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Porous carbon-containing compounds as water carriers and cell size controlling agents for polymeric foams

A technology of porous carbon and compounds, applied in the field of extruded foam products, can solve the problems of increasing production costs and increasing downtime, and achieve the effect of increasing production costs

Inactive Publication Date: 2012-07-04
OWENS CORNING INTELLECTUAL CAPITAL LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Components must often be repaired or replaced due to corrosion to the extruder and associated extrusion equipment, resulting in increased production costs and increased downtime

Method used

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  • Porous carbon-containing compounds as water carriers and cell size controlling agents for polymeric foams
  • Porous carbon-containing compounds as water carriers and cell size controlling agents for polymeric foams
  • Porous carbon-containing compounds as water carriers and cell size controlling agents for polymeric foams

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0086] Composed of 75 wt% polystyrene (NOVA1600 from NOVA Chemical, PA) and 25 wt% powdered activated carbon (DARCO KB-G from Norit Americas, Texas) was prepared by extrusion process using an LMP twin extruder from Leistitz. Microporous compound (PS / PAC25).

[0087] The porosity, pore size and density of the formed microporous compound PS / PAC25 were measured by mercury intrusion analysis. The results are listed in Table 1.

[0088] Table 1 Porosity analysis of microporous PS / PAC25 compounds

[0089] project

[0090] The microporous compound was further processed by (1) temperature and humidity conditioning and (2) steam impregnation. For temperature and humidity conditioning tests, the microporous compounds were placed in a conditioning chamber for 24 to 72 hours, where the temperature was controlled between 20°C and 30°C and the relative humidity was maintained between 50 and 98%. The PS / PAC25 compound particles have a size of about 2-3 mm. Table 2 summarizes t...

Embodiment 2

[0100] In the following samples and comparative samples, rigid polystyrene foam boards were produced by a twin-screw LMP extruder. Table 4 shows the processing operating conditions for the samples in the twin-screw extruder used to make foam boards with a width of 16 inches and a thickness of one inch.

[0101] Table 4

[0102] The processing conditions of the samples

[0103] wt% of HFC-134a

4

CO 2 wt%

2

Injection pressure, Kpa(psi)

13000-17000(1950-2400)

Mold melting temperature (℃)

110-130

Die pressure, Kpa(psi)

6900-8280(1000-1200)

Linear speed, m / min (feet / min)

5-10(16-35)

Output, kg / h

150-200

Die gap, mm

0.8-1.5

Vacuum KPa(inch Hg)

0-3.4(0-16)

[0104] The results of Example 2 are summarized in Tables 5 and 6. Pore ​​size was determined by Nikon Optiphot-2 light microscope and Clemex Vision image analysis software. Foam density was measured a...

Embodiment 3

[0112] The polystyrene resin used in this example was polystyrene (NOVA 1600 from NOVA Chemical Company, PA) with a melt index of approximately 5.2 and a molecular weight of 250,000. The microporous compound PS from Example 1 was mixed before feeding the microporous compound / polystyrene mixture into a co-rotating twin extruder (Leistritz ZSE-27 with D 27 mm and L / D 40) / PAC25 with the polystyrene.

[0113] Blowing agent carbon dioxide (from Praxair) was injected into the extruder at L / D 16 position (melting and mixing zone) via a model ISCO 1000D syringe pump. During the entire extrusion process, the temperature and pressure are maintained above the supercritical point, that is, the carbon dioxide remains in the supercritical stage before foaming at the end of the die.

[0114] Water was injected through a separate ISCO 1000D syringe pump at the L / D 26 location (transfer zone) close to the die. During the extrusion process prior to foaming, water remains in liquid phase acco...

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Abstract

Polymeric foam and polymeric foam products that contain a foamable polymer material, at least one blowing agent, activated carbon, and water are provided. The activated carbon acts as both a water absorbent and carrier for the water. The activated carbon is able to control and increase cell size even in the presence of carbon dioxide, HFCs, and / or infrared attenuating agents. Additionally, the activated carbon permits a desired amount of water to be introduced into the polymer melt. By controlling the amount of activated carbon and its water content during an extrusion process, a broad range of cell sizes can be obtained in the extruded product. In exemplary embodiments, the activated carbon is added to a primary extruder and water is directly injected into a secondary extruder. Alternatively, the activated carbon is compounded with a polymer resin, pre-hydrated by conditioning or steam impregnation, and added to a primary or secondary extruder.

Description

[0001] Technical field and industrial application of the invention [0002] The present invention relates generally to extruded foam products, particularly extruded polymeric foams comprising porous carbon-containing compounds such as activated carbon as water absorbents and carriers to control the cell size and improve the physical properties of the extruded foam products. A method of forming the polymeric foam is also provided. Background of the invention [0003] Foamed resin structures can be used in a variety of applications such as thermal insulation, in cushioning, as packaging, and as adsorbents. Extruded foams are generally prepared by melting a polymer with any desired additives to produce a polymer melt. A foamable gel mixture is produced by mixing a blowing agent with a polymer melt at appropriate temperature and pressure. The foamable gel mixture is then cooled and extruded into a reduced pressure zone, which results in foaming of the gel and formation of the de...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C08J9/00C08J9/18
CPCC08J2201/03C08J9/0066C08J2205/052
Inventor N·安南R·洛R·科克伦Y·德拉维兹T·布拉默
Owner OWENS CORNING INTELLECTUAL CAPITAL LLC
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