U.S. patent application number 11/250365 was filed with the patent office on 2006-03-16 for expandable vinylaromatic polymers and process for their preparation.
This patent application is currently assigned to POLIMERI EUROPA S.p.A.. Invention is credited to Alessandro Casalini, Gilberto Frigerio, Dario Ghidoni, Roberto Lanfredi.
Application Number | 20060058407 11/250365 |
Document ID | / |
Family ID | 11448522 |
Filed Date | 2006-03-16 |
United States Patent
Application |
20060058407 |
Kind Code |
A1 |
Ghidoni; Dario ; et
al. |
March 16, 2006 |
Expandable vinylaromatic polymers and process for their
preparation
Abstract
Expandable vinylaromatic polymers which comprise: a) a matrix
obtained by polymerizing 50-100% by weight of one or more
vinylaromatic monomers and 0.50% by weight of a copolymerizable
monomer; b) 1-10% by weight, calculated with respect to the polymer
(a), of an expanding agent englobed in the polymeric matrix; c)
0.05-25% by weight, calculated with respect to the polymer (a), of
an inorganic filler homogeneously distributed in the polymeric
matrix with a substantially spherical granulometry, an average
diameter ranging from 0.01 to 100 .mu.m, a refraction index higher
than 1.6 and a white index, as defined in "Colour Index" (third
edition published by the Society of Dyers and Colourists, 1982),
equal to or lower than 22.
Inventors: |
Ghidoni; Dario;
(Gonzaga-Mantova, IT) ; Lanfredi; Roberto;
(Virgilio-Mantova, IT) ; Frigerio; Gilberto;
(Curtatone-Mantova, IT) ; Casalini; Alessandro;
(Mantova, IT) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
POLIMERI EUROPA S.p.A.
Brindisi
IT
|
Family ID: |
11448522 |
Appl. No.: |
11/250365 |
Filed: |
October 17, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10488298 |
Mar 2, 2004 |
|
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PCT/EP02/10050 |
Oct 3, 2002 |
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11250365 |
Oct 17, 2005 |
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Current U.S.
Class: |
521/142 ; 521/56;
521/82 |
Current CPC
Class: |
C08J 9/20 20130101; C08J
9/16 20130101; C08J 2325/06 20130101; C08J 2201/03 20130101; C08J
9/0066 20130101 |
Class at
Publication: |
521/142 ;
521/056; 521/082 |
International
Class: |
C08J 9/16 20060101
C08J009/16; B29C 44/34 20060101 B29C044/34 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 18, 2001 |
IT |
MI2001A002168 |
Claims
1-17. (canceled)
18. A process for preparing expandable vinyl aromatic polymers,
comprising: polymerizing one or more vinyl aromatic monomers
present as an aqueous suspension in the presence of an inorganic
filler having substantially spherical granulometry, an average
diameter ranging from 0.01-100 micron, a refractive index higher
than 1.6, and a white index equal to or lower than 22, and adding
an expanding agent to the aqueous suspension before, during or
after the polymerizing, wherein white index is defined in "Color
Index" (3.sup.rd edition published by The Society of Dyers and
Colorists, 1982).
19. The process according to claim 18, wherein the aqueous
suspension further comprises one or more polymerizable comonomers
in an amount of up to 50% by weight based on the total weight of
the monomers.
20. The process according to claim 18, wherein the polymerizing is
carried out to form substantially spherical beads of a polymer
having an average diameter of from 0.2-2 mm and which comprise the
inorganic filler homogeneously dispersed therein.
21. The process according to claim 18, further comprising: adding
one or more flame-retarding agents in an amount of from 0.1-8% by
weight based on the weight of the polymer formed in the process,
during the polymerizing.
22. The process according to claim 21, wherein the flame-retarding
agent is at least one selected from the group consisting of a
brominated aliphatic compound, a cycloaliphatic compound and an
aromatic compound.
23. The process as claimed in claim 18, wherein the expanding agent
is added during the polymerization and the expanding agent is at
least one selected from the group consisting of an aliphatic
hydrocarbon, a cycloaliphatic hydrocarbon containing from 3 to 6
carbon atoms, a halogenated derivative of a aliphatic hydrocarbon
containing from 1 to 3 carbon atoms, carbon dioxide, water and
mixtures thereof.
