 89 (b) 52 .+-. 0.3 pF/m; .+-. 25 M 2000 89 3000 51LS-10 63 152 125 178 (b) 52 .+-. 0.3 pF/m; .+-. 101 M 250 127 500 101 1000 127KS-8C 500 100 1000 75 (b) 52 .+-. 0.3 pF/m; .+-. 25 M 2000 64 3000 40NTBP 500 127 1000 76 (b) 56 .+-. 0.3 pF/m; .+-. 25 M 1500 25 3000 76NaS-1 500 76 (b) 56 .+-. 0.3 pF/m; .+-. 25 M 1000 64 (b) 3000 51 (b)KS-1 500 203 1000 178 (a) 52-88 pF/m; .+-. 75 M 3000 152KS-1(H) 500 330 (a) 69-85 pF/m; .+-. 50 M 1000 152 2000 89 (b) 56 .+-. 0.3 pF/m; .+-. 25 M 3000 64BaS-3(H) 500 175 62 .+-. 0.7 pF/m; .+-. 31 M 1000 38 (b) 60 .+-. 0.3 pF/m; .+-. 13 M 2000 60 59 .+-. 0.2 pF/m; .+-. 6 MBaP-A 1000 75 (b) 59 .+-. 0.2 pF/m; .+-. 13 M 2000 100 60 .+-. 0.2 pF/m; .+-. 25 MNaP-A 500 325 (a) 60-70 pF/m; .+-. 75 M 1000 100 (b) 59 .+-. 0.2 pF/m; .+-. 25 M 2000 100 59.5 .+-. 0.2 pF/m; .+-. 25 MBaS-A1(H) 1000 75 (b) 58 .+-. 0 pF/m; .+-. 25 M 2000 75 58.5 .+-. 0.1 pF/m; .+-. 25 MNaS-A(II) 1000 100 (b) 57.5 .+-. 0 pF/m; .+-. 38 M 2000 100 56.0 .+-. 0 pF/m; .+-. 25 MTEAS-10 1000 28 (b) 60 .+-. 0 pF/m; .+-. 25 M 2000 275 (a) 91 .+-. 16 pF/m; .+-. 100______________________________________ M (a) unstable capacitance (b) stable capacitance As seen from these results, all of these salts act as nucleants, with the KS-8 and KS-8C being especially effective. Of the S-10 salts, iron nd calcium are very effective nucleants.

COMPARATIVE EXAMPLE B

Several other types of organic acid salts were incorporated into the same polyethylene blend as specified in Example 11 and foamed onto wire using the conditions of Example 11. The results are shown in Table 16. The last column shows the capacitance and the deviation from the average diameter (2150 micrometers) of the foam insulated wire.

TABLE 16______________________________________ AFCD Conc. (% V = 60)Additive (ppm) (M) Remarks______________________________________None -- 475NS-12(H) 63 508 (b) 56 to 75 pF/m; .+-. 152 M 250 300 500 254 1000 406 2000 457CC-18(H) 500 457 (b) 56 to 75 pF/m; .+-. 152 M 1000 457 2000 457BS-12(H) 600 230 (b) 52 to 76 pF/m; .+-. 100 M 1200 230 1800 230(a) 2940 230(a)NS-12(H) 600 300 (c) 1200 380 (b) like BS-12(H)Na TCA 1000 304 (b) like BS-12(H) 2000 280 3000 254______________________________________ (a) Partial plugging of the gas injector probe (b) unstable extrusion (c) fairly stable As seen from the above results, these specific salts are not effective as nucleants for polyethylene.

EXAMPLE 12

A broad molecular weight distribution, high density polyethylene copolymer (density=0.945 g/cc, melt index=0.4, standard method 190.degree. C./2.16 kg) containing 0.75% by weight azodicarbonamide blowing agent was foamed into wire using the conditions given in Table 3, Column G. This was compared with two, similarly chemically-blown, blended polyethylene resins, one with BaS-10 added and one without. As seen from Table 17, the BaS-10 is a very effective nucleant for this chemically blown polyethylene system.

