NL2033077B1 - Expanded polymer foam particle - Google Patents
Expanded polymer foam particle Download PDFInfo
- Publication number
- NL2033077B1 NL2033077B1 NL2033077A NL2033077A NL2033077B1 NL 2033077 B1 NL2033077 B1 NL 2033077B1 NL 2033077 A NL2033077 A NL 2033077A NL 2033077 A NL2033077 A NL 2033077A NL 2033077 B1 NL2033077 B1 NL 2033077B1
- Authority
- NL
- Netherlands
- Prior art keywords
- polymer foam
- weight
- expanded polymer
- expanded
- skin layer
- Prior art date
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- 239000002245 particle Substances 0.000 title claims abstract description 69
- 239000006260 foam Substances 0.000 title claims abstract description 61
- 229920000642 polymer Polymers 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 claims abstract description 6
- 239000008199 coating composition Substances 0.000 claims description 32
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 22
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 22
- 239000004794 expanded polystyrene Substances 0.000 claims description 21
- -1 polyethylene Polymers 0.000 claims description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000004971 Cross linker Substances 0.000 claims description 9
- 239000002253 acid Substances 0.000 claims description 8
- 239000011324 bead Substances 0.000 claims description 7
- 239000000945 filler Substances 0.000 claims description 7
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 claims description 6
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 6
- 239000004626 polylactic acid Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229920001276 ammonium polyphosphate Polymers 0.000 claims description 5
- 239000010439 graphite Substances 0.000 claims description 5
- 229910002804 graphite Inorganic materials 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 239000005995 Aluminium silicate Substances 0.000 claims description 4
- 239000004114 Ammonium polyphosphate Substances 0.000 claims description 4
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 4
- 235000012211 aluminium silicate Nutrition 0.000 claims description 4
- 235000019826 ammonium polyphosphate Nutrition 0.000 claims description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 4
- 239000008188 pellet Substances 0.000 claims description 4
- 229920000573 polyethylene Polymers 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 229920000877 Melamine resin Polymers 0.000 claims description 3
- 229910019142 PO4 Inorganic materials 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 3
- 230000007062 hydrolysis Effects 0.000 claims description 3
- 238000006460 hydrolysis reaction Methods 0.000 claims description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 239000010452 phosphate Substances 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- RYCLIXPGLDDLTM-UHFFFAOYSA-J tetrapotassium;phosphonato phosphate Chemical compound [K+].[K+].[K+].[K+].[O-]P([O-])(=O)OP([O-])([O-])=O RYCLIXPGLDDLTM-UHFFFAOYSA-J 0.000 claims description 3
- 229910002012 Aerosil® Inorganic materials 0.000 claims description 2
- 229920000388 Polyphosphate Polymers 0.000 claims description 2
- QLJCFNUYUJEXET-UHFFFAOYSA-K aluminum;trinitrite Chemical compound [Al+3].[O-]N=O.[O-]N=O.[O-]N=O QLJCFNUYUJEXET-UHFFFAOYSA-K 0.000 claims description 2
- JUNWLZAGQLJVLR-UHFFFAOYSA-J calcium diphosphate Chemical compound [Ca+2].[Ca+2].[O-]P([O-])(=O)OP([O-])([O-])=O JUNWLZAGQLJVLR-UHFFFAOYSA-J 0.000 claims description 2
- 229940043256 calcium pyrophosphate Drugs 0.000 claims description 2
- 235000019821 dicalcium diphosphate Nutrition 0.000 claims description 2
- 235000013312 flour Nutrition 0.000 claims description 2
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims description 2
- 125000002467 phosphate group Chemical group [H]OP(=O)(O[H])O[*] 0.000 claims description 2
- 239000001205 polyphosphate Substances 0.000 claims description 2
- 235000011176 polyphosphates Nutrition 0.000 claims description 2
- 229940098424 potassium pyrophosphate Drugs 0.000 claims description 2
- 239000010453 quartz Substances 0.000 claims description 2
- FQENQNTWSFEDLI-UHFFFAOYSA-J sodium diphosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])([O-])=O FQENQNTWSFEDLI-UHFFFAOYSA-J 0.000 claims description 2
- 229940048086 sodium pyrophosphate Drugs 0.000 claims description 2
- 235000019818 tetrasodium diphosphate Nutrition 0.000 claims description 2
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 2
- 239000004408 titanium dioxide Substances 0.000 claims description 2
- 239000010456 wollastonite Substances 0.000 claims description 2
- 229910052882 wollastonite Inorganic materials 0.000 claims description 2
- 239000000546 pharmaceutical excipient Substances 0.000 claims 2
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims 1
- 239000008187 granular material Substances 0.000 claims 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims 1
- 239000010410 layer Substances 0.000 description 39
