TWI419793B - 透光性發泡聚合物板及製造彼之方法 - Google Patents

透光性發泡聚合物板及製造彼之方法 Download PDF

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TWI419793B
TWI419793B TW97124945A TW97124945A TWI419793B TW I419793 B TWI419793 B TW I419793B TW 97124945 A TW97124945 A TW 97124945A TW 97124945 A TW97124945 A TW 97124945A TW I419793 B TWI419793 B TW I419793B
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Taiwan
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mixture
equal
polymeric material
foamed polymer
weight
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TW97124945A
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TW200920599A (en
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Jonas Erik Borgsten
Nooijer Rene De
Christianus J J Maas
Hamersveld Eelco M S Van
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Gen Electric
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Description

透光性發泡聚合物板及製造彼之方法
本揭示一般係關於發泡聚合物板和彼之製法，特別係關於透光性發泡聚合物板和彼之製法。
在自然發光結構(如，花房、水池圍牆、溫室、露天大型運動場、日光浴室..等)之建構中，玻璃用於許多應用中作為透光結構組件(如，窗、飾面和屋頂)。然而，在許多應用中，因為數個顯著的優點，以聚合物板代替玻璃。
聚合物板的一個優點在於，相較於玻璃，其具有極佳的耐衝擊性。此轉而降低在有時會因遭遇野蠻行為、冰雹、收縮/膨脹..等而引發破裂的應用中之維護成本。聚合物板的另一優點在於，相較於玻璃，重量顯著降低。此使得聚合物板比玻璃較易安裝且降低安裝玻璃時之結構載重要求。
除了這些優點以外，聚合物板最顯著的優點之一在於，相較於玻璃，其提供改良的絕緣性。因為消費者希望結構組件具有改良的效能以降低加熱和/或冷卻成本，且以具減低的重量為佳，所以，此特性明顯影響聚合物板的總市場接受度。因此，希望使用發泡聚合物板。然而，這樣的板不透光並因此而無法被接受。
因此，此技術對於透光性發泡聚合物板有需求存在。
本揭示係透光性發泡聚合物板和彼之製法。
一些體系中，發泡聚合物板包含：聚合材料和位於聚合材料中的氣泡。此氣泡之尺寸分佈D90 大於或等於300微米且此板的透光率高於或等於約5%。
