WO2009058455A1 - Mousse de perles de polymère ayant des propriétés améliorées et procédé de formation et d'utilisation de celle-ci - Google Patents

Mousse de perles de polymère ayant des propriétés améliorées et procédé de formation et d'utilisation de celle-ci Download PDF

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Publication number
WO2009058455A1
WO2009058455A1 PCT/US2008/072984 US2008072984W WO2009058455A1 WO 2009058455 A1 WO2009058455 A1 WO 2009058455A1 US 2008072984 W US2008072984 W US 2008072984W WO 2009058455 A1 WO2009058455 A1 WO 2009058455A1
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WO
WIPO (PCT)
Prior art keywords
polymer
polymer beads
beads
bead foam
foam
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Application number
PCT/US2008/072984
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English (en)
Inventor
Mario Wallis
Jurgen Schellenberg
Original Assignee
Dow Global Technologies, 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
Application filed by Dow Global Technologies, Inc. filed Critical Dow Global Technologies, Inc.
Publication of WO2009058455A1 publication Critical patent/WO2009058455A1/fr

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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
    • C08J9/16—Making expandable particles
    • C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
    • 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
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products
    • C08J9/232—Forming foamed products by sintering expandable particles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape

Definitions

  • the present invention relates to a polymer bead foam for sound insulation such as in floors or between adjoining rooms of a building.
  • the present invention also relates to a process for forming the polymer bead foam as well as using the foam.
  • Foams formed of polymer beads have been known for some time and are well described in the literature. Of special significance here, are polymer bead foams, which are prepared by foaming beads containing blowing agent, and simultaneously or subsequently fusing the resulting foamed particles into blocks, shaped articles or other foamed objects.
  • expandable polymer beads e.g., expandable styrene beads
  • blowing agent can be added during polymerization or prior to extrusion, however, it is also possible to add the blowing agent to the polymer beads in a subsequent processing step.
  • preferred blowing agents inlcude C 3 to CQ hydrocarbons such as pentanes.
  • U.S. Patent Nos. 5,332,761 and 5,369,137 describe a process of forming polymer foams, and in one embodiment polymer bead foams, having improved properties.
  • those patents describe a process that creates a bimodal foam structure having cells of at least two different sizes for providing the foams with improved toughness, improved insulating capability or the like.
  • polymer bead foams are discussed in PCT Publication WO 2004/087798 and in a book titled Modern Styrenic Polymers: Polystyrenes and Styrenic Copolymers, Copyright 2003, ISBN: 0-471-49752-5, both of which are incorporated herein by reference for all purposes.
  • Industry has been particularly concerned with forming and using polymer bead foam for the purpose of sound insulation.
  • polymer bead foam is often employed to limit the amount of sound that travels through floors and walls of building structures. To effectively limit the transmission of sound, it is typically desirable for the polymer bead foam to exhibit particular properties.
  • a foam can be desirable for a foam to exhibit relatively low compressibility such that the foam can assist in limiting sound transmitting vibrations.
  • a lower dynamic stiffness of the foam can also limit transmission of such vibrations.
  • the foam can also be desirable for the foam to exhibit a relatively high degree of sound absorption.
  • competing material characteristics it is often difficult to make a foam with a desired combination of these properties. That is, it is often the case that forming a foam that exhibits a desired degree of one property can result in that foam exhibiting a less desirable degree of another property.
  • the present invention provides a polymer bead foam that meets the above needs.
  • the present invention provides a polymer bead foam that exhibits improved compressibility while maintaining desired dynamic stiffness.
  • the present invention is a result of surprisingly discovering that a polymer bead foam comprising a combination of larger and smaller polymer foam beads can be foamed to a lower density than a foam containing the smaller polymer foam beads without the larger foam beads and that has a lower compressibility and yet similar or lower dynamic stiffness than a similar polymer bead foam (substantially same density formed under substantially identical conditions) made using the larger polymer foam bead without the smaller foam beads.
