US20060125136A1 - Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones - Google Patents

Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones Download PDF

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Publication number
US20060125136A1
US20060125136A1 US11/349,980 US34998006A US2006125136A1 US 20060125136 A1 US20060125136 A1 US 20060125136A1 US 34998006 A US34998006 A US 34998006A US 2006125136 A1 US2006125136 A1 US 2006125136A1
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weight
blowing agent
mixture
water
parts
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Abandoned
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US11/349,980
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Wolfgang Kratzmuller
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Priority to US11/349,980 priority Critical patent/US20060125136A1/en
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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
    • C08J9/0014—Use of organic additives
    • C08J9/0047—Use of organic additives containing boron
    • 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
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/125—Water, e.g. hydrated salts
    • 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
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
    • C08J9/142—Compounds containing oxygen but no halogen atom
    • 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
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
    • C08J9/149—Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143
    • 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
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/03—Extrusion of the foamable blend
    • 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
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/10—Water or water-releasing compounds
    • 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
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/12—Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
    • 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
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/18—Binary blends of expanding agents
    • C08J2203/182—Binary blends of expanding agents of physical blowing agents, e.g. acetone and butane
    • 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
    • C08J2321/00—Characterised by the use of unspecified rubbers

Definitions

  • the invention relates to a process for producing foam webs from a polysulfone or a polyether sulfone by extruding a mixture of the thermoplastic with from 1 to 10% by weight of a volatile blowing agent, under pressure into the open atmosphere.
  • Blowing agents used there are oxygen-containing aliphatic liquids, such as alcohols, ketones, esters, and ethers, in particular acetone.
  • oxygen-containing aliphatic liquids such as alcohols, ketones, esters, and ethers, in particular acetone.
  • blowing agent water or a mixture of water with up to 200 parts by weight, based on 100 parts by weight of water, of an inert gas or organic liquid as ancillary blowing agent.
  • the blowing agent is water or else a mixture with the following ancillary blowing agents
  • water and also to mixtures of water with up to 100 parts by weight, based on 100 parts by weight of water, of an alcohol or of a ketone with a boiling point between 50 and 100° C.
  • the amounts used of the blowing agent are from 1 to 10% by weight, preferably from 2 to 8% by weight, based on the thermoplastics. It is possible to add conventional auxiliaries, e.g. nucleating agents, to regulate the number of cells.
  • the polymer used comprises a mixture of a high-molecular-weight and a low-molecular-weight polysulfone or polyether sulfone, preferably in a mixing ratio of from 5:1 to 1:5. It is preferable here for the flowability MVR 360° C./10 kg to ISO 1133 of the high-molecular-weight polymer to be below 75 [cm 3 /10 min], and that of the low-molecular-weight polymer to be greater than 80 (cm 3 /10 min].
  • the process of the invention is preferably carried out on a plant composed of two extruders.
  • the thermoplastic is firstly melted at above its glass transition temperature, then the blowing agent is injected into the melt under pressure and homogeneously mixed with the same, whereupon the glass transition temperature of the mixture falls.
  • the mixture is cooled to a temperature at which the viscosity of the melt is still sufficiently high to form a good foam.
  • the mixture is extruded into the open atmosphere, whereupon it foams.
  • the foam sheets obtained preferably have a thickness of from 0.5 to 8 cm and a density of from 30 to 100 g/l.
  • the foam specimens were extruded on a tandem plant. This is composed of a melting extruder and a cooling extruder.
  • a polyether sulfone (ULTRASON 2010 from BASF AG) is fed to the first extruder.
  • the polymer is melted, and the blowing agent or the mixture of the blowing agent is injected and then mixed into the melt, the temperature of which is 340° C.
  • the melt comprising blowing agent is then cooled in the second extruder to the temperature needed for foaming (see table). After discharge from a slot die, the melt foams and is shaped in a calibrator to give sheets.
  • foam sheets were produced from polyether sulfone. Instead of a single grade, a mixture composed of a free-flowing, low-viscosity PES (low molecular weight) and a low-flowability, high-viscosity PES (high molecular weight) was foamed.
  • the materials used are PES E1010, E2010, and E3010 from BASF.
  • the mixture of grades has broad molecular weight distribution and can be foamed with water as sole blowing agent to give lower densities than those given by the individual components.

Abstract

The invention relates to a process for producing foam webs by foam extrusion of a mixture of a polysulfone or polyether sulfone and a volatile blowing agent, where the blowing agent is water or a mixture of water with an inert gas or organic liquid, e.g. an alcohol or a ketone.