另一體系中，發泡聚合物板包含：聚合材料和位於聚合材料中的氣泡。此氣泡的平均直徑(延主軸測得者)約1毫米至約4毫米且此板的透光率高於或等於約5%。
一體系中，一種製造發泡聚合板之方法包含：熔解聚合材料，使發泡劑與聚合材料在擠壓機中混合形成混合物，在離開擠壓機之前，抑制發泡，使混合物中的泡沫成核，及將混合物形成板。此混合物處於足以製造氣泡尺寸(沿主軸測定)大於或等於1毫米之氣泡的溫度下，且此板的透光率高於或等於5%。
另一體系中，一種製造發泡聚合板之方法包含：發泡劑與聚合材料混合形成混合物，使混合物中的泡沫成核而形成氣泡，和在校正板之間冷卻此混合物以製造發泡聚合物板。此混合物處於足夠的溫度且氣泡具有足夠的氣泡尺寸，使得發泡聚合物板之透光率高於或等於10%。
藉之後的圖和詳細描述作為前述和其他特徵的例證。
本揭示為透光性發泡聚合物板、透光性發泡聚合多壁 板，及彼之製法。此發泡板之透光率大於或等於1%，或者，特定言之，大於或等於約5%，或者，更特定言之，大於或等於約10%，或者，更特定言之，大於或等於約20%，或者，更特定言之，約30%至約60%，或者，更特定言之，約35%至約55%。除非特別聲明，否則此處的透光率係藉ASTM D－1003－00(程序B，光譜計，使用亮度C以擴散亮度和以單一方向觀察)測定，其中透光率定義為： 其中：I＝光穿透試樣的強度I0 ＝入射光強度
不為理論所限，已發現影響發泡聚合物之透光率的因素之一為氣泡尺寸。許多方法製造小的氣泡尺寸(如，低於或等於100微米)。於這些氣泡尺寸，發泡聚合物不透光(透光率0%)，即使此聚合物在未發泡之前具有高透光率(如，大於80%)亦然。因此，本發泡聚合物具有足夠的氣泡尺寸和/或尺寸分佈，以得到所欲的透光率。此發泡聚合物可以具有氣泡尺寸分佈D90 (即，大於或等於90%氣泡之直徑，延主軸測得)大於或等於約300微米，或特別地，約300微米至4毫米，或更特別地，約500微米至約4毫米或，再更特別地，約1毫米至約3.5毫米，和，更特別地，約1.5毫米至約3毫米，的密閉氣泡。平 均氣泡尺寸(延主軸測得)可大於或等於1毫米，或特別地，約1毫米至4毫米，或更特別地，約1.5毫米至約3.5毫米或，再更特別地，約1.5毫米至約3毫米，其中標準偏差是2毫米。
此發泡聚合物具有足夠數目的氣泡，使得此板具有所欲性質並同時具有所欲透光率。一些體系中，氣泡的數目可低於或等於約500個氣泡(如，空洞)/立方公分(c/cm3 )，或，特別地，約1個氣泡/立方公分至約500個氣泡/立方公分，或，更特別地，約5個氣泡/立方公分至約250個氣泡/立方公分，和更特別地，約10個氣泡/立方公分至約100個氣泡/立方公分。
這些氣泡尺寸可藉由模具之前的壓力、加工溫度、發泡劑(類型和濃度)和/或所用的發泡法之組合而得。發泡聚合物可在任何得到所欲氣泡尺寸的方法中製得。例如，發泡聚合物可在擠壓法中製得。此方法中所用的溫度係足以得到所欲氣泡尺寸，即，抑制氣泡之成核(如，抑制添加發泡劑之後之發泡並維持所欲黏度及使得材料於離開擠壓器(模具後)之後立即發泡)的溫度。此溫度為足以得到有助於產製透光性發泡聚合物板(如，透光率大於或等於約5%)的氣泡尺寸之溫度。例如，用於聚碳酸酯，此溫度可為約180℃至約260℃，此取決於起泡劑的類型和量，或特別地，約200℃至約260℃，或，更特別地，約220℃至約255℃，和更特別地，約230℃至約250℃。
