Methods of reducing polystyrene foams using dibasic esters with extruders
OwnerHarvey Katz, Claudia Iovinoinventors
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Abstract
The present invention is directed to novel polystyrene foam reduction recycling compositions and methods that solve the volume problem of recycling polystyrene foam materials while simultaneously allowing the easy and inexpensive shipment of the foamed materials after reduction in volume by use of one or more dibasic ester compositions in combination with one or more low heat based mechanical extruders. The methods of the present invention are applicable to all types of expanded or foamed polystyrene materials known to those of skill in the art.
Claims18
A method of reducing/recycling polystyrene foam comprising the steps of
- (a) providing polystyrene foam;
- (b) applying to said polystyrene foam a solution comprising:
- one or more standard dibasic ester (DBE) compositions selected from the group consisting of dimethyl glutarate, dimethyl adipate, and dimethyl succinate;
- (c) subjecting the resultant polygel to a low source of heat over a temperature range not to exceed 200-300° C.;
- (d) subjecting the resultant polygel to one or more extruders over a temperature range not to exceed 200-300° C.;
- and
- (e) recapturing the dibasic esters;
- wherein said recaptured dibasic esters are reused or recycled and the resultant polystyrene foam polygel may be recycled into high quality beaded polystyrene foam.
A method of reducing/recycling polystyrene foam comprising the steps of
- (a) providing polystyrene foam;
- (b) applying to said polystyrene foam a solution comprising:
- one or more low vapor pressure dibasic ester (LVP-DBE) compositions selected from the group consisting of dimethyl glutarate, dimethyl adipate, and dimethyl succinate;
- (c) subjecting the resultant polygel to a low source of heat over a temperature range not to exceed 200-300° C.;
- (d) subjecting the resultant polygel to one or more extruders over a temperature range not to exceed 200-300° C.;
- and
- (e) recapturing the low vapor pressure dibasic esters;
- and wherein said recaptured low vapor pressure dibasic esters are reused or recycled and the resultant polystyrene foam polygel may be recycled into high quality beaded polystyrene foam.
A method of reducing/recycling polystyrene foam comprising the steps of
- (a) providing polystyrene foam;
- (b) applying to said polystyrene foam a solution comprising:
- (i) one or more terpenes or isopernoids or any combination thereof and (ii) one or more surfactants;
- (c) subjecting the resultant polygel to a low source of heat over a temperature range not to exceed 200-300° C.;
- (d) subjecting the resultant polygel to one or more extruders over a temperature range not to exceed 200-300° C.;
- and
- (e) recapturing the terpenes or isopernoids;
- and wherein said recaptured terpenes or isopernoids are reused or recycled and the resultant polystyrene foam polygel may be recycled into high quality beaded polystyrene foam.
A polystyrene low heat treatment extruder recycling system comprising the steps of
- (a) exposing polystyrene foam in a container to a solution of specific esters comprising dimethyl glutrate [CAS # 1119-40-0] and dimethyl adipate [CAS# 627-93-0], wherein the esters specifically exclude dimethyl succinate in weight percentage amounts greater than 1%;
- (b) optionally covering said container;
- (c) subjecting the resultant polygel to a low source of heat over a temperature range not to exceed 200-300° C.;
- (d) subjecting the resultant polygel to one or more extruders over a temperature range not to exceed 200-300° C.;
- (e) optionally supplementing polystyrene foam until maximum reduction is achieved and
- (f) recapturing the dibasic esters;
- and wherein said recaptured dibasic esters are reused or recycled and the resultant polystyrene foam polygel may be recycled into high quality beaded polystyrene foam.
A method of reducing/recycling polystyrene foam comprising the steps of
- (a) providing polystyrene foam;
- (b) applying to said polystyrene foam a solution comprising:
- (i) one or more low vapor pressure dibasic ester compositions selected from the group consisting of dimethyl glutarate, dimethyl adipate, and dimethyl succinate;
- (ii) one or more dibasic ester compositions selected from the group consisting of dimethyl glutarate, dimethyl adipate, and dimethyl succinate or (iii) (a) one or more terpenes or isopernoids or any combination thereof and (b) one or more surfactants;
- or any combination thereof of (i)-(iii);
- (c) subjecting the polygel to a low source of heat over a temperature range not to exceed 200-300° C.;
- (d) subjecting the polygel to one or more extruders over a temperature range not to exceed 200-300° C.;
- and
- (e) recapturing the dibasic esters, the low vapor pressure dibasic esters and/or the terpenes or isopernoids;
- and wherein said recaptured dibasic esters, low vapor pressure dibasic esters and/or the terpenes or isopernoids are reused or recycled and the resultant polystyrene foam polygel may be recycled into high quality beaded polystyrene foam.
A polystyrene low heat treatment extruder recycling system comprising an LVP-DBE composition that exhibits one or more of the following characteristics:
- (a) a significantly lower vapor pressure than standard DBE, (b) the distillation range of the solvent is narrower, (c) chemically more stable than standard DBE, (d) that is incompatible or can react with, inter alia, strong oxidizers, acids, alkalies, etc., (e) that will not undergo polymerization, (f) that reduces foamed polystyrene at a rate of action that equals or exceeds that of standard DBE, (g) that exhibits a greater holding capacity than standard DBE, (h) that exhibits a higher flash point than standard DBE, (i) that is not regulated as a hazardous material by DOT, IMO, or IATA, and (j) for which none of the components present in the LVP-DBE composition are listed by IARC, NTP, OSHA or ACGIH as a carcinogen.
A polystyrene low heat treatment extruder recycling system comprising exposing said foams to liquid sprays of specific esters exhibiting one or more of the aforementioned characteristics.
A polystyrene low heat treatment extruder recycling system comprising exposing said foams to liquid sprays of specific esters comprising dimethyl glutarate [CAS # 1119-40-0] and dimethyl adipate [CAS# 627-93-0], wherein the ester specifically excludes dimethyl succinate in weight percentage amounts greater than 1%, and wherein said esters exhibit one or more of the aforementioned characteristics.
A polystyrene low heat treatment extruder recycling system comprising exposing said foams to liquid sprays of specific esters, wherein the ester is selected from the group consisting of dimethyl glutarate [CAS # 1119-40-0] and dimethyl adipate [CAS# 627-93-0], wherein the esters specifically exclude dimethyl succinate in weight percentage amounts greater than 1%, and wherein said esters exhibit one or more of the aforementioned characteristics.
A recycling system to reduce the volume of polystyrene foams wherein said polystyrene foams are exposed to vapors of low vapor pressure dibasic esters over an extended period in a container which prevents escape of said vapors, liquid or a combination thereof.
Dependencies are inferred from the claim text.