24. The process according to claim 18, wherein the polymerization
in suspension takes place through a solution of vinyl aromatic
polymer in the monomer, or mixture of monomers, wherein the
concentration of polymer ranges from 1-30% by weight.
25. A process for continuously preparing expandable vinyl aromatic
polymer in bulk, comprising the following steps in series: feeding
the vinyl aromatic polymer to an extruder together with one or more
inorganic fillers, wherein the inorganic filler has a substantially
spherical granulometry, an average diameter ranging from 0.01-100
micron, a refractive index higher than 1.6, and a white index as
defined in "Color Index" (3.sup.rd edition published by The Society
of Dyers and Colorists, 1982) of 22 or lower; heating the vinyl
aromatic polymer to a temperature higher than the relative melting
point of the vinyl aromatic polymer; injecting one or more
expanding agents into the molten vinyl aromatic polymer obtained by
the heating; and forming beads by passing the molten vinyl aromatic
polymer through a dye, wherein the beads are substantially
spherical and have an average diameter of from 0.2-2 mm and the
expanding agent is injected into the molten polymer before the
molten polymer is passed through the dye.
26. The process as claimed in claim 25, wherein the expanding agent
is injected into the molten polymer as a mixture with one or more
additives.
27. The process as claimed in claim 25, wherein the beads formed by
passing the molten vinyl aromatic polymer through the dye are
expandable.
28. The process as claimed in claim 18, further comprising:
carrying out the polymerizing to form expandable beads and
pretreating the beads by (i) coating the beads with a liquid
antistatic agent; and (ii) applying a coating to the treated beads
wherein the coating comprises a mixture of mono-, di- and
trimesters of glycerine with one or more fatty acids and one or
more metallic stearates.
29. The process as claimed in claim 28, wherein the liquid
antistatic agent is at least one selected from the group consisting
of an amine, a tertiary ethoxylated alkyl amine, and an ethylene
oxide-propylene oxide copolymer.
30. The process as claimed in claim 29, wherein the coating further
comprises the inorganic filler.
31. The process as claimed in claim 28, wherein the metallic
stearate is at least one selected from the group consisting of zinc
stearate and magnesium stearate.
32. A process for continuously preparing expandable vinylaromatic
polymers, which comprises the following steps in series: feeding a
vinylaromatic polymer, as described above, to an extruder, together
with an inorganic filler, having a substantially spherical
granulometry, an average diameter ranging from 0.01 to 100 .mu.m, a
refraction index higher than 1.6 and a white index, as defined in
"Colour Index" (third edition published by The Society of Dyers and
Colourists, 1982), equal to or lower than 22; heating the
vinylaromatic polymer to a temperature higher than the relative
melting point; injecting the expanding agent and possible
additives, into the molten polymer, before extrusion through a die;
and forming beads, optionally expandable, through a die, in a
substantially spherical form with an average diameter ranging from
0.2 to 2 mm.
33. The process as claimed in claim 32, further comprising:
carrying out the polymerizing to form expandable beads and
pretreating the beads by (i) coating the beads with a liquid
antistatic agent; and (ii) applying a coating to the treated beads
wherein the coating comprises a mixture of mono-, di- and
tri-esters of glycerine with one or more fatty acids and one or
more metallic stearates.
34. The process as claimed in claim 32, wherein the liquid
antistatic agent is at least one selected from the group consisting
of an amine, a tertiary ethoxylated alkyl amine, and an ethylene
oxide-propylene oxide copolymer.
35. The process as claimed in claim 32, wherein the coating further
comprises the inorganic filler.
36. The process as claimed in claim 32, wherein the metallic
stearate is at least one selected from the group consisting of zinc
stearate and magnesium stearate.
Description
[0001] The present invention relates to expandable vinylaromatic
polymers and the process for their preparation.
[0002] More specifically, the present invention relates to a
process for the preparation of expandable vinylaromatic polymers
which, after expansion, have a reduced thermal conductivity also
with a low density and to the products thus obtained.
[0003] Expandable vinylaromatic polymers, and among these
expandable polystyrene in particular, are known products which have
been used for a long time in various applicative sectors, among
which one of the most important is the field of thermal
insulation.