  • the present invention provides an expanded polymer bead foam.
  • the foam is preferably for sound insulation of a building.
  • the foam includes a plurality of first foamed thermoplastic polymer beads having an average first volume and a plurality of second foamed thermoplastic polymer beads having an average second volume.
  • the first average volume is at least 4 times the second average volume.
  • the plurality of first foamed thermoplastic polymer beads is at least about 50% by weight of the foam and the plurality of second foamed thermoplastic polymer beads is at least about 2% by weight of the foam.
  • the present invention provides a process of forming the foam includes the following steps: (a) providing a plurality of first polymer beads, the first polymer beads having a first mean diameter; (b) providing a plurality of second polymer beads, the second polymer beads having a second mean diameter, wherein the first mean diameter is at least 1.2 times the second mean diameter; (c) intermixing the first polymer beads and the second polymer beads to form an admixture of the first polymer beads and the second polymer beads, wherein the first polymer beads are at least about 50 percent (%) by weight of the admixture and the second polymer beads are at least about 2 % by weight of the admixture; (d) impregnating the first polymer beads and second polymer beads are impregnated with blowing agent and such impregnation can take place before or after intermixing of the first and second polymer beads; (e) expanding the first polymer beads and the second polymer beads through exposure to a stimulus, wherein the first
  • Fig. 1 is a schematic diagram of foam being formed according to an exemplary process of the present invention.
  • the present invention is predicated upon the provision of a polymer bead foam.
  • the present invention is also predicated upon the provision of a process of forming the polymer bead foam, forming parts from the foam, using the foam or a combination thereof.
  • the polymer bead foam exhibits at least one improved property or a balance of improved properties.
  • the foam has been found to be suitable for use in walls or floors of buildings (e.g., homes, office buildings, apartments etc.). Further, the foam has been found to be particularly suitable as cushion beneath hard materials (e.g., wood or cement) of floors (e.g., floating floors) of buildings.
  • the polymer bead foam is typically formed of first foamed polymer beads and second foamed polymer beads where the first foamed polymer beads have an average size (e.g., volume or diameter) that is larger than the average size of the second foamed polymer beads.
  • the process of forming and/or using the polymer bead foam typically includes any combination of two or more of the following steps:
  • first polymer beads intermixing the first polymer beads and the second polymer beads to form an admixture (14) of the first polymer beads and the second polymer beads wherein the first polymer beads preferably comprise a greater portion of the admixture by weight; and/or 5) forming the admixture into a polymer bead foam (16) and/or shaping the polymer bead foam by molding the foam, cutting the foam or both.
  • polymer beads can include masses of most any three dimensional shape and the shape can be a regular geometric shape or irregular geometric shape.
  • the polymer beads are provided as at least two different groups of polymer beads with the different groups of polymer beads having different average sizes (e.g., volumes or diameters).
  • discussions of the sizes (e.g., mean diameters and average volumes) of the first polymer beads and second polymer beads which may be discussions of actual sizes or relative sizes, can apply to 100% or substantially 100% of the first polymer beads, the second polymer beads or both.
  • the such discussions may only apply to at least 70%, more preferably at least 80% and even more preferably at least 90% of the first polymer beads, the second polymer beads or both.
  • a volume or a mean diameter is specified for the first polymer beads, the second polymer beads or both, it means that such volume or mean diameter applies to, at a minimum, at least 70% of the first polymer beads, the second polymer beads or both.
  • the first polymer beads will preferably have a mean diameter that is greater than the mean diameter of the second polymer beads.
  • the first polymer beads prior to expansion, have a mean diameter that is at least 1.2 times, more preferably at least 2.5 times and even more preferably at least 3.5 times or even 4.0 times the mean diameter of the second polymer beads. It is also typical for the first polymer beads, prior to expansion to have a mean diameter that is no greater that 100 times, more preferably no greater than 20 times and even more preferably no greater than 10 times relative the mean diameter of the second polymer beads.