聚合物板可由包含聚合材料(如，熱塑物、熱固物和包含前述者中之至少一者之組合)之聚合物組成物(其具有足夠的初始透光率，使其於發泡之後，具有所欲透光率)形成。例如，此聚合材料之透光率可大於或等於約80%，或，特別地，大於或等於約85%。除透光率以外，此聚合材料可經選擇以具有足夠的耐衝擊性，使得此板能夠耐得住因衝擊(如，冰雹、鳥類、石塊..等)而造成之破損(如，破裂、斷裂之類)。因此，希望聚合物具有的衝擊強度大於或等於約7.5英呎－磅/平方英吋(4.00焦耳/平方公分)，更特別地，大於約10.0英呎－磅/平方英吋(5.34焦耳/平方公分)或更特別地，大於或等於約12.5英呎－磅/平方英吋(6.67焦耳/平方公分)，此係根據ASTM D－256－93(Izod切口衝擊試驗)測定。此外，所欲地，聚合材料具有高韌度，以使得製得的板可用於應用板通常在板的二或多側被用於支撐和/或夾住(夾在四個側邊)的應用上，如用於包含管鋼框架結構的花房應用。此處之足夠的韌度定義為聚合物包含楊氏模量(如，彈性模量)大於或等於約200,000磅/平方英吋，psi(14,061公斤/平方公分)，更特別地，大於或等於約250,000 psi(17,577公斤/平方公分)，或更特別地，大於或等於約300,000 psi(21,092公斤/平方公分)。
熱塑性物的例子包括聚鏈烯(如，聚乙烯、聚丙烯、聚對酞酸烷二酯(如，聚對酞酸乙二酯(PET)、聚對酞酸丁二酯、聚(對酞酸乙二酯)二醇(PETG)))、聚 碳酸酯、丙烯酸系物、聚縮醛、苯乙烯(如，耐衝擊性經修飾的聚苯乙烯、丙烯腈－丁二烯－苯乙烯(ABS)、苯乙烯－丙烯腈)、聚(甲基)丙烯酸酯(如，聚丙烯酸丁酯、聚甲基丙烯酸甲酯)、聚醚醯亞胺、聚胺基甲酸酯、聚苯硫醚、聚氯乙烯、聚碸、聚醚酮、聚醚醚酮、聚醚酮酮..等，及包含前述者中之至少一者之組合。熱塑性摻合物的例子包含丙烯腈－丁二烯－苯乙烯/尼龍、聚碳酸酯/丙烯腈－丁二烯－苯乙烯、丙烯腈丁二烯苯乙烯/聚氯乙烯、聚苯醚/聚苯乙烯、聚苯醚/尼龍、聚碸/丙烯腈－丁二烯－苯乙烯、聚碳酸酯/熱塑性胺基甲酸酯、聚碳酸酯/聚對酞酸乙二酯、聚碳酸酯/聚對酞酸丁二酯、熱塑性彈料摻雜物、尼龍/彈料、聚酯/彈料、聚對酞酸乙二酯/聚對酞酸丁二酯、乙縮醛/彈料、苯乙烯－馬來酐/丙烯腈－丁二烯－苯乙烯、聚醚醚酮/聚醚碸、聚乙烯/尼龍、聚乙烯/聚乙縮醛，和類似者。但在所列的特定體系中，預料使用聚碳酸酯材料，如註冊名稱Lexan者，其為General Electric Company,GE Plastics,Pittsfield,MA的市售品。
添加劑可用以修飾聚合材料之效能、性質或加工。添加劑的例子包含抗氧化劑(如，有機亞磷酸酯，例如，亞磷酸參(壬基－苯基)酯、亞磷酸參(2,4－二－第三丁基苯基)酯、二亞磷酸雙(2,4－二－第三丁基苯基)季戊四醇酯或二亞磷酸二硬脂基季戊四醇酯、烷基化的單酚、聚酚和聚酚與二烯之烷基化的反應產物(例如，肆([伸甲基 (3,5－二－第三丁基－4－羥基丁二酸酯)]甲烷、3,5－二－第三丁基－4－羥基丁二酸酯十八碳烷基、亞磷酸2,4－二－第三丁基苯酯、對－甲酚和環戊二烯之丁基化的反應產物、烷基化的氫醌、羥基化的硫代二苯醚、亞烷基－雙酚、苯甲基化合物、β－(3,5－二－第三丁基－4－羥基苯基)丙酸與一羥基或多羥基醇之酯、β－(5－第三丁基－4－羥基－3－甲基苯基)－丙酸與一羥基或多羥基醇之酯；硫烷基或硫醯基化合物之酯類，如，硫丙酸二硬脂酯、硫丙酸二月桂酯、硫二丙酸二(十三烷基)酯、β－(3,5－二－第三丁基－4－羥苯基)丙酸的醯胺；填料和強化劑，如，矽酸鹽、纖維、玻璃纖維(包括連續和切斷的纖維)、雲母和其他添加劑；如、脫模劑、UV吸收劑、安定劑(如，光安定劑和其他者)、潤滑劑、塑化劑、顏料、染料、著色劑、抗靜電劑、阻燃劑、衝擊修飾劑及其他者。
