US4179540A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fabrication of foamed articles
Assignee: BP Corp North America Inc
•
Filing: 1976-02-19
•
Granted: 1979-12-18
•
Expires: 1996-02-19
Abstract
Abstract Foamed, low density polymeric articles have been fabricated from a non-tacky hydrogel obtained by blending normally solid thermoplastic polymer resin with a normally liquid organic solvent and water, at lower molding temperatures and energy requirements than those conventionally used in melt extrusion foam processing.
Inventors
- 👤 Walter H. Smarook
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 10:25
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; B; B29; B29C; B29C44/00; B29C44/02; B29C44/10; B29C67/00; B29C67/20; B29C67/202; B29C33/00; B29C33/38; B29K; B29K2105/00; B29K2105/06; B29K2105/16; B29L; B29L2009/00; Y; Y10; Y10S; Y10S264/00; Y10S264/05; Y10T; Y10T428/00; Y10T428/23; Y10T428/233; Y10T428/234; Y10T428/236; Y10T428/24; Y10T428/24149; Y10T428/24157
Claims Analysis
Total Claims: 62
Claim 1
Independent Claim
153 words
Method of fabricating low density, foamed articles comprising the steps of: (a) blending at least one normally solid thermoplastic polymer resin with about 25 to about 80 parts per 100 parts by weight of said resin of a normally liquid organic solvent having a solubility parameter, δ, within about (1.3 calories/cc) 1/2 of that of said resin or a mixture of normally liquid organic solvents having an average solubility parameter, δ, within about (1.3 calories/cc) 1/2 of that of said resin; (b) blending the mixture obtained in step (a) with at least about 1 part by weight, per 100 parts of said resin, of water until a white homogeneous mixture of resin, solvent, and water is obtained whereby a non-tacky hydrogel dough is obtained; (c) shaping the non-tacky hydrogel dough obtained in step (b); (d) vaporizing the solvent and water; (e) removing the solvent and water; and (f) recovering a foamed resin article.
Claim 2
Dependent Claim
153 words
Method of fabricating low density, foamed articles comprising the steps of: (a) blending at least one normally solid thermoplastic polymer resin with about 25 to about 80 parts per 100 parts by weight of said resin of a normally liquid organic solvent having a solubility parameter, δ, within about (1.3 calories/cc) 1/2 of that of said resin or a mixture of normally liquid organic solvents having an average solubility parameter, δ, within about (1.3 calories/cc) 1/2 of that of said resin; (b) blending the mixture obtained in step (a) with at least about 1 part by weight, per 100 parts of said resin, of water until a white homogeneous mixture of resin, solvent, and water is obtained whereby a non-tacky hydrogel dough is obtained; (c) shaping the non-tacky hydrogel dough obtained in step (b); (d) vaporizing the solvent and water; (e) removing the solvent and water; and (f) recovering a foamed resin article.
Claim 3
Dependent Claim
11 words
Method claimed in claim 1 wherein the solvent is methylene chloride.
Claim 4
Dependent Claim
10 words
Method claimed in claim 1 wherein the solvent is 1,1,2-trichloroethane.
Claim 5
Dependent Claim
51 words
Method claimed in claim 1 wherein the resin is a polyarylene polyether polysulfone containing repeating units having the formula: --Ar--SO.sub.2 -- wherein Ar is a divalent aromatic radical containing at least one unit having the structure ##STR11## in which Y is oxygen, sulfur or the radical residuum of an aromatic diol.
Claim 6
Dependent Claim
23 words
Method claimed in claim 4 wherein the polyarylene polyether polysulfone repeating units have the formula: ##STR12## wherein n is 10 to about 500.
Claim 7
Dependent Claim
10 words
Method claimed in claim 1 wherein the resin is polystyrene.
Claim 8
Dependent Claim
11 words
Method claimed in claim 1 wherein the resin is impact polystyrene.
