Polymer foam process

Claim 5

The process of claim 2 wherein said atmosphere is at a temperature about 35° to 135° C.

Claim 6

A process for preparing rapidly aged thermoplastic resin foam sheet comprising (a) melting a thermoplastic resin; (b) introducing thereto under pressure, a foaming agent in liquid form, said agent being a member selected from the group consisting of a low molecular weight alphatic hydrocarbon, a low molecular weight halocarbon and mixtures thereof; (c) extruding the combination in sheet form into a lower pressure atmosphere of air to cause foaming of said resin; and transporting said foamed resin through a confined region having an atmosphere of at least substantially carbon dioxide to age said foamed resin at a rate faster than in the absence of the carbon dioxide.

Claim 7

A process for preparing rapidly aged thermoplastic resin foam sheet comprising (a) melting a thermoplastic resin; (b) introducing thereto under pressure, a foaming agent in liquid form, said agent being a member selected from the group consisting of a low molecular weight alphatic hydrocarbon, a low molecular weight halocarbon and mixtures thereof; (c) extruding the combination in sheet form into a lower pressure atmosphere of air to cause foaming of said resin; and transporting said foamed resin through a confined region having an atmosphere of at least substantially carbon dioxide to age said foamed resin at a rate faster than in the absence of the carbon dioxide.

Claim 8

The process of claim 4 wherein said resin is a styrene polymer.

Claim 9

The process of claim 5 wherein said polymer is a polystyrene.

Claim 10

The process of claim 5 wherein said polymer is poly-p-methylstyrene.

Claim 11

The process of claim 4 wherein a nucleating agent, in an amount effective for nucleating foam cells, is added to said resin prior to extrusion thereof.

Claim 12

The process of claim 8 wherein said nucleating agent is a mixture of citric acid and sodium bicarbonate.

Claim 13

The process of claim 4 wherein the aged, foamed polymer is thereafter thermoformed into articles without any additional aging.

Claim 14

A continuous process for preparing a thermoplastic resin foam sheet comprising: (a) feeding a thermoplastic resin to a screw-type extruder and heating the resin to a first temperature above the melting temperature of the resin; (b) introducing thereto, under pressure, a foaming agent in liquid form, while mixing the resin at said first temperature, said foaming agent being a member selected from the group consisting of a low molecular weight aliphatic hydrocarbon, a low molecular weight halocarbon and a mixture thereof; (c) cooling the mixture of molten resin and blowing agent to a second temperature below the first temperature and above the melting temperature; (d) extruding a sheet of said resin into a lower pressure atmosphere of air to cause foaming of said resin; and (e) transporting said foamed resin sheet through a confined region of substantially carbon dioxide to cause aging of said foamed resin at least at a rate faster than in the absence of said carbon dioxide.

Claim 15

A continuous process for preparing a thermoplastic resin foam sheet comprising: (a) feeding a thermoplastic resin to a screw-type extruder and heating the resin to a first temperature above the melting temperature of the resin; (b) introducing thereto, under pressure, a foaming agent in liquid form, while mixing the resin at said first temperature, said foaming agent being a member selected from the group consisting of a low molecular weight aliphatic hydrocarbon, a low molecular weight halocarbon and a mixture thereof; (c) cooling the mixture of molten resin and blowing agent to a second temperature below the first temperature and above the melting temperature; (d) extruding a sheet of said resin into a lower pressure atmosphere of air to cause foaming of said resin; and (e) transporting said foamed resin sheet through a confined region of substantially carbon dioxide to cause aging of said foamed resin at least at a rate faster than in the absence of said carbon dioxide.

Claim 16

The process of claim 11 wherein said aging on subsequent heating effects a density decrease of at least about 20%.

Claim 17

The process of claim 12 wherein said resin is a styrene polymer.

Claim 18

The process of claim 13 wherein said foaming agent is a C 1 to C 10 hydrocarbon or a fluorocarbon or mixtures thereof.

Claim 19

The process of claim 14 wherein said blowing agent is pentane.

Claim 20

The process of claim 15 wherein said resin is polystyrene.

Claim 21

The process of claim 15 wherein said resin is poly-p-methylstyrene.

Claim 22

The process of claim 16 wherein a nucleating agent, in an amount effective for nucleating foam cells, is added to said resin prior to extrusion thereof.

Claim 23

The process of claim 18 wherein said nucleating agent is a mixture of citric acid and sodium bicarbonate.