  • the mean diameter of the second polymer beads, prior to expansion can be at least about 0.7 mm, more preferably at least about 1.1 mm and still more preferably at least about 1.4 or even 2.0 mm and can be less than about 20 mm, more preferably less than about 8.0 mm and even more preferably less than about 4.2 mm. Also, it is contemplated that the mean diameter of the second polymer beads can be at least about 0.01 mm, more preferably at least about 0.07 mm and still more preferably at least about 0.1 or even 0.2 mm and can be less than about 5 mm, more preferably less than about 1.8 mm and even more preferably less than about 1.1 mm. Of course, larger or smaller mean diameter polymer beads may be used for the first and second polymer beads unless otherwise stated. The average mean diameters of the first polymer beads and the second polymer beads can be determined according to DIN 66165-2:1987.
  • the first polymer beads will preferably have an average volume that is greater than the average volume of the second polymer beads.
  • the first polymer beads have an average volume that is at least 4 times, more preferably at least 10 times and even more preferably at least 25 times or even 40 times the average volume of the second polymer beads. It is also typical for the first polymer beads to have an average volume that is no greater that 10,000 times, more preferably no greater than 1000 times and even more preferably no greater than 100 times relative the average volume of the second polymer beads.
  • the average volume of the first polymer beads can be at least about 0.5 mm 3 , more preferably at least about 0.8 mm 3 and still more preferably at least about 1.1 or even 1.4 mm 3 and can be less than about 100 mm 3 , more preferably less than about 60 mm 3 and even more preferably less than about 35 mm 3 .
  • the average volume of the second polymer beads can be at least about 0.0001 mm 3 , more preferably at least about 0.0008 mm 3 and still more preferably at least about 0.003 or even 0.004 mm 3 and can be less than about 3 mm 3 , more preferably less than about 1.0 mm 3 and even more preferably less than about 0.7 mm 3 .
  • the polymer beads could be formed of a variety of expandable polymeric materials, more particularly an expandable (e.g., foamable) thermoplastic material. Although other thermoplastic materials can be used, some preferred materials are styrenic materials. Generally, a styrenic material will include at least one styrene group. Such styrenic materials can be homopolymers, copolymers, a combination thereof or the like. In one preferred embodiment, either or both of the first and second polymer beads are formed of an expandable (e.g., foamable) polystyrene material.
  • polystyrenic polymeric material in the context of the polymeric articles herein, includes polymeric materials containing greater than about 50, preferably about 75 or more, more preferably about 90 or more weight percent of a polymer derived from one or more alkenyl aromatic compounds such as styrene.
  • the polymeric material may be entirely one or more alkenyl aromatic compound.
  • Suitable amounts (e.g., less than 50 percent by weight of the substrate) of copolymerizable compounds, such as Ci -4 methacrylates and acrylates, acrylic acid, methacrylic acid, maleic acid, acrylonitrile, maleic anhydride, and vinyl acetate may be incorporated into the styrenic polymeric material.
  • the polymeric material that forms the polymer beads will preferably be impregnated with a blowing agent for forming expandable polymer beads.
  • a blowing agent for forming expandable polymer beads.
  • such impregnation can occur during or after formation of the beads.
  • such impregnation can occur during formation of the beads during polymerization.
  • the beads may be formed and then impregnated with blowing agent by placing the polymer beads under pressure in a blowing agent rich environment.
  • the blowing agent forms and/or expands a gas within the polymeric material for forming a cellular structure, and more preferably a network of cells, such as a network of closed cell containing a gas (e.g., a gas substantially free of chlorofluorocarbons) phase.
  • a gas e.g., a gas substantially free of chlorofluorocarbons
  • the network of cells will be substantially free of voids between walls defining the cells.
