Shell Oil Comapny

Maryanne Mores

Pui Kwan Wong

William P Gergen

Ronald Marshall Bass

Thomas F Brownscombe

Robert P Adamski

Diana D Davis

George C Blytas

A process is provided for the production of a porous crosslinked polymeric foam comprising the steps of: (a) providing a first water-in-oil emulsion comprising (i) a first mixture of polymerizable monomers comprising at least one oil-soluble vinyl monomer and from about 2 to about 70 weight percent, based on the mixture, of a multifunctional unsaturated crosslinking monomer, (ii) at least 70 weight percent, based on the emulsion, of water as the internal phase (iii) an effective amount to produce the water-in-oil emulsion of a first surfactant, and (iv) a first polymerization initiator; (b) providing a second water-in-oil emulsion comprising (i) a mixture of polymerizable monomers comprising at least one oil-soluble vinyl monomer and from about 2 to about 70 weight percent, based on the mixture, of a second multifunctional unsaturated crosslinking monomer, (ii) at least 70 weight percent, based on the emulsion, of water as the internal phase (iii) an effective amount to produce the water-in-oil emulsion of a second surfactant, and (iv) a second polymerization initiator; (c) combining the first and second emulsions; and (d) curing said polymerizable monomers under conditions effective to polymerize and crosslink the polymer prior to significant diffusion between the emulsions. Polymeric foams can be prepared by this process that exhibit positive attributes of foams formed by curing of each of the emulsions individually.

Process to prepare two phase foam compositions and two phase foam

Stable high internal phase water-in-oil emulsions containing polymerizable vinyl monomers, crosslinking monomers and polymerization initiators are obtained by using saccharide fatty acid esters as surfactants. The amount of surfactants necessary to form stable high internal phase water-in-oil emulsions is decreased by using saccharide fatty acid esters as surfactants. Further, hydrophobic foams can be obtained by using saccharide fatty acid esters.

Low density porous crosslinked polymeric materials

In a process for the preparation of a low density porous crosslinked polymeric material by polymerizing a water-in-oil high internal phase emulsion, curing time of the monomers in the emulsion can be reduced without adversely affecting polymer properties or substantially affecting the emulsion by carrying out the curing in multiple-stages. The emulsion is first pre-cured at a temperature less than about 65.degree. C. until the emulsion reaches a Rheometrics dymanic shear modulus of at least about 500 and subsequently curing at a temperature above about 70.degree. C.

Process for preparing low density porous crosslinked polymeric materials

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Houston, TX, United States of America

Maryanne Mores