Description

  • The invention relates to a process for producing foam webs from a polysulfone or a polyether sulfone by extruding a mixture of the thermoplastic with from 1 to 10% by weight of a volatile blowing agent, under pressure into the open atmosphere.
  • A process of this type is described in DE-A 4 207 257. Blowing agents used there are oxygen-containing aliphatic liquids, such as alcohols, ketones, esters, and ethers, in particular acetone. However, a problem arising is that the use of these readily combustible liquids represents a considerable safety risk at the high temperatures used.
  • It is an object of the present invention to eliminate this risk or at least to reduce it.
  • We have found that this object is achieved by using, as blowing agent, water or a mixture of water with up to 200 parts by weight, based on 100 parts by weight of water, of an inert gas or organic liquid as ancillary blowing agent.
  • The blowing agent is water or else a mixture with the following ancillary blowing agents
      • inert gases, such as CO2, nitrogen, argon,
      • hydrocarbons, such as propane, butane, pentane, hexane,
      • aliphatic alcohols, such as methanol, ethanol, propanol, isopropyl alcohol, butanol,
      • aliphatic ketones, such as acetone or methyl ethyl ketone,
      • aliphatic esters, such as methyl or ethyl acetate,
      • fluorohydrocarbons (e.g. 134a, 152a),
      • a mixture of these.
  • Particular preference is given to water, and also to mixtures of water with up to 100 parts by weight, based on 100 parts by weight of water, of an alcohol or of a ketone with a boiling point between 50 and 100° C.
  • The amounts used of the blowing agent are from 1 to 10% by weight, preferably from 2 to 8% by weight, based on the thermoplastics. It is possible to add conventional auxiliaries, e.g. nucleating agents, to regulate the number of cells.
  • Surprisingly, it has been found that foam webs of particularly low density are obtained if the polymer used comprises a mixture of a high-molecular-weight and a low-molecular-weight polysulfone or polyether sulfone, preferably in a mixing ratio of from 5:1 to 1:5. It is preferable here for the flowability MVR 360° C./10 kg to ISO 1133 of the high-molecular-weight polymer to be below 75 [cm3/10 min], and that of the low-molecular-weight polymer to be greater than 80 (cm3/10 min].
  • The process of the invention is preferably carried out on a plant composed of two extruders. In the first extruder, the thermoplastic is firstly melted at above its glass transition temperature, then the blowing agent is injected into the melt under pressure and homogeneously mixed with the same, whereupon the glass transition temperature of the mixture falls. In the second extruder, the mixture is cooled to a temperature at which the viscosity of the melt is still sufficiently high to form a good foam. Finally, the mixture is extruded into the open atmosphere, whereupon it foams. If a slot die is used, the foam sheets obtained preferably have a thickness of from 0.5 to 8 cm and a density of from 30 to 100 g/l.
  • The proportions of materials mentioned in the example are percentages by weight.
    • EXAMPLE 1
  • The foam specimens were extruded on a tandem plant. This is composed of a melting extruder and a cooling extruder.
  • A polyether sulfone (ULTRASON 2010 from BASF AG) is fed to the first extruder. The polymer is melted, and the blowing agent or the mixture of the blowing agent is injected and then mixed into the melt, the temperature of which is 340° C. The melt comprising blowing agent is then cooled in the second extruder to the temperature needed for foaming (see table). After discharge from a slot die, the melt foams and is shaped in a calibrator to give sheets.
    H2O Acetone ST Thickness Density
    Experiment (%) (%) (° C.) (mm) (g/l)
    1 5 246.5 11 46
    2 1 4 249.1 11 43
    3 2 3 249.4 10 46
    4 2 2 248.7 10 52
    5 3 1 248.1 10 63
    6 2 243.8 10 82
    7 2 247.8 10 124
    8 1.5 250.2 10 178
  • Experiments 1 and 2 are non-inventive.
    • EXAMPLE 2
  • As described in Example 1, foam sheets were produced from polyether sulfone. Instead of a single grade, a mixture composed of a free-flowing, low-viscosity PES (low molecular weight) and a low-flowability, high-viscosity PES (high molecular weight) was foamed.
  • The materials used are PES E1010, E2010, and E3010 from BASF.
  • The following MFR values describe the flowability of these materials.
    MVR 360° C./10 kg
    (cm3/10 min)
    ISO 1133
    E1010 150
    E2010 77
    E3010 40
  • The mixture of grades has broad molecular weight distribution and can be foamed with water as sole blowing agent to give lower densities than those given by the individual components.
    E1010 E2010 E3010 H2O Density
    (%) (%) (%) (%) (g/l)
    100 3 84
    100 3 82
    100 3 98
    67 33 3 66

