US5128073A
Expired / Lapsed
US
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Expanding thermoplastic resin beads with very high frequency energy
Assignee: General Electric Co
•
Filing: 1989-10-26
•
Granted: 1992-07-07
•
Expires: 2009-10-26
Abstract
Abstract Expandable thermoplastic resin beads coated with a novel very high frequency energy absorbing material are expanded with microwave energy.
Inventors
- 👤 Richard B. Allen
- 👤 Bang M. Kim
- 👤 David S. Miller, III
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 03:16
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/06; C08J9/10; C08J9/101; B; B29; B29C; B29C44/00; B29C44/34; B29C44/3415; B29C44/3461; C08J9/104; C08J9/12; C08J9/14; C08J9/22; C08J9/224
Claims Analysis
Total Claims: 54
Claim 1
Independent Claim
110 words
A process for producing a foamed thermoplastic resin article from expandable thermoplastic resin beads comprising: (a) providing a thermoplastic resin in particulate form impregnated with a blowing agent; (b) coating the particulate thermoplastic resin with an effective amount of a very high frequency energy absorbing organic material or its water solution or organic material coated on a substrate selected from the group consisting of alkanolamines, alkyl glycols and polyalkylene glycols or the water solutions or coatings on a substrate thereof; (c) delivering the coated particles to a very high frequency energy transparent vessel; and (d) expanding said coated particles with very high frequency energy sufficient to fuse the coated particles.
Claim 2
Dependent Claim
110 words
A process for producing a foamed thermoplastic resin article from expandable thermoplastic resin beads comprising: (a) providing a thermoplastic resin in particulate form impregnated with a blowing agent; (b) coating the particulate thermoplastic resin with an effective amount of a very high frequency energy absorbing organic material or its water solution or organic material coated on a substrate selected from the group consisting of alkanolamines, alkyl glycols and polyalkylene glycols or the water solutions or coatings on a substrate thereof; (c) delivering the coated particles to a very high frequency energy transparent vessel; and (d) expanding said coated particles with very high frequency energy sufficient to fuse the coated particles.
Claim 3
Dependent Claim
20 words
A process as defined in claim 1 wherein step (a) also comprises pre-expanding the particulate thermoplastic resin to low density.
Claim 4
Dependent Claim
28 words
A process as defined in claim 2 wherein said pre-expansion is carried out with steam heating, hot air, hot water, high frequency energy or very high frequency energy.
Claim 5
Dependent Claim
58 words
A process as defined in claim 1 wherein said thermoplastic resin is selected from the group consisting of a polyphenylene ether, an alkenyl aromatic polymer or copolymer, a polycarbonate, a polyamide, a polysulfone, a polyethersulfone, a polyester, a poly(etherimide), a poly(etherimide ester), a polyethylene, a polypropylene, an acrylonitrile-butadiene-styrene terpolymer and mixtures and copolymers of any of the foregoing.
Claim 6
Dependent Claim
15 words
A process as defined in claim 4 wherein said thermoplastic resin comprises a polyphenylene ether.
Claim 7
Dependent Claim
25 words
A process as defined in claim 5 wherein said polyphenylene ether comprises poly(2,6-dimethyl-1,4-phenylene)ether, poly(2,3,6-trimethyl-1,4-phenylene) ether, poly(2,6-diemthyl-co-2,3,6-trimethyl-1,4-phenylene) ether or a mixture of any of the foregoing.
Claim 8
Dependent Claim
13 words
A process as defined in claim 6 wherein said polyphenylene ether comprises poly(2,6-dimethyl-1,4-phenylene)ether.
Claim 9
Dependent Claim
18 words
A process as defined in claim 4 wherein said thermoplastic resin comprises an alkenyl aromatic polymer or copolymer.
Claim 10
Dependent Claim
49 words
A process as defined in claim 8 wherein said alkenyl aromatic polymer or copolymer is selected from the group consisting of principally atactic polystyrene, high impact polystyrene, poly(alpha-methylstyrene), poly(nuclear-methylstyrene), poly(para-methylstyrene), poly(para-tert-butylstyrene), a halogenated polystyrene, styrene-maleic anhydride copolymer, an acrylonitrile-butadiene-styrene terpolymer and mixtures and copolymers of any of the foregoing.