  • the polymeric material includes or is based upon a thermoplastic material that includes blowing agent that is a gas or liquid solvent or hydrocarbon (e.g., pentane, butane or propane) that is dispersed within the material such that, upon exposure to a stimulus such as heat, humidity or both, the material can expand and develop cells and thereby form expanded thermoplastic (e.g., expanded styrenic or polystyrene (EPS)) polymer beads.
  • the blowing agent may be a physical blowing agent which changes phase upon exposure to a stimulus such as heat to a gas phase.
  • the gas phase of the resulting foam thus will include the same composition as the blowing agent.
  • the blowing agent may be free of water, carbon dioxide or both.
  • the polymer beads may be coated with some functional ingredient.
  • the beads may also be free of any such coating.
  • suitable polymer beads are sold under the tradename SCONAPOR and are commercially available from The Dow Chemical Company, Midland, Michigan.
  • the polymer beads are preferably brought from a temperature below the glass transition temperature of the thermoplastic material of the polymer beads to a temperature above that glass transition temperature to allow the blowing agents to form open spaces in the polymer beads.
  • a blowing agent stabilizer may be employed as taught in U.S. Patent No.
  • the foams herein are prepared in the absence of any blowing agent stabilizer, and the resulting foam will be free of blowing agent stabilizer. Further, the process an foams herein may be free of the employment of any absorbent clay. However, it is possible that it may include the employment of an absorbent clay such as is disclosed in U.S. Patent No. 6,750,264, which is incorporated herein by reference for all purposes.
  • the polymer beads can also include a variety of different additional additives and ingredients, which will preferably depend upon the intended use of the foam that the polymer beads are to form. Examples of additives and ingredients include, without limitation, flame retardants, infrared (IR) attenuators (carbon black, graphite or the like), coatings, fillers, combinations thereof or the like.
  • Expanding (e.g., foaming) and intermixing of the polymer beads, including the first polymer beads and second polymer beads, can take place in any order and/or simultaneously. Furthermore, impregnation of the polymer beads with a blowing agent can occur before, during or after intermixing of the first and second polymer beads.
  • the manner by which the polymer beads are expanded can depend upon the type of polymer beads employed. Preferably the polymer beads are exposed to a stimulus such as heat, humidity, a chemical, radiation, light, adhesive a combination thereof or the like for causing the expansion.
  • first polymer beads and second polymer beads could be expanded through different mechanisms (e.g., exposure to different stimuli), it is preferred that the mechanisms be the same.
  • polymer beads formed of polymeric materials with solvent or hydrocarbon dispersed within the material of the polymer beads it is preferably desirable to expand (e.g., foam) the materials through exposure to heat, humidity or both as discussed above.
  • the polymer beads, including the first polymer beads and the second polymer beads are exposed to steam, which heats the blowing agent and expands the polymer beads.
  • the polymer beads preferably expand to a volume that is at least about 2 times, more preferably at least about 10 times, and even more preferably at least about 30 times or even at least about 35 times and is preferably less than about 150 times, more preferably less than about 90 times and even more preferably less than about 48 times their original unexpended size. Such exposure may be in multiple cycles.
  • the polymer beads may be stored for amounts of time sufficient to remove a desired amount of water from the polymer beads.
  • the g cells formed in the beads during expansion are all typically similar in size. It is contemplated however, that the cells could be of different sizes such as the bimodal foam structures of U.S. Patent Nos. 5,332,761 and 5,369,137, which are incorporated herein be reference for all purposes.
  • this expanding or foaming of the polymer beads is an initial expansion that is followed by a secondary expansion, which is discussed further below. However, as also discussed below, it could be the only expansion of the polymer beads during processing.
  • the first polymer beads can expand a different amount than the second polymer beads.
  • the first polymer beads could expand to 10 times their original volume while the second polymer beads could expand to 15 times their original volume. However, it is preferable for the first polymer beads and the second polymer beads to expand the same or substantially the same proportionate amount as each other. [0026] After expansion, the first polymer beads will preferably have an average volume that is greater than the average volume of the second polymer beads. After expansion, the first polymer beads preferably have an average volume that is at least 4 times, more preferably at least 10 times and even more preferably at least 25 times or even 40 times the average volume of the second polymer beads after expansion of the first and second polymer beads.