欲得到所欲發泡板，此聚合性組成物亦包含起泡劑。此起泡劑可為分解型(在化學分解反應下，形成氣體(如，二氧化碳(CO2 )、氮(N2 )和/或氨氣))和/或蒸發型(其無化學反應地蒸發)。可能的起泡劑包括碳酸氫鈉、疊氮化合物、碳酸銨、亞硝酸銨、輕質金屬(其藉與水之反應而生成氫)、氯化烴、氯氟化碳、偶氮基二碳化醯胺、N,N’－二亞硝基戊四胺、三氯一氟甲烷、三氯三氟乙烷、二氯甲烷、有機羧酸(如，甲酸、乙酸、草酸、蓖麻油酸..等)、戊烷、丁烷、乙醇、丙酮、CO2 、N2 、氨氣..等，及包含前述中之至少一者之組合。
起泡劑的用量取決於方法、製程條件和特定聚合材料。一些體系中，起泡劑的量可約0.5重量%至約10重量%，或，特別地，約0.5重量%至約5重量%，或更特別地，約1重量%至約4重量%，其中重量%係基於聚合物組成物(如，聚合材料、添加劑、起泡劑、成核劑..等)總重。一些體系中，起泡劑可為約0.5重量%至約4重量%CO2 ，或，特別地，約1重量%至約3重量%CO2 ，和約0.25重量%至約2重量%額外的起泡劑(CO2 以外)，或，特別地，約0.5重量%至約1.5重量%額外的起泡劑。
添加劑或氣泡控制劑藉由改變聚合物組成物的表面張力或藉由作為可生成氣泡的成核位址而影響發泡氣泡之成核作用。成核劑可加至聚合物組成物中以促進製程期間內的泡沫生成。可以選擇成核劑以發展特別孔洞尺寸的氣泡。一些可能的成核劑包括滑石(矽酸鎂)、玻璃纖維、發煙二氧化矽、二氧化鈦、檸檬酸和碳酸氫鈉之混合物、氧化鋅..等，及包含前述者中之至少一者之組合。所用成核劑的量取決於方法、處理濃度、特定聚合材料、起泡劑和所欲氣泡尺寸。一些體系中，成核劑的量可低於或等於約7重量%，或，特別地，約0.01重量%至約5重量%，或，更特別地，約0.5重量%至約1重量%，其中重量%係基於聚合物組成物之總重。
眾多技巧可用以形成透光性發泡聚合物板，包括連續法或批次法。此批次法主要用以製造具有非常特定性質或每批次體積較小的發泡體。但是，連續法有利於產製規模 操作之高產量。一體系中，連續法使用擠壓機，如，單螺旋擠壓機或串聯設備。每一處理可使用共旋轉雙螺旋。此方法包含：聚合材料和任何添加劑引至擠壓機頸部，熔解聚合材料，起泡劑溶解於熔解的聚合材料中，將聚合材料加以塑化，氣泡之成核作用(如，由於模具的壓力下降)，泡沫於模具之後生長，氣泡結構安定化作用(如，在冷卻和校正板步驟中)。所欲地，氣泡成核數目有限且所有方向以相同速率生長，以製造具有均勻三維機械性質的透光性發泡體。
發泡聚合物板可以其他層一併擠壓。例如，此板可以與包覆層(其可與發泡板的任一側(如，頂、底和/或側面)相鄰)一併擠壓。此包覆層之厚度可低於或等於約200微米，或，特別地，約20微米至約200微米，或更特別地，約30微米至約100微米，可包含所製得之物件的透光率不低於所欲程度之塑料。此未發泡的塑料包括熱塑物、熱固物及包含前述者中之至少一者之組合。塑料的一些例子包括在前文中被視為聚合材料之材料。所欲地，此塑料包含UV吸收劑。