Claim 11
Dependent Claim
16 words
A process as defined in claim 9 wherein said alkenyl aromatic polymer comprises principally atactic polystyrene.
Claim 12
Dependent Claim
16 words
A process as defined in claim 9 wherein said alkenyl aromatic polymer comprises high impact polystyrene.
Claim 13
Dependent Claim
17 words
A process as defined in claim 1 wherein said thermoplastic resin comprises a polyphenylene ether/polystyrene resin blend.
Claim 14
Dependent Claim
48 words
A process as defined in claim 12 wherein said polyphenylene ether/polystyrene resin blend comprises from about 1 to about 99 parts by weight polyphenylene ether resin and from about 99 to about 1 part by weight polystyrene resin based on 100 parts by weight of the combined resins.
Claim 15
Dependent Claim
48 words
A process as defined in claim 13 wherein said polyphenylene ether/polystyrene resin blend comprises from about 20 to about 80 parts by weight polyphenylene ether resin and from about 80 to about 20 parts by weight polystyrene resin based on 100 parts by weight of the combined resins.
Claim 16
Dependent Claim
40 words
A process as defined in claim 1 wherein said blowing agent comprises a volatile liquid or gas capable of being absorbed by the thermoplastic resin and which will vaporize at or below the glass transition temperature of the thermoplastic resin.
Claim 17
Dependent Claim
87 words
A process as defined in claim 15 wherein said blowing agent is selected from the group consisting of n-pentane, neopentane, cyclopentane, butane, isobutane, pentene, hexane, heptane, octane, propane, methylene chloride, chloroform, carbon tetrachloride, trichlorofluoromethane (CCl 3 F), dichlorodifluoromethane (CCl 2 F 2 ), chlorodifluoromethane (CHClF 2 ), CClF 2 - CClF 2 , HCFC-123, HCFC-123A, HCFC-124, HFC-134A, HCFC-141B, HCFC-142B, HFC-152A, acetone, alcohols having from 1 to 5 carbon atoms, halogenated alcohols, carbon dioxide, nitrogen, methylethyl ketone, ethyl acetate, water, air and mixtures of any of the foregoing.
Claim 18
Dependent Claim
24 words
A process as defined in claim 16 wherein said blowing agent comprises n-pentane, isopentane, neopentane, cyclopentane or a mixture of any of the foregoing.
Claim 19
Dependent Claim
34 words
A process as defined in claim 16 wherein said blowing agent is selected from the group consisting of HCFC-22, HCFC-124, HCFC-123A, HCFC-124, HFC-134A, HCFC-141B, HCFC-142B, HFC-152A or a mixture of any of the foregoing.
Claim 20
Dependent Claim
31 words
A process as defined in claim 1 wherein said blowing agent comprises from about 2 to about 20 parts by weight based on 100 parts by weight of the thermoplastic resin.
Claim 21
Dependent Claim
18 words
A process as defined in claim 1 wherein said organic material comprises a solution of water/triethanolamine/2-hydroxyethyl ether/polyethylene glycol.
Claim 22
Dependent Claim
33 words
A process as defined in claim 1 wherein said organic material is selected from the group consisting of triethanolamine, tripropanolamine, monohydroxyamine, dihydroxyamine, their water solutions or coatings on a substrate and mixtures thereof.
Claim 23
Dependent Claim
18 words
A process as defined in claim 1 wherein said organic material comprises 2-hydroxyethyl ether or its water solution.
Claim 24
Dependent Claim
39 words
A process as defined in claim 1 wherein said organic material or its water solution or organic material coated on a substance has a boiling point of at least the TG of the expandable particle impregnated with blowing agent.
Claim 25
Dependent Claim
16 words
A process as defined in claim 1 wherein said very high frequency energy comprises microwave energy.
Claim 26
Dependent Claim
22 words
A process as defined in claim 24 wherein said microwave energy comprises frequencies ranging from about 40 MHz to about 2450 MHz.
