Flexible, low density thermoplastic foams and methods for lowering the density and increasing the flexibility of thermoplastic foams

Abstract

A flexible, low density thermoplastic foam and a method for lowering the density and increasing the flexibility of a thermoplastic foam having a melting temperature and being either amorphous with a softening temperature or semicrystalline with a glass transition temperature. The method comprises the steps of (a) decreasing the pressure on the thermoplastic foam to a subatmospheric pressure, farther providing that while the thermoplastic foam is under the subatmospheric pressure, the thermoplastic foam is also at a temperature in the range of less than the melting temperature and greater than the softening temperature if the thermoplastic foam is amorphous, or greater than the glass transition temperature if the thermoplastic foam is semicrystalline, whereby the thermoplastic foam expands; (b) then exposing the thermoplastic foam to a superatmospheric pressure and a secondary expansion gas for a sufficient amount of time to allow the secondary blowing gas to permeate into the thermoplastic foam; and (c) then releasing the superatmospheric pressure on the thermoplastic foam whereby the thermoplastic foam expands. With this method, it is possible to produce thermoplastic foams having densities as low as 0.008 grams/cc. Also included in his invention are insulations made from these low density foams.

What is claimed:  
     
         1 . A method for lowering the density and increasing the flexibility of a thermoplastic foam having a melting temperature and being either amorphous with a softening temperature or semicrystalline with a glass transition temperature, said thermoplastic foam being under a pressure, said method comprising the steps of: 
 (a) decreasing said pressure on said thermoplastic foam to a subatmospheric pressure, further providing that while said thermoplastic foam is under said subatmospheric pressure, said thermoplastic foam is also at a temperature in the range of less than said melting temperature and greater than said softening temperature if said thermoplastic foam is amorphous, or greater than said glass transition temperature if said thermoplastic foam is semicrystalline, whereby said thermoplastic foam expands;    (b) then exposing said thermoplastic foam to a superatmospheric pressure and a secondary expansion gas for a sufficient amount of time to allow said secondary blowing gas to permeate into said thermoplastic foam; and    (c) then releasing said superatmospheric pressure on said thermoplastic foam whereby said thermoplastic foam expands.    
     
     
         2 . The method of    claim 1    wherein said subatmospheric pressure is in a range from about −5 Pa gauge to about −96 kPa gauge.  
     
     
         3 . The method of    claim 1    wherein said superatmospheric pressure is in a range of from 1 Pa over atmospheric pressure to about 1000 kPa over atmospheric pressure.  
     
     
         4 . The method of    claim 1    which results in a density reduction in the range of from about 15% to about 96%.  
     
     
         5 . The method of    claim 1    wherein said secondary expansion gas is selected from the group consisting of carbon dioxide, air, nitrogen, argon, a fluorocarbon, a hydrochlorofluorocarbon, a hydrocarbon, and mixtures thereof.  
     
     
         6 . The method of    claim 1    wherein during step (b) while said thermoplastic foam is exposed to said superatmospheric pressure, said thermoplastic foam has a temperature in the range of less than said melting temperature of said thermoplastic foam and greater than said softening temperature if said thermoplastic foam is amorphous, or greater than said glass transition temperature if said thermoplastic foam is semicrystalline.  
     
     
         7 . The method of    claim 6    wherein step (c) is performed while said thermoplastic foam is in the temperature range of step (b).  
     
     
         8 . A method for lowering the density and increasing the flexibility of a thermoplastic foam having a melting temperature and being either amorphous with a softening temperature or semicrystalline with a glass transition temperature, said thermoplastic foam being under a pressure, said method comprising the steps of: 
 (a) heating said thermoplastic foam to a temperature not above the melting point of said thermoplastic foam and holding said temperature for a sufficient amount of time to cause said thermoplastic foam to expand;    (b) then exposing said thermoplastic foam to a superatmospheric pressure and a secondary expansion gas for a sufficient amount of time to cause the gas to permeate into said thermoplastic foam; and    (c) then releasing said superatmospheric pressure whereby said thermoplastic foam expands.    
     
     
         9 . The method of    claim 8    wherein during step (b) while said thermoplastic foam is subject to said superatmospheric pressure, said thermoplastic foam has a temperature in the range of less than said melting temperature of said thermoplastic foam and greater than said softening temperature if said thermoplastic foam is amorphous, or greater than said glass transition temperature if said thermoplastic foam is semicrystalline.  
     
     
         10 . The method of    claim 9    wherein said temperature of said thermoplastic foam during step (c) is maintained in said range of step (b).  
     
     
         11 . The method of    claim 8    wherein said pressure of step (a) is between atmospheric and about −100 kPa gauge.  
     
     
         12 . The method of    claim 8    wherein said superatmospheric pressure is in a range of from 1 Pa over atmospheric to 1000 kPa over atmospheric.  
     
     
         13 . A method for producing a thermoplastic polymer foam which is flexible and has a low density comprising the steps of: 
 (a) forming said thermoplastic polymer foam by primarily blowing a thermoplastic polymer which has a melting temperature and which can be either amorphous with a softening temperature or semicrystalline with a glass transition temperature, said thermoplastic polymer foam being under a pressure;    (b) decreasing said pressure acting on said thermoplastic polymer foam to a subatmospheric pressure, and adjusting the temperature of said thermoplastic polymer foam to a temperature in a range of less than said melting temperature of said thermoplastic polymer foam and greater than said softening temperature if said thermoplastic polymer foam is amorphous, or greater than said glass transition temperature if said thermoplastic polymer foam is semicrystalline, whereby said thermoplastic foam expands;    (c) then exposing said thermoplastic polymer foam to a superatmospheric pressure and a secondary expansion gas for a sufficient amount of time to cause said gas to permeate into said thermoplastic polymer foam; and    (d) then releasing the pressure on said thermoplastic polymer foam whereby said thermoplastic polymer foam expands.    
     
