Degradation of expandable polymer bead products

Abstract

From an environmental viewpoint, it is desireable to cause degradation of expanded EPS beads and foam cups and other products formed from expanded EPS beads, which are composed of polystyrene and a blowing agent such as pentane. For this purpose, the present invention utlizes the pre-expansion step as an opportunity to initiate foam product degradation by treating the expandable polymer beads during their pre-expansion. The objective of this degradation treatment is to initiate degradation of at least the surfaces of individual beads during their pre-expansion and before they are molded into the final foam articles. For this purpose, a number of degradation treatment options are disclosed for application during bead pre-expansion, including heating the beads by circulation with heated air, admixture of the beads with ozone, aromatic ketones such as acetophenone and benzophenone, and metallic salts, as well as irradiation of the expanding beads with uv radiation (e.g of a wavelength of about 260 nanometers). As a result of the interposed degradation treatment, the foam products degrade first into individual beads, and subsequently into polymeric dust, at a rate that depends upon the intensity of the degradation treatment that is selected.

What is claimed is:  
     
         1 . A method of expanding beads of expandable polymer, each bead comprising a mixture of polymer and a blowing agent, said polymer comprising molecules of high molecular weight, said method comprising the steps of; 
 a) heating said beads until substantially every bead is enlarged to a desired degree due to thermal expansion of said blowing agent therein to form a plurality of cells, each cell comprising said polymer and a quantity of said blowing agent therein,    b) during step a), treating said beads to initiate degradation of at least some of said molecules of high molecular weight into molecules of lower molecular weight, and    c) cooling the enlarged beads to set said cells thereof in an enlarged state thereof.    
     
     
         2 . A method of expanding beads of expandable polymer, each bead comprising a mixture of polymer and a blowing agent, said polymer comprising molecules of high molecular weight, said method comprising the steps of; 
 a) heating a quantity of dry gas,    b) maintaining the heated dry gas in contact with said beads until substantially every bead is enlarged to a desired degree due to thermal expansion of said blowing agent therein to form a plurality of both peripheral and interior, mutually joined, cells, each cell comprising said polymer and a quantity of blowing agent therein,    c) during step b), treating said beads to initiate degradation of at least some of said molecules of high molecular weight into molecules of lower molecular weight, and    d) cooling the enlarged beads to set said cells thereof in an enlarged state thereof.    
     
     
         3 . A method as set forth in  claim 2 , said expandable polymer comprising expandable polystyrene, said gas comprising air, and said blowing agent comprising pentane.  
     
     
         4 . A method as set forth in  claim 3 , wherein step c) of treating said beads comprises mixing a quantity of an aromatic ketone with said beads.  
     
     
         5 . A method as set forth in  claim 4  wherein said quantity of aromatic ketone comprises acetophenone in a concentration of between 1% and 5% by weight of said beads.  
     
     
         6 . A method as set forth in  claim 4 , wherein said quantity of aromatic ketone comprises benzoophenone in a concentration of between 1% and 5% by weight of said beads.  
     
     
         7 . A method as set forth in  claim 4 , wherein step c) of treating said beads further comprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         8 . A method as set forth in  claim 5 , wherein step c) of treating said beads further comprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 310 nm to 330 nm.  
     
     
         9 . A method as set forth in  claim 6 , wherein step c) of treating said beads furthercomprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 355 nm to 375 nm.  
     
     
         10 . A method as set forth in  claim 7 , wherein said selected time period exceeds one hour.  
     
     
         11 . A method as set forth in  claim 3 . wherein step c) of treating said beads comprises heating said beads during step b) to a temperature in the range of 100 to 200 degrees Celsius for a time period of at least 5 minutes, while exposing said beads to air.  
     
     
         12 . A method as set forth in  claim 11 , said temperature is in the range of 150 to 170 degrees Celsius, and said time period is 15 to 30 minutes.  
     
     
         13 . A method as set forth in  claim 3  wherein step c) of treating said beads comprises: circulating a gas comprising ozone through said beads.  
     
     
         14 . A method as set forth in  claim 13 , wherein step c) further comprises heating said beads during step b) to a temperature in the range of 50 to 200 degrees Celsius for a time period of at least 5 minutes.  
     
     
         15 . A method as set forth in  claim 13 , wherein step c) of treating said beads further comprises irradiating said bead for at least one hour with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         16 . A method as set forth in  claim 14 , wherein step c) of treating said beads comprises irradiating said beads for at least one hour with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         17 . A method as set forth in  claim 13 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         18 . A method as set forth in  claim 14 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         19 . A method as set forth in  claim 15 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         20 . A method as set forth in  claim 13 , wherein steps b) and c) comprise steps of: 
 i) circulating a gas comprising ozone and heated air at the bottom of a chamber, and    ii) then introducing a batch quantity of said beads into said chamber while circulating said gas therein to stir said beads..    
     
