CA1186850A - Expandable polymeric styrene particles - Google Patents

Expandable polymeric styrene particles

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Publication number
CA1186850A
CA1186850A CA000429202A CA429202A CA1186850A CA 1186850 A CA1186850 A CA 1186850A CA 000429202 A CA000429202 A CA 000429202A CA 429202 A CA429202 A CA 429202A CA 1186850 A CA1186850 A CA 1186850A
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CA
Canada
Prior art keywords
particle
bis
polymeric styrene
weight
blowing agent
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.)
Expired
Application number
CA000429202A
Other languages
French (fr)
Inventor
Richard A. Schwarz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cosden Technology Inc
Original Assignee
Cosden Technology Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US06/422,629 external-priority patent/US4389495A/en
Priority claimed from US06/443,309 external-priority patent/US4393147A/en
Application filed by Cosden Technology Inc filed Critical Cosden Technology Inc
Application granted granted Critical
Publication of CA1186850A publication Critical patent/CA1186850A/en
Expired legal-status Critical Current

Links

Abstract

Abstract of the invention An improved expandable polymeric styrene particle is provided containing a blowing agent and either a minor amount of ethylene-bis-stearamide and dibromoethyldibromo-cyclohexane or a minor amount of bis (allyl ether) of tetrabromobisphenol A and a minor amount of pentabromo-monochlorocyclohexane. An improved particle results in a significantly reduced final mold cooling cycle in producing the finished molded product when ethylene-bis-stearamide and dibromoethyldibromocyclohexane are incorporated therein. An improved particle exhibiting reduced flammability characteristics results when bis (allyl ether) of tetrabromobisphenol A and pentabromomonochlorocyclo-hexane are incorporated therein. These additives can be incorporated during impregnation with the blowing agent or by blending with the expandable particles after impregnation.

Description

~ COS-4~4/447 EXPANDABLE POLYMERIC STYRENE PARTICLES

Technical Field This invention relates to expandable or foamable polymeric styrene particles. More particularly, this invention relates to such expandable particles having increased utility in the manufacture of foamed articles by reducing the final mold cooling cycle and in exhibiting reduced flammability characteristics.

Background or the Invention Expandable polymeric styrene particles and the articles produced from such particles are well known in the art. Such articles include insulated building panels, decorative display objects, novelties, cushioning materials, floatation devices, hot or cold beverage containers, portable ice or cooling chests or boxes, etc.
The principal utilitarian characteristics of such foamed articles are their light weight and good heat insulation qualities.
Expandable polymeric particles are generally prepared by impregnating the particles with from 1% to ~0~ by weight of a suitable expanding or blowing agent such as pentane.
In producing the foamed articles, the impregnated particles, or beads, are first subjected to a pre-expansion step wherein the beads are heated with steam in an unconEined space to produce a prepuff having a relatively low density. Prepuffed beads are then placed into the desired confined mold and final expansion accomplished with the Eurther introduction of steam, follwed by cooling and removal of the molded article.
In evaluating the utility of a particular expandable polymeric styrene particle in producing the desired foamed article, consideration must be given to the final mold cooling cycle as it affects the rate, and consequently the cost, of the production of the finished product.
In addition a prerequisite for the use of foamed articles in certain applications is that such foamed articles must exhibit reduced flammability. This would be particularly true of foamed articles or panels employed in building construction. While the prior art discloses a number of additives that can be employed to reduce the flammability characteristics of foamed articles, there remains much room for further improvement.

Summary of the Invention It is now been found that an expandable polymeric styrene particle having incorprated therein a blowing agent and a minor amount of ethylene-bis-stearamide and a minor amount of dibromoethyldibromocyclohexane significantly reduces the final mold cooling cycle in producing the q 9 finished molded article. It has been found that in reducing the final mold cooling cycle in producing the finished molded article, the combination of the two stated additives exhibit a synergistic efEect; the reduction in the Einal mold cooling cycle using the combination of the two additives being greater than the theoretical expected additive effects of the two.
It has also been Eound that finished foamed articles having reduced Elammability characteristics are obtained from expandable polymeric styrene particles having incorporated therein a blowing agent, a minor amount of bis (allyl ether) of tetrabromobisphenol A and a minor amount of pentabromomonochlorocyclohexane. It has been Eound that in reducing the flammability characteristics of the finished foamed articles, the combination of the tWG stated additives exhibit a synergistic effect; the reduction in flammability characteristics using the combination of the two additves being greater than the theoretical expected additive effects of the two.

