U.S. patent number 3,624,192 [Application Number 04/726,857] was granted by the patent office on 1971-11-30 for production of foamed resins.
This patent grant is currently assigned to Mensanto Chemicals Limited. Invention is credited to William Rees Foster, John Gerald McCoy.
United States Patent |
3,624,192 |
McCoy , et al. |
November 30, 1971 |
PRODUCTION OF FOAMED RESINS
Abstract
Die assemblies and processes for extruding a foamable
thermoplastic polyvinylaromatic resin through a rectangular die
orifice into a zone of lower pressure such that foaming of the
resin occurs as it moves through the zone, said zone being defined
by a pair of opposing concave surfaces maintained at a temperature
lower than the extrusion temperature and curved so that they
substantially conform to the corresponding surfaces of the freely
expanding resin without exerting a substantial compressive force
thereon. The die assemblies and processes are particularly useful
for the production of low-density foamed boards having smooth
surfaces.
Inventors: |
McCoy; John Gerald (Newport,
EN), Foster; William Rees (Cwmbran, EN) |
Assignee: |
Mensanto Chemicals Limited
(London, EN)
|
Family
ID: |
10193438 |
Appl.
No.: |
04/726,857 |
Filed: |
May 6, 1968 |
Foreign Application Priority Data
|
|
|
|
|
May 19, 1967 [GB] |
|
|
23,303/67 |
|
Current U.S.
Class: |
264/51; 264/48;
425/4R; 425/817R; 264/237; 425/325; 425/4C; 425/817C |
Current CPC
Class: |
B29C
44/505 (20161101); B29C 44/468 (20130101); B29L
2007/00 (20130101) |
Current International
Class: |
B29C
44/46 (20060101); B29C 44/34 (20060101); B29d
027/00 () |
Field of
Search: |
;264/51,53,48,177,237
;18/12,5 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Anderson; Philip E.
Claims
What is claimed is:
1. A process for the production of foamed thermoplastic
polyvinylaromatic resins having an improved surface finish which
comprises extruding a foamable thermoplastic polyvinylaromatic
resin through a rectangular die orifice into a zone of lower
pressure such that foaming of the resin occurs as it moves through
the zone, said zone being defined by a pair of opposing concave
surfaces maintained at a temperature lower than the extrusion
temperature and curved so that they substantially conform to the
corresponding surfaces of the freely expanding resin whereby
substantially no compressive force is exerted by said opposing
concave surfaces upon said freely expanding resin.
2. The process of claim 1 wherein the resin is polystyrene.
3. The process of claim 1 wherein the die has a plurality of
obstructions transversely distributed therein whereby substantial
resistance to the flow of the foamable resin is provided and back
pressure within the die is increased.
4. The process of claim 3 wherein the die has extending into it at
its inlet end a plurality of separate channels communicating with a
number of slits arranged in the form of a network at the outlet end
of the die, each slit having a row of channels associated with
it.
5. The process of claim 4 wherein each of at least the majority of
the meshes of the slit network has a substantially central passage
leading back from the front face of the die to the inlet end of the
die and not communicating directly with the slits.
6. The process of claim 5 wherein grooves extending from the outlet
end of each of at least the majority of the passages toward the
outlet of its surrounding mesh of slits are provided in the front
face of the die to assist in ensuring that a strand of foamed resin
extruded from each passage substantially fills the space formed by
the enveloping foamed resin issuing from the surrounding mesh of
slits.
7. The process of claim 1 wherein the zone-defining surfaces have a
concave curved cross section that conforms exactly to the
corresponding surfaces of the freely expanding resin.
8. The process of claim 1 wherein the zone-defining surfaces have a
concave cross section corresponding to an arc of a circle.
9. The process of claim 1 wherein the zone-defining surfaces reach
their greatest distance apart where the foamed resin is completely
expanded and thereafter extend parallel to each other.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
This application relates to the extrusion of foamable thermoplastic
polyvinylaromatic resins and more particularly relates to improve
processes for extruding such resins to form foamed products, e.g.,
low-density boards, which are strong and have smooth surfaces.
Description of the Prior Art
Because of their excellent heat-insulating and other properties,
foamed thermoplastic resins such as foamed polystyrene are useful
industrial products. These products are often made by molding
processes, but extrusion processes are often considered to be more
convenient. However, extrusion processes present difficulties in
some instances, e.g., in the production of foamed board of good
quality. (The term "board" is used to describe flat sheet material
of substantial thickness, usually at least 0.75 inch and often
1.5-4 inches thick, such as the sheet materials frequently used as
insulating media.) For example, it is difficult to produce an
extruded low-density foamed polystyrene board having a good surface
finish.
SUMMARY OF THE INVENTION
An object of the invention is to provide novel processes for
extruding foamable thermoplastic polyvinylaromatic resins.