[0004] These expanded products are obtained by swelling in a closed
mould beads of expanded polymer impregnated with a gas and molding
the swollen particles contained inside the mould by means of the
contemporaneous effect of pressure and temperature. The swelling of
the particles is generally effected with vapour, or another gas,
maintained at a temperature slightly higher than the glass
transition temperature (Tg) of the polymer.
[0005] A particular applicative field of expanded polystyrene is
that of thermal insulation in the building industry where it is
generally used in the form of flat sheets. The flat expanded
polystyrene sheets are usually used with a density of about 30 g/l
as the thermal conductivity of the polymer shows a minimum at these
values. It is not advantageous to fall below this density limit,
even if it is technically possible, as it causes a drastic increase
in the thermal conductivity of the sheet which must be compensated
by an increase in its thickness.
[0006] U.S. Pat. No. 6,130,265 describes a method for preparing
particles of expandable polystyrene which allows thermoinsulating
sheets to be prepared for the building industry, having a density
lower than 30 g/l but with a thermal conductivity analogous to that
of traditional sheets. According to this method, particles of
expandable polystyrene can be prepared, which are capable of giving
articles, for example, sheets, with a density ranging from 10 to 15
g/l and a thermal conductivity which is such as to satisfy the
request of class 035 of the DIN 18164, Part 1, Standard englobing
in the particle itself from 0.05 to 25% by weight of graphite
powder in the form of substantially spherical particles with an
average diameter ranging from 0.1 to 50 .mu.m. More specifically,
the method of the U.S. patent cited above comprises polymerizing
the styrene monomer, or a solution of polystyrene in styrene, in an
aqueous suspension, in the presence of graphite particles and
conventional reagents and/or polymerization additives. Expandable
polystyrene spherical beads are thus obtained with an average
diameter ranging from 0.2 to 2 mm in which the graphite in powder
form is homogeneously distributed.
[0007] The Applicant has now found that it is possible to obtain
expandable styrene polymers capable of providing low density
expanded materials, with characteristics comparable to those of the
materials obtained with the method of the known art, without having
to resort to the use of an athermanous additive such as graphite
which has, among other things, the defect of giving the polymer,
before and after expansion, an unaesthetic grey colour, sometimes
intense. It has been found, in fact, that it is possible to obtain
products based on vinylaromatic polymers with a density much lower
than 30 g/l and with a thermal conductivity also capable of
satisfying class 035 of the DIN 18164 Part 1, Standard by
substituting athermanous graphite, i.e. capable of absorbing
infrared radiation, with materials having a refraction index which
is sufficiently higher than that of the polymer and which are
therefore capable of favouring the reflection of infrared
radiation. This result is particularly interesting as it also
allows a material such as titanium dioxide to be selected, which,
as it is white, does not alter the colouring of the polymer, in
particular polystyrene.
[0008] An object of the present invention therefore relates to
expandable vinylaromatic polymers which comprise: [0009] a) a
matrix obtained by polymerizing 50-100% by weight of one or more
vinylaromatic monomers and 0.50% by weight of a copolymerizable
monomer; [0010] b) 1-10% by weight, calculated with respect to the
polymer (a), of an expanding agent englobed in the polymeric
matrix; [0011] c) 0.05-25% by weight, calculated with respect to
the polymer (a), of an inorganic filler homogeneously distributed
in the polymeric matrix with a substantially spherical
granulometry, an average diameter ranging from 0.01 to 100 .mu.m, a
refraction index higher than 1.6 and a white index, as defined in
"Colour Index" (third edition published by The Society of Dyers and
Colourists, 1982), equal to or lower than 22.
[0012] The term "vinylaromatic monomer", as used in the present
description and claims, essentially refers to a product which
corresponds to the following general formula: ##STR1## wherein R is
a hydrogen or a methyl group, n is zero or an integer ranging from
1 to 5 and Y is a halogen, such as chlorine or bromine, or an alkyl
or alkoxyl radical having from 1 to 4 carbon atoms.