  • the first polymer beads prefferably have an average volume that is no greater that 10,000 times, more preferably no greater than 1000 times and even more preferably no greater than 100 times relative the average volume of the second polymer beads after expansion of the first and second polymer beads. It is contemplated that the average volume of the first polymer beads, after expansion, can be at least about 35 mm 3 , more preferably at least about 50 mm 3 and possibly at least about 65 mm 3 and can be less than about 2000 mm 3 , more preferably less than about 1000 mm 3 and even more preferably less than about 500 mm 3 .
  • the average volume of the second polymer beads, after expansion can be at least about 0.05 mm 3 , more preferably at least about 0.1 mm 3 and still more preferably at least about 0.15 or even 0.2 mm 3 and can be less than about 50 mm 3 , more preferably less than about 25 mm 3 and even more preferably less than about 20 mm 3 or even 5 mm 3 .
  • larger or smaller average volume polymer bead may be used for the first and second polymer beads unless otherwise stated.
  • the first and second polymer beads can be intermixed prior to or after expansion for forming an admixture of the first polymer beads and second polymer beads.
  • the polymer beads are intermixed, it is preferable for the polymer beads to be substantially consistently and continuously interspersed with each other for forming a substantially homogeneous admixture.
  • the first polymer beads can be said to be substantially consistently and continuously interspersed within the second polymer beads. While this is preferable, for certain applications, it is also possible to control intermixing of beads to create selectively higher concentrations of the first or second polymer beads at particular locations in the admixture.
  • the first polymer beads and second polymer beads are mixed together in, for example, a DRAIS blender.
  • the first polymer beads and second polymer beads are preferably intermixed in relative weight percentages.
  • the polymer beads are at intermixed in a ratio between about 1:5 and 100:1 , more preferably between about 1 :1 and 20:1 still more preferably between about 1.5:1 and 10:1 and even still more preferably between 2:1 and 5:1 and even possibly between 2.5:1 and 4:1 for weight percents of first or larger polymer beads relative to second or smaller polymer beads.
  • the first polymer beads can be at least about 30% more preferably at least about 50%, even more preferably at least about 55% and even possibly at least about 63% by weight of the admixture.
  • the first polymer beads are also preferably less than about 98%, more preferably less than about 95%, even more preferably less than about 93% and even possibly less than about 82% by weight of the admixture.
  • the second polymer beads can be at least about 0.5% more preferably at least about 2%, even more preferably at least about 10% and even possibly at least about 20% by weight of the admixture.
  • the second polymer beads are also preferably less than about 70%, more preferably less than about 55%, even more preferably less than about 50% and even possibly less than about 38% by weight of the admixture.
  • Forming and/or shaping of the polymer bead foam preferably includes interconnecting (e.g., fusing or welding) of the first polymer beads and the second polymer beads with themselves and/or each other, in accordance with art-disclosed bead processing techniques.
  • the beads may be subjected to heat or a combination of heat and pressure by which the surface of the bead is brought above its melting point.
  • Such interconnecting preferably creates an interface between the polymer beads where the polymer beads are connected to each other. There may also be interstitial spaces between the polymer beads after interconnection.
  • the admixture of expanded (e.g., foamed) polymer beads are located within a tool (e.g., a cavity of a mold) and exposed to a stimulus (i.e., heat and/or moisture) such as steam, which cause the polymer beads to undergo a secondary expansion.
  • a stimulus i.e., heat and/or moisture
  • Such secondary expansion may cause the polymer beads to interconnect and form a polymer bead foam that has assumed the shape of the compartment.
  • the polymer bead foam can then be removed from the compartment and it will retain its shape as a coherent foam structure.