TABLE 17______________________________________ PE Blend High PE plus 1250 ppmProperties Density PE Blend BaS-10______________________________________C (pF/m) 6.52 6.04 5.64Foam Diameter (mm) 2.08 2.23 2.28DC 1.77 1.72 1.63% V 33 38 44AFCD (M) 34 41 34Cell Nature (a) (b) (b)cc/cm.sup.3 16,500,000 11,500,000 22,000,000______________________________________ (a) irregular and interconnecting cells (b) spherical and distinct separate cells

EXAMPLE 13

Polyarylate of the following composition was foamed according to the conditions given in Table 3, Column H.

polyarylate 2000 ppm BaS-10 powder (dry blend) 1250 ppm Expandex.RTM. chemical blowing agent

The resultant foamed composition comprised a 0.16 mm wire coating on AWG-26 solid copper wire. This coating was an excellent foam containing 30% voids with foam cells of 17 micrometers.

EXAMPLE 14

A nylon blend was foamed according to the conditions given in Table 3, Column I.

Zytel.RTM. 301 HS, nylon resin (commercially available) 5000 ppm KS-8, fully compounded

The comparison which was made in extrusion foaming, with and without KS-8 as the nucleating agent, is shown in Table 18.

TABLE 18______________________________________ AFCDResin % V (M) cc/cm.sup.3______________________________________Zytel .sup..RTM. 301HS 3 762 60Zytel .sup..RTM. 301HS 65 508 7,8005000 ppmKS-8______________________________________

EXAMPLE 15

A melt processible rubber (thermoplastic elastomer) having a dielectric constant of 10.2 was foamed according to the conditions in Table 3, Column J, producing the results, with and without KS-8 as the nucleating agent, shown in Table 19.

TABLE 19______________________________________KS-8 nucleant, ppm none 5,000% V .about.25 .about.40AFCD (M) 457 89cc/cm.sup.3 4.5 .times. 10.sup.3 1 .times. 10.sup.6______________________________________

The aforesaid description, including the examples, and the claims which follow are intended as a disclosure of the invention and preferred embodiments thereof. There is no intent to limit the invention to only those embodiments disclosed, since one skilled in the art will readily envision other embodiments from the teaching provided herein.

EXAMPLE 16

Polymer A of this example was a copolymer of ethylene and 12% methacrylic acid, 40% neutralized with a basic zinc compound, to give a polymer with a melt index of 10. Polymer B of this example was a high pressure, branched polyethylene with a density of 0.929 g/cm.sup.3 and a melt index of 1.9. A concentrate was made of 4% KS-8 in Polymer A. This concentrate was diluted with a blend of 98% Polymer A and 2% Polymer B to give various concentrations of KS-8 in the blends to be extruded, as shown in Table 20. These samples were extruded using the conditions of Table 3, column F. The average foam cell diameter results are shown in Table 20, as are the deviations from the average capacitance.

TABLE 20______________________________________ Conc. AFCDAdditive (ppm) (M) Remarks______________________________________None 0 241 .+-.3 pF/m*KS-8 500 76 .+-.1.5 pF/mKS-8 1000 51 .+-.1.5 pF/mKS-8 2000 51 .+-.0.7 pF/m______________________________________ *Very low void content (20%)

Claims

1. Foamable, thermoplastic resin extrusion composition containing as a nucleating agent a nucleating-effective amount of at least one thermally stable compound which is selected from the group consisting of sulfonic and phosphonic acids and salts thereof.

2. The foamable composition of claim 1 in which the nucleating agent is selected from

(a) free acids and salts of partially or totally fluorinated aliphatic sulfonic and phosphonic acids, which optionally may contain cycloalkyl groups and/or ether oxygen; and

(b) free acids and salts of aromatic sulfonic and phosphonic acids, in which the aromatic ring, optionally, is substituted with alkyl, fluorine-containing alkyl, and/or hydroxyl groups.