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 239000000203 mixture Substances 0.000 description 8
- 229920005989 resin Polymers 0.000 description 8
- 239000011347 resin Substances 0.000 description 8
- 239000003063 flame retardant Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 229920006248 expandable polystyrene Polymers 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 3
- 238000010348 incorporation Methods 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- BZQKBFHEWDPQHD-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-[2-(2,3,4,5,6-pentabromophenyl)ethyl]benzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1CCC1=C(Br)C(Br)=C(Br)C(Br)=C1Br BZQKBFHEWDPQHD-UHFFFAOYSA-N 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 235000016068 Berberis vulgaris Nutrition 0.000 description 1
- 241000335053 Beta vulgaris Species 0.000 description 1
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 240000000111 Saccharum officinarum Species 0.000 description 1
- 235000007201 Saccharum officinarum Nutrition 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 244000061456 Solanum tuberosum Species 0.000 description 1
- 235000002595 Solanum tuberosum Nutrition 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229920002988 biodegradable polymer Polymers 0.000 description 1
- 239000004621 biodegradable polymer Substances 0.000 description 1
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 1
- 229910052794 bromium Inorganic materials 0.000 description 1
- 239000011489 building insulation material Substances 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- 235000011132 calcium sulphate Nutrition 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000013538 functional additive Substances 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- ZQKXQUJXLSSJCH-UHFFFAOYSA-N melamine cyanurate Chemical compound NC1=NC(N)=NC(N)=N1.O=C1NC(=O)NC(=O)N1 ZQKXQUJXLSSJCH-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910000000 metal hydroxide Inorganic materials 0.000 description 1
- 150000004692 metal hydroxides Chemical class 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 244000005700 microbiome Species 0.000 description 1
- 239000005445 natural material Substances 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 235000012015 potatoes Nutrition 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 239000012744 reinforcing agent Substances 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 235000000346 sugar Nutrition 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 230000002459 sustained effect Effects 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000000326 ultraviolet stabilizing agent Substances 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/36—After-treatment
- C08J9/365—Coating
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/10—Homopolymers or copolymers of propene
- C08J2323/12—Polypropene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J2325/02—Homopolymers or copolymers of hydrocarbons
- C08J2325/04—Homopolymers or copolymers of styrene
- C08J2325/06—Polystyrene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
- C08J2367/04—Polyesters derived from hydroxy carboxylic acids, e.g. lactones
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
The present invention relates to expanded polymer foam particles provided with a functional skin layer and to a process for producing expanded polymer foam particles provided with a functional skin layer. The present invention also relates to moulded products manufactured on basis of such particles.
Description
Title: Expanded polymer foam particle
The present invention relates to expanded polymer foam particles provided with afunctional skin layer and to a process for producing expanded polymer foam particles provided with a functional skin layer. The present invention also relates to moulded products manufactured on basis of such particles.
Expanded polymer foam particles provided with a functional skin layer are known in the art.
For example, US 2012/052127 discloses expanded polystyrene particle provided on the surface thereof with a skin layer with superior moldability wherein the skin layer comprises a binder selected from the group consisting of a thermoplastic resin-based adhesive, a thermosetting resin-based adhesive, an inorganic adhesive, a protein-based adhesive, and a mixture thereof, wherein the skin layer further comprises methylene diphenyl diisocyanate.
EP 1 709 110 discloses an expanded polystyrene particle with a functional skin layer wherein the functional skin layer is formed by coating the surface of the inner expanded polystyrene layer with a functional coating composition having 10 to 99 wt. % of a vinyl acetate based polymer and 0.1 to 90 wt. % of at least one functional additive, such as ultraviolet stabilizers, fillers, reinforcing agents, colorants, impact- resistant agents, flame retardants, antistatic agents, and thermal conductivity- imparting agents.