圖1為製造透光性發泡聚合物板之連續法的例示。如由圖可看出者，聚合材料(樹脂)加至混合擠壓機的頸部。擠壓機下游，起泡劑加至熔解的樹脂中。自混合擠壓機，組成物進入冷卻用的擠壓機。自冷卻用的擠壓機，組成物經擠壓(視情況而定地與其他層一併擠壓)通過模具，於此處，壓力改變而誘發泡沫之成核作用。自此模 具，板通過校正板，於此處得到發泡板的最終物理形狀包括表面(如，表面形成)。所得發泡聚合物板的透光率高於或等於約5%，厚度高於或等於約0.1毫米(如，約0.1毫米至約40毫米，或，特別地，約4毫米至約25毫米)。此板的密度可低於或等於約600公斤/立方米，或，特別地，約60公斤/立方米至約600公斤/立方米，或，更特別地，約70公斤/立方米至約400公斤/立方米，和更特別地，約80公斤/立方米至約200公斤/立方米，此係根據擠壓機測定(如，Berstorff,Hannover,德國；DIN 53420/ISO 845：1998)。U值高於或等於約0.5瓦特/平方米K。
特定言之，U－值係在兩個板側之間的溫度差為1°K時，通過一平方米板2的熱能。此U－值可根據EN 675和Deutches Institute fur Normung(“DIN”)European Norm(“EN”)12667/12664測定。U－值係根據下列式(II)計算： 其中：χ＝λ/s λ＝熱導電率s＝板厚度(1/αi )＝內側的熱轉變阻抗(1/αa )＝外側的熱轉變阻抗
U－值係使用在Norm NEN 1068(2001年)中所謂的熱轉變阻抗值計算，其中(1/αi )是0.13平方米K/瓦特而(1/αa )是0.04平方米K/瓦特。此發泡板的U值可低於或等於約5瓦特/平方米K，或，特別地，低於或等於約3瓦特/平方米K，或，更特別地，低於或等於約2瓦特/平方米K。
此發泡板可為多壁板。現參考圖2和3，所示之例示的多壁板之部分截面圖具有主層2，包含第一外側層(如，頂層)10和第二外側層(如，底層)12，其藉橫向層(如，肋狀物)4連接。頂層10和底層12及內層14通常彼此平行。橫向層4通常位於其間，並垂直於頂層10和底層12。
此外，此板具有足夠數目的橫向層4以得到所欲的結構整體性。除了主層和橫向層(肋狀物4)以外，可以有分隔物6和8。此分隔物可具有眾多幾何形狀，如，呈直角(如，交錯(如，X)形狀(如，請參考圖2，交錯的分隔物6)、正弦曲線形狀(如，請參考圖3，正弦形狀分隔物8)，及任何其他形狀及包含這些形狀中之至少一者之組合。
多壁板的層數取決於顧客需求，如，結構整體性、總厚度、透光性質和絕緣性質。多壁板具有至少2層，或特別地，大於或等於3層(如，主層)，或，更特別地，約3層至約10層，和，更特別地，約4層至約8層。一些體系中，此層每一者的厚度低於或等於約1毫米，或，特別 地，約0.2毫米至約0.8毫米，或，更特別地，約0.3毫米至約0.6毫米。雖然板的總厚度(箭頭16)可高至甚至超過約10公分，通常，此厚度低於或等於約32毫米，或特別地，低於或等於約16毫米，和更特別地，低於或等於約12毫米。通常，多壁板的總厚度高於或等於約8毫米。一些體系中，橫向層每一者的厚度低於或等於約1毫米，或，更特別地，約0.2毫米至約0.8毫米，或，更特別地，約0.25毫米至約0.6毫米。
每一氣泡18可包含寬度約10毫米，但可以使用能夠提供所欲用途(如，作為屋頂或片產品)之足夠韌度的任何寬度。更特別地，組合時，板2可曝於因雪、雨、風和之類所造成的眾多力量。因此，如果此板被用來作為屋頂，則希望能夠耐得住這些力量且不會失效(如，彎曲、破裂、鼓起..等)。可以選擇最終板2的特定尺寸(如，總寬度、長度和厚度)及頂層4、底層6和肋狀物8的厚度，使得板2能夠耐得住這些力量。