3. The foamable composition of claim 1 in which the nucleating agent is of the formula

[Z(CF.sub.2).sub.x (CF.sub.2 CFX).sub.p (R').sub.y (CH.sub.2).sub.z RO.sub.3 ].sub.n M

wherein:

the bivalent groups, except for RO.sub.3, may be present in any sequence;

Z is selected from CCl.sub.3, CCl.sub.2 H, H, F, Cl, and Br;

each X, independently, is selected from H, F, Cl and CF.sub.3 ;

R is selected from sulfur and phosphorus;

M is selected from H and a metallic, ammonium, substituted ammonium and quaternary ammonium cation;

each of x and z, independently, is an integer and is 0 to 20;

p is an integer and is 0 to 6;

y is 0 or 1;

x+y+z+p is a positive integer or, if x+y+z +p is 0, then Z is CCl.sub.3 or CCl.sub.2 H;

n is the valence of M; and

R' is selected from

a C.sub.5-6 perfluorinated alicyclic ring diradical;

a C.sub.1-16 perfluorinated aliphatic polyether diradical with repeat units selected from [CF.sub.2 O], [CF.sub.2 CF.sub.2 O], and [CF.sub.2 CF(CF.sub.3)O]; and

a substituted or unsubstituted aromatic diradical, in which case, Z is H.

4. Composition of claim 3 wherein R is sulfur.

5. Composition of claim 3 wherein R is phosphorus.

6. Composition of claim 3 wherein M is a metallic cation.

7. Composition of claim 3 wherein the thermoplastic resin is a fluoropolymer selected from:

(a) a homopolymer of chlorotrifluoroethylene or 2,2-difluoroethylene;

(b) a copolymer of tetrafluoroethylene and chlorotrifluoroethylene or 2,2-difluoroethylene; or

(c) a copolymer of at least one of the monomers of (a) and (b) and one or more of the monomers selected from ethylene, terminally unsaturated perfluoroalkene of 3-8 carbon atoms, perfluoro(alkyl vinyl ether) of 3-8 carbon atoms, oxy-containing perfluoro(alkyl vinyl ether) of 5-12 carbon atoms, and perfluoroalkyl ethylene of 3-8 carbon atoms.

8. Composition of claim 3 wherein the thermoplastic resin is a tetrafluoroethylene/hexafluoropropylene copolymer.

9. Composition of claim 3 wherein the thermoplastic resin is a tetrafluoroethylene/perfluoro(propyl vinyl ether) copolymer.

10. Composition of claim 3 wherein the thermoplastic resin is an ethylene/tetrafluoroethylene copolymer.

11. Composition of claim 10 wherein the thermoplastic resin is an ethylene/tetrafluoroethylene/perfluorobutyl ethylene copolymer.

12. Composition of claim 3 wherein the thermoplastic resin is an ethylene/chlorotrifluoroethylene copolymer.

13. Composition of claim 3 wherein the thermoplastic resin is polyvinylidene fluoride.

14. Composition of claim 8 wherein:

Z is F;

R is sulfur;

M is selected from barium, iron and zirconium;

x is a mixture of 6, 8, 10 and possibly 12, predominantly 8;

y and p are 0; and

z is 2.

15. Composition of claim 14 wherein the concentration of nucleating agent, based on the composition, is 250 to 2000 ppm.

16. Composition of claim 9 wherein:

Z is F;

R is sulfur;

M is selected from barium, iron and zirconium;

x is a mixture of 6, 8, 10 and possibly 12, predominantly 8;

y and p are 0; and

z is 2.

17. Composition of claim 16 wherein the concentration of nucleating agent, based on the composition, is 500 to 2000 ppm.

18. Composition of claim 11 wherein the concentration of nucleating agent, based on the composition, is 1000 to 3000 ppm.

19. Composition of claim 18 wherein

Z is F;

R is sulfur;

M is calcium;

x is a mixture of 6, 8, 10 and possibly 12, predominantly 8;

y and p are 0; and

z is 2.

20. Composition of claim 18 wherein:

Z is F;

R is sulfur;

M is potassium;

x is 1 to 10; and each of y, p and z is 0.

21. Composition of claim 3 wherein the thermoplastic resin is a polyolefin.

22. Composition of claim 3 wherein the thermoplastic resin is substantially a high density polyethylene.

23. Composition of claim 22 wherein the nucleating agent is the potassium salt of perfluorooctane sulfonic acid, and the concentration of nucleating agent, based on the composition, is 500-3000 ppm.

24. Composition of claim 22 wherein

Z is F;

R is sulfur;

M is selected from calcium, iron and chromium;

x is a mixture of 6, 8, 10 and possibly 12, predominantly 8;

y and p are 0;

z is 2; and

the concentration of nucleating agent, based on the composition, is 500-3000 ppm.