Claim 27
Dependent Claim
17 words
A process as defined in claim 1 wherein said very high frequency energy comprises radio frequency energy.
Claim 28
Dependent Claim
108 words
A foamed thermoplastic article produced from expandable thermoplastic resin beads by a process comprising: (a) providing a thermoplastic resin in particulate form impregnated with a blowing agent; (b) coating the particulate thermoplastic resin with an effective amount of a very high frequency energy absorbing material or its water solution or organic material coated on a substrate selected from the group consisting of alkanolamines, alkyl glycols, and polyalkylene glycols or the water solutions or coatings on a substrate thereof; (c) delivering the coated particles to a very high frequency energy transparent vessel; and (d) expanding said coated particles with very high frequency energy sufficient to fuse the coated particles.
Claim 29
Dependent Claim
108 words
A foamed thermoplastic article produced from expandable thermoplastic resin beads by a process comprising: (a) providing a thermoplastic resin in particulate form impregnated with a blowing agent; (b) coating the particulate thermoplastic resin with an effective amount of a very high frequency energy absorbing material or its water solution or organic material coated on a substrate selected from the group consisting of alkanolamines, alkyl glycols, and polyalkylene glycols or the water solutions or coatings on a substrate thereof; (c) delivering the coated particles to a very high frequency energy transparent vessel; and (d) expanding said coated particles with very high frequency energy sufficient to fuse the coated particles.
Claim 30
Dependent Claim
25 words
A foamed article producted by the process as defined in claim 27 wherein step (a) also comprises pre-expanding the particulate thermoplastic resin to low density.
Claim 31
Dependent Claim
33 words
A foamed article produced by the process as defined in claim 28 wherein said pre-expansion is carried out with steam heating, hot air, hot water, high frequency energy or very high frequency energy.
Claim 32
Dependent Claim
63 words
A foamed article produced by the process as defined in claim 27, wherein said thermoplastic resin is selected from the group consisting of a polyphenylene ether, an alkenyl aromatic polymer or copolymer, a polycarbonate, a polyamide, a polysulfone, a polyethersulfone, a polyester, a poly(etherimide), a poly(etherimide ester), a polyethylene, a polypropylene, an acrylonitrile-butadiene-styrene terpolymer and mixtures and copolymers of any of the foregoing.
Claim 33
Dependent Claim
20 words
A foamed article produced by the process as defined in claim 30 wherein said thermoplastic resin comprises a polyphenylene ether.
Claim 34
Dependent Claim
29 words
A foamed article produced by the process as defined in claim 31 wherein said polyphenylene ether comprises poly(2,6-dimethyl-1,4-phenylene)ether, poly(2, 3,6-trimethyl-1,4-phenylene)ether, poly(2,6-dimethyl-co-2,3,6-trimethyl-1,4-phenylene)ether or a mixture of any of the foregoing.
Claim 35
Dependent Claim
18 words
A foamed article produced by the process as defined in claim 32 wherein said polyphenylene ether comprises poly(2,6-dimethyl-1,4-phenylene)ether.
Claim 36
Dependent Claim
23 words
A foamed article produced by the process as defined in claim 30 wherein said thermoplastic resin comprises an alkenyl aromatic polymer or copolymer.
Claim 37
Dependent Claim
47 words
A foamed article produced by the process as defined in claim 34 wherein said alkenyl aromatic polymer or copolymer comprises principally atactic polystyrene, high impact polystyrene, poly(alpha-methylstyrene), poly(nuclear-methylstyrene), poly(para-methylstyrene), poly(para-tert-butylstyrene), a halogenated polystyrene, styrene-maleic anhydride copolymer, acrylonitrile-butadiene-styrene terpolymer or mixtures and copolymers of any of the foregoing.
Claim 38
Dependent Claim
21 words
A foamed article produced by the process as defined in claim 35 wherein said alkenyl aromatic polymer comprises principally atactic polystyrene.
Claim 39
Dependent Claim
21 words
A foamed article produced by the process as defined in claim 35 wherein said alkenyl aromatic polymer comprises high impact polystyrene.