製造此板2的期間內，亦可施以共擠壓法和/或塗佈法以於板形狀的任何表面部分供應不同的聚合物，以改良和/或改變板的效能，和/或降低原料成本。一體系中，共擠壓法可用以將人工著色劑加至頂層10中。此塗層可位於板表面的任何處，以改良板的效能和/或性質。例示塗層或共擠壓層可包含抗黴塗層、疏水塗層，親水塗層、光分散塗層、抗凝結塗層、耐刮塗層、紫外光吸收塗層、光安定劑塗層和類似者。嫻於共擠壓技術之人士知道，利 用共擠壓法，可製造出無數體系。
實例
以直鏈聚碳酸酯(即，Lexan(102X)，GE Plastics,Pittsfield,MA之市售品)和支鏈聚碳酸酯(即，Lexan(ML3324)，亦為GE Plastics市售品)二者評估聚合材料之發泡。樣品1包含102X/ML3324，其餘樣品包含ML3324。
所用的眾多發泡劑(此處中亦稱為起泡劑)示於表1。一些情況中，除了另一發泡劑以外，亦使用二氧化碳CO2 。當擠壓機非於最大扭矩操作時，與戊烷、丁烷和/或准許的IPA混合的CO2 有利於發泡結構。溫度條件示於表1和2，其中“Tz”為溫度區，“T”是溫度，“P”是壓力。單位如下：l/min是升/分鐘；kW是千瓦特；amp是安培；Kg/h是公斤/小時；g/s是克/秒鐘；%是百分比；而V是電壓。
以試驗的樣品測定平均密度(根據DIB53420/ISO845：1998)、U－值(DIN EN 12664/12667)、透光率和氣泡尺寸並示於表3。參數之間有關聯性，但一干擾分析的參數是表面形狀且，特別干擾透光率值。可看出，當樣品厚度之間之密度變化不大時，U－值隨樣品厚度而降低。主要看來，11毫米和23毫米樣品的氣泡尺寸並無不同，預料U－值與樣品厚度之間有線性關係。但透光率對於氣泡尺寸的變化更為敏感。因此，相較於11毫米樣品，6毫米樣品之透光率與樣品厚度之間的關係較為有利。在23毫米樣品的例子中，其變差程度於11毫米樣品呈比例，此主要係形成不均勻的表面之故。
本發泡聚合物板可預見被用於希望使用聚合物板的任何應用中。例示應用包含自然發光結構(如，花房、日光浴室、水池圍牆、浴室圍牆)、可開關的汽車頂、遮篷、遮蓋物、窗、發光固定物、曬黑床、露天大型運動場屋頂..等。
此處揭示的範圍含括並可合併(如，“高至約25重量%”，或，更特別地，約5重量%至約20重量%，係含括“約5重量%至約25重量%..等”範圍之終點和所有的內值)。“組合”係含括摻合物、混合物、衍生物、摻雜物、反應產物..等。此外，此處的“第一”、“第二”..等非指任何順序、量或重要性，而是用以區別組件之間，且此處的“一”並非限制量，而是代表有至少一個所指品項存在。與量有關的所用修飾字“約”含括指定值且具有文脈所指意義，(如，包括與特別的量之測定有關之誤差程度)。此處所用的字尾“(s)”意欲包括其所指品項之單數和複數，藉此包括一或多個該品項(如，著色劑包括一或多種著色劑)。“一體系”、“另一體系”、“一個體系”..等意指體系中所欲之特別的要素(如，特徵，構造和/或特性)含括於此處所述的至少一體系中，並可存在或不存在於其他體系中。此外，應瞭解所述要件可以任何適當方式合併於眾多體系中。
茲將所有引用的專利案、專利申請案和其他參考資料全數以納入方式列入參考。但若本申請案之名詞與列入參考者之名詞相矛盾或抵觸，則來自本申請案之名詞優先於來自列入參考者之相抵觸的名詞。
已提出典型的體系用於說明，但不應將前文之描述視為此處的範圍之限制。據此，嫻於此技術者能夠在不違背此處之精神和範圍的情況下，作出眾多修飾、改編和改變。