EP2656995 discloses a skin-covered foamed molded article, comprising: a skin having an interior surface defining a hollow interior space; and a foam layer of expanded polystyrene beads which are fuse-bonded to each other, said foam-layer being provided within the hollow interior space and fuse-bonded to the interior surface.
WO 2008/090333 discloses an aqueous gel-forming composition comprising from 5% to 40% by weight of an aluminosilicate comprising alkali metal aluminate and alkali metal silicate and from 0.1% to 10% by weight of an organic liquid. The aqueous gel-forming composition is coated onto the expanded polystyrene beads by spraying into a fluidized bed followed by drying in the bed to a moisture content of 12% by weight.
WO 2010/128797 relates to a method for producing non-flammable expandable polystyrene particles wherein expandable polystyrene particles and 10 to 60% by weight of incombustible material powder having a particle size of 1 to 70 um, such as metal oxides, non-metal oxides, metal hydroxides, silicon dioxide-containing materials, graphite, and vermiculite, are mixed and a mixture of a solvent capable of dissolving polystyrene and water is sprayed to form expandable polystyrene particles.
A surface layer of the polystyrene particles in a softened state is formed and the incombustible material powder will penetrate and coat the surface of the expanded polystyrene particles. An amount of 0.1 to 10% by weight of a water-soluble resin is additionally coated on the expandable polystyrene particles that have been infiltrated and coated, wherein the water-soluble resin includes a vinyl acetate based resin, an acrylic-based resin, a polyvinyl alcohol resin, and an ethylene vinyl acetate based resin. The water-soluble resin contains 0.1 to 10% by weight of one or more selected from bromine-based flame retardants, phosphorus-based flame retardants, and antimony trioxide. The expanded polystyrene particles having been infiltrated and coated are additionally coated with a sodium silicate solution.
KR 2022 0021801 relates to a flame retardant composition for manufacturing
EPS beads, the flame retardant composition containing, per 100 parts by weight of water, 30 to 45 parts by weight expanded graphite, 5 to 15 parts by weight gypsum, 0.5 to 15 parts by weight talc, 3 to 7 parts by weight of calcium carbonate, 10 to 20 parts by weight of ammonium polyphosphate, 3 to 7 parts by weight of decabromodiphenylethane, 1 to 3 parts by weight of MDI, 3 to 7 parts by weight of melamine cyanurate, 3 to 7 parts by weight of pentaerythritol, and 50 to 60 parts by weight of an organic binder selected from the group consisting of polyvinyl acetate, ethylene vinyl acetate copolymers, melamine resin, epoxy resin, and acrylic resin.
The problem with using a silicate based fire retardant composition for building insulation materials such as expanded polystyrene (e.g. roofing insulation) is that, until needed, such materials are often left exposed to the adverse weather conditions after delivery to the building site. Unless precautions are taken to protect them against the wet, such exposure can result in significant loss of the fire retardancy properties of the silicate-based composition.
The problem with the use of solvents is that it makes large scale production extremely difficult.
An object of the present invention is to provide expanded polymer foam particles that meet the industrial requirements of fire resistance.
Another object of the present invention is to provide expanded polymer foam particles having a functional skin layer that is water resistant and does not leach out overtime.
Another object of the present invention is to provide expanded polymer foam particles having a functional skin layer resulting in the formation of char when exposed to fire.
Another object of the present invention is to provide expanded polymer foam particles having a functional skin layer that does not melt when exposed to elevated temperatures.
Another object of the present invention is to provide expanded polymer foam particles having a functional skin layer that can be shape moulded.
Another object of the present invention is to provide expanded polymer foam particles having a functional skin layer that has a high water resistance.