Claim 9
Dependent Claim
66 words
Method claimed in claim 1 wherein a resin is a thermoplastic polyhydroxyether having repeating units of the formula: --D-O-E-O--.sub.a wherein a is an integer denoting the degree of polymerization and has a sufficiently high value so as to afford a normally solid polymer, D is the radical residuum of a dihydroxy aromatic hydrocarbon having both hydroxyls removed and, E is the radical residuum of an epihalohydrin.
Claim 10
Dependent Claim
17 words
Method claimed in claim 1 wherein D is ##STR13## and E is --CH 2 CHOH--CH 2 --.
Claim 11
Dependent Claim
12 words
Method claimed in claim 1 wherein the resin is an acrylonitrile/butadiene/styrene terpolymer.
Claim 12
Dependent Claim
12 words
Method claimed in claim 1 wherein a resin is an olefin copolymer.
Claim 13
Dependent Claim
13 words
Method claimed in claim 1 wherein the resin is a vinyl chloride polymer.
Claim 14
Dependent Claim
19 words
Method claimed in claim 12 wherein the vinyl chloride polymer is a copolymer of vinyl chloride and an alpha-olefin.
Claim 15
Dependent Claim
10 words
Method claimed in claim 13 wherein the alpha-olefin is ethylene.
Claim 16
Dependent Claim
18 words
Method claimed in claim 1 wherein the hydrogel dough is charged to a mold and foamed by heating.
Claim 17
Dependent Claim
28 words
Method claimed in claim 1 wherein the hydrogel dough is shaped and then foamed by lowering the pressure to a point where the solvent and water are vaporized.
Claim 18
Dependent Claim
18 words
Method claimed in claim 1 wherein the hydrogel dough is shaped and foamed in hot water or steam.
Claim 19
Dependent Claim
20 words
Method claimed in claim 1 wherein the hydrogel dough is shaped by containment of a screen and foamed by heating.
Claim 20
Dependent Claim
13 words
Method claimed in claim 1 wherein the solvent is a mixture of solvents.
Claim 21
Dependent Claim
18 words
Method claimed in claim 19 wherein the mixture of solvents is a mixture of ethanol and methylene chloride.
Claim 22
Dependent Claim
17 words
Method claimed in claim 19 wherein the mixture of solvents is a mixture of 1,1,1-trichloroethane and ethanol.
Claim 23
Dependent Claim
13 words
Method claimed in claim 1, wherein the resin is a mixture of resins.
Claim 24
Dependent Claim
21 words
Method claimed in claim 22 wherein the mixture of resins is a mixture of impact polystyrene and a polyarylene polyether polysulfone.
Claim 25
Dependent Claim
21 words
Method claimed in claim 22 wherein the mixture of resins is a mixture of acrylonitrile/butadiene/styrene terpolymer and a polyarylene polyether polysulfone.
Claim 26
Dependent Claim
46 words
Method claimed in claim 22 wherein the mixture of resins is a mixture of a polyarylene polyether polysulfone having repeating units of the formula: --Ar--SO.sub.2 -- and a thermoplastic polyhydroxyether having repeating units of the formula: --D--0--E--O].sub.n wherein Ar, D and E are as defined above.
Claim 27
Dependent Claim
17 words
Method claimed in claim 1 wherein particulate or fibrous filler is physically blended into the polymeric hydrogel.
Claim 28
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is glass fibers.
Claim 29
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is carbon fiber.
Claim 30
Dependent Claim
12 words
Method claimed in claim 26 wherein the filler is a cellulosic material.
Claim 31
Dependent Claim
10 words
Method claimed in claim 26 wherein the filler is graphite.
Claim 32
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is molybdenum sulfide.
Claim 33
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is polytetrafluoroethylene fibers.
Claim 34
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is metal particles.
Claim 35
Dependent Claim
12 words
Method claimed in claim 33 wherein the metal is powdered bronze metal.
Claim 36
Dependent Claim
12 words
Method claimed in claim 26 wherein the metal is powdered tin metal.
Claim 37
Dependent Claim
11 words
Method claimed in claim 26 wherein the filler is barium ferrite.
Claim 38
Dependent Claim
16 words
Method claimed in claim 26 wherein the filler is Al 2 O 3 .3H 2 O.
Claim 39
Dependent Claim
25 words
Method claimed in claim 1 wherein the foamed article is a laminate of alternating layers of foamed resin and a fibrous filler in mat form.
Claim 40
Dependent Claim
12 words
Method claimed in claim 15 wherein the mold is polytetrafluoroethylene coated steel.
Claim 41
Dependent Claim
10 words
Method claimed in claim 15 wherein the mold is plaster.
Claim 42
Dependent Claim
12 words
Method claimed in claim 15 wherein the mold is a silicone rubber.
Claim 43
Dependent Claim
33 words
Method claimed in claim 1 wherein structural members are inserted into the mold with the aqueous colloidal gel to form a foamed composite wherein the members are adhesively bonded to the foamed composite.
Claim 44
Dependent Claim
13 words
Method claimed in claim 42 wherein the structural member is an electrical conductor.
Claim 45
Dependent Claim
13 words
Method claimed in claim 42 wherein the structural member is an electromagnetic coil.
Claim 46
Dependent Claim
13 words
Method claimed in claim 42 wherein the structural member is a permanent magnet.
Claim 47
Dependent Claim
15 words
Method claimed in claim 42 wherein the structural member is a metallic mesh or grid.
Claim 48
Dependent Claim
13 words
Method claimed in claim 42 wherein the structural member is a cellulosic material.
Claim 49
Dependent Claim
14 words
Method claimed in claim 42 wherein the structural member is a woven glass cloth.
Claim 50
Dependent Claim
14 words
Method claimed in claim 42 wherein the foamed composite consists of encapsulated electrical components.
Claim 51
Dependent Claim
51 words
Method claimed in claim 1 wherein the foamed articles are pellets whose density and sphericity is controlled by vaporizing that portion of the solvent and water on the surface of said pellets by allowing them to stand at ambient temperature exposed to the atmosphere and then exposing them to elevated temperatures.
Claim 52
Dependent Claim
27 words
Method claimed in claim 50 wherein the mixture of normally solid thermoplastic polymer resin, organic solvent and water contains a minor amount of a water soluble additive.
Claim 53
Dependent Claim
13 words
Method claimed in claim 50 wherein the additive is an alkali metal bicarbonate.
Claim 54
Dependent Claim
14 words
A low density foamed article fabricated according to the method claimed in claim 1.
Claim 55
Dependent Claim
17 words
Article claimed in claim 53 wherein the normally solid thermoplastic polymer resin is a polyarylene polyether polysulfone.
Claim 56
Dependent Claim
14 words
A low density foamed article fabricated according to the method claimed in claim 15.
Claim 57
Dependent Claim
17 words
Article claimed in claim 55 wherein the normally solid thermoplastic polymer resin is a polyarylene polyether polysulfone.
Claim 58
Dependent Claim
16 words
Article claimed in claim 55 wherein the normally solid thermoplastic polymer is a mixture of resins.
Claim 59
Dependent Claim
14 words
A low density foamed article fabricated according to the method claimed in claim 26.
Claim 60
Dependent Claim
16 words
Article claimed in claim 58 wherein the filler is Al 2 O 3 .3H 2 O.
Claim 61
Dependent Claim
14 words
A low density foamed article fabricated according to the method claimed in claim 42.
Claim 62
Dependent Claim
14 words
A low density foamed article fabricated according to the method claimed in claim 49.
References Cited (Backward Citations)
US2561351A
Cited
US2450436A
Cited
US2856639A
Cited
US3044127A
Cited
US3102865A
Cited
US3227784A
Cited
US3384531A
Cited
US3344221A
Cited
US3375212A
Cited
US3511736A
Cited
US3503907A
Cited
US3959197A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-12-17 | 1983-06-18 | 1983-12-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-12-17 | 1987-06-18 | 1987-12-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-12-17 | 1991-06-18 | 1991-12-18 | $7700.00 | Window Closed / Lapsed |