Novel olefin polymer compositions and foamed articles prepared therefrom having improved elevated temperature dimensional stability

Claim 2

An expandable olefin polymer composition comprising an olefin polymer, a volatile organic blowing agent and from about 0.15 to about 10 weight percent based upon the weight of said olefin polymer of an N-substituted fatty acid amide of the Formula: ##STR4## wherein R 1 represents an alkyl group of from about 11 to about 17 carbon atoms and R 2 represents an alkyl group of from about 12 to about 18 carbon atoms, said N-substituted fatty acid amide being selected from the group consisting of N-lauryl lauric acid amide, N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-lauryl palmitamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide; said N-substituted fatty acid amide being employed in an amount sufficient to prevent a freshly prepared foam made from such composition from shrinking by more than 10% from its initial foamed volume when subjected to prolonged exposure to atmospheric pressure air at 150° F.

Claim 3

The expandable composition of claim 1, wherein the volatile organic blowing agent is selected from halogenated hydrocarbon compounds having from 1 to 4 carbon atoms.

Claim 4

The expandable composition of claim 2, wherein the volatile organic blowing agent is employed in an amount of from about 0.12 to about 0.35 gram-mole of such blowing agent per 100 grams of the olefin polymer component thereof.

Claim 5

The expandable composition of claim 3, wherein the blowing agent comprises from about 75 to about 90 weight percent of dichlorodifluoromethane and from about 10 to about 25 weight percent of trichloromonofluoromethane.

Claim 6

The expandable composition of claim 1 wherein the N-substituted fatty acid amide is N-stearyl stearamide, N-palmityl stearamide or N-palmityl palmitamide.

Claim 7

The expandable composition of claim 1 which further comprises an auxiliary stability control agent selected from the group consisting of (a) higher alkyl amines, (b) fatty acid esters and (c) fatty acid amides different from those of Formula I above and wherein the combined weight of such auxiliary stability control agent and the Formula I compound is no more than about 10 weight percent based upon the weight of the olefin polymer.

Claim 8

The expandable composition of claim 6 wherein the auxiliary stability control agent is stearamide.

Claim 9

The expandable composition of claim 6 wherein the N-substituted fatty acid amide is employed in an amount ranging from about 0.2 to about 2 weight percent based upon the weight of the olefin polymer.

Claim 10

The expandable composition of claim 1 wherein the N-substituted fatty acid amide is employed in an amount of from about 0.7 to about 5 weight percent based upon the olefin polymer.

Claim 11

The expandable composition of claim 1 wherein the N-substituted fatty acid amide is selected from the group consisting of N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide.

Claim 12

An expanded article of an olefin polymer comprising a substantially closed-cell foam having a density of from about 0.6 to about 10 pounds per cubic foot and being composed of a polymer composition comprising (a) an olefin polymer and (b) from about 0.15 to about 10 weight percent based upon the weight of said olefin polymer of an N-substituted fatty acid amide of the Formula: ##STR5## wherein R 1 represents an alkyl group of from about 11 to about 17 carbon atoms and R 2 represents an alkyl group of from about 12 to about 18 carbon atoms, said N-substituted fatty acid amide being selected from the group consisting of N-lauryl lauric acid amide, N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-lauryl palmitamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide; said N-substituted fatty acid amide being employed in an amount sufficient to prevent said expanded article, when in freshly foamed form, from shrinking by more than 10% from its initial foamed volume when subjected to prolonged exposure to atmospheric pressure air at 150° F.

Claim 13

An expanded article of an olefin polymer comprising a substantially closed-cell foam having a density of from about 0.6 to about 10 pounds per cubic foot and being composed of a polymer composition comprising (a) an olefin polymer and (b) from about 0.15 to about 10 weight percent based upon the weight of said olefin polymer of an N-substituted fatty acid amide of the Formula: ##STR5## wherein R 1 represents an alkyl group of from about 11 to about 17 carbon atoms and R 2 represents an alkyl group of from about 12 to about 18 carbon atoms, said N-substituted fatty acid amide being selected from the group consisting of N-lauryl lauric acid amide, N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-lauryl palmitamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide; said N-substituted fatty acid amide being employed in an amount sufficient to prevent said expanded article, when in freshly foamed form, from shrinking by more than 10% from its initial foamed volume when subjected to prolonged exposure to atmospheric pressure air at 150° F.

Claim 14

The expanded article of claim 11 wherein the olefin polymer is polyethylene, an ethylene-vinyl acetate copolymer or an ethylene-acrylic acid copolymer.

