Pactiv Corporation

Tenneco Packaging Inc.

Columbia University

Gary A Francis

Y Paul Handa

Glenn C Castner

Mohammad Zafar

Wen Pao Wu

Yash Paul Handa

Process for producing a thermoplastic polymer foam article includes preparing an expandable polymeric formulation comprising a thermoplastic polymer and a blowing agent blend, forming the formulation into an expandable bead, and expanding the expandable bead to form a thermoplastic polymer foam article. The blowing agent blend includes methyl formate, hydrocarbon, and either carbon dioxide or 1,1,1,2-tetrafluoroethane (HFC-134a). The blowing agent blend has a higher effective volatility than that of methyl formate alone. A thermoplastic polymer foam article prepared by a process is also provided.

Reduced-VOC and non-VOC blowing agents for making expanded and extruded thermoplastic foams

A blowing agent blend for making thermoplastic polymer foams includes methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The thermoplastic polymer foam can be an alkenyl aromatic polymer foam, e.g. a polystyrene foam. The blowing agent blend includes methyl formate and one or more co-blowing agents. The methyl formate-based blowing agent blends produce dimensionally stable foams that have improved resistance to flame spread. A process for the preparation of such foams is also provided.

Expanded and extruded polyolefin foams are obtained using environmentally benign non-VOC methyl formate as a blowing agent. The blowing agent can be a blend further including at least one co-blowing agent, preferably an environmentally friendly species (e.g., non-VOC), which is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s) or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The blowing agent blend can include any combination of methyl formate and one or more co-blowing agents. The polymer foam can include polyethylene, polypropylene or a combination thereof. The methyl formate-based blowing agent blends produce stable foams for various applications, including containers, packaging systems, as well as for insulation and protective cushioning. Processes for the preparation of such foams are also provided.

Expanded and extruded polyolefin foams made with methyl formate-based blowing agents

A blowing agent blend for making thermoplastic polymer foams comprises methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The thermoplastic polymer foam can be an alkenyl aromatic polymer foam, e.g. a polystyrene foam. The blowing agent blend can comprise 100 mol % methyl formate, or it can comprise any combination of methyl formate and one or more co-blowing agents. The methyl formate-based blowing agent blends produce stable foams. A process for the preparation of such foams is also provided.

Thermoplastic foams made with methyl formate-based blowing agents

A method for producing an alkenyl aromatic polymer foam structure that comprises melting at least one alkenyl aromatic polymer resin. An effective amount of blowing agent mixture is dissolved in the at least one alkenyl aromatic polymer. The blowing agent mixture comprises at least one VOC blowing agent and acetone. The majority by mole percent of the VOC blowing agent is selected from n-butane, iso-butane, propane and combinations thereof. An extrudate is formed comprising the at least one alkenyl aromatic polymer resin, the at least one VOC blowing agent, and acetone. The extrudate comprises less than about 2.7 wt. % of the at least one VOC blowing agent. The extrudate is transferred to an expansion zone and permitted to expand to produce the foam structure. The foam structure has an extruded density less than about 7 lbs/ftand a basis weight of less than about 20 grams per 100 in.

Reduced VOC emission alkenyl aromatic polymer foams and processes

A blowing agent for foaming polystyrene consisting essentially of at least one low permeability compound (preferably a volatile organic compound (VOC)), at least one low volatility compound (preferably a non-VOC) and, optionally, at least one high volatility compound (preferably a non-VOC). In one embodiment, the low permeability volatile organic compound is selected from the group consisting of isopentane and isobutane, the low volatility non-volatile organic compound is acetone and the high volatility non-volatile organic compound is carbon dioxide. The blowing agent of the present invention may be used to foam a polystyrene foam structure. The blowing agent is directed to achieving low fugitive VOC emissions.

High productivity, low fugitive emission foams and foam processes

Disposable toothbrush with toothpaste and mouth wash

A blowing agent for foaming polystyrene consisting essentially of at least one low permeability volatile organic compound, at least one low volatility non-volatile organic compound and, optionally, at least one high volatility non-volatile organic compound. In one embodiment, the low permeability volatile organic compound is selected from the group consisting of isopentane and isobutane, the low volatility non-volatile organic compound is acetone and the high volatility non-volatile organic compound is carbon dioxide. The blowing agent of the present invention may be used to foam a polystyrene foam structure. The blowing agent is directed to achieving low fugitive volatile organic compounds (VOC) emissions.

Growing community of inventors

Canandaigua, NY, United States of America

Gary A Francis