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
  • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/3461—Making or treating expandable particles
• • 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
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
  • B29K2025/04—Polymers of styrene
  • B29K2025/06—PS, i.e. polystyrene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
  • B29K2105/048—Expandable particles, beads or granules
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/26—Scrap or recycled material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
  • B29K2995/0015—Insulating
• • 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
  • C08J2300/00—Characterised by the use of unspecified polymers
• • 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
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/30—Polymeric waste or recycled polymer
• • 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
  • C08J2425/00—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
  • C08J2425/02—Homopolymers or copolymers of hydrocarbons
  • C08J2425/04—Homopolymers or copolymers of styrene
  • C08J2425/06—Polystyrene

Definitions

• Present invention relates to method o preparation of green form polystyrene with desired properties to use in varied applications promoting green technologies by reusing the used plastic, in specific the method of preparation comprises of using compounds like general purpose poSystyrene fGPPS), recycled polystyrene ⁇ piastic waste) and with minimal amount of expandable polystyrene (EPS) to obtain green form polystyrene with increased melt flow index ⁇ MPS) and there by after gas injection it will give tendency to expand as expandable polystyrene eps) capsules termed as green form expandable polystyrene
• EPS expandable polystyrene
• Styrene also known as vinyl benzene
• vinyl benzene is an aromatic compound that is produced In industrial quantities front ethyl bemene.
• the most common method of styrene production comprises the dehydrogenation of ethylbenzene, which produces a crude product of styrene and ethyl benzene.
• Polystyrene is an aromatic polymer produced from the styrene monomer. Polystyrene can be solid or foamed.
• General purpose poSystyrene is clear, hard, and rather brittle.
• Polystyrene is one of the roost widely used plasties. It is a rather poor barrier to oxygen and wate vapour and has a: relatively low melting point. Polystyrene can be naturally transparent, but can be coloured with colorants,
• Expanded polystyrene is well known and can be produced by combining an expandable as>. such as C02 t with poSystyrene, such as during the production of foamed products and can include extruded polystyrene ' ⁇ HPS ⁇ .
• EPS can b used in applications such as insulation material and thereof as the entrapped gaseous content resists the flow of heat thereby giving insulating properties,
• fOOOS More In particular, it relates to a process comprising the reduction in volume of expanded polystyren by means of ⁇ dissolution, in a solvent, separation of the insoluble components, the selective precipitation of polystyrene with anti-solvent, the separation, drying and extrusion of the precipitated polystyrene, recovery by distillation and recycling of the solvent.
• the fire-retardant insulation board is widely used in the construction industry, but the current high cost of raw materials for the production of fire-retardant insulation board, and there is the expansion ratio, low intensity, poor performance and toughness, low surface defects.
• Expandable polystyrene Is expensive component when mpa ed to recycled polystyrene and general purpose polystyrene
• GPPS general purpose polystyrene
• EPSJ expandable polystyrene
• An object of the present invention is to provide a green form expandable polystyrene using combined compounds like recycled polystyrene, general purpose polystyreneCGPPS ⁇ , with minimal amount of expandable polystyrene (EPS) for increasing the free or melt flow index ( R) iOOilJ
• An object of the present nvention Is to provide a green form expandable polystyrene with minima! cost and high; strength.
• the other object of the present invention Is to provide green form expandable polystyrene can acts as a insulatio means for sound and vibration and flame retardant.
• the othe object of the present Invention is to provide green form expandable polystyrene can acts as a power saving medium.
• the other object of the present invention is to provide green form expandable polystyrene can acts as a power booster.
• fQOlS The other object of the present invention is to uti!& plastic waste or used plastic and thereby promoting green technology..
• [0017J Present inventio discloses a method of preparing green form polystyrene resin where the method comprises of steps which includes mixing desired quantities of compounds comprising of virgin expandable material, where the virgin expandable material can be a genera! purpose polymer fGPPS), virgin Hardening ' polymer where virgin hardening material can be a expandable polystyren ⁇ EPS ⁇ , recyclable expandable material where the recyclable expandable material can be used polystyrene processed using process like extrusion process where the recycled polystyrene can utilized or waste plastic like used bottles and thereof . Other necessary recipes are added to the compound mixture. Thereby the compound mixture is processed through an extrusion process whereby the process yields green form compounded polystyrene with high melt flow index.