Claim 15

The expanded article of claim 11 wherein the N-substituted fatty acid amide is N-stearyl stearamide, N-palmityl stearamide or N-palmityl palmitamide.

Claim 16

The expanded article of claim 11 wherein the N-substituted fatty acid amide is employed in an amount ranging from about 0.2 to about 5 weight percent based upon the weight of the olefin polymer.

Claim 17

The expanded article of claim 11 wherein the N-substituted fatty acid amide is selected from the group consisting of N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide.

Claim 18

The expanded article of claim 11 which further comprises an auxiliary stability control agent selective agent selected from the group consisting of (a) fatty acid amides, (b) fatty acid esters, and (c) fatty acid amides different from those of the Formula I above; the total combined amount of such auxiliary stability control agent and such Formula I compound being less than about 10 weight percent based upon the weight of the olefin polymer employed.

Claim 19

The expanded article of claim 16 wherein the auxiliary stability control agent is stearamide.

Claim 20

A process for preparing a substantially closed-cell olefin polymer foam which comprises incorporating, at elevated temperature and pressure, into a heat-plastified olefin polymer, (a) from about 0.15 to about 10 weight percent, based upon the olefin polymer weight, of an N-substituted fatty acid amide of the Formula ##STR6## wherein R 1 represents an alkyl group having from about 11 to about 17 carbon atoms and R 2 represents an alkyl group having from about 12 to about 18 carbon atoms, said N-substituted fatty acid amide being selected from the group consisting of N-lauryl lauric acid amide, N-lauryl myristamide, N-myristyl myristamide, N-pamityl myristamide, N-lauryl palmitamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide, and (b) from about 0.12 to about 0.35 gram-mole, per 100 grams of olefin polymer, of a volatile organic blowing agent to thereby form a flowable gel of an expandable olefin polymer composition and thereafter extruding said gel into a zone of lower pressure to thereby form said substantially closed-cell olefin polymer foam; said N-substituted fatty acid amide being employed in an amount sufficient to prevent a freshly prepared foam made by said process from shrinking by more than 10% from its initial foamed volume when subjected to prolonged exposure to atmospheric pressure air at 150° F.

Claim 21

A process for preparing a substantially closed-cell olefin polymer foam which comprises incorporating, at elevated temperature and pressure, into a heat-plastified olefin polymer, (a) from about 0.15 to about 10 weight percent, based upon the olefin polymer weight, of an N-substituted fatty acid amide of the Formula ##STR6## wherein R 1 represents an alkyl group having from about 11 to about 17 carbon atoms and R 2 represents an alkyl group having from about 12 to about 18 carbon atoms, said N-substituted fatty acid amide being selected from the group consisting of N-lauryl lauric acid amide, N-lauryl myristamide, N-myristyl myristamide, N-pamityl myristamide, N-lauryl palmitamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide, and (b) from about 0.12 to about 0.35 gram-mole, per 100 grams of olefin polymer, of a volatile organic blowing agent to thereby form a flowable gel of an expandable olefin polymer composition and thereafter extruding said gel into a zone of lower pressure to thereby form said substantially closed-cell olefin polymer foam; said N-substituted fatty acid amide being employed in an amount sufficient to prevent a freshly prepared foam made by said process from shrinking by more than 10% from its initial foamed volume when subjected to prolonged exposure to atmospheric pressure air at 150° F.

Claim 22

The process of claim 18 wherein said lower pressure zone is ambient air pressure.

Claim 23

The process of claim 18 wherein said volatile organic blowing agent comprises a halogenated hydrocarbon compound having from 1 to 4 carbon atoms.

Claim 24

The process of claim 18 wherein the N-substituted fatty acid amide comprises N-stearyl stearamide, N-palmityl stearamide or N-palmityl palmitamide.

Claim 25

The process of claim 18 wherein the N-substituted fatty acid amide is selected from the group consisting of N-lauryl myristamide, N-myristyl myristamide, N-palmityl myristamide, N-myristyl palmitamide, N-palmityl palmitamide, N-palmityl stearamide and N-stearyl stearamide.

Claim 26

The process of claim 18 wherein an auxilary stability control agent selected from the group consisting of (a) fatty acid amines, (b) fatty acid esters and (c) fatty acid amides different from those of the Formula I is also incorporated into the heat-plastified olefin polymer along with the blowing agent and the N-substituted fatty acid amide of Formula I.

Claim 27

The process of claim 18 wherein the volatile organic blowing agent comprises from about 10 to about 25 weight percent of trichloromonofluoromethane and from about 75 to about 90 weight percent of dichlorodifluoromethane.