  • it may be subjected to secondary operations for forming a finished article.
  • this preferred protocol is not the only manner in which the polymer bead foam can be formed and shaped according to the present invention.
  • heat and compression may be employed to interconnect the expanded polymer beads of the admixture.
  • the first and second polymer beads could be intermixed prior to their original expansion and the initial expansion could take place in a compartment such that the initial expansion interconnects the polymer beads and shapes the polymer bead foam thereby eradicating the need for a secondary expansion of the polymer beads.
  • the polymer beads of the admixture will preferably be interconnected at interfaces. While this interconnection can effectively change the mean diameters of the first polymer beads and the second polymer beads of the admixture and/or polymer bead foam, it preferably does not change the volumes or weight percents of the polymer beads in actual or relative terms. Moreover, for the preferred protocol, the secondary expansion of the polymer beads does not significantly change such volumes or weight percents of the polymer beads.
  • the volumes and weight percents of the first polymer beads and second polymer beads, as recited for the polymer beads after initial expansion, can also be applied to the first and second polymer beads in the polymer bead foam after interconnection of the polymer beads.
  • the relative weight percentages of the first and second polymer beads is preferably the same for the polymer bead foam as they were for the admixture since the polymer bead foam is preferably formed entirely or substantially entirely from the admixture of the polymer beads without having substantial (e.g., greater than 5% by weight) other additives.
  • Average volumes for the first and second polymer beads can be determined with the aid of an optical and/or scanning electron microscope (SEM) that produces images of the polymer beads, such as by following the protocol of ASTM D3576-04.
  • SEM scanning electron microscope
  • Multiple techniques are known for calculating volumes using an SEM and such techniques can be used to calculate actual volumes within less than 1 % and even less than 0.1 % error.
  • Such techniques can be used to calculate the volume of each polymer bead of a random sampling of a set quantity, preferably 20 or more, of either the first polymer beads or the second polymer beads and then those volumes of the polymer beads can be summed and divided by the set quantity to determine an average volume.
  • the polymer bead foam may already be in the shape desired. However, it is contemplated that the polymer bead foam may undergo further shaping. For example, the polymer bead foam may be cut into blocks, sheet or the like depending upon the desired application for the polymer bead foam. The polymer bead foam may also undergo one, two or more pressing cycles.
  • the polymer bead foam of the present invention may be used for a variety of applications. Generally, however, it has been found to work quite well for sound insulation between spaces. Thus, the polymer bead foam will preferably be provided as a sheet between a first space and a second space to limit the amount of sound that transfers between the spaces.
  • the polymer bead foam may stand alone, but more often is associated with (e.g., connected to and/or coextensive with) a divider between the two spaces.
  • the polymer bead foam may be used in buildings such as homes, office buildings, apartments or the like and may be associated with (e.g., connected to and/or coextensive with) a divider such as a wall, a floor, ceiling or a combination thereof of the building.
  • a divider such as a wall, a floor, ceiling or a combination thereof of the building.
  • the polymer bead foam is employed in a floor of a building.
  • the polymer bead foam is located beneath a rigid floor substrate in one or more layers.
  • the rigid floor substrate can be, for example, a cement floor, a wood floor (e.g., a hardwood floor), a combination thereof or the like.
  • the polymer bead foam inhibits noise, particularly impact noise (e.g., noise of 100-3150 Hz), from traveling through the polymer bead foam, floor or both and/or from one room to another room of a building.
  • a standard polymer bead foam is formed using only relatively large polymer beads.
  • Two polymer bead foams i.e., example foam A and example foam B
  • example foam A and example foam B are then produced according to the present invention and compared to the standard polymer bead foam.
  • Each of the polymer bead foams are produced by foaming the polymer beads with saturated steam using a Handle pressure pre-foamer under the following conditions:
  • Second Pre-foaming w/ further bead expansion (Dingeldein continuous pre-foamer) Bulk density attained 11.6 g/l
  • the standard polymer bead foam is formed using relatively large EPS polymer beads with greater than or equal to 94% of the polymer beads having a diameter of 1.6 mm to 2.5 mm.