Claim 40
Dependent Claim
22 words
A foamed article produced by the process as defined in claim 27, wherein said thermoplastic resin comprises a polyphenylene ether/polystyrene resin blend.
Claim 41
Dependent Claim
53 words
A foamed article produced by the process as defined in claim 38 wherein said polyphenylene ether/polystyrene resin blend comprises from about 1 to about 99 parts by weight polyphenylene ether resin and from about 99 to about 1 part by weight polystyrene resin based on 100 parts by weight of the combined resins.
Claim 42
Dependent Claim
53 words
A foamed article produced by the process as defined in claim 39 wherein said polyphenylene ether/polystyrene resin blend comprises from about 20 to about 80 parts by weight polyphenylene ether resin and from about 80 to about 20 parts by weight polystyrene resin based on 100 parts by weight of the combined resins.
Claim 43
Dependent Claim
45 words
A foamed article produced by the process as defined in claim 27 wherein said blowing agent comprises a volatile liquid or gas capable of being absorbed by the thermoplastic resin and which will vaporize at or below the glass transition temperature of the thermoplastic resin.
Claim 44
Dependent Claim
87 words
A foamed article produced by the process as defined in claim 41 wherein said blowing agent is selected from the group consisting of n-pentane, isopentane, neopentane, cyclopentane, butane, isobutane, pentene, hexane, heptane, octane, propane, methylene chloride, chloroform, carbon tetrachloride, trichlorofluoromethane (CCl 3 F), dichlorodifluoromethane (CCl 2 F 2 ), chlorodifluoromethane (CHClF 2 ), CClF 2 - CClF 2 , HCFC-123, HCFC-123A, HCFC-124, HFC-134A, HCFC-141B, HCFC-142B, HFC-152A, acetone, alcohols having from 1 to 5 carbon atoms, carbon dioxide, nitrogen, water, air and mixtures of any of the foregoing.
Claim 45
Dependent Claim
29 words
A foamed article produced by the process as defined in claim 42 wherein said blowing agent comprises n-pentane, isopentane, neopentane, cyclopentane or a mixture of any of the foregoing.
Claim 46
Dependent Claim
33 words
A foamed article produced by the process as defined in claim 43 wherein said blowing agent comprises HCFC-22, HCFC-123, HCFC-123A, HCFC-124, HFC-134A, HCFC-141B, HCFC-142B, HFC-152A or a mixture of any of the foregoing.
Claim 47
Dependent Claim
36 words
A foamed article produced by the process as defined in claim 28 wherein said blowing agent comprises from about 2 to about 20 parts by weight based on 100 parts by weight of the thermoplastic resin.
Claim 48
Dependent Claim
23 words
A foamed article produced by the process as defined in claim 27 wherein said organic material comprises a solution of water/triethanolamine/2-hydroxyethyl ether/polyethylene glycol.
Claim 49
Dependent Claim
32 words
A foamed article produced by the process as defined in claim 27 wherein said organic material comprises triethanolamine, tripropanolamine, monohydroxyamine, dihydroxyamine, their water solutions or coatings on a substrate and mixtures thereof.
Claim 50
Dependent Claim
23 words
A foamed article produced by the process as defined in claim 27 wherein said organic material comprises 2-hydroxyethyl ether or its water solution.
Claim 51
Dependent Claim
44 words
A foamed article produced by the process as defined in claim 27 wherein said organic material or its water solution or organic material coated on a substrate has a boiling point of at least the Tg of the expandable particle impregnated with blowing agent.
Claim 52
Dependent Claim
21 words
A foamed article produced by the process as defined in claim 27 wherein said very high frequency energy comprises microwave energy.
Claim 53
Dependent Claim
27 words
A foamed article produced by the process as defined in claim 50 wherein said microwave energy comprises frequencies ranging from about 40 MHz to about 2450 MHz.
Claim 54
Dependent Claim
22 words
A foamed article produced by the process as defined in claim 27 wherein said very high frequency energy comprises radio frequency energy.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-07-07 | 1996-01-06 | 1996-07-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-07-07 | 2000-01-06 | 2000-07-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-07-07 | 2004-01-06 | 2004-07-07 | $7700.00 | Window Closed / Lapsed |