# US 2023/0265255 A1 · Foamable thermoplastic compositions, thermoplastic foams and methods of making same

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- Number: US 2023/0265255 A1
- Document ID: US20230265255A1
- Status: Published application
- Kind: A1
- Application number: 18/113,605
- Filed: 2023-02-23
- Published: 2023-08-24
- Earliest claimed: 2022-02-23
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: Hayim Abrevaya; Erin Broderick; Alexey Kruglov; Keith Lehuta; Tianyu Liu; Rodrigo Lobo; David Mackowiak; Susie Martins; Peter Nickl; Mark Triezenberg; Syed Hassan Mahmood; Mary Bogdan
- Web page: https://patentgrep.com/patent/US20230265255A1

## CPC

- C08J 9/144: {containing carbon, halogen and hydrogen only}
- C08J 9/146: {only fluorine as halogen atoms}
- C08K 5/02: Halogenated hydrocarbons {(C08K5/0091 takes precedence)}
- C08G 63/181: Acids containing aromatic rings
- C08J 2201/03: Extrusion of the foamable blend
- C08J 2203/142: Halogenated saturated hydrocarbons, e.g. H3C-CF3
- C08J 2203/162: Halogenated unsaturated hydrocarbons, e.g. H2C=CF2
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- C08J 2467/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08J2467/06 takes precedence)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

## Abstract

A low-density, thermoplastic foam comprising: (a) thermoplastic polymer cells comprising cell walls forming closed cells, wherein said thermoplastic polymer comprises ethylene furanoate moieties and optionally ethylene terephthalate moieties, wherein said polymer comprises from about 1 mole % to about 100 mole % of ethylene furanoate moieties and optionally at least about 1 mole % ethylene terephthalate moieties; and (b) one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms contained in the closed cells.

## Claims

### Claim 1

A low-density, thermoplastic foam comprising:
(a) thermoplastic polymer cells comprising cell walls forming closed cells, wherein said thermoplastic polymer consists essentially of ethylene furanoate moieties and optionally ethylene terephthalate moieties, wherein said polymer comprises from about 1 mole % to about 100 mole % of ethylene furanoate moieties and optionally at least about 1 mole % ethylene terephthalate moieties; and
(b) one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms contained in the closed cells.

### Claim 2 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said thermoplastic polymer has a crystallinity of at least about 5%.

### Claim 3 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said polymer consists essentially of about 1 mole % to about 100 mole % of ethylene furanoate moieties and optionally at least about 1 mole % ethylene terephthalate moieties.

### Claim 4 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said polymer consists essentially of about 1 mole % to about 100 mole % of ethylene furanoate moieties and at least about 1 mole % ethylene terephthalate moieties.

### Claim 5 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said thermoplastic polymer has a molecular weight of at least about 10,000 kg/mole and a crystallinity of at least about 5% and consists essentially of ethylene furanoate moieties and ethylene terephthalate moieties, wherein said polymer comprises from about 1 mole % to about 20 mole % of ethylene furanoate moieties and at least about 80 mole % ethylene terephthalate moieties.

### Claim 6 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said thermoplastic polymer has a molecular weight of at least about 10,000 kg/mole and a crystallinity of at least about 5% and consists essentially of ethylene furanoate moieties and ethylene terephthalate moieties, wherein said polymer comprises from about 0.5 mole % to about 2 mole % of ethylene furanoate moieties and from about 98 mole % to about 99.5 mole % ethylene terephthalate moieties.

### Claim 7 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms comprises one or more of 1234ze(E), 1336mzz and 1233zd.

### Claim 8 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms consists essentially of one or more of 1234ze(E), 1336mzz(Z) and 1233zd(E).

### Claim 9 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said closed cells contain a gas and said gas consists essentially of said one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms.

### Claim 10 (depends on 1)

The low-density, thermoplastic foam of claim 1 wherein said closed cells contain a gas and said gas consists essentially of comprises one or more of 1234ze(E), 1336mzz(Z) and 1233zd(E).

### Claim 11

A method for forming a thermoplastic foam comprising:
(a) providing an extruding a foamable composition comprising:
(c) thermoplastic material consists essentially of ethylene furanoate moieties and optionally ethylene terephthalate moieties, wherein said thermoplastic material comprises from about 1 mole % to about 100 mole % of ethylene furanoate moieties and optionally at least about 1 mole % ethylene terephthalate moieties; and
(d) blowing agent comprising one or more HFOs having three or four carbon atoms and/or one or more HFCOs having three or four carbon atoms; and
(b) foaming said foamable composition.

### Claim 12 (depends on 11)

The method of claim 11 wherein said foaming step comprises extruding said foamable composition.

### Claim 13 (depends on 12)

The method of claim 12 wherein said extruding step comprises introducing said foamable composition into a commercial scale extruder.

### Claim 14 (depends on 13)

A foam formed from the method of claim 13.

### Claim 15 (depends on 14)

A wind energy turbine comprising the foam of claim 14.

### Claim 16 (depends on 14)

A wind energy turbine blade comprising a foam of claim 14.

### Claim 17

A method of forming thermoplastic compositions having improved crystallinity comprising:
(d) forming a thermoplastic material comprising polymer chains containing ethylene furanoate moieties and/or ethylene terephthalate moieties; and
(e) dissolving at least a portion of said thermoplastic material in a solvent wherein said thermoplastic material comprises from about 1 mole % to about 100 mole % of ethylene furanoate moieties and optionally at least about 1 mole % ethylene terephthalate moieties; and
(f) distilling said solvent from said thermoplastic material.

### Claim 18 (depends on 17)

The method of claim 17 wherein said solvent comprises gamma-valerolactone.

### Claim 19 (depends on 18)

The method of claim 18 wherein said dissolving step comprises mixing said gamma-valerolactone at a temperature above room temperature.

### Claim 20 (depends on 19)

The method of claim 19 wherein said distilling step comprises exposing said mixture to a vacuum.