  • Example polymer bead foam A is formed with the same large polymer beads of the standard polymer bead foam mixed with 12.5% by weight smaller polymer beads with greater than or equal to 98% of the polymer beads having a diameter of 0.4 mm to 0.7 mm.
  • Example polymer bead foam B is formed with the same large polymer beads of the standard polymer bead foam mixed with 25% by weight smaller polymer beads with greater than or equal to 98% of the polymer beads having a diameter of 0.4 mm to 0.7 mm.
  • Tables 1-3 present the properties of the resulting foams. Notably, a polymer foam prepared with the smaller beads but not the larger beads could not be foamed to a density below about 18 g/l using similar processes to the other foams.
  • the polymer bead foam exhibits desirable properties such as desirable compressibility and dynamic stiffness relative to a polymer bead foam made of substantially entirely larger polymer beads.
  • the polymer bead foam of the present invention exhibits lower compressibility relative to a polymer bead foam made of substantially entirely larger polymer beads without exhibiting raises in dynamic stiffness to an undesirable degree.
  • the polymer bead foam of the present invention having a mixture of small polymer beads and larger polymer beads exhibit a desired relative compressibility, a desired relative dynamic stiffness or both, which is relative to a substantially identically formed and processed polymer bead foam that is formed of only the larger polymer beads and has substantially the same density (i.e., a density that is within 10% of the density of the polymer bead foam with the small polymer beads and the larger polymer beads).
  • Relative compressibility and relative dynamic stiffness values are expressed as ratios of values for a subject foam (made from a combination of smaller and larger polymer foam beads) divided by values for a foam formed from only the larger polymer foam beads.
  • Such relative compressibility is preferably less than about 1.0, more preferably less than 0.90, still more preferably less than 0.85 and even possibly less than 0.7 or even 0.65 for polymer bead foams having a density of between 12 and 20 g/l, more particularly between 13 and 18 g/l and even more particularly between 14 and 16 g/l when tested according to DIN 18164-2.
  • these polymer bead foam preferably maintain a relative dynamic stiffness that is less than 1.4, more preferably less than 1.2 and even more preferably less than 1.06 when tested according to the DIN standard.
  • there are other standards for testing compressibility and dynamic stiffness which are expected to produce the same results.

Abstract

La présente invention porte sur une mousse de perles de polymère pour fournir une isolation phonique entre des espaces (par exemple dans des planchers et/ou entre des pièces de bâtiment). La présente invention porte également sur un procédé de formation de la mousse de perles de polymère ainsi que sur l'utilisation de la mousse. De préférence, la mousse de perles de polymère est formée à partir d'une pluralité de perles de polymère plus petites et d'une pluralité de perles de polymère plus grandes qui se rassemblent pour former une mousse avec des propriétés améliorées.
PCT/US2008/072984 2007-10-31 2008-08-13 Mousse de perles de polymère ayant des propriétés améliorées et procédé de formation et d'utilisation de celle-ci WO2009058455A1 (fr)

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US60/984,109 2007-10-31

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5332761A (en) * 1992-06-09 1994-07-26 The Dow Chemical Company Flexible bimodal foam structures
US20030130364A1 (en) * 2002-01-04 2003-07-10 Vo Chau Van Multimodal polymeric foam containing an absorbent clay
WO2005056655A1 (fr) * 2003-12-12 2005-06-23 Basf Aktiengesellschaft Granules de polystyrene expanse a repartition des poids moleculaires bimodale ou multimodale

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5332761A (en) * 1992-06-09 1994-07-26 The Dow Chemical Company Flexible bimodal foam structures
US20030130364A1 (en) * 2002-01-04 2003-07-10 Vo Chau Van Multimodal polymeric foam containing an absorbent clay
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