# US 9,752,004 B2 · Cell size enlargers for polystyrene foams

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- Number: US 9,752,004 B2
- Document ID: US9752004B2
- Status: Granted
- Kind: B2
- Application number: 11/472,772
- Filed: 2006-06-22
- Published: 2007-12-27
- Granted: 2017-09-05
- Earliest claimed: 2006-06-22
- Assignees: Owens Corning Intellectual Capital, LLC
- Applicants: Bharat Patel; Yadollah Delaviz; Raymond M. Breindel; Mitchell Z. Weekley; Roland R. Loh; Manoj K. Choudhary
- Inventors: Bharat Patel; Yadollah Delaviz; Raymond M. Breindel; Mitchell Z. Weekley; Roland R. Loh; Manoj K. Choudhary
- Web page: https://patentgrep.com/patent/US9752004B2

## CPC

- C08J 9/0061: {characterized by the use of several polymeric components}
- C08J 9/0014: {Use of organic additives}
- C08J 2325/06: Polystyrene
- C08J 2423/00: Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J 2471/00: Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
- 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)

## Abstract

Polymer extruded foams that contain cell size enlarging agents are provided. The inventive composition includes a foamable polymer material, at least one blowing agent, and at least one cell size enlarging agent. The blowing agent utilized in the inventive composition is preferably selected such that the composition has a zero ozone depletion and low global warming potential. Examples include any inorganic blowing agents and/or non-hydrogenated chlorofluorocarbons (non-HCFCs). The foamable polymer material is preferably polystyrene. The cell size enlarging agent may be chosen from ethylene vinyl acetate (EVA) and/or ethylene methyl acrylate (EMA). The cell size enlarging agent permits the formation of a foam with large cell sizes that are desirable to achieve a high insulation value and to optimize the physical properties of the foamed product. In addition, the cell size enlarging agent provides an increased cell size to the foamed product without detracting from the physical and thermal properties.

## Claims

### Claim 1

A polymer foam formed from a composition comprising:
a foamable alkenyl aromatic polymer material;
from 2% to 18% by weight of a blowing agent comprising carbon dioxide; and
from 0.1% to 2.0% by weight of at least one cell size enlarging agent comprising ethylene methyl acrylate,
wherein the composition does not include chlorofluorocarbons (CFCs), HFCs, or non-hydrogenated chlorofluorocarbons (HCFCs), and
wherein the polymer foam has no more than 5% open cells.

### Claim 2 (depends on 1)

The polymer foam of claim 1, wherein the polymer foam has a density from 1.0 lbs/ft3 to 5.0 lbs/ft3.

### Claim 3 (depends on 1)

The thermoplastic polymer foam of claim 1, wherein the dimensional stability of the thermoplastic polymer foam in any direction is 5% or less.

### Claim 4 (depends on 1)

The polymer foam of claim 1, wherein the at least one cell size enlarging agent provides an increased cell size to a resulting foamed product without detracting from the physical and thermal properties of the foamed product as compared to an equivalent foamed product formed without the at least one cell size enlarging agent.

### Claim 5 (depends on 1)

The polymer foam of claim 1, wherein the composition comprises from 0.25% to 0.4% by weight of the at least one cell size enlarging agent.