CA2473611A1 - Thermoplastic foam containing particulate additive - Google Patents

Thermoplastic foam containing particulate additive Download PDF

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Publication number
CA2473611A1
CA2473611A1 CA002473611A CA2473611A CA2473611A1 CA 2473611 A1 CA2473611 A1 CA 2473611A1 CA 002473611 A CA002473611 A CA 002473611A CA 2473611 A CA2473611 A CA 2473611A CA 2473611 A1 CA2473611 A1 CA 2473611A1
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CA
Canada
Prior art keywords
foam
polymer
acid
particulate additive
polymer resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002473611A
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French (fr)
Other versions
CA2473611C (en
Inventor
Suresh Subramonian
Chung P. Park
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Dow Global Technologies LLC
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Individual
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Filing date
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Application filed by Individual filed Critical Individual
Publication of CA2473611A1 publication Critical patent/CA2473611A1/en
Application granted granted Critical
Publication of CA2473611C publication Critical patent/CA2473611C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0066Use of inorganic compounding ingredients
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2351/00Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
    • C08J2351/06Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond

Abstract

A cellular thermoplastic polyolefin foam comprising at least one particulate additive in admixture with a polymer matrix is disclosed, along with a process and foamable gel for manufacturing the same, wherein the polyolefin matrix comprises at least one polymer resin graft-modified with at least one polar group selected from the group consisting of acid, acid ester, and acid anhydride, and salts thereof. The invention facilitates the manufacture of macrocellular foams useful for acoustic absorption having increased amounts of particulate additives that provide certain desired properties difficult to achieve without the particulate additives, such as improved flame retardancy.

Claims (25)

1. A macrocellular polymer foam having an average cell size, measured according to ASTM D3575, of at least 1.5 mm and a density less than 100 kilograms per cubic meter comprising:
A) at least one particulate additive in admixture with B) a polymer matrix, wherein. the polymer matrix comprises at least one polymer resin graft-modified with at least one polar group selected from the group consisting of acid, acid ester, or acid anhydride, pr a salt thereof.
2. The foam of claim 1, wherein the acid of the acid, acid ester, or acid anhydride, or salt thereof, is a mono-unsaturated carboxylic acid.
3. The foam of claim l, wherein the acid is acrylic acid and the acid anhydride is maleic anhydride.
4. The foam of claim 3; wherein the polymer resin graft-modified with at least one polar group has at least one pendant polar group selected from the group consisting of poly(acrylic acid), methyl acetate, succinic acid and maleic anhydride.
5. The foam of any one of the preceding claims; wherein the polymer matrix B) comprises at least one polyolefin resin.
6. The foam of claim 5, wherein the at least one polyolefin resin is at least one ethylene polymer or at least one propylene polymer, or a mixture of at least one ethylene polymer and at least one propylene polymer.
7. The foam of Claim 6, wherein the ethylene polymer is an ethylene homopolymer or an interpolymer of ethylene and at least one monomer selected from the group consisting of one or more C3-C10 .alpha.-olefin polymers.
8. The foam of claim 6 or 7, wherein the propylene polymer is a propylene homopolymer or an interpolymer of propylene with ethylene or one or more C4-.alpha.-olefin polymers.
9, The foam of any one of the preceding claims, wherein the particulate additive comprises a metal oxide, halides, borate, silicate, or stannate.
10. The foam of any one of the preceding claims, wherein the particulate additive is a flame retardant adjuvant, flame retardant, antioxidant, antiblock additive, colorant, pigment, filler, or acid scavenger.
11. The foam of Claim 10, wherein the dame retardant adjuvant is a flame retardant synergist, a smoke suppressant or a char forming agent.
12. The foam of claim 11, wherein the particulate additive comprises an antimony oxide flame retardant synergist.
13. The foam of any one of the preceding claims, wherein the at least one polymer resin of the polymer matrix B) comprises at least one first-category polymer resin that has, on the average, at least one polar group per resin molecule and at least one second-category polymer resin that has, on the average, less than 0.1 polar group per polymer resin molecule.
14. The foam of claim 13, wherein the at least one second-category polymer resin is an ethylene polymer or a propylene polymer, or a mixture of an ethylene polymer and a propylene polymer.
15. The foam of claim 13 or 14, wherein the ratio of the average melt flow rate of the first-category polymer resins(s) to the average melt flow rate of the second-category polymer resin(s), each melt flow rate measured according to ASTM D1238 (2.16 kg,.), is in the range from l:2 to 15:1.
16. The foam of any one of the preceding claims further comprising a halogenated flame retardant C).
17. The foam of any one of claims 13 to 16, wherein the first category polymer resin of the polymer matrix B) is graft modified with at least 0.1 weight-percent polar groups.
18. The foam of any one of claims 13 to 16, wherein the first category polymer resin of the polymer matrix B) is graft-modified with up to 10 weight-percent polar groups.
19. The foam of any one of claims 13 to 18, wherein the weight ratio of the first category polymer resin of the polymer matrix B) to the particulate additive A) is in the range from 0.1:1 to 3:1.
20. The foam of any one of the preceding claims having an average cell size, measured according to ASTM D3575. of at least 4.5 mm.
21. The foam of any one of the preceding claims having an average sound absorption coefficient (measured via ASTM E1050 at 250, 500, 1000 and 2000 hertz (Hz) sound frequencies) o~ at least 0.15.
22. The foam of any one of the preceding claims in the form of an office partition, automotive decoupler, domestic appliance sound insulation, industrial noise absorber, sound proofing panel, hanging baffle, or machine enclosure.
23. Use of the foam of any one of the preceding claims as an acoustic absorption material.
24. A foamable gel suitable for making the foam according to claim 1 comprising:
1) at least one particulate additive in admixture with at least one polymer matrix and 2) at least one blowing agent, wherein the polymer matrix comprises at least one polymer resin graft-modified with at least one polar group selected from the group consisting of acid, acid ester, or acid anhydride, or salt thereof and the weight ratio of the polymer resin graft-modifed with at least one polar group to the particulate additive is not greater than 5:1.
25. A method for making macrocellular polymer foams containing at least one particulate additive comprising expanding a foamable gel according to claim 24.
CA2473611A 2002-02-22 2003-01-15 Thermoplastic foam containing particulate additive Expired - Fee Related CA2473611C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US35883202P 2002-02-22 2002-02-22
US60/358,832 2002-02-22
PCT/US2003/002053 WO2003072644A2 (en) 2002-02-22 2003-01-15 Thermoplastic foam containing particulate additive