2‧‧‧主層
4‧‧‧橫向層
6‧‧‧分隔物
8‧‧‧分隔物
10‧‧‧第一外側層
12‧‧‧第二外側層
14‧‧‧內層
16‧‧‧總厚度
現參考圖，其為例示體系，且其中類似的元件具類似的編號。
圖1為製造透光性發泡聚合物板之連續法的例示圖。
圖2為例示多壁板的部分正面圖。
圖3為另一例示多壁板的部分正面圖。

Claims (18)

  1. 一種發泡聚合物板，其包含：聚合材料；和位於聚合材料中的氣泡，其中氣泡之尺寸分佈D90 為300微米至1.5毫米；和其中此板的透光率高於或等於約5%。
  2. 一種發泡聚合物板，其包含：聚合材料；和位於聚合材料中的氣泡，其中氣泡的平均直徑(延主軸測得者)約1毫米至約4毫米；和其中此板的透光率高於或等於約5%。
  3. 如申請專利範圍第1至2項中任一項之板，其中透光率高於或等於10%。
  4. 如申請專利範圍第1至2項中任一項之板，其中透光率高於或等於約20%。
  5. 如申請專利範圍第1至2項中任一項之板，其中透光率是約30%至約60%。
  6. 一種製造發泡聚合物板之方法，其包含：熔解聚合材料；使發泡劑與聚合材料在擠壓機中混合形成混合物；在離開擠壓機之前，抑制發泡；使混合物中的泡沫成核，其中混合物處於能製造氣泡的180℃至260℃溫度下，其中該氣泡之尺寸分佈D90 為300微米至1.5毫米；和 將混合物形成板；其中此板的透光率高於或等於5%。
  7. 如申請專利範圍第6項之方法，其中透光率高於或等於10%。
  8. 一種製造發泡聚合物板之方法，其包含：發泡劑與聚合材料混合形成混合物；使混合物中的泡沫成核而形成氣泡；和在校正板之間冷卻此混合物以製造發泡聚合物板；其中此混合物處於180℃至260℃的溫度且氣泡之尺寸分佈D90 為300微米至1.5毫米，使得發泡聚合物板之透光率高於或等於10%。
  9. 如申請專利範圍第6至8項中任一項之方法，其中此板之密度低於或等於約600公斤/立方米。
  10. 如申請專利範圍第6至8項中任一項之方法，其中擠壓機之冷卻部分的溫度是約200℃至約260℃。
  11. 如申請專利範圍第10項之方法，其中溫度是約220℃至約255℃。
  12. 如申請專利範圍第6至8項中任一項之方法，其中與聚合材料混合的發泡劑的量以混合物總重計為約0.5重量%至約10重量%。
  13. 如申請專利範圍第12項之方法，其中發泡劑的量為約0.5重量%至約5重量%。
  14. 如申請專利範圍第6至8項中任一項之方法，其中與聚合材料混合的發泡劑的量係約0.5重量%至約4重 量%的CO2 和約0.25重量%至約2重量%的不同發泡劑，其中重量%係基於混合物總重計。
  15. 如申請專利範圍第6至8項中任一項之方法，其進一步包含使成核劑與聚合材料混合，其中成核劑選自滑石、玻璃纖維、發煙二氧化矽、二氧化鈦、檸檬酸和碳酸氫鈉混合物、氧化鋅及包含前述者中之至少一者之組合。
  16. 如申請專利範圍第15項之方法，其中成核劑包含滑石。
  17. 如申請專利範圍第6至8項中任一項之方法，其中發泡劑係選自戊烷、丁烷、乙醇、IPA、丙酮、CO2 、N2 、氨氣及包含前述者中之至少一者之組合。
  18. 如申請專利範圍第6至8項中任一項之方法，其中將混合物製成板包含將混合物製成多壁板。
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