The Ohio State University

Owens Corning Intellectual Capital, LLC

Kurt W Koelling

Xiangmin Han

L James Lee

Changchun Zeng

David Lane Tomasko

Yadollah Delaviz

Roland R Loh

Mark E Polasky

Joseph P Rynd

James L Lee

This invention relates to foam insulating products, particularly extruded polystyrene foam, containing multi-layered nano-graphite as a process additive for improving the physical properties of foam products.

Polymer foams containing multi-functional layered nano-graphite

Nano-sized particles such as nano-clays can be mixed with polymers through either melt compounding or in-situ polymerization. By modifying the particle surface with various surfactants and controlling processing conditions, we are able to achieve either intercalated (partial dispersion) or exfoliated (full dispersion) nano-clay distribution in polymers with the clay content up to 35% by weight. When a blowing agent is injected into the nanocomposite in an extruder (a continuous mixer) or a batch mixer, polymeric foam can be produced. Supercritical carbon dioxide, an environmentally friendly, low-cost, non-flammable, chemically benign gas is used as the blowing agent. This process forms a microcellular foam with very high cell density (&#x3e;10cells/cc) and small cell size (&#x3c;5 microns) can be achieved by controlling the COcontent, melt and die temperature, and pressure drop rate.

Polymer nanocomposite foams

Nano-sized particles such as nano-clays can be mixed with polymers through either melt compounding or in-situ polymerization. By modifying the particle surface with various surfactants and controlling processing conditions, we are able to achieve either intercalated (partial dispersion) or exfoliated (full dispersion) nano-clay distribution in polymers with the clay content up to 35% by weight. When a blowing agent is injected into the nanocomposite in an extruder (a continuous mixer) or a batch mixer, polymeric foam can be produced. Supercritical carbon dioxide, an environmentally friendly, low-cost, non-flammable, chemically benign gas is used as the blowing agent. This process forms a microcellular foam with very high cell density (>10 cells/cc) and small cell size (<5 microns) can be achieved by controlling the CO content, melt and die temperature, and pressure drop rate.

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Powell, OH, United States of America

Kurt W Koelling