• Method of preparing green form polystyrene further discloses composition of compounds to he used where desired Cfuantities of the compounds mixed can be varied, where the desired quantities can the range of following percentages whereby the genera! purpose polymer can be in the range 35 to 60, the expandable polystyrene can be in the range 1 to 20 and the recyciabSe polystyrene can be in the range 35 to 65 whereb the desired properties of the green form polymer is attained as per usage or application area.
• melt flow index of the green form polystyrene where the attained melt flo index ca be more than 35 units and whereby varying the ratios in the mixture melt flo Index can be varied where: the melt flow index can b increased or
• fQGlSJ Furthe the present in ention discloses a method of preparing green form polystyrene heads coinpf isin of steps whic include mixing desired quantities of compounds comprising of virgin expandable materia!, virgin hardening polymer, recyclable expandabie materia! and other required materials thereof.
• the compound mixture is processed through an extruding process whe e the mixture yields green form compounded polystyrene resin with high melt flow index. Further using gas injection technique gas is injected into the green form expandable polystyrene resin to synthesize green form expandable capsules o beads thereof with desired properties,
• JOOIS Further also present invention discloses a method of preparing green form polystyrene beeds comprising of steps which include mixing desired quantities of compounds comprising of virgin expandable materia!, virgi hardening polymer, recyclabie expandable material and other required materials thereof.
• the compound mixture Is processed through an extruding process where the mixture yields green form compounded polystyrene resin with high melt flow index.
• gas injection technique gas is injected into the green form expandable polystyrene resi to synthesize green form expandabie capsules or beads thereof with desired properties and thereby puffing expandabl green form capsules with pre-expaoder to synthesize green polystyrene molded foam which can be used for applications like insulation of wafe amj thereby promoting; green technology.
• Pig.i shows the process f manufacturing of green foam polystyrene accordin one exemplary embodiment of the invention.
• Fig.2 shows the process of manufacturing of green foam polystyrene with injection of blowing agent according one exemplary embodiment of the invention.
• FIG.3 shows the process of manufacturing of green foam polystyrene for treating of capsules in pre-expander for pre-puffing accordin one exemplary embodiment of the invention.
• the present Invention is about the method of preparation of green form polystyrene with desired properties to use in varied applications promoting green technologies by reusing the used plastic for high melt flow index ⁇ MR ⁇
• IO026J I specific the method of preparation comprises of using ompounds Site general purpose polystyrene ⁇ GPPSj, recycled polystyrene ⁇ plastic w s e) and with minima! amount of expandable poSystyrene (EPS ⁇ to obtain green form polystyrene with increased melt flow index ⁇ MR).
• Site general purpose polystyrene ⁇ GPPSj recycled polystyrene ⁇ plastic w s e
• EPS ⁇ expandable poSystyrene
• Th method of manufacturing a green expandable polystyrene ⁇ EPS) or a polymer that can be formed by addition of different carbon containing and coloring composition like green color enhancer and thereof along with the recipe formulation uses different polymerization process like sus e ion and thereo for the production of green EPS.
• Suspension polymerization i a heterogeneous radical polymeraa ion process that uses mechanical agitation to mix a monomer or mixture of monomers in a liquid phase, such as water, while the monomers polymerize, forming spheres of polymer.
• expandable materials can be recycled. Recycling of expandable materia! where the recyclable expandable material can be a expandable polystyrene where the recycling Is a process of reusing the available polystyrene products that are generally available in different forms like bottles, packing's and thereof are processed using extrusion process and infecting gas into the extrusion for the preparation of capsules,
• the virgin expandable material where the virgin expandable material can be a genera i purpose polymer (GPPS)
• a virgin expandable material 101 that can be a general purpose polymer (GPPS); virgin hardening polymer 102 where virgin hardening material can be an expandable polystyrene ⁇ EPS ⁇ ; recyclable expandable material 103 where the recyclable expandable materia! can be used polystyre e processed using process like extrusion roc ss where the recycled polystyren 103 ca be obtained from utilized or waste plastic products like used bottles and thereef are rnked to form a compound mixture and other necessary recipes are also added to the compound mixture.
• the compound mixture is processed through extrusion process 104,
• exemplary extrusion process 104 the compound mixture with recipes are feeded into the hopper the the ⁇ material, undergoes compression and melting with predetermined temperature.