     
         21 . A method as set forth in  claim 14 , wherein steps b) and c) comprise steps of: 
 i) circulating a gas comprising ozone and heated air at the bottom of a chamber, and    ii) then introducing a batch quantity of said beads into said chamber while circulating said gas therein to stir said beads.    
     
     
         22 . A method as set forth in  claim 15 , wherein steps b) and c) comprise steps of: 
 i) circulating a gas comprising ozone and heated air at the bottom of a chamber, and    ii) then introducing a batch quantity of said beads into said chamber while circulating said gas therein to stir said beads..    
     
     
         23 . A method as set forth in  claim 4 , wherein step c) of treating said beads comprises mixing a quantity of a metal salt with said beads.  
     
     
         24 . A method as set forth in  claim 23 , wherein said metal salt is zinc stearate.  
     
     
         25 . A method as set forth in  claim 13 , wherein step c) of treating said beads comprises mixing a quantity of a metal salt with said beads.  
     
     
         26 . A method as set forth in  claim 25 , wherein said metal salt is zinc stearate.  
     
     
         27 . A method of molding articles from beads of expandable polymer, each bead comprising a mixture of polymer and a blowing agent, said polymer comprising molecules of high molecular weight, said method comprising the steps of; 
 a) heating said beads until substantially every bead is enlarged to a desired degree due to thermal expansion of said blowing agent therein to form a plurality of both peripheral and interior, mutually joined, cells, each cell comprising said polymer and a quantity of blowing agent therein,    b) during step a), treating said beads to initiate degradation of at least some of said molecules of high molecular weight into molecules of lower molecular weight, and    c) cooling said beads to set cells thereof in an enlarged state thereof to thereby form pre-expanded beads,    d) introducing said pre-expanded beads into a mold defining a shape of an article, and    e) heating said pre-expanded beads in said mold to further expand said pre-expanded beads to form said article.    
     
     
         28 . A method of molding articles from beads of expandable polymer, each bead comprising a mixture of polymer and a blowing agent, said polymer comprising molecules of high molecular weight, said method comprising the steps of; 
 a) heating a quantity of dry gas,    b) maintaining the heated dry gas in contact with said beads until substantially every bead is enlarged to a desired degree due to thermal expansion of said blowing agent therein to form a plurality of both peripheral and interior, mutually joined, cells, each cell comprising said polymer and a quantity of blowing agent therein, by: 
 i) circulating heated dry gas at the bottom of a chamber, and  
 ii) then introducing a batch quantity of said beads into said chamber while circulating said heated gas therein.to stir said beads,  
   c) during step b), treating said beads to initiate degradation of at least some of said molecules of high molecular weight into molecules of lower molecular weight, and    d) cooling said beads to set cells thereof in an enlarged state thereof to thereby form pre-expanded beads,    e) introducing said pre-expanded beads into a mold defining a shape of an article, and    f) heating said pre-expanded beads in said mold to further expand said pre-expanded beads to form said article.    
     
     
         29 . A method as set forth in  claim 28 , said expandable polymer comprising expandable polystyrene, said gas comprising air, and said blowing agent comprising pentane.  
     
     
         30 . A method as set forth in  claim 29 , wherein step c) of treating said beads comprises mixing a quantity of an aromatic ketone with said beads.  
     
     
         31 . A method as set forth in  claim 30 , wherein said quantity of aromatic ketone comprises acetophenone in a concentration of between 1% and 5% by weight of said beads.  
     
     
         32 . A method as set forth in  claim 30 , wherein said quantity of aromatic ketone comprises benzoophenone in a concentration of between 1% and 5% by weight of said beads.  
     
     
         33 . A method as set forth in  claim 30 , wherein step c) of treating said beads further comprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         34 . A method as set forth in  claim 31 , wherein step c) of treating said beads furthercomprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 310 nm to 330 nm.  
     
     
         35 . A method as set forth in  claim 32 , wherein step c) of treating said beads furthercomprises irradiating said beads for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 355 nm to 375 nm.  
     
     
         36 . A method as set forth in  claim 33 , wherein said selected time period exceeds one hour.  
     
     
         37 . A method as set forth in  claim 29 . wherein step c) of treating said beads comprises heating said beads during step b) to a temperature in the range of 100 to 200 degrees Celsius for a time period of at least 5 minutes while exposing said beads to air..  
     
     
         38 . A method as set forth in  claim 37 , said temperature is in the range of 150 to 170 degrees Celsius, and said time period is 15 to 30 minutes.  
     
     
         39 . A method as set forth in  claim 29  wherein step c) of treating said beads comprises: circulating a gas comprising ozone through said beads.  
     
     
         40 . A method as set forth in  claim 39 , wherein step c) further comprises heating said beads during step b) to a temperature in the range of 100 to 200 degrees Celsius for a time period of at least 5 minutes.  
     