Claims (6)

1. A process for producing a foam sheet having a thickness of more than 0.5 cm, said process comprising mixing thermoplastic polymers selected from polysulfone or polyether sulfone or mixtures thereof and from 1 to 10% by weight, based on the thermoplastic polymers, of a volatile blowing agent, at above 300° C. under pressure, and extruding the mixture into the open atmosphere using a slot die, wherein the blowing agent is a mixture of water with up to 200 parts by weight, based on 100 parts by weight of water, of an alkanol or of an aliphatic ketone.
2. The process of claim 1, wherein the blowing agent is a mixture of water with up to 100 parts by weight, based on 100 parts by weight of water, of an alkanol or of an aliphatic ketone with a boiling point between 50 and 100° C.
3. (canceled)
4. The process of claim 1, wherein acetone is used as ancillary blowing agent.
5. The process of claim 1, wherein the foam sheet has a thickness of from 0.5 to 8 cm and a density of from 30 to 100 g/l.
6. The process of claim 1, wherein the foam sheet has a thickness of from 1 to 8 cm and a density of from 43 to 63 g/l.
US11/349,980 2001-12-20 2006-02-09 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones Abandoned US20060125136A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/349,980 US20060125136A1 (en) 2001-12-20 2006-02-09 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE10162602A DE10162602A1 (en) 2001-12-20 2001-12-20 Production of foam sheet from polysulfone or polyether-sulfone involves extruding with a blowing agent consisting of water or a mixture of water and volatile alkanol or aliphatic ketone
DE10162602.9 2001-12-20
US10/319,642 US7045082B2 (en) 2001-12-20 2002-12-16 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones
US11/349,980 US20060125136A1 (en) 2001-12-20 2006-02-09 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones

Related Parent Applications (1)

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US10/319,642 Division US7045082B2 (en) 2001-12-20 2002-12-16 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones

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US11/349,980 Abandoned US20060125136A1 (en) 2001-12-20 2006-02-09 Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones

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EP (1) EP1333051B1 (en)
JP (1) JP4170749B2 (en)
AT (1) ATE317871T1 (en)
DE (2) DE10162602A1 (en)
ES (1) ES2256398T3 (en)

Cited By (9)

* Cited by examiner, † Cited by third party
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US8829119B2 (en) 2011-09-27 2014-09-09 Baker Hughes Incorporated Polyarylene compositions for downhole applications, methods of manufacture, and uses thereof
US20140299352A1 (en) * 2013-03-15 2014-10-09 General Cable Technologies Corporation Foamed polymer separator for cabling
US8939222B2 (en) 2011-09-12 2015-01-27 Baker Hughes Incorporated Shaped memory polyphenylene sulfide (PPS) for downhole packer applications
US9144925B2 (en) 2012-01-04 2015-09-29 Baker Hughes Incorporated Shape memory polyphenylene sulfide manufacturing, process, and composition
US9260568B2 (en) 2011-07-08 2016-02-16 Baker Hughes Incorporated Method of curing thermoplastic polymer for shape memory material
US9707642B2 (en) 2012-12-07 2017-07-18 Baker Hughes Incorporated Toughened solder for downhole applications, methods of manufacture thereof and articles comprising the same
US10031301B2 (en) 2014-11-07 2018-07-24 Cable Components Group, Llc Compositions for compounding, extrusion, and melt processing of foamable and cellular polymers
US10032542B2 (en) 2014-11-07 2018-07-24 Cable Components Group, Llc Compositions for compounding, extrusion and melt processing of foamable and cellular halogen-free polymers
US10815354B2 (en) 2014-09-30 2020-10-27 Sekisui Plastics Co., Ltd. Bead expanded molded article, resin expanded particles, method for producing resin expanded particles, expandable resin particles and method for producing bead expanded molded article

