Extruded polymer foam with filler particles and method

a polymer foam and filler technology, applied in the field of foamed polymer materials, can solve the problems of limited use of filler materials, damage to the foam, and inability to produce polymer foams, etc., and achieve the effect of inhibiting the reaction of mixed components within the screw and high quality dispersion

Inactive Publication Date: 2001-03-13
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

Polymer foam board is disclosed which includes high levels of filler material, such as 15%-20% by weight filler particles, or higher. Polyisocyanurate or polyurethane foam is made using a screw-type extruder for mixing the components of the composition. Isocyanate and polyol are introduced into a screw of an extruder. Filler particles are also introduced in the extruder screw. The isocyanate, polyol, and filler particles are mixed together with a foaming agent and, optionally, a surfactant with the extruder to produce a high quality dispersion. The mixture is cooled via a cooling manifold of the screw extruder and the addition of the various components in the mixture. Cooling inhibits reaction of the mixed components within the screw.

Problems solved by technology

Polymer foams, such as polyisocyanurate and polyurethane foams, have not previously been able to be produced using an extruder.
Additionally, use of filler materials has been limited using conventional methods to produce foam sheets.
Richie discloses that the apparatus can be used for thermosetting materials, such as polyurethanes, but that steam or hot water would have a damaging effect and therefore are not used.

Method used

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  • Extruded polymer foam with filler particles and method
  • Extruded polymer foam with filler particles and method
  • Extruded polymer foam with filler particles and method

Examples

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Effect test

second embodiment

With reference to FIG. 5, an extrusion system 102 which is also suitable for practicing the invention is illustrated. Extrusion system 102 includes a single or twin screw extruder 104 and an associated reservoir system 106. The extruder 104 includes a series of barrels C1-C12 and an extruder head 120. The reservoir system 106 includes a plurality of reservoirs 150-156 from which the foam components are supplied.

The reservoirs 150-156 feed the foam component materials to the barrels C1-C12 and head 120 of the extruder 104 via a network of feed lines and valves as illustrated.

In manufacturing foam using the extrusion system of FIG. 5, filler material is preferably provided to the extruder 104 at barrels C1 and C4 from reservoirs 150 and 152. Isocyanate solution is mixed and fed to barrels C2 and C6 of the extruder 104 from reservoirs 151 and 153. The isocyanate solution may be optionally mixed with a dispersing agent and / or surfactant. Surfactant may be mixed at reservoirs 151 and 153...

examples

The following Examples 1-48 were made in accordance with the process described in conjunction with FIGS. 1-4. Examples 49-60 were made using the alternate embodiment of the process as described in conjunction with FIGS. 5-6.

examples 1 to 33

Carbon Black Dispersion Made in the Extruder Screw

Table 1 shows the composition used for each formulation and Table 2 shows the composition of each polyol premix, used as indicated in Table 1. Pelron P-344 dispersant and Cabot Black Pearls 280 carbon black were used in all the examples. The catalyst was a 3:1 blend, by weight, of potassium octoate and DMP-30. A catalyst blend of 3:1 to 6:1 may be used. The ratio of the catalyst blend is dependent upon how close the catalyst is added to the extruder outlet. The average equivalent weight of BASF 226 prepolymer (polymer / isocyanate mix) and ICI high viscosity isocyanate is about 152.

TABLE 1 Parts by % Formulation Component Weight % Index Trimer I Premix I 40.6 11.8 2.74 12.4 2852E Polyol 59.4 17.2 MR-200 Isocyanate 192.0 55.7 Catalyst 7.5 2.2 HCFC - 14 lb 45.0 13.1 II Premix II 40.6 11.2 2.93 12.8 Carbon Black (C / B) 17.4 4.8 2852E Polyol 59.4 16.4 MR-200 Isocyanate 192.0 53.0 Catalyst 7.5 2.1 HCFC - 14 lb 45.0 12.4 III Premix III 63.5 1...

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Abstract

A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Description

BACKGROUND OF THE INVENTION1. Field of the InventionThe invention relates to foamed polymer material, methods for producing polymer foams, and, particularly, to a method for extruding polymer foam material, such as polyisocyanurate and polyurethane foams, using a screw-type extruder. The extruded polymer foams contain substantial amounts of filler particles.2. Description of the Prior ArtPolymer foams, such as polyisocyanurate and polyurethane foams, have not previously been able to be produced using an extruder. The foaming material "firms" in the extruder and blocks the equipment. Additionally, use of filler materials has been limited using conventional methods to produce foam sheets.U.S. Pat. No. 3,466,705, (Richie) describes an apparatus for extruding foamable thermoplastic material, such as polystyrene, preferably in tubular form. Richie discloses that the apparatus can be used for thermosetting materials, such as polyurethanes, but that steam or hot water would have a damaging...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): B29C44/34C08J9/00C08J9/14
CPCB29C44/3442C08J9/14C08J2201/03C08J2375/04
Inventor GLORIOSO, SAMMIE J.BURGESS, JAMES H.
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