25. Composition of claim 3 which contains at least one additional nucleating agent.

26. Composition of claim 25 wherein the additional nucleating agent is boron nitride.

27. Composition of claim 25 wherein the additional nucleating agents are boron nitride and calcium tetraborate.

28. Composition of claim 3 which contains a chemical blowing agent.

29. Composition of claim 11 which contains a chemical blowing agent.

30. Composition of claim 29 wherein the blowing agent is a formulated zinc compound or a high temperature azo compound, and the nucleating agent is the potassium salt of a perfluorinated alkane sulfonic acid.

31. Composition of claim 29 wherein:

Z is F;

R is sulfur;

M is calcium;

x is a mixture of 6, 8, 10 and possibly 12, predominantly 8;

y and p are 0; and

z is 2,

and the blowing agent is a formulated zinc compound or a high temperature azo compound.

32. Foamed structure produced by the improved process for producing a foam of a thermoplastic resin composition, the improvement characterized in that the process is carried out with a nucleating-effective amount of the nucleating agent of the formula

[Z(CF.sub.2).sub.x (CF.sub.2 CFX).sub.p (R').sub.y (CH.sub.2).sub.z RO.sub.3 ].sub.n M

wherein:

the bivalent groups, except for RO.sub.3, may be present in any sequence;

Z is CCl.sub.3, CCl.sub.2 H, H, F, Cl or Br;

each X independently, is selected from H, F, Cl and CF.sub.3 ;

R is sulfur or phosphorus;

M is H or a metallic, ammonium, substituted ammonium or quaternary ammonium cation;

x is an integer and is 0 to 20;

p is an integer and is 0 to 6;

y is 0 or 1;

z is an integer and is 0 to 20;

x+y+z+p is a positive integer or, if x+y+z +p is 0, Z is CCl.sub.3 or CCl.sub.2 H;

n is the valence of M; and

R' is selected from

a C.sub.5-6 perfluorinated alicyclic ring diradical;

a C.sub.1-16 perfluorinated aliphatic polyether diradical with repeat units selected from [CF.sub.2 O], [CF.sub.2 CF.sub.2 O], and [CF.sub.2 CF(CF.sub.3)O]; and a substituted or unsubstituted aromatic diradical, in which case, z is H;

so as to produce a foam having uniformity of cell size, small cell size, and high void content.

33. Foamed structure of claim 32 in which the thermoplastic resin is a tetrafluoroethylene/hexafluoropropylene copolymer, the average cell size is less than 100 micrometers, and the void content is greater than 60%.

34. Foamed structure of claim 32 in which the thermoplastic resin is substantially a polyethylene of high density, the average cell size is less than 100 micrometers, and the void content is greater than 50%.

35. Foamed structure of claim 32 in which the thermoplastic resin is an ethylene/tetrafluoroethylene copolymer, the average cell size is less than 100 micrometers, and the void content is greater than 50%.

36. Foamed structure of claim 32 in which the thermoplastic resin is an ethylene/tetrafluoroethylene/perfluorobutyl ethylene copolymer.

37. The foamable composition of claim 3 in which the nucleating agent contains only two of the diradical units selected from (CF.sub.2).sub.x, (CF.sub.2 CFX).sub.p, (R').sub.y, and (CH.sub.2).sub.z.

38. The foamable composition of claim 37 in which the nucleating agent has a total of no more than 20 carbon atoms and M is selected from H, , Na, Ba, Zr, Cr, Ce, Al, Sr, Ca, Zn, Li, Fe, and triethyl ammonium.

39. The foamable composition of claim 38 in which the nucleating agent comprises at least one salt of the acid of the formula F(CF.sub.2).sub.x (CH.sub.2).sub.z SO.sub.3 H, in which x is 6 to 12 and z is 0, 1, or 2.

40. The foamable composition of claim 3 wherein the thermoplastic resin is selected from polystyrene, a styrene copolymer, and a blend comprising a styrene polymer.

41. The foamable composition of claim 3 wherein the thermoplastic resin is selected from copolymers of alpha-olefins and alpha, beta-unsaturated carboxylic acids having 3 to 8 carbon atoms, and their metal salts of Groups I to III of the Periodic Chart of the Elements.

42. The foamable composition of claim 41 wherein the nucleating agent is the potassium salt of perfluorooctane sulfonic acid, and the concentration of nucleating agent, based on the composition, is 500-3000 ppm.