[0013] Examples of vinylaromatic monomers having the general
formula defined above are: styrene, .alpha.-methylstyrene,
methylstyrene, ethylstyrene, butylstyrene, dimethylstyrene, mono-,
di-, tri-, tetra- and penta-chlorostyrene, bromo-styrene,
methoxy-styrene, acetoxy-styrene, etc. Preferred vinylaromatic
monomers are styrene and .alpha.-methylstyrene.
[0014] The vinylaromatic monomers having general formula (I) can be
used alone or in a mixture of up to 50% by weight with other
copolymerizable monomers. Examples of these monomers are
(meth)acrylic acid, C.sub.1-C.sub.4 alkyl esters of (meth)acrylic
acid, such as methyl acrylate, methylmethacrylate, ethyl acrylate,
ethylmethacrylate, isopropyl acrylate, butyl acrylate, amides and
nitriles of (meth)acrylic acid such as acrylamide, methacrylamide,
acrylonitrile, methacrylonitrile, butadiene, ethylene,
divinylbenzene, maleic anhydride, etc. Preferred copolymerizable
monomers are acrylonitrile and methylmethacrylate.
[0015] Any expanding agent capable of being englobed in the
vinylaromatic polymeric matrix, can be used in a combination with
the vinylaromatic polymers object of the present invention. Typical
examples are aliphatic hydrocarbons, freon, carbon dioxide, water,
etc.
[0016] The inorganic filler with a refraction index higher than
1.6, preferably from 1.6 to 3, extremes included, and with a white
index equal to or lower than 22, preferably between 21 and 5,
extremes included, can be added to the vinylaromatic polymer both
by polymerization in suspension and by means of the continuous mass
technique, in such quantities as to give a final concentration in
the polymer ranging from 0.05-25% by weight, preferably from 0.5 to
8%. The granulometry of the filler preferably ranges from 0.1 to 50
.mu.m. The preferred inorganic filler is represented by titanium
dioxide and barium sulfate.
[0017] At the end of the addition of the filler, an expandable
polymer is obtained, which can be transformed to produce expanded
articles having a density ranging from 5 to 50 g/l, preferably from
10 to 25 g/l. These materials also have an excellent thermal
insulation capacity expressed by a thermal conductivity ranging
from 25 to 50 mW/mK, preferably from 30 to 45 mW/mK which is
generally on an average even over 10% lower than that of equivalent
non-filled expanded materials currently on the market, for example
EXTIR A-5000 of EniChem S.p.A., as illustrated in Tables 1 and 2
enclosed. Thanks to these characteristics of the expandable
polymers object of the present invention, it is possible to prepare
thermo-insulating articles with significant material savings or,
for example, to prepare sheets having a lesser thickness than those
produced with traditional nonfilled polymers, with a consequent
reduction in space.
[0018] Conventional additives, generally used with traditional
materials, such as pigments, stabilizers, flame-retardants,
antistatic agents, detaching agents, etc. can be added to the
expandable polymers object of the present invention.
[0019] A further object of the present invention relates to the
processes for the preparation of expandable polymers with an
improved thermal conductivity, after expansion, with a density
lower than 30 g/l.
[0020] In particular, a further object of the present invention
relates to a process for preparing expandable vinylaromatic
polymers which comprises polymerizing in aqueous suspension one or
more vinylaromatic monomers, optionally together with at least one
polymerizable comonomer in a quantity of up to 50% by weight, in
the presence of an inorganic filler with a substantially spherical
granulometry, an average diameter ranging from 0.01 to 100 .mu.m, a
re-fraction index higher than 1.6 and a white index, as defined in
"Colour Index" (third edition published by The Society of Dyers and
Colourists, 1982), equal to or lower than 22, and an expanding
agent added before, during or after the end of the
polymerization.
[0021] At the end of the polymerization, substantially spherical
polymer beads are obtained, with an average diameter ranging from
0.2 to 2 mm, inside which the inorganic additive is homogeneously
dispersed.
[0022] During the polymerization in suspension, polymerization
additives, typically used for producing expandable vinylaromatic
polymers, are adopted, such as peroxide initiators, stabilizing
agents of the suspension, chain transfer agents, expanding aids,
nucleating agents, plasticizers, etc. In particular, it is
preferable to add flame-retardant agents during the polymerization,
in a quantity ranging from 0.1% to 8% by weight, with respect to
the weight of the resulting polymer. Flame-retardant agents
particularly suitable for the expandable vinylaromatic polymers,
object of the present invention, are brominated aliphatic,
cycloaliphatic, aromatic compounds such as hexabromocyclododecane,
pentabromomonochlorocyclohexane and pentabromophenyl allyl
ether.