Another object is to provide novel processes for preparing extruded
foamed boards, particularly low-density boards, having a good
surface finish.
These and other objects are attained by extruding a foamable
thermoplastic polyvinylaromatic resin through a rectangular die
orifice into a zone of lower pressure such that foaming of the
resin occurs as it moves through the zone, said zone being defined
by a pair of opposing concave surfaces maintained at a temperature
lower than the extrusion temperature (i.e., the temperature of the
resin at the die orifice) and curved so that they substantially
conform to the corresponding surfaces of the freely expanding resin
without exerting a substantial compressive force thereon.
DESCRIPTION OF THE DRAWING
An extrusion die assembly of the invention is exemplified (not to
scale) in the drawing, in which
FIG. 1 is a front elevation of the assembly and
FIG. 2 is a section along the line 2--2 in FIG. 1.
The die comprises a mild steel block 1 having 82 cylindrical
channels 2 extending into it from one side. The channels are
arranged to communicate with a rectangular network of three
horizontal and 17 vertical intercommunicating slits 3. Each
horizontal slit thus has 16 channels associated with it, and each
vertical slit has two channels. There are also 32 cylindrical
passages 4 extending completely through the block, each passage
being positioned centrally in one of the square meshes 5 of the
network of slits. The network of slits communicates with a zone
defined by the profiled surfaces 6 and 7 of two mild steel plates 8
and 9. The length of each of the plates is greater (usually about
l.l-1.75 times greater) than the overall length of the slit network
to ensure that the foamed resin surface is always in contact with
the profiled surfaces during its initial expansion. The concave
surfaces of the plates adjacent to the slit network are spaced
apart at a distance corresponding approximately to the width of the
slit network. The plates 8 and 9 are cut away as shown at 10 and 11
so as to minimize the area of contact with the block 1 and thus
minimize heat transfer from the die outlet to the plates, and they
have adjustable clamp mountings (not shown) by means of which they
can be set at various distances from each other as desired. A
series of liquid-cooling channels (not shown) is drilled through
each of the plates. The die also has means (not shown) for
attaching it to the front end of an extruder so that, when the die
is in use, a foamable resin such as foamable polystyrene is fed
into the network of slits and thence through the zone into the
atmosphere. The concave surfaces of the plates are so shaped that
they conform to the corresponding surfaces of the freely expanding
resin without exerting a substantial compressive force thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following example is given to illustrate the invention and is
not intended as a limitation thereof.
EXAMPLE
Part A
Using the die assembly described above in which the overall length
of the slit network is 1.535 inches, the width of the network is
0.785 inch, the width of the individual slits is 0.025 inch, the
plates are clamped so that they are 0.79 inch apart at the lips of
the die orifice and 1.375 inches apart at the end of the expansion
zone, and the radius of curvature of the profiled surfaces of each
of the plates is 0.5 inch, extrude foamable polystyrene containing
0.25 percent by weight of silica and 10 percent by weight of butane
at a pressure of 700 p.s.i. and a temperature of 110.degree. C.
through the die at a flow rate of 15 pounds per hour, while
maintaining the temperature of the plates at 15.degree. C. by
circulating cold water through the cooling channels.
The product is a foamed polystyrene board having a width of 2.75
inches, a thickness of 1.625 inches, an overall average density of
1.25 pounds per cubic foot, good strength in both the transverse
and longitudinal directions, and smooth top and bottom surfaces
with an excellent finish.
Part B
Repeat Part A except for extruding the foamable polystyrene through
the die directly into the atmosphere instead of using the plates to
define a zone. The product is a foamed polystyrene board, the
density of which is similar to that of the board of Part A, but the
surface finish of which is inferior in that it is slightly
ribbed.
The die used in the practice of the invention is one having an
orifice from which an extruded freely expanding and foaming resin
issues with a rectangular or substantially rectangular cross
section. According to a preferred embodiment of the invention, the
die is one which incorporates features designed to increase its
resistance to resin flow, e.g., the dies described in British Pat.
Nos. 1,034,120, 1,084,000, and 1,098,408 and in copending U.S.
application Ser. No. 726,061, filed May 2, 1968 in the names of
William R. Foster and Stanley J. Skinner and assigned to the
assignee of the present application.