The present invention as discussed above relates to an expanded polymer foam particle provided with a functional skin layer comprising: an inner expanded polymer foam layer and an outer functional skin layer, wherein the inner expanded polymer foam layer is formed by heating and expanding an expandable polymer foam bead or pellet, and the functional skin layer is formed by coating the outer surface of the inner expanded polymer foam layer with a functional coating composition, wherein the expanded polymer foam particle is chosen from the group of expanded polyethylene (EPE), expanded polypropylene (EPP), polylactic acid (PLA) and expanded polystyrene (EPS), the functional coating composition is based on 5 to 40 wt. %, preferably 10 to 25 wt.%, of a polyvinyl alcohol, 4 to 30 wt. %, preferably 7 to 15 wt.%, of an acid donor and 40 to 90 wt.%, preferably 50 to 80 wt.%, of at least one or more auxiliaries, the weight percentages are based on the total weight of the coating composition and all weight percentages add up to 100%.
On basis of the above specific coating composition one or more objects are achieved. The present inventors found that an unexpected advantage of the present coating composition is the excellent char formation as will be shown in the experimental section of this description. In addition, the present coating composition is qualified as a non-hazardous, water based coating composition. In that context it is to be noted that a standard intumescent coating is activated at a temperature of approximately 250°C, which is well above the melting temperature of the polymer foam particle. Consequently, a standard intumescent coating cannot be used for the present polymer foam particles. A minimum amount of 5 wt.% polyvinyl alcohol is needed to create a sufficient char layer since the present inventors found that an amount lower than 5 wt.% of polyvinyl alcohol leads to a significant reduction of the fire properties.
The expanded polymer foam particle is a foam particle having a density of at most 100 kg/m?3. The expanded polymer foam particle is a spherical particle wherein the diameter of the expanded polymer foam particle without the functional skin layer is between about 0,5 — 10 mm.
In an example polylactic acid (PLA) is a bio-based polylactic acid, preferably a bio-based biodegradable polymer that can be produced from renewable resources including starch from corn and potatoes, sugar from beets and sugar cane, and so forth. In this context biodegradable means that it will convert into natural material, such as water, carbon dioxide, and composite. This process is conducted by microorganisms and influenced by, inter alia, temperature and humidity.
In an example of the present invention the polyvinyl alcohol is a polyvinyl alcohol having an Mw of at least 5000, preferably at least 6000 and at most 120.000, preferably at most 100.000. The present inventors found that an Mw of at least 5000 is necessary for the formation of a strong char network char when exposed to fire.
In an example of the present invention the polyvinyl alcohol is a polyvinyl alcohol having a hydrolysis degree in a range of at least 50, preferably at least 60 and more preferably of at least 80 and at most 100. The present inventors also found that a hydrolysis degree of at least 50 is necessary for the formation of a strong char network char when exposed to fire.
In an example of the present invention the at least one or more auxiliaries are chosen from the group of graphite and fillers. The use of such fillers in a coating composition increases the fire resistance thereof.
In an example of the present invention the filler is selected from pulverulent inorganic substances such as talc, chalk, kaolin, aluminium hydroxide, aluminium nitrite, aluminium silicate, barium sulfate, calcium carbonate, titanium dioxide, calcium sulfates, silica, quartz flour, aerosil, alumina or wollastonite. Another example of a filler is expandable graphite resulting in an increase of the fire resistance and an improvement of the fire reaction. The incorporation of aluminium hydroxide in the present coating composition should be kept as low as possible since aluminium hydroxide is a weak base (pH= 8-9) and may interfere with other components resulting 5 in less char formation.
In an example of the present invention the thickness of the functional skin layer is between 1 micrometre and about 300 micrometre. In an embodiment wherein the thickness of the functional skin layer is lower than 1 micrometre the fire resistance of the expanded polymer foam particle will be too low since there is a risk that the particle itself will be exposed to elevated temperatures resulting in a complete melt of the particles. If the thickness of the functional skin layer is more than about 300 micrometre no additional beneficial effects with regard to fire resistance will be observed. The thickness of the functional skin layer is at least 1 micrometre, preferably at least 50 micrometre, more preferably at least 60 micrometre and at most 300 micrometre, preferably at most 200, more preferably at most 110 micrometre.
The diameter of the expanded polymer foam particle provided with a functional skin layer according to the invention is in a range of 0,502 and 10,6 mm. The diameter of a foam particle without the functional skin layer is in a range of about 0,5 — 10 mm.
In an example of the present invention the functional coating composition is further based on 1 to 10 wt.%, preferably 2 to 8 wt.% of a cross linker, the weight percentages are based on the total weight of the coating composition and all weight percentages add up to 100%, to form a functional skin layer. The present inventors found that the water resistant of the functional coating composition can be improved by the incorporation of a cross linker in the functional coating composition.
