Patent GB-1049642-A (GB)
Title: Organic carbonates as foaming agents
IPC: C08J9/02
Filed: 1963-05-21
Abstract: Thermoplastic polymers are foamed or expanded by heating the polymer, which includes as part of its structure, or is admixed with a compound containing, at least one 1,2-carbonate group <FORM:1049642/C3/1> in the presence of an activator which is one or more oxides or hydroxides of the metals of Groups I, II and III of the Periodic Table, an inorganic acidic salt of these metals, a salt of a weak inorganic acid, or a salt of an organic acid. Suitable 1,2-carbonates are simple carbonates such as ethylene- or propylene-carbonate; substituted carbonates such as alpha-chloropropane carbonate; hemi- or di-esters of dibasic organic acids with triol carbonates, preferably with neutralization in the case of hemi-esters by an alkali or alkaline earth metal of the unesterified -COOH group; and carbonates of unsaturated polymerizable molecules, such as esters of unsaturated acids with alcohol carbonates, e.g. acrylic acid and glycerol 1,2 carbonate.  These latter esters may be polymerized or co-polymerized to thermoplastic polymers expandable by the inventive process. The 1,2-carbonates decompose to evolve CO2, which effects foaming or expansion, at fairly low temperatures-i.e. about 100 DEG  to 150 DEG  C.-when in the presence of the aforesaid activators. Numerous examples are given for:  (a) Preparing 1,2-carbonates which are monomeric (see Division C2) and are useful both for homo- and co-polymerization to form polymers expandable of themselves, and as foaming agents for admixture with thermoplastic polymers; (b) Preparing polymers having the 1,2-carbonates; moiety as part of the molecule; (c) Expanding polymers by admixture with 1,2-carbonates; (d) Expanding 1,2-carbonate-group-containing polymers.  Particular examples under (b) are the preparation of (1) A copolymer of 100 parts of methyl methacrylate with 7.5 parts of 4-(1,3-dioxolone-2)-methylene hydrogen dodecylene succinate; (2) A copolymer of 93 parts of styrene, 5 parts of methyl itaconyl monoglyceryl carbonate and 2 parts of acrylic acid; and (3) A copolymer of styrene, acrylyl monoglyceryl carbonate, and acrylic acid; these copolymers are subsequently expanded by heating. Also disclosed are polymers wherein in (2) above, the acrylic acid is replaced with methacrylic, vinyl benzoic, itaconic, maleic, or fumaric acids, half esters which are methyl, ethyl, propyl, benzyl, and phenyl half esters of maleic, fumaric, itaconic, cyanoacrylic or chloroacrylic acids, and in (3) the styrene is to some extent replaced with methyl methacrylate, or dimethyl itaconate. Further examples disclose a copolymer of 90 parts of styrene with 10 parts of itaconyl glyceryl carbonate, and homo- and copolymers of acrylic and methacrylic esters of C3 to C6 triols.  Under (c) above, examples are given for expanding polystyrene with succinyl monoglyceryl carbonate, and with ethylene-, propylene- and glycerine-carbonates, and also for expanding the following with such carbonates:  plasticized cellulose acetate, cellulose aceto-butyrate, ethyl cellulose, polyvinyl acetate, plasticized polyvinyl chloride, vinyl chloride-dibutyl maleate copolymer, vinyl chloride-vinyl acrylate copolymer, styrene-acrylonitrile copolymer, polyethylene, polypropylene, polybutene-1, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylonitrile copolymer, succinic or adipic acid modified ethylene terephthalate polymer, Nylon 6, Nylon 6-6, acrylonitrile-butadiene-styrene terpolymers, and styrene-butadiene copolymer.