British Pat. No. 1,034,120 describes a die having extending into it
at its inlet end a plurality of separate channels communicating
with a number of slits arranged in the form of a network at the
outlet end of the die, each slit having a row of channels
associated with it. British Pat. No. 1,084,000 describes a die
having a plurality of obstructions transversely distributed therein
so that, when a foamable resin is extruded through the die, the
obstructions together offer a substantial resistance to the flow of
resin. British Pat. 1,098,408 describes a particularly useful type
of die which comprises a plurality of channels extending into it at
its inlet end and communicating with a number of slits arranged to
form the meshes of a network at the outlet end of the die, each of
at least the majority of the meshes having a substantially central
passage leading back from the front face of the die to a point
nearer the inlet end of the die (preferably to the inlet end of the
die) and not communicating directly with the slits. U.S.
application Ser. No. 726,061 filed May 2, 1968 and assigned to the
assignee of the present application describes an improved die of
the latter type wherein grooves extending from the outlet end of
each of at least the majority of the passages toward the outlet of
its surrounding mesh of slits are provided in the front face of the
die to assist in ensuring that a strand of foamed resin extruded
from each passage substantially fills the space formed by the
enveloping foamed resin issuing from the surrounding mesh of
slits.
In general the zone-defining surfaces have a concave curved cross
section that preferably conforms exactly to the corresponding
surfaces of the freely expanding and foaming resin. One manner in
which it is possible to machine the surfaces so that they conform
exactly is by using a working drawing produced from a photograph of
the foaming resin extruding freely from the die orifice. Exact
conformity is not essential, however, and a cross section
corresponding to an arc of a circle usually provides a sufficiently
good approximation. Other simple geometric shapes such as part of a
parabola can also be used if desired.
At the die face the zone-defining surfaces are normally spaced
apart by a distance equal to or slightly greater than the width of
the die orifice, and from this point they diverge as the distance
from the die increases, reaching their greatest distance apart
where the foamed resin is completely expanded. Preferably they
thereafter extend parallel to each other for a short distance.
Their greatest distance apart depends of course on the overall
width of the die orifice, the degree to which the foamable resin
expands, and to some extent on the type of die which is used, but
it is generally about 1.2-6 times the width of the die orifice.
When the die incorporates features designed to increase the
resistance to resin flow, the greatest distance apart of the
zone-defining surfaces is usually 1.2-4 times, particularly 1.5-3
times, the overall width of the die orifice. For example, when the
die is of the type described above and in British Pat. No.
1,098,408 particularly good results are obtained using
zone-defining surfaces having a greatest distance apart
corresponding to twice the overall width of the die orifice.
In general the curvature of the zone-defining surfaces is dependent
on the thickness of the foamed board which it is desired to
extrude, thicker boards normally requiring a larger radius of
curvature for optimum results. For example, when a foamed board
having a thickness of 1.5 inches is to be extruded through a die of
the type described above and in British Pat. No. 1,098,408,
excellent results are obtained when each of the zone-defining
surfaces has a section corresponding to a segment of a circle
having a radius of 0.5 inch.
From the position of maximum expansion, the resin board can be
allowed to move through the air for a time while out of contact
with other surfaces, but it is frequently desirable to support the
board between a pair of flat parallel surfaces spaced apart at a
distance corresponding to the thickness of the board. If desired,
provision can be made for reducing or eliminating relative movement
between the extruding foamed resin and the second pair of surfaces.
For example, each of the second pair of surfaces can be part of an
endless belt carried on rollers. The belt can be driven so that the
part in contact with the resin moves along with it, or it can be
free to move so that it is driven by the fractional force between
it and the moving resin. Preferably the mounting of each endless
belt is attached to one of the contoured surfaces so that the belt
and the contoured surface move together when the position of the
latter is adjusted. Alternatively, instead of being flat, each of
this pair of surfaces can be constituted by a roller of relatively
large diameter, or there can be a series of rollers traversed in
succession by the extruding resin.
The polyvinylaromatic resin which is extruded in accordance with
the invention is a polymer of one or more vinyl or vinylidene
aromatic monomers such as styrene, a chlorostyrene,
alpha-methylstyrene, o-, m-, or p-methylstyrene, other
aralkylstyrenes, etc., including interpolymers of such monomers
with one or more copolymerizable ethylenicallyunsaturated monomers
such as acrylonitrile, methacrylonitrile, vinyl chloride, vinyl
acetate, methyl and other alkyl acrylates and methacrylates, etc.
The invention is particularly applicable to polystyrene resins,
such as polystyrene itself or a toughened polystyrene, i.e., a
polystyrene having physically or chemically combined therewith a
minor proportion, e.g., 1-15 percent by weight, of a natural or
synthetic rubber, e.g., substantially linear or branched polymers
of conjugated dienes, such as butadiene, isoprene, etc., including
copolymers thereof with lesser amounts of comonomers such as
styrene, acrylonitrile, methyl methacrylate, etc.
