Patent GB-918329-A (GB)
Title: Production of foamed thermoplastic shaped articles
IPC: C08J9/224
Filed: 1959-10-07
Abstract: A mould formed from material of low dielectric loss factor is filled with particles of a partially foamed thermoplastic material in which is dispersed an organic liquid which boils below the softening point of the thermoplastic material, the surface of the particles being coated with a layer of an aqueous solution of an electrolyte, and the filled mould is then closed and a high frequency alternating current passed through its contents for a period at least sufficient to convert the water present in the coating layer into steam and to foam the thermoplastic material. The material from which the mould is constructed should preferably have a loss factor of less than 0,02 and a dielectric constant of less than 4,0, both measured at 10 mc/s. Examples of materials which may be employed are polyethylene, polypropylene, polytetrafluoroethylene, polymethylmethacrylate, polystyrene, styreneacrylonitrile copolymers, glass, quartz, porcelain, and phenolic or melamine resin impregnated paper laminates.  As an illustration, foamed polystyrene mouldings up to 3 inches thick can be prepared in not more than 20 secs. when the partially foamed particles are coated with 20% by weight of a 1% electrolyte solution and an alternating current at 6,000 volts and 80 mc/s. is passed through a polytetrafluoroethylene mould with the electrodes of the heating apparatus spaced apart by not more than 6 inches.  Preferred thermoplastic materials for use in the process are the vinylidene aromatic polymers in which are dispersed as foaming agent an aliphatic hydrocarbon of boiling point 10 DEG  to 90 DEG C., e.g. pentane.  The polymer is preferably a homopolymer of styrene, a nuclear alkylated styrene such as ortho-, meta-, or paravinyltoluene or 2,4-dimethylstyrene, a nuclear halogenated styrene such as ortho-, meta-, or para-chlorostyrenes, 2,4 or 2,5-dichlorostyrenes, or a nuclear alkylated and halogenated styrene such as 2-methyl-4-chlorostyrene, or an interpolymer of one of the above with a suitable vinylidene monomer.  A cellulose ester or ether, e.g. ethyl cellulose, or cellulose acetate, nitrate or butyrate may also be used, as may a wide range of other thermoplastic material including polyethylene, polypropylene, polyvinyl chloride and polyvinylidene chloride.  Virtually any water soluble or dispersible material which will ionize in aqueous solution may be employed as the electrolyte, an ionic surface active agent such as a salt of an alkyl sulphonate, an alkyl sulphate or an aryl sulphonic acid, or a quaternary ammonium compound preferably being used in the aqueous coating solution and functioning both as an electrolyte and as a surface active agent.ALSO:A mould formed from material of low dielectric loss factor is filled with particles of a partially foamed thermoplastic material in which is dispersed an organic liquid which boils below the softening point of the thermoplastic material, the surface of the particles being coated with a layer of an aqueous solution of an electrolyte, and the filled mould is then closed and a high frequency alternating current passed through its contents for a period at least sufficient to convert the water present in the coating layer into steam and to foam the thermoplastic material The material from which the mould is constructed should preferably have a loss factor of less than 0,02 and a dielectric constant of less than 4,0, both measured at 10 mc/s.  Examples of materials which may be employed are polyethylene, polypropylene, polytetrafluoroethylene, polymethylmethacrylate, polystyrene, styreneacrylontrile copolymers, glass, quartz, porcelain, and phenolic or melamine resin impregnated paper laminates.  As an illustration, foamed polystyrene mouldings up to 3 inch thick can be prepared in not more than 20 secs. when the partially foamed particles are coated with 20% by weight of a 1% electrolyte solution and an alternating current at 6000 volts and 80 mc/s is passed through a polytetrafluoroethylene mould with the electrodes of the heating apparatus spaced apart by not more than 6 inch.  Preferred thermoplastic materials for use in the process are the vinylidene aromatic polymers in which are dispersed as foaming agent an aliphatic hydrocarbon of boiling point 10 to 90 DEG C., e.g. pentane.  The polymer is preferably a homopolymer of styrene, a nuclear alkylated styrene such as ortho-, meta-, or paravinyltoluene or 2, 4-dimethylstyrene, a nuclear halogenated styrene such as ortho-, meta-, or parachlorostyrenes, 2, 4 or 2, 5- dichlorostyrenes, or a nuclear alkylated and halogenated styrene such as 2-methyl-4-chlorostyrene, or an interpolymer of one of the above with a suitable vinylidene monomer.  A cellulose ester or ether, e.g. ethyl cellulose, or cellulose acetate, nitrate or butyrate may also be used, as may a wide range of other thermoplastic material including polyethylene, polypropylene, polyvinyl chloride and polyvinylidene chloride.  Virtually any water soluble or dispersible material which will ionise in aqueous solution may be employed as the electrolyte, an ionic surface active agent such as a salt of an alkyl sulphonate, an alkyl sulphate or an aryl sulphonic acid, or a quaternary ammonium compound preferably being used in the aqueous coating solution and functioning both as an electrolyte and as a surface active agent.