Description of a Preferred Embodiment EX~MPLE 1 To a kettle equipped with an agitator was charged 100 parts by weight of water, 2 parts by weight of tricalcium phosphate, .05 parts by weight of sodium dodecylbenzene sulfonate, 10Q parts by weight of polystyrene beads having a diameter of about 1 mm. and 8.0 parts by weight oE
n-pentane. In the examples which follow, ethylene-bis-stearamide and dibromoethyldibromocyclohexane were also charged at this point in the amounts indicated.

~ L~

The kettle was heated to a temperature of 215-230F
(102-110C) and maintained within this temperature range for 7-10 hours with agitation. The kettle was then cooled to room temperature, the contents acidiEied with nitric acidl the beads separated from the aqueous medium, washed with water and air dried at room temperature.
For pre-expansion, the beads were placed in a kettle equipped with agitators and means for passing steam through the beads. Prepuffs were formed by passlng steam at 5 psig (34 kPa) through the beads for approximately ~ minutes.
The prepuff particles had a diameter of approximately 3/16 inch (5 mm.).
To test the qualities and characteristics of the finished molded foamed article, a test mold 6"x12"x6" (15 cmO x 30 cm. x 15 cm.) was employed. The mold was jacke-ted to permit steam injection into the contents of the mold.
The mold was partially filled with prepuffs, closed and steam passed through the hold at 220F (104C) for approximately 10-20 seconds. The molded article was then allowed to cool until capable of removal from the mold.
Samples of the molded foamed articles were prepared using the above procedure, with and without -the incorporation of the ethylene-bis-stearamide and dibromo-cyclohexane. The following examples illustrate the comparative results.

~. L~ b~
Example No. Additive Mold Cooling Cycle 1 None 33 minutes
2 0.3% ethylene-bis- 22 minutes stearamide
3 1.0% dibromoethyl- 28 minutes dibromocyclohexane
4 0.3% ethylene-bis-stearamide and 14 1/2 minutes 1.0% dibromoethyl-dibromocyclohexane The cooling cycle for the Einished molded foam article was measured by the time required from steam shut off in the final molding, using steam at 15 psig (103 kPa), to the permissible removal of the article from the mold. The dibromoethyldibromocyclohexane employed was a white crystalline powder having a molecular weight of 428, bromine content of 74% by weight, and a melting point of 65-80C.
Comparing the results of Examples 2 and 3 with the results of Example 4, clearly illustrates the synergistic effect of the additives of this invention.

~f_~

The improved characteristics of expandable polymeric styrene particles discussed herein are realized by incorporating only minor amounts of ethylene-bis-stearamide into the polymeric styrene particles. Expandable polymeric styrene particles containing from about 0.l~ to about 1.0%
of ethylene-bis-stearamide and from about 1.0~ to about 1.5~ of dibromoethyldibromocyclohexane, both by weight of polymeric styrene, are particularly useful. In accordance with the preferred embodiment of this invention, the additives of this invention are preferably incorporated into the polymeric styrene particle during the incorporation of the blowing agent. ~owever, advantageous results are also accomplished by external blending of the additives with expandable polymeric styrene particles after first incorporating the blowing agent. This can be carried out by tumbling dried expandable polymeric styrene particles with the desired quantity of the additives.

To a kettle equipped with an agitator was charged 100 parts by weight of water, 2 parts by weight of tricalcium phosphate, .05 parts by weight of sodium dodecylbenzene sulfonate, 100 parts by weight of polystyrene beads having a bead diameter of about 1 mm. and 8.0 parts by weight of n-pentane. In the examples which follow, the flammability reducing additives of thi~ invention were also charged at this point in the amounts indicated.
The kettle was heated to a temperature of 215-230F
(102-110C) and maintained within this temperature range :~. L~t~