In an example of the present invention the cross linker is an 4,4'-methylene diphenyl diisocyanate (MDI) ether-based component. The incorporation of such a type of cross linker increases the wet bending strength of the polyvinyl alcohol present in the coating composition.
In an example of the present invention the acid donor is a phosphate component, preferably chosen from the group of sodium pyrophosphate, calcium pyrophosphate, potassium pyrophosphate, ammonium polyphosphate and melamine polyphosphate, or a combination thereof.
The present invention also relates to a functional expanded polymer foam moulded product manufactured by heat expanding moulding of the expanded polymer foam particle with a functional skin layer as discussed above. The necessary heat can be provided via steam, hot air and of radio-frequency heating, or a combination thereof.
The present invention also relates to a process for producing expanded polymer foam particles provided with a functional skin layer, comprising the steps of: heating and expanding expandable polymer foam beads or pellets to produce expanded polymer foam particles; applying a functional coating composition to the outer surface of the above expanded polymer foam particles, the functional coating compasition being prepared by mixing or dissolving 5 to 40 wt.%, preferably 10 to 25 wt.%, of a polyvinyl alcohol, 4 to 30 wt. %, preferably 7 to 15 wt.%, of an acid donor and 40 to 90 wt.%, preferably 50 to 80 wt.%, of at least one or more auxiliaries, the weight percentages are based on the total weight of the coating composition and all weight percentages add up to 100% to form a functional skin layer; and drying the thus coated polymer foam particles for obtaining the expanded polymer provided with a functional skin layer.
In an example the functional coating composition further comprises 1 to 10 wt.%, preferably 2 to 8 wt.% of a cross linker, the weight percentages are based on the total weight of the coating composition and all weight percentages add up to 100%, to form a functional skin layer.
The present invention will now be described in more detail with reference to the following several examples of the manufacture of functional expanded polymer foam particles and molded products manufactured thereof.
Examples A-F
An amount of 150 g polyvinyl alcohol (manufactured by Sigma Aldrich) having an Mw of 70.000 and a degree of hydrolyse of 99,2-99,7% was dissolved in 850 g water using the following steps: filling a tank with demineralized water (Temp: <30°C), adding polyvinyl alcohol while stirring and dissolving the polyvinyl alcohol at elevated temperature. The number of dry solids in this example was 15% w/w.
After preparing the aqueous polyvinyl alcohol solution additional components, namely acid donor Novaflam APP (ammonium polyphosphate, manufactured by
Allinova), auxiliaries kaolin (manufactured by Sigma Aldrich) and crosslinker 4,4'- methylene diphenyl diisocyanate (manufactured by Sigma Aldrich) were added thereto according to Table 1 (See examples A-F). The final coating composition was coated onto expanded polystyrene particles by using a mixing device and the particles thus coated were dried by using an air flow stream.
The expanded polystyrene particles used in these Examples have an average diameter of 5 mm and a density of 15 kg/m3. These expanded polystyrene particles were obtained by pre-expanding expandable polystyrene particles having an average bead size range 95% between 0,9-1,8 mm (manufactured by BEWi RAW) in an expanding machine at a temperature of 103-105°C followed by drying and aging in a silo.
The expanded polystyrene particles provided with a functional skin layer were stored in big bags. The thickness of the functional skin layer was 60 micrometre.
The expanded polystyrene particles having a functional skin layer thus produced were charged into a steam moulder for expanded polystyrene, heated at a steam pressure of 0.6 kg/cm? for 40 seconds, sustained for 10 seconds, and cooled to manufacture an expanded polystyrene molded product having a density of 40 kg/m?.
According to Table 1 several experiments were conducted as shown in Table 2. Table 2 refers to the physical properties of expanded polystyrene molded products according to Examples A-F.
Comparable results were obtained with other types of expanded polymer foam particles, such as expanded polyethylene (EPE), expanded polypropylene (EPP) and bio-based polylactic acid (PLA).
The inventors conducted an additional set of experiments according to the coating composition, except for another acid donor being potassium pyrophosphate (manufactured by Sigma Aldrich).