Publications (2)

Publication Number Publication Date
CA2473611A1 true CA2473611A1 (en) 2003-09-04
CA2473611C CA2473611C (en) 2010-03-16

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2473611A Expired - Fee Related CA2473611C (en) 2002-02-22 2003-01-15 Thermoplastic foam containing particulate additive

Country Status (12)

Country Link
US (1) US7226955B2 (en)
EP (1) EP1476499B1 (en)
JP (1) JP4276082B2 (en)
KR (1) KR20040094713A (en)
CN (1) CN1266202C (en)
AT (1) ATE415444T1 (en)
AU (1) AU2003214883B2 (en)
CA (1) CA2473611C (en)
DE (1) DE60324896D1 (en)
ES (1) ES2314186T3 (en)
TW (1) TW200303885A (en)
WO (1) WO2003072644A2 (en)

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Publication number Publication date
ATE415444T1 (en) 2008-12-15
JP2005518471A (en) 2005-06-23
US7226955B2 (en) 2007-06-05
TW200303885A (en) 2003-09-16
WO2003072644A2 (en) 2003-09-04
JP4276082B2 (en) 2009-06-10
CN1639241A (en) 2005-07-13
EP1476499A2 (en) 2004-11-17
ES2314186T3 (en) 2009-03-16
DE60324896D1 (en) 2009-01-08
AU2003214883A1 (en) 2003-09-09
CA2473611C (en) 2010-03-16
KR20040094713A (en) 2004-11-10
WO2003072644A3 (en) 2003-11-20
AU2003214883B2 (en) 2007-10-04
EP1476499B1 (en) 2008-11-26
CN1266202C (en) 2006-07-26
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