for 7-10 hours with agitation. The kettle was then cooled to room temperature, the contents acidiEied with nitric acid, the beads separated from the aqueous medium, washed with water and air dried at room temperature.
For pre-expansion, the beads were placed in a kettle equipped with agitators and means for passing steam through the beads. Prepuffs were formed by passing steam at 5 psig (34 kPa) through the beads Eor approximately 2 minutes~
The pre-puff particles had a diameter of approximatley 3/16 inch (5 mm.).
To test the qualities and characteristics of the finished molded foamed article, a test mold 6"x12"~6" (15 cm. x 30 cm. x 15 cm.) was employed. The mold was jacketed to permit steam injection into the contents of the mold.
The mold was partially filled with prepuffs, closed and steam passed through the mold at 220F (104C) for approximately 10-20 seconds. The molded article was then allowed to cool until capable of removal from the mold.
Samples of molded foamed articles were prepared using the above procedure, with and without the incorporation of the flammability reduciny additives of this invention. The following illustrates the comparative results obtained.
To measure the flammability characteristics of finished molded foam articles, using a hot wire a test strip was cut from the molded block prepared as described above. The test strip measured 9"x4"x1/2" (23 cm. x 10 cm.
x 1.3 cm.). The test strip was suspended vertically, with its longest dimension in the vertical position. A gas flame approximately 1/2l' (1.3 cm.) long was directed against the test strip approximately 1" (2.5 cm.) above its base. The gas flame was directed against the test strip until the material ignited, and the gas flame then removed. The vertical (height) and horizontal (width) of the burn area were measured and the combination of these two measurements used to establish a burn rating in accordance with Table 1; rating 1 being excellent and rating 4 failing.

Table 1 Rating ~ertical Burn Horizontal Burn 1 0 to 10 ~m. 3 to 4 om.
2 greater than 10 to 16 cm. greater than 4 to 6 c~.
3 greater than 16 to 20 cm. greater than 6 to 8 cm.
4 greater than 20 cm. greater than 8 cm.
The bis (allyl ether) of tetrabromobisphenol A employed was an offwhite crystalline solid having a molecular weight oE 623.9, bromine content of 51.2% by weight and a melting point of 110-120C.
Table 2 sets forth the flammability characteristics of molded foamed polystyrene articles containing the flammability reducing additives of this invention compared with molded foamed polystyrene articles containing no additives. In each case the content of the additive is expressed as percent by weight of polystyrene.

Table 2 Exampl_ Additive Test surn Rating 1 None 4 2 0.3% bis (allyl ether) of tetrabromobisphenol A 4 3 0.6% pentabromomonochloro-cyclohexane 3-4 4 0.3~ bis (allyl ether) of tetrabromobisphenol A
and 1.4-1.6 0.6% pentabromomonochloro-cyclohexane Comparing the results of Examples 2 and 3 ~ith the results of Example 4, clearly illustrates the synergistic effect of the flammability reducing additives of this invention.
The improved flammability characteristics of expandable polymeric styrene particles discussed herein are reali~ed by incorporating only minor amounts of bis (allyl ether) of tetrabromobisphenol A and pentabromomonchloro-cyclohexane into the polymeric styrene particles.
Expandable polymeric styrene particles containing -from about 0.1~ to about 0.5~ of bis (allyl ether) of tetrabromobisphenol A and from about 0.6% to about 1 5~ of pentabromomonochlorocyclohexane, both by weight of polymeric styrene are particularly useful. In accordance with the preEerred embodiment of this inven-tion, the additives are preferably incorporated into the polymeric styrene particles during the incorporation of the blowing agent. However, advantageous results are also accomplished by external blending of the additives with expandable polymeric styrene particles after first incorporating the blowing agent. This can be carried out by tumbling dried expandable polymeric styrene particles with the desired ~uanti-ty of the additives.
The invention has been described herein with particular regard to expandable polystyrene particles having incorporated therein a minor amount of the additives of this invention. In its applicability, the invention is not limited to polystyrene as other vinyl aromatic polymers can be employed. These include polymers derived from such vinyl aromatic monomers as vinyl toluene, isopropylstyrene, alpha-methylstyrene, chlorostyrene, tertiarybutylstyrene as well as to copolymers of vinyl aromatic monomers and butadiene, alkyl acrylates, acrylonitrile~ etc. As used in the specification and claims herein the expression "polymeric styrene particles" is meant to include particles of all such polymers and copolymers.
The invention has been described herein using pentane as the blowing agent. The inveniton is not limited to the use of pentane as other blowing agents can be employed.
Suitable blowing agents include butane, isopentane, cyclo-~ 3 pentane, hexane, heptane, cyclohexane and the lower boilinghalogenated hydrocarbons. Mixtures of the various mentioned blowing agents can also be employed. Expandable polymeric styrene particles usually contain from 1 to 20 by weight of the blowing agent. Impregnation with the blowing agent to produce expandable polymeric styrene particles can be carried out over a wide temperature range, namely, at temperatures ranging from about 140C (60C) to about 302F (150 C).