Table 1: coating composition
Component Amount (wt%) Amount (wt.%) Amount (wt 3%) Amount (wt) Amount (wt) Amount (wt%).
Polyvinylalcohol 0
Aciddonor 0 0 ws 0 amiliaries 70 8 0% 0% 3» To ‘Examples A B C D: Ei Fi
Table 2: physical properties
Example Firetest water resistance
A
De
From Table 2 it is clear that Example C does not meet the requirements of both fire test and water resistance due to the high amount of acid donor. From Table 2 it is clear that Example D does not meet the requirements of both fire test and water resistance due to the high amount of polyvinyl alcohol. From Table 2 it is also clear that Example E does not meet the requirements of both fire test and water resistance due to the low amount of auxiliaries.
Claims (12)
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2033077A NL2033077B1 (en) | 2022-09-20 | 2022-09-20 | Expanded polymer foam particle |
| PCT/NL2023/050484 WO2024063643A1 (en) | 2022-09-20 | 2023-09-19 | Expanded polymer foam particle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2033077A NL2033077B1 (en) | 2022-09-20 | 2022-09-20 | Expanded polymer foam particle |
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| NL2033077B1 true NL2033077B1 (en) | 2024-03-26 |
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| NL2033077A NL2033077B1 (en) | 2022-09-20 | 2022-09-20 | Expanded polymer foam particle |
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| NL (1) | NL2033077B1 (en) |
| WO (1) | WO2024063643A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1709110A1 (en) | 2004-01-30 | 2006-10-11 | Ltd. Polma Co. | Expanded polystyrene bead having functional skin layer, manufacturing process thereof, and functional eps product and manufacturing process thereof using the same |
| WO2008090333A2 (en) | 2007-01-23 | 2008-07-31 | Pq Silicas Uk Limited | Aqueous compositions, precursor systems and application systems |
| WO2010128797A2 (en) * | 2009-05-04 | 2010-11-11 | Kim Jae-Cheon | Expandable, incombustible polystyrene particles and preparation method thereof, and styropor made from the particles |
| US20120052127A1 (en) | 2009-05-06 | 2012-03-01 | Polma Co., Ltd. | Expanded polystyrene particles having skin layer with superior moldability, method for preparing the same and expanded polystyrene molded article using the same |
| EP2656995A1 (en) | 2012-04-23 | 2013-10-30 | Jsp Corporation | Method for producing skin-covered foamed molded article and resulting product |
| KR20220021801A (en) * | 2020-08-14 | 2022-02-22 | 전남대학교산학협력단 | Organic-inorganic hybrid flame retarding compositions for preparing flame retarding EPS beads, the flame retarding EPS beads coated by the compositions and the method for preparing the same |
-
2022
- 2022-09-20 NL NL2033077A patent/NL2033077B1/en active
-
2023
- 2023-09-19 WO PCT/NL2023/050484 patent/WO2024063643A1/en unknown
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1709110A1 (en) | 2004-01-30 | 2006-10-11 | Ltd. Polma Co. | Expanded polystyrene bead having functional skin layer, manufacturing process thereof, and functional eps product and manufacturing process thereof using the same |
| WO2008090333A2 (en) | 2007-01-23 | 2008-07-31 | Pq Silicas Uk Limited | Aqueous compositions, precursor systems and application systems |
| WO2010128797A2 (en) * | 2009-05-04 | 2010-11-11 | Kim Jae-Cheon | Expandable, incombustible polystyrene particles and preparation method thereof, and styropor made from the particles |
| US20120052127A1 (en) | 2009-05-06 | 2012-03-01 | Polma Co., Ltd. | Expanded polystyrene particles having skin layer with superior moldability, method for preparing the same and expanded polystyrene molded article using the same |
| EP2656995A1 (en) | 2012-04-23 | 2013-10-30 | Jsp Corporation | Method for producing skin-covered foamed molded article and resulting product |
| KR20220021801A (en) * | 2020-08-14 | 2022-02-22 | 전남대학교산학협력단 | Organic-inorganic hybrid flame retarding compositions for preparing flame retarding EPS beads, the flame retarding EPS beads coated by the compositions and the method for preparing the same |
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|---|---|
| WO2024063643A1 (en) | 2024-03-28 |
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