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10162602A1 (en) * 2001-12-20 2003-07-10 Basf Ag Production of foam sheet from polysulfone or polyether-sulfone involves extruding with a blowing agent consisting of water or a mixture of water and volatile alkanol or aliphatic ketone
DE10307736A1 (en) * 2003-02-24 2004-09-02 Basf Ag Open-cell foam made of high-melting plastics
EP2072248A1 (en) 2007-12-21 2009-06-24 Basf Se Heat insulation compound system for façade cladding
BR112015008010A2 (en) 2012-10-12 2017-07-04 Solvay Specialty Polymers Usa high temperature sulfone foam materials (hts)
EP3372632B1 (en) 2017-03-08 2019-08-21 Solvay Specialty Polymers USA, LLC. Foam materials made of a combination of poly(biphenyl ether sulfone) (ppsu) and polyethersulfone (pes)
US11499028B2 (en) 2017-08-04 2022-11-15 Basf Se Expandable, expanding-agent-containing granules based on high-temperature thermoplastics
EP3632970B1 (en) 2018-10-04 2022-04-27 Basf Se Method for the continuous production of a partly-crystalline thermoplastic polymer foam
JP7270887B2 (en) * 2019-06-27 2023-05-11 睦月電機株式会社 Method for producing foam molded article
WO2023148102A1 (en) 2022-02-04 2023-08-10 Basf Se Method for production of open-celled polymer foams for ultrafiltration applications

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US7045082B2 (en) * 2001-12-20 2006-05-16 Basf Aktiengesellschaft Production of foam webs from high-temperature-resistant polysulfones or polyether sulfones

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US4013810A (en) * 1975-08-22 1977-03-22 The Babcock & Wilcox Company Sandwich panel construction
US4352893A (en) * 1977-07-30 1982-10-05 Mobil Oil Corporation Production of foamed polymer
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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9260568B2 (en) 2011-07-08 2016-02-16 Baker Hughes Incorporated Method of curing thermoplastic polymer for shape memory material
US8939222B2 (en) 2011-09-12 2015-01-27 Baker Hughes Incorporated Shaped memory polyphenylene sulfide (PPS) for downhole packer applications
US8829119B2 (en) 2011-09-27 2014-09-09 Baker Hughes Incorporated Polyarylene compositions for downhole applications, methods of manufacture, and uses thereof
US8940841B2 (en) 2011-09-27 2015-01-27 Baker Hughes Incorporated Polyarylene compositions, methods of manufacture, and articles thereof
US9144925B2 (en) 2012-01-04 2015-09-29 Baker Hughes Incorporated Shape memory polyphenylene sulfide manufacturing, process, and composition
US9707642B2 (en) 2012-12-07 2017-07-18 Baker Hughes Incorporated Toughened solder for downhole applications, methods of manufacture thereof and articles comprising the same
US20140299352A1 (en) * 2013-03-15 2014-10-09 General Cable Technologies Corporation Foamed polymer separator for cabling
US9831009B2 (en) * 2013-03-15 2017-11-28 General Cable Technologies Corporation Foamed polymer separator for cabling
US9953742B2 (en) 2013-03-15 2018-04-24 General Cable Technologies Corporation Foamed polymer separator for cabling
US10522264B2 (en) 2013-03-15 2019-12-31 General Cable Technologies Corporation Foamed polymer separator for cabling
US10815354B2 (en) 2014-09-30 2020-10-27 Sekisui Plastics Co., Ltd. Bead expanded molded article, resin expanded particles, method for producing resin expanded particles, expandable resin particles and method for producing bead expanded molded article
US10947359B2 (en) 2014-09-30 2021-03-16 Sekisui Plastics Co., Ltd. Bead expanded molded article, resin expanded particles, method for producing resin expanded particles, expandable resin particles and method for producing bead expanded molded article
US10031301B2 (en) 2014-11-07 2018-07-24 Cable Components Group, Llc Compositions for compounding, extrusion, and melt processing of foamable and cellular polymers
US10032542B2 (en) 2014-11-07 2018-07-24 Cable Components Group, Llc Compositions for compounding, extrusion and melt processing of foamable and cellular halogen-free polymers
US10825580B2 (en) 2014-11-07 2020-11-03 Cable Components Group, Llc Compositions for compounding, extrusion and melt processing of foamable and cellular halogen-free polymers

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DE10162602A1 (en) 2003-07-10
EP1333051A2 (en) 2003-08-06
EP1333051B1 (en) 2006-02-15
ATE317871T1 (en) 2006-03-15
US20040212119A1 (en) 2004-10-28
ES2256398T3 (en) 2006-07-16
JP4170749B2 (en) 2008-10-22
US7045082B2 (en) 2006-05-16
EP1333051A3 (en) 2003-10-08
DE50205825D1 (en) 2006-04-20
JP2003192818A (en) 2003-07-09

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