Claims (16)

The embodiments of the invention in which an exclusive property or privilege is claimed is defined as follows:
1. An expandable polymeric styrene particle having incorporated therein a blowing agent, a minor amount of ethylene-bis-stearamide and a minor amount of dibromoethyldibromocyclohexane.
2. The particle of Claim 1 having incorporated therein from about 0.1% to about 1.0% by weight of ethylene-bis-stearamide and from about 1.0% to about 1.5%
of dibromoethyldibromocyclohexane, all percentages being based upon the weight of the polymeric styrene.
3. The particle of Claim 2 wherein the polymeric styrene is polystyrene.
4. The particle of Claim 3 wherein the blowing agent is pentane.
5. A process for producing an expandable polymeric styrene particle comprising impregnating the polymeric styrene particle with a minor amount of ethylene-bis-stearamide and a minor amount of dibromoethyldibromo-cyclohexane during impregnation of said polymeric particle with a blowing agent.
6. The process of Claim 5 wherein the polymeric styrene particle is impregnated with from about 0.1% to about 1.0% by weight of ethylene-bis-stearamide and from about 1.0% to about 1.5% of dibromoethyldibromocyclohexane, all percentages being based on the weight of said polymeric styrene.
7. The process of Claim 6 wherein the polymeric styrene is polystyrene.
8. The process of Claim 7 wherein the blowing agent is pentane.
9. An expandable polymeric styrene particle having incorporated therein a blowing agent, a minor amount of bis (allyl ether) of tetrabromobisphenol A and a minor amount of pentrabromomonochlorocyclohexane.
10. The particle of Claim 9 having incorporated therein from about 0.1% to about 0.5% by weight of bis (allyl ether) of tetrabromobisphenol A and from about 0.6%
to about 1.5% by weight of pentabromomonochlorocyclohexane, all percentages being based upon the weight of the polymeric styrene.
11. The particle of Claim 10 wherein the polymeric styrene is polystyrene.
12. The particle of Claim 11 wherein the blowing agent is pentane.
13. A process for producing an expandable polymeric styrene particle comprising impregnating the polymeric styrene particle with a minor amount of bis (allyl ether) of tetrabromobisphenol A and a minor amount of pentabromo-monochlorocyclohexane during impregantion of said polymeric particle with a blowing agent.
14. The process of Claim 13 wherein the polymeric styrene particle is impregnated with from about 0.1% to about 0.5% by weight of bis (allyl ether) of tetrabromobisphenol A and from about 0.6% to about 1.5% by weight of pentabromomonochlorocyclohexane, all percentages being based on the weight of said polymeric styrene.
15. The process of Claim 14 wherein the polymeric styrene is polystyrene.
16. The process of Claim 15 wherein the blowing agent is pentane.
CA000429202A 1982-09-24 1983-05-30 Expandable polymeric styrene particles Expired CA1186850A (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US06/422,629 US4389495A (en) 1982-09-24 1982-09-24 Foamable polymeric styrene particles
US443,309 1982-11-22
US06/443,309 US4393147A (en) 1982-11-22 1982-11-22 Expandable polymeric styrene particles
US422,629 1989-10-17

Publications (1)

Publication Number Publication Date
CA1186850A true CA1186850A (en) 1985-05-07

Family

ID=27025688

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000429202A Expired CA1186850A (en) 1982-09-24 1983-05-30 Expandable polymeric styrene particles

Country Status (1)

Country Link
CA (1) CA1186850A (en)

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