[0023] The expanding agents are preferably added during the
polymerization phase and are selected from aliphatic or
cycloaliphatic hydrocarbons containing from 3 to 6 carbon atoms
such as n-pentane, isopentane, cyclopentane or their mixtures; the
halogenated derivatives of aliphatic hydrocarbons containing from 1
to 3 carbon atoms such as, for example, dichlorodifluoromethane,
1,2,2-trifluoroethane, 1,1,2-trifluoroethane; carbon dioxide and
water.
[0024] To improve the stability of the suspension, it is possible
to use a solution of vinylaromatic polymer in the monomer, or
mixture of monomers, in which the concentration of polymer ranges
from 1 to 30% by weight, preferably from 5 to 20%. The solution can
be obtained either by dissolving a preformed polymer (for example
fresh polymer or the waste products of previous polymerizations
and/or expansions) in the monomer or by pre-polymerizing the
monomer, or mixture of monomers, in mass, in order to obtain the
above concentrations, and then continuing the polymerization in
aqueous suspension in the presence of the remaining additives.
[0025] Another object of the present invention relates to a process
for preparing in mass and in continuous, expandable vinylaromatic
polymers, which comprises the following steps in series: [0026] i.
feeding a vinylaromatic polymer, as described above, to an
extruder, together with an inorganic filler, having a substantially
spherical granulometry, an average diameter ranging from 0.01 to
100 .mu.m, a refraction index higher than 1.6 and a white index, as
defined in "Colour Index" (third edition published by The Society
of Dyers and Colourists, 1982), equal to or lower than 22; [0027]
ii. heating the vinylaromatic polymer to a temperature higher than
the relative melting point; [0028] iii. injecting the expanding
agent and possible additives such as flame-retardant agents, into
the molten polymer before extrusion through a die; and [0029] iv.
forming expandable beads, through a die, in a substantially
spherical form with an average diameter ranging from 0.2 to 2
mm.
[0030] A detailed method for preparing vinylaromatic polymers in
mass and in continuous is provided in European patent EP
126,459.
[0031] At the end of the polymerization, either it be carried out
in suspension or in continuous mass, the expandable beads produced
are subjected to pre-treatment generally applied to conventional
expandable beads and which essentially consists in: [0032] 1.
coating the beads with a liquid antistatic agent such as amines,
tertiary ethoxylated alkylamines, ethylene oxide-propylene oxide
copolymers, etc. The purpose of this agent is to facilitate both
the adhesion of the "coating" and also the screening of the beads
prepared in suspension; [0033] 2. applying the "coating" to the
above beads, said coating essentially consisting of a mixture of
mono-, di- and tri-esters of glycerin (or other alcohols) with
fatty acids and of metallic stearates such as zinc and/or magnesium
stearate.
[0034] Alternatively, the inorganic filler can also be added in the
coating, together with the mixture of esters.
[0035] Some illustrative but non-limiting examples are provided for
a better understanding of the present invention and for its
embodiment.
EXAMPLE 1
[0036] A mixture of 150 parts by weight of water, 0.1 parts of
sodium pyrophosphate, 100 parts of styrene, 0.15 parts of benzoyl
peroxide, 0.25 parts of ter-butyl perbenzoate and 1 part of
titanium dioxide with a substantially spherical granulometry and an
average diameter of about 0.2 .mu.m, are charged into a closed,
stirred container. The mixture is heated to 90.degree. C. under
stirring.
[0037] After about 2 hours at 90.degree. C., 4 parts of a solution
at 10% of polyvinylpyrrolidone are added. The mixture is heated,
under stirring, for a further 2 hours to 100.degree. C., 7 parts of
a 70/30 mixture of n-pentane and i-pentane are added and the
mixture heated for a further 4 hours to 125.degree. C.
[0038] The beads of expandable polymer thus produced are
subsequently recovered, washed with deionized water, dried in a
stream of warm air, added with 0.02% of ethoxylated amine, and
screened by separating the fraction with a diameter ranging from 1
to 1.5 mm.