     
         14 . The method of    claim 13    wherein during step (c) the temperature of said thermoplastic polymer foam is in a range of less than said melting temperature of said thermoplastic polymer foam and greater than said softening temperature if said thermoplastic polymer foam is amorphous, or greater than said glass transition temperature if said thermoplastic polymer foam is semicrystalline.  
     
     
         15 . The method of    claim 14    wherein during step (d) the temperature of said thermoplastic polymer foam is in the same range as during step (c).  
     
     
         16 . The method of    claim 13    wherein said subatmospheric pressure is in the range of from about −5 Pa gauge to about −96 kPa gauge.  
     
     
         17 . The method of    claim 13    wherein said superatmospheric pressure is in a range of from 1 Pa over atmospheric pressure to about 1000 kPa over atmospheric pressure.  
     
     
         18 . The method of    claim 13    wherein at the end of step (a) said thermoplastic polymer foam is at the temperature required in step (b).  
     
     
         19 . A thermoplastic polymer foam having a melting temperature and being either an amorphous thermoplastic polymer foam with a softening temperature or a semicrystalline thermoplastic polymer foam with a glass transition temperature, said thermoplastic foam further having a lower density and increased flexibility after being subjected to a process comprising the steps of: 
 (a) decreasing the pressure on a primarily foamed thermoplastic polymer foam which had an initial density and which was under an initial pressure to a subatmospheric pressure, and adjusting the temperature of said primarily foamed thermoplastic polymer foam to be in a range of less than said melting temperature of said thermoplastic polymer foam and greater than said softening temperature if said thermoplastic polymer foam is amorphous, or greater than said glass transition temperature if said thermoplastic polymer foam is semicrystalline, whereby said thermoplastic foam expands;    (b) then exposing said thermoplastic polymer foam to a superatmospheric pressure and a secondary expansion gas for a sufficient amount of time to cause said gas to permeate into said thermoplastic polymer foam; and    (c) then releasing said superatmospheric pressure acting on said thermoplastic polymer foam whereby said thermoplastic polymer foam expands.    
     
     
         20 . The thermoplastic polymer foam of    claim 19    wherein during step (c) said thermoplastic foam is in the same range as during step (b).  
     
     
         21 . The thermoplastic polymer foam of    claim 19    which has a density in the range of from 0.008 to 0.02 grams/cubic centimeter after step (c).  
     
     
         22 . The thermoplastic polymer foam of    claim 19    which is comprised of poly(ethylene terephthalate).  
     
     
         23 . The thermoplastic polymer foam of    claim 19    which is comprised of poly(ethylene).  
     
     
         24 . The thermoplastic polymer foam of    claim 19    which is comprised of a thermoplastic polymer which is one of a polystyrene and a polyolefin.  
     
     
         25 . The thermoplastic polymer foam of    claim 19    wherein said thermoplastic polymer foam has a density in the range of from about 15% to about 96% lower than the initial density of the primarily foamed thermoplastic polymer foam.  
     
     
         26 . A thermoplastic polymer foam having a melting temperature and being either an amorphous thermoplastic polymer foam with a softening temperature or a semicrystalline thermoplastic polymer foam with a glass transition temperature, said thermoplastic polymer foam having a lower density and increased flexibility after being subjected to a process comprising the steps of: 
 (a) heating a primarily foamed thermoplastic polymer with an initial density to a temperature sufficient to cause said thermoplastic polymer foam to expand;    (b) exposing said thermoplastic polymer foam to a superatmospheric pressure and a secondary blowing gas for a sufficient amount of time to cause said gas to permeate into said thermoplastic polymer foam; and    (c) releasing said superatmospheric pressure on said thermoplastic polymer foam whereby said thermoplastic polymer foam expands.    
     
     
         27 . The thermoplastic polymer foam of    claim 26    wherein during step (c) the temperature of said thermoplastic polymer foam is in a range of less than said melting temperature of said thermoplastic polymer foam and greater than said softening temperature if said thermoplastic polymer foam is amorphous, or greater than said glass transition temperature if said thermoplastic polymer foam is semicrystalline.  
     
     
         28 . The thermoplastic polymer foam of    claim 27    wherein during step (c) said thermoplastic foam is under said temperature of step (b).  
     
     
         29 . The thermoplastic polymer foam of    claim 26    which has a density in the range of from 0.008 to 0.02 grams/cubic centimeter after step (c).  
     
     
         30 . The thermoplastic polymer foam of    claim 26    which is comprised of poly(ethylene terephthalate).  
     
     
         31 . The thermoplastic polymer foam of    claim 26    which is comprised of poly(ethylene).  
     
     
         32 . The thermoplastic polymer foam of    claim 26    which is comprised of a thermoplastic polymer which is one of a polystyrene and a polyolefin.  
     
     
         33 . The thermoplastic polymer foam of    claim 26    wherein said thermoplastic polymer foam has a density in the range of from about 15% to about 96% lower than said initial density of said primarily foamed thermoplastic polymer foam.  
     
     
         34 . A thermoplastic polymer foam having a density ranging from 0.008 grams/cc to 0.02 grams/cc.  
     
     
         35 . The thermoplastic polymer foam of    claim 34    which is comprised of a polymer selected from the group consisting of poly(ethylene terephthalate) and poly(ethylene).  
     
     
         36 . An insulation material comprising a thermoplastic polymer foam having a density ranging from 0.008 grams/cc to 0.02 grams/cc.