Being foamable, the resin is in admixture with a blowing agent,
which is preferably a normally gaseous substance but which can be a
volatile liquid. In many cases the blowing agent is one that is
normally gaseous but which, while under pressure before extrusion,
is present in the liquid state. Exemplary of volatile substances
that can be used are lower aliphatic hydrocarbons such as ethane,
propane, a butane or butene, a pentane or pentene, etc.; lower
alkyl halides such as methyl chloride, trichloromethane,
1,2-dichlorotetrafluoroethane, etc.; and inorganic gases such as
carbon dioxide and nitrogen. The blowing agent can also be a
chemical blowing agent, e.g., a bicarbonate such as sodium
bicarbonate, ammonium bicarbonate, etc., or an organic compound
that yields nitrogen on heating such as
dinitrosopentamethylenediamine, barium azodicarboxylate, etc. The
amount of blowing agent employed is often in the range of 3-30
percent, especially 7-20 percent, based on the weight of the resin.
For example, excellent results are achieved by the use of 7'-15
percent by weight of butane in conjunction with polystyrene.
The foamable resin preferably also contains a nucleating agent,
which assists in the formation of a large number of small cells.
The conventional nucleating agents can be employed, e.g., finely
divided inert solids such as silica or alumina, preferably in
conjunction with zinc stearate, or small quantities of a substance
that decomposes at the extrusion temperature to give a gas.
Exemplary of the latter class of nucleating agents is sodium
bicarbonate, optionally used in conjunction with a weak acid such
as tartaric or citric acid. A small proportion of the nucleating
agent, e.g., up to 5 percent by weight of the resin, is usually
effective.
Since expansion occurs as the foamable resin leaves the die
orifice, the dimensions of the orifice are less than the cross
section of the desired product. Expansion takes place along both
dimensions of the die, but generally greater expansion takes place
across the width of the die than along its length. In this way a
board is produced. By choice of a suitable die size, an extruded
product of the desired cross section can be obtained. For example,
a foamed board having a width of 4 feet or more and a thickness of
up to perhaps 2 inches can be produced. Generally, the thickness is
at least 0.75 inch, e.g., 1.5-4 inches. Often an increase in the
dimensions of the board (with a corresponding reduction in density)
can be obtained by heating it, preferably by exposing it to steam
or hot Water in a suitable container for a few moments. Such
treatment is usually more effectively conducted after the board has
been exposed to the atmosphere for a day or two.
The surfaces defining the zone of lower pressure are maintained at
a temperature lower than the extrusion temperature. Oil- or
water-cooling can be employed if desired, and it can be applied,
e.g., through channels within the surfaces. Sometimes, however, air
cooling is sufficient, although the backs of the surfaces can be
provided with fins in order to increase the cooling rate. Normally
the surfaces of the zone lead off directly from the die orifice. It
is desirable to prevent as far as possible the conduction of heat
from the extruder to the cooled surfaces. This can be achieved,
e.g., by the use of a thermally insulating material or by arranging
for the area of contact between the surfaces and the extruder to be
as small as possible.
Cooling of the surfaces causes a certain amount of "drag" as the
resin is extruded so that the viscosity of the resin in contact
with the surfaces is much higher than that of the resin within the
extruder, and in fact the resin flow through the zone is normally
of a "plug" character. The temperature of the zone-defining
surfaces (i.e., the average temperature of the mass of metal) to be
used in a particular instance depends partly on the nature of the
resin and any plasticizing effect of the blowing agent, but it is
usually 10.degree.-120.degree. C. lower, preferably
60.degree.-105.degree. C. lower, than the extrusion temperature.
For example, when the resin is being extruded at 120.degree. C., it
is usually suitable for the zone-defining surfaces to be cooled to
a temperature of 10.degree.-40.degree. C.
The extrusion temperature depends to some extent on the softening
point of the resin being extruded, but in general temperatures of
95.degree.-140.degree. C., are suitable. For example, when foamable
polystyrene is being extruded, the temperature is frequently
110.degree.-130.degree. C., particularly about 120.degree. C.
The pressure within the extruder is sufficient to prevent any
substantial foaming of the resin until it leaves the die orifice
and enters the zone of lower pressure. For example, pressures
greater than 250 p.s.i., especially 250-5,000 p.s.i., can be
employed. Preferably, the pressure is 300-1,000 p.s.i.
The processes and die assemblies of the invention are of particular
value in the production of extruded foamed material, e.g., board,
having a low density, e.g., 0.9-1.5 pounds per cubic foot, and a
substantial thickness, i.e., at least 1 inch and, e.g., up to about
2.5 inches. However, a broader range of density can be produced,
although there is often little advantage to be gained by increasing
it above 2 or 3 pounds per cubic foot. A density close to 1 pound
per cubic foot, for instance 1-1.5, such as about 1.2 pounds per
cubic foot, is usually preferable.
As produced from the die, the extruded resin, e.g., a board has
substantially flat upper and lower surfaces and slightly curved
edges. These edges can be trimmed if required, but they are often
sufficiently true for may purposes.
It is obvious that many variations can be made in the apparatus and
processes set forth above without departing from the spirit and
scope of this invention.
* * * * *