     
         41 . A method as set forth in  claim 39 , wherein step c) of treating said beads comprises irradiating said bead for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         42 . A method as set forth in  claim 40 , wherein step c) of treating said beads comprises irradiating said bead for a selected time period with ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm.  
     
     
         43 . A method as set forth in  claim 41  wherein said selected time period exceeds one hour.  
     
     
         44 . A method as set forth in  claim 35 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         45 . A method as set forth in  claim 37 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         46 . A method as set forth in  claim 43 , said peripheral cells substantially surrounding and being substantially larger than said interior cells.  
     
     
         47 . A method as set forth in  claim 39 , wherein said dry gas comprises ozone and air.  
     
     
         48 . A method as set forth in  claim 40 , wherein said dry gas comprises ozone and air.  
     
     
         49 . A method as set forth in  claim 41 , wherein said dry gas comprises ozone and air.  
     
     
         50 . An apparatus for expanding beads of expandable polymer, said apparatus comprising: 
 a) a vertical expansion chamber for receiving a selected batch quantity of said beads, said expansion chamber comprising a lower portion and an upper portion, said lower portion being formed of substantially gas-impermeable material, said upper portion being formed of substantially gas-permeable material,    b) a loading bin for discharging said selected batch quantity of beads into said lower portion,    c) a source of dry, heated, pressurized gas connected in gas-communicating relationship with said lower portion, said source being operable to direct the heated gas into said lower portion to stir and percolate through said selected batch quantity of beads therein.    d) a degradation device operable to treat said beads to initiate degradation of at least some of said molecules of high molecular weight into molecules of lower molecular weight.    
     
     
         51 . An apparatus as set forth in  claim 50 , wherein said polymer is polystyrene and said gas comprises air.  
     
     
         52 . An apparatus as set forth in  claim 51 , wherein said degradation device (d) comprises a source of ozone connected in gas-communicating relationship with said lower portion, said source of ozone being operable to direct the heated gas into said lower portion to percolate through said selected batch quantity of beads therein  
     
     
         53 . An apparatus as set forth in  claim 51 , said apparatus further comprising a source of ultraviolet electromagnetic radiation of a wavelength in the range of 250 nm to 375 nm, said source of ultraviolet electromagnetic radiation being disposed within said lower portion and being operable to irradiate said selected batch quantity of beads therein.  
     
     
         54 . An apparatus as set forth in  claim 52 , wherein said source of dry, heated pressurized gas comprises a hot air blower having an output nozzle directed away from a vertical central axis of said lower portion of said expansion chamber.  
     
     
         55 . An apparatus as set forth in  claim 54 , said apparatus further comprising a sensor operable to detect a selected level of expanded beads within said expansion chamber, said apparatus further comprising a discharge outlet in said lower portion of said expansion chamber, said discharge outlet being openable to discharge expanded beads upon detection of said selected level by said sensor.  
     
     
         56 . A partially expanded bead of expandable polymer, said bead having an outer surface, said polymer comprising molecules of high molecular weight, said pre-expanded bead comprising a plurality of both peripheral and interior, mutually joined, cells, each cell comprising a cell wall of said polymer and a quantity of blowing agent enclosed thereby, wherein the peripheral cells substantially surround and are substantially larger than the interior cells, and wherein at least said outer surface of said bead exhibits degradation of said molecules of high molecular weight into molecules of lower molecular weight.  
     
     
         57 . A partially expanded bead as set forth in  claim 56 , wherein said polymer is polystyrene and said blowing agent is pentane.  
     
     
         58 . A partially expanded bead as set forth in  claim 56 , wherein cell walls of said interior cells are characterized by a greater thickness than cell walls of said peripheral cells.  
     
     
         59 . A partially expanded bead as set forth in  claim 58  wherein, after prolonged exposure to ambient sunlight, said outer surface exhibits a yellowed appearance and feels powdery to the touch.  
     
     
         60 . An article formed from partially expanded beads of expandable polymer, each bead having an outer surface, said polymer comprising molecules of high molecular weight, said pre-expanded bead comprising a plurality of both peripheral and interior, mutually joined, cells, each cell comprising a cell wall of said polymer and a quantity of blowing agent enclosed thereby, wherein the peripheral cells substantially surround and are substantially larger than the interior cells, and wherein at least said outer surface of said bead exhibits degradation of said molecules of high molecular weight into molecules of lower molecular weight.  
     
     
         61 . An article as set forth in claim  60 , wherein said polymer is polystyrene and said blowing agent is pentane.  
     
     
         62 . Article as set forth in claim  61 , wherein cell walls of said interior cells are characterized by a greater thickness than cell walls of said peripheral cells.  
     
     
         63 . An article as set forth in claim  62  wherein, after prolonged exposure to ambient sunlight, said article is brittle and said outer surface exhibits a yellowed appearance and feels powdery to the touch.