• the basics of foam extrusion consist of mixing a chemical foaming agent (CFA) with the polymer to be extruded.
• CFA chemical foaming agent
• the heat generated to melt the polymer decomposes the chemical foaming agent resulting: 3 ⁇ 4 gas bein liberated.
• This gas s dispensed in the polymer meit and expands upon exiting the die.
• all common extruders can be used for foaming if the following requirements are met:
• the melt temperature must be hig enough to guarantee a total decomposition of the foaming agent.
• the pressure of the meit must be kept high enoug to kee the gas generated by the decomposition of the foaming agent dissolved in the poiymer meit until the melt exits the extrusion die. if the meit temperature is too iow the decomposition of the foaming agent wilt be incomplete, resulting in an uneconomical process, And, un-decomposed foaming agent particles can lead to agglomerates, which ca clog the meit filter or cause voids, poor cel structure, or poor surface appearance. A pressure profile that is not high enough can lead to "pre-foaming". Even with a subsequent pressure increase, the gas cannot he "re-dissolved 5*" ,, resulting i large irregular celi structure with broken and collapsed cells.
• a virgin expandable materia! 201 that can be a general purpose poiymer (6PP$); virgin hardening poiymer 202 where virgin hardening material can be an expandable polystyrene ⁇ £?$ ⁇ ; recyclable expandable material 203 where the recyclable expandable material, ears be used polystyrene processed using process like extrusion process where the recycled polystyrene 203 can utilized or waste plastic lik used bottles and thereof are mixed: to form a compound mixture and other necessary recipes are aiso added to the compound mixture.
• 6PP$ general purpose poiymer
• virgin hardening poiymer 202 where virgin hardening material can be an expandable polystyrene ⁇ £?$ ⁇
• recyclable expandable material 203 where the recyclable expandable material, ears be used polystyrene processed using process like extrusion process where the recycled polystyrene 203 can utilized or waste plastic lik used bottles and thereof are mixed: to form a compound mixture and other necessary recipes are aiso added
• gas injection process 206 gaseous agents are injected into the MPS 205 to convert the pellets into capsules or bead 207, Where the gas Injection process 206 can use any type of gas used for forming capsules 207 based on the requirement.
• gas injection technique 306 a blowing agent is injected into the MPS 305 to convert the pellets into capsules 307.
• gas injecti on process 306 can use any type of gas used fo forming capsules or beads 307 with desired properties based on the requirement.
• pre-expander for pre-puffing 308 the capsules 307 to form a green form expandable poiystyrene molding 309.
• the method of preparin green form poiystyrene further discloses composition of compounds to be used where desired quantities of the compounds mixed can be varied.
• the desired quantities can be in the range of following percentages whereby the general purpose polymer can be in th range 35 to 6G t the expandable poiystyrene can be In the rang i to 20 and the recyclable polystyrene cars be In the range 35 to 65.
• the method of preparing green form poiystyrene further discloses composition of compounds to be used where desired quantities of the compounds mixed can be varied.
• the desired quantities can be in the range of following percentages of general purpose polymer; expandable polystyrene; and the recyclable polystyrene can be varied from application to application based on the requirement.
• the ratio of percentage of virgin general purpose polymer, recyclable expandable material and expandable polystyrene contribute to increase in melt flow index of th green form poiystyrene where the atfainedymett flow inde tan be more than 35 units and whereby varying the ratios in the mixture melt fiow index can be varied where the melt fiow index can be increased or reduced.
• This invention promotes green ⁇ technologies by the usage of recyclable plastic and also reduces the overall cost of the product. Because the cost of recyclable- polystyrene is less when compared with virgin EPS or virgin GPP8. So recyclable polystyrene acts as a substitute to the virgin EPS a d virgin GPPS whereby the amount of virgin EPS used In the production is of very less percentage.
• the green form polystyrene obtained have several advantages and improved properties like the overall cost of the production of green form polystyrene is ver economical, the strength of the product obtained is high because of the molecular weight maintained., the overall thickness can be varied as required, whereby insulation properties are improved.
• the green form expandable polystyrene ears acts as a insulation means for sound and vibration, can acts as a flame reiardant means, high power saving medium.

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• 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)
• Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

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• 2015
  • 2015-07-15 IN IN2143DE2015 patent/IN2015DE02143A/en unknown
• 2016
  • 2016-07-13 WO PCT/IN2016/050238 patent/WO2017009871A1/en not_active Ceased
  • 2016-07-13 US US15/744,837 patent/US20180208731A1/en active Pending

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