[0039] 0.2% of glycerylmonosterate and 0.05% of magnesium stearate
are then added to the fraction.
[0040] The product is pre-expanded with vapour at a temperature of
100.degree. C. for three contact times and aged for a day (density
in Table 1).
[0041] A part of the beads is expanded a second time to reach even
lower densities.
[0042] Both the beads expanded once only and those expanded twice
were used for the moulding of blocks (dimensions
1040.times.1030.times.550 mm) at a pressure of 0.4 bars, and the
cooling time was measured (data in Table 2--sheet 1).
[0043] The blocks were then evaluated (shrinkage, or the difference
between the volume of the block and the volume of the mould) and
cut to prepare flat sheets for measuring the sintering and thermal
conductivity. The thermal conductivity was 36.7 mW/mK whereas that
of a sheet having the same density prepared with a traditional
non-filled reference product (EXTIR A-5000), was 42.5 mW/mK.
[0044] Table 2 indicates the physical characteristics of an
expanded polystyrene block obtained with the expandable beads,
object of the present invention, in a first and second expansion
and compared with an analogous block obtained from the commercial
reference product. The block obtained with the beads object of the
present invention surprisingly shows a drastic increase in the
sintering degree.
EXAMPLE 2
[0045] A polystyrene having a Melt Index of 10 g/10' at 200.degree.
C./5 kg premixed with titanium dioxide alone (2 and 4%) in a first
phase, and with barium sulfate alone (2%) in a second phase, is fed
into a twin-screw extruder equipped with a feeding hopper. After
bringing the polymer to the molten state, 6 parts of a mixture of
n-pentane/i-pentane with a weight ratio of 70/30, are injected.
[0046] The resulting mass is drawn through an extrusion head
equipped with holes. The polymer emerging from the holes is cut by
a series of rotating knives in contact with the surface of the die
in order to obtain substantially spherical beads having an average
diameter of about 1.2 mm. The die is immersed in a water bath.
[0047] The beads are sent by the stream of water, cooled to
35.degree. C., separated from the water and dried in a stream of
warm air.
[0048] Ethoxylated amine and the coating are then added to the
beads as described in Example 1.
[0049] The expansion and moulding were effected as described in
Example 1. The thermal conductivity was about 36 and 35.5 mW/mK
with 2 and 4% respectively of titanium dioxide.
[0050] The thermal conductivity value of 36.7 mW/mK was obtained,
on the other hand with a flat sheet containing 2% by weight of
BaSO.sub.4, with a density however of 17 g/l.
[0051] Table 2 indicates the physical characteristics of expanded
blocks obtained from expandable beads modified with titanium
dioxide. Also in these cases, the blocks obtained with the beads,
object of the present invention, show a drastic increase in the
sintering degree with respect to the reference block.
TABLE-US-00001 TABLE 1 Contact time (min.) Density (g/l) Reference
1 20.5 2 17.2 3 15.5 Example 1(1% TiO.sub.2) 1 19.5 2 15.6 3 14.2
THERMAL CONDUCTIVITY Sheets DENSITY (mW/mK) Reference 14 g/l 42.5
Sheet 1 (1% TiO.sub.2) 14 g/l 36.7 Sheet 2 (2% TiO.sub.2) 14 g/l 36
Sheet 3 (4% TiO.sub.2) 14.4 g/l 35.5
[0052] TABLE-US-00002 TABLE 2 Blocks from beads of first and second
expansion Reference Density (g/l) 16.5 7.8 Cooling time 30' 2' 30''
Shrinkage (mm) -7 -5 Sintering (%) 15 20 Sheet 1 (1% TiO.sub.2)
Density (g/l) 15 8.3 Cooling time 25' 2' 30'' Shrinkage (mm) -2 -3
Sintering (%) 85 35 Sheet 2 (2% TiO.sub.2) Density (g/l) 18.1 8
Cooling time 30' 2' Shrinkage (mm) -4 -4 Sintering (%) 80 30 Sheet
3 (4% TiO.sub.2) Density (g/l) 15 8.4 Cooling time 25' 2' 30''
Shrinkage (mm) -2 -4 Sintering (%) 80 40
* * * * *