Alkenyl aromatic monomer olefinically unsaturated acid foams and method for the preparation thereof

Claim 1

A method for the preparation of an improved, alkenyl aromatic polymer foam, the method consisting essentially of intimately admixing a polymer having a weight average molecular weight of from about 100,000 to about 350,000 gram moles, the polymer having polymerized therein from about 99 to 70 parts by weight of alkenyl aromatic monomer and from about 1 to 30 parts by weight of an olefinically unsaturated acid selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid and mixtures thereof with a blowing agent which is a carbonate, carbonate hydrate or bicarbonate of an ion selected from the group consisting of sodium, magnesium, zinc, ammonium and mixtures thereof, the carbonate, carbonate hydrate or bicarbonate being present in the proportion of from about 0.5 to 20 parts by weight per hundred parts by weight of polymer, heat plastifying the polymer under a pressure sufficient to prevent foaming and a temperature sufficiently high to decompose the carbonate, carbonate hydrate or bicarbonate under a pressure sufficient to prevent foaming, subsequently passing the heat plastified polymer to a zone of lower pressure to thereby obtain a polymeric foam having a density of from about 0.5 to 8 pounds per cubic foot having a cell size of from about 0.1 to 5 millimeters.

Claim 2

A method for the preparation of an improved, alkenyl aromatic polymer foam, the method consisting essentially of intimately admixing a polymer having a weight average molecular weight of from about 100,000 to about 350,000 gram moles, the polymer having polymerized therein from about 99 to 70 parts by weight of alkenyl aromatic monomer and from about 1 to 30 parts by weight of an olefinically unsaturated acid selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid and mixtures thereof with a blowing agent which is a carbonate, carbonate hydrate or bicarbonate of an ion selected from the group consisting of sodium, magnesium, zinc, ammonium and mixtures thereof, the carbonate, carbonate hydrate or bicarbonate being present in the proportion of from about 0.5 to 20 parts by weight per hundred parts by weight of polymer, heat plastifying the polymer under a pressure sufficient to prevent foaming and a temperature sufficiently high to decompose the carbonate, carbonate hydrate or bicarbonate under a pressure sufficient to prevent foaming, subsequently passing the heat plastified polymer to a zone of lower pressure to thereby obtain a polymeric foam having a density of from about 0.5 to 8 pounds per cubic foot having a cell size of from about 0.1 to 5 millimeters.