Expandable styrene series resin composition and process for production thereof

Claim 2

An expandable styrene series resin composition comprising a styrene series resin containing in its molecular structure one or more groups of the formula: --SiY.sub.n R.sub.3-n (I) wherein R is an inert monovalent organic group; Y is a hydrolyzable group; and n is an integer of 1 to 3, and a blowing agent, said group or groups being chemically bonded to the molecular structure of the styrene series resin by addition polymerization, by graft polymerization or by free radicals.

Claim 3

A composition according to claim 1, which further comprises one or more organosilane compounds having at least two hydrolyzable groups in its molecule.

Claim 4

A composition according to claim 1 or 2, wherein the group of the formula (I) is contained in the styrene series resin in an amount of 0.03 to 20% by weight.

Claim 5

A composition according to claim 1 or 2, wherein the group of the formula (I) is contained in the styrene series resin in an amount of 0.05 to 10% by weight.

Claim 6

A composition according to claim 1 or 2, wherein the group of the formula (I) is contained in the styrene series resin in an amount of 0.05 to 5% by weight.

Claim 7

A composition according to claim 1 or 2, wherein in the formula (I) Y is an alkoxy group or an acyloxy group and R is an alkyl group or an aryl group.

Claim 8

A composition according to claim 1 or 2, wherein the composition is in the form of beads or particles.

Claim 9

A composition according to claim 2, wherein the organosilane compound having at least two hydrolyzable groups is represented by the formula: Y.sub.n SiR'.sub.4-n wherein Y is a hydrolyzable group; R' is a monovalent organic group; and n is an integer of 2 to 4.

Claim 10

A composition according to claim 1 or 2, wherein the styrene series resin is in the form of beads or particles and is produced by polymerizing at least one styrene series monomer and at least one vinyl series monomer containing a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; Y is a hydrolyzable group; R is an inert monovalent organic group; and n is an integer of 1 to 3, in an aqueous medium.

Claim 11

A composition according to claim 9, wherein the compound of the formula (II) is γ-methacryloxypropyltrimethoxysilane.

Claim 12

A composition according to claim 1 or 2, wherein the styrene series resin is in the form of beads or particles and is produced by conducting suspension polymerization in an aqueous medium a polymer solution comprising at least one styrene series polymer and at least one styrene series monomer and/or at least one vinyl series monomer, in which a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; Y is a hydrolyzable group; R is an inert monovalent organic group; and n is an integer of 1 to 3, is included as a part of component constituting said styrene series polymer and/or as a part of said vinyl series monomer.

Claim 13

A process for producing an expandable styrene series resin composition comprising a styrene series resin containing in its molecular structure one or more groups of the formula: --SiY.sub.n R.sub.3-n (I) wherein R is an inert monovalent organic group; Y is a hydrolyzable group; and n is an integer of 1 to 3, and a blowing agent, which comprises suspension polymerizing at least one styrene series monomer and at least one vinyl series monomer containing a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; and Y, R and n are as defined above, in an aqueous medium to give a styrene series resin, and impregnating the styrene series resin with a blowing agent during or after the completion of the polymerization to give the expandable styrene series resin composition in the form of beads or particles.

Claim 14

A process for producing an expandable styrene series resin composition comprising a styrene series resin containing in its molecular structure one or more groups of the formula: --SiY.sub.n R.sub.3-n (I) wherein R is an inert monovalent organic group; Y is a hydrolyzable group; and n is an integer of 1 to 3, and a blowing agent, which comprises suspension polymerizing at least one styrene series monomer and at least one vinyl series monomer containing a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; and Y, R and n are as defined above, in an aqueous medium to give a styrene series resin, and impregnating the styrene series resin with a blowing agent during or after the completion of the polymerization to give the expandable styrene series resin composition in the form of beads or particles.

Claim 15

A process according to claim 12, wherein the styrene series monomer is used in an amount of 50% by weight or more based on the total amount of the monomers.

Claim 16

A process according to claim 12, wherein the compound of the formula (II) has a --OCH 3 group as Y.

Claim 17

A process according to claim 12, wherein the compound of the formula (II) has a group of the formula: ##STR2## as X.

Claim 18

A process according to claim 12, wherein the polymerization in the aqueous medium is aqueous suspension polymerization.

Claim 19

A process for producing an expandable styrene series resin composition comprising a styrene series resin containing in its molecular structure one or more groups of the formula: --SiY.sub.n R.sub.3-n (I) wherein R is an inert monovalent organic group; Y is a hydrolyzable group; and n is an integer of 1 to 3, and a blowing agent, which comprises conducting suspension polymerization in an aqueous medium a polymer solution comprising at least one styrene series polymer and at least one styrene series monomer and/or vinyl series monomer, in which a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; and Y, R and n one as defined above, is included as a part of the component constituting said styrene series polymer and/or as a part of said vinyl series monomer, and impregnating the resulting styrene series resin with a blowing agent during or after the completion of the polymerization to give the expandable styrene series resin composition in the form of beads or particles.

Claim 20

A process for producing an expandable styrene series resin composition comprising a styrene series resin containing in its molecular structure one or more groups of the formula: --SiY.sub.n R.sub.3-n (I) wherein R is an inert monovalent organic group; Y is a hydrolyzable group; and n is an integer of 1 to 3, and a blowing agent, which comprises conducting suspension polymerization in an aqueous medium a polymer solution comprising at least one styrene series polymer and at least one styrene series monomer and/or vinyl series monomer, in which a compound of the formula: XSiY.sub.n R.sub.3-n (II) wherein X is an organic group having at least one copolymerizable double bond; and Y, R and n one as defined above, is included as a part of the component constituting said styrene series polymer and/or as a part of said vinyl series monomer, and impregnating the resulting styrene series resin with a blowing agent during or after the completion of the polymerization to give the expandable styrene series resin composition in the form of beads or particles.

Claim 21

A process according to claim 17, wherein the polymer solution is obtained by conducting bulk polymerization of 0.1 to 50 parts by weight of the compound of the formula (II) and 50 to 99.9 parts by weight of one or more styrene series monomers and containing 95 to 40% by weight of unreacted components, and if required, adding the compound of the formula (II) and/or one or more other vinyl series monomers.

Claim 22

A process according to claim 17, wherein the styrene series monomers and/or the vinyl series monomers contain 50% by weight or more of styrene.

Claim 23

A process according to claim 17, wherein the compound of the formula (II) has a --OCH 3 group as Y.

Claim 24

A process according to claim 17, wherein the compound of the formula (II) has a group of the formula: ##STR3## as X.

Claim 25

A process according to claim 17, wherein the styrene series resin contains the unit derived from the compound of the formula (II) in an amount of 0.1 to 50% by weight and the unit derived from the styrene series monomers and vinyl series monomers in an amount of 99.9 to 50% by weight.