nanocomposite compositions, expandable articles obtained from nanocomposite compositions, expanded e

专利摘要:
Nanocomposite COMPOSITIONS, STRETCH ITEMS OBTAINED OF nanocomposites COMPOSITIONS, Polymeric OF extruded SHEETS EXPANDED THERMOPLASTIC, E, PROCESSES FOR PREPARING COMPOSITIONS OF POLYMERS THERMOPLASTIC FOR PREPARING MASS AS POLYMER COMPOSITIONS THERMOPLASTIC AND PRODUCTION OF extruded SHEETS POLYMER EXPANDED THERMOPLASTIC St. nanocomposite compositions provided based on expandable thermoplastic polymer which comprise: a) a polymeric matrix produced by polymerizing a base comprising one or more polymerizable monomers; b) 1-10% by weight, calculated with respect to the polymer (a), of a blowing agent included in the polymeric matrix; c) 0,004-15% by weight, calculated with respect to the polymer (a), of an athermic charge comprising graphene plates in nanometer scale with a thickness (orthogonal to the graphene sheet) of no more than 150nm, an average dimension ( length, width or diameter) of no more than 10 micrometers and a surface area> 50m2 / g.
公开号:BR112012007978B1
申请号:R112012007978-6
申请日:2010-10-06
公开日:2020-07-07
发明作者:Riccardo Felisari；Olga Valentino；Alessandro Casalini
申请人:Versalis S.P.A.；
IPC主号:

专利说明:

FIELD OF THE INVENTION
[0001] The present invention relates to nanocomposite compositions, based on expandable thermoplastic polymers loaded with graphene plates on a nanoscale, suitable for the preparation of expanded articles with a better thermal insulation capacity, the process for their preparation and the expandable articles obtained from these.
[0002] More specifically, the present invention relates to granules / beads based on expandable thermoplastic vinyl aromatic polymers, for example, expandable polymers of styrene, loaded with graphene plates on a nanoscale which, after expansion, have a conductivity reduced thermal even with a low density, less than 20 g / L, for example, and the expanded products obtained from it, that is, the extruded and expanded leaves obtained initially from said aromatic vinyl compositions. The present invention, in the manner described below, can also be applied to polymer of expandable thermoplastic vinyls, for example polyethylene, in the manner also illustrated and claimed. BACKGROUND OF THE INVENTION
[0003] Expandable thermoplastic polymers, and among these, in particular, expandable polystyrene (EPS), are known products that have been used for a long period to prepare expandable articles that can be adopted in various areas of application, among which , one of the most important is thermal insulation.
[0004] These expanded products are obtained by first swelling the polymer granules, in a closed environment, impregnated with an expandable fluid, for example, an aliphatic hydrocarbon such as pentane or hexane, and then molding / sintering the swollen particles, loaded in. of a mold, due to the contemporary effect of pressure and temperature. The swelling of the particles, as well as their sintering, is usually carried out with steam, or another gas, kept at a temperature slightly higher than the glass transition temperature (Tg) of the polymer.
[0005] A particular field of application, for example, of expanded polystyrene, is that of thermal insulation in the construction industry, where it is generally used in the form of flat sheets. Expanded polystyrene flat sheets are generally used with a density of about 30 g / L, since the thermal conductivity of the polymer has a minimum of these values. It is not advantageous to be below this limit, even if it is technically possible, since it causes a sharp increase in the thermal conductivity of the sheet, which must be compensated by an increase in its thickness. In order to avoid this obstacle, suggestions were made to fill the polymer with athermic materials, such as graphite, carbon black or aluminum. Athermic materials are in fact capable of interacting with the radioactive flow (infrared radiation), reducing their transmission and thus increasing the thermal insulation of the expanded materials in which they are contained.
[0006] The best thermal insulation performance allows a significant reduction in the density of the expanded article, or thickness, without reducing the value of total thermal resistance.
[0007] European patent 620,246, for example, describes a process for preparing expandable polystyrene granules containing an athermic material, for example, carbon black, distributed on the surface or, alternatively, incorporated within the particle itself.
[0008] The use of carbon black is known as a filler or pigment, or even as a nucleating agent (see, for example, Chem. Abstr., 1987, "Carbon Black Containing Polystyrene Beads").
[0009] Among the various types of carbon black, the most important are carbon black from oil combustion ("black oil"), carbon black from gas combustion, carbon black from acetylene, lamp carbon black, channel carbon black, thermal carbon black and electrically conducting carbon black. The international patent application WO 1997/45477 describes compositions based on expandable polystyrene which comprise a styrene polymer with 0.05 to 25% carbon black of the lamp carbon black type, and with 0.6 to 5% of a brominated additive to prepare the fireproof product.
[0010] Depending on the manufacturing process, these carbon blacks have diameters ranging from approximately 10 nm to 1,000 nm, and have very different specific surfaces (from 10 to 2,000 m2 / g). These differences lead to different blocking capabilities of infrared rays. The international patent application WO 2006/61571 describes compositions based on expandable polystyrene comprising a styrene polymer with an average molecular weight, weight Mw, of 150,000-450,000, with 2 to 20% by weight of a blowing agent and with 0 , 05 less than 1% carbon black, with a surface area ranging from 550 to 1,600 m2 / g.
[0011] It is known that graphite can also be used efficiently as a blackbody (as described, for example, in JP 63-183941, WO 04/022636, WO 96/34039). Its use as an attenuating agent for infrared radiation in polymeric foams is, however, more recent. Patent application JP 63-183941 is among the first to propose the use of some additives, active in blocking infrared rays at wavelengths ranging from 6 to 14 microns and therefore obtaining thermoplastic resins capable of maintaining permanently low thermal conductivity. Among all additives, graphite is preferred.
[0012] DE 9305431U describes a method for producing expandable molded products with a density less than 20 kg / m3 and a lower thermal conductivity. This result is achieved by incorporating an athermic material, such as graphite and also carbon black, in the rigid polystyrene foam.
[0013] International patent application WO 98/51735 describes expandable polystyrene particulates containing 0.05 to 25% by weight of synthetic or natural graphite particles, homogeneously distributed in the polystyrene matrix. The graphite preferably has an average diameter ranging from 1 to 50 pm, an apparent density ranging from 100 to 500 g / L, and a surface area ranging from 5 to 20 m2 / g. DESCRIPTION OF THE INVENTION
[0014] The applicant has now observed that it is possible to prepare a composition based on vinyl or expandable aromatic vinyl polymers with better thermal insulation properties, using graphene plates on a nanometric scale as an athermic agent.
[0015] It is observed that the foams obtained from said expandable composites exhibit, with the same density obtained, a better thermal insulation when compared to the polymer foams that do not contain said nanometer-scale plates. The thermal insulation capacity is generally surprisingly better than foams obtained using other athermic agents such as, for example, coal, graphite and aluminum flakes. This is even more surprising, considering that graphene plates on a nanometer scale in compact polymers confer a high thermal conductivity (see, for example, Wang et al, "Thermal Expansion of Graphene Composites", Macromolecules), which would consequently induce one skilled in the art to consider them unsuitable to improve thermal insulation, for example, EPS.
[0016] It is also observed that, in these innovative nanocomposite foams, it is possible to confer flame retardant characteristics with a lower concentration of traditional flame retardant additives, such as halogen derivatives.
[0017] Graphene plates at the nanoscale have recently aroused greater interest in the scientific field, since it is observed that they are a more efficient and economical alternative for carbon nanotubes.
[0018] Carbon nanotubes (CNT) are nanomaterials on a graphite basis that, thanks to the high aspect ratio (L / D) and exceptional electrical, mechanical and other properties, are widely applied in the field of polymeric nanocomposites.
[0019] International patent application WO 2008/091308, for example, describes electrically conductive thermoplastic polymeric foams based on MWNT (nanotube with multiple walls), used in a concentration ranging from 0.05% to 1% by weight .
[0020] International patent application WO 2006/114495 describes polymeric foams (thermoplastic and thermosetting) with cell dimensions <150 pm, based on nanotubes in a concentration less than 60% by weight. These foams are used in the field of packaging and food, thermal insulation, membranes, etc.
[0021] Patent application WO 03/085681 concerns polymeric foams, loaded with carbon nanotubes, with a volumetric resistivity ranging from 10'3 ohm-cm to 108ohm-cm.
[0022] CNTs are generally divided into two main groups: single-walled nanotubes (SWNT) and multiple-walled nanotubes (MWNT). An ideal SWNT can be described as a rolled graphene sheet, forming a tubular structure closed at the ends by two semi-fullerenes. SWNTs typically have diameters of 1-10 nm and sizes in the order of microns, from which there is an L / D aspect ratio> 1,000. Depending on the direction of the graphene sheet winding, it is possible to distinguish chiral (helical) and non-chiral structures.
[0023] Studies on the electrical properties of SWNTs have shown that, with respect to diameter and chirality, they can exhibit both metallic and semiconductor behavior.
[0024] MWNTs, described as concentric graphene tubes connected by weak Van der Walls forces, typically have similar electronic properties to SWNTs.
[0025] Graphene plates at the nanoscale, to which the present invention refers, are different from carbon nanotubes. These nanometer-scale graphene plates consist of one or more graphene sheets. Graphene is a two-dimensional hexagonal lattice of carbon atoms. Graphene sheets can be at least partially overlapped with each other, thus forming graphene plates on a nanoscale.
[0026] These graphene sheets can possibly be functionalized or chemically modified. These functionalizations or modifications can transmit a different interplanar distance, in general greater, than that obtained by superimposing pure graphene. In particular, graphene plates in nanometer scale , to which the present invention refers, have a thickness (orthogonal to the graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, even more preferably the thickness ranges from 0.3 to 5 nm. Said nanometer scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably no more than 1 micrometer, even more preferably no more than 500 nm. Graphene plates on the nanometer scale , which the present invention refers to, have a surface area> 50 m2 / g. The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area ranges from 300 to 2,600 m2 / g.
[0027] It is specified in the literature that a single sheet of graphene has extremely high Young modules (about 1.1 TPa) (Lee et al, Science, 321,385-388, 2008) and semiconductor electronic properties with zero intervals.
[0028] In particular, studies carried out on a single sheet of graphene (RR Nair et al, "Universal Dynamic Conductivity and Quantized Visible Opacity of Suspended Graphene", Science 320, 1308, 2008) have shown that the latter, despite the thickness comparable with the dimensions of an atom (about 0.3 nm), is capable of absorbing 2.3% of the incident light, regardless of the À wavelength. This indicated an exclusive electronic structure in graphene: the behavior of electrons as relativistic fermions (Dirac) without mass, in such a way that interactions with light are independent of the crystalline structure.
[0029] Several studies have been carried out in recent years in order to optimize the synthesis processes of these materials. In a first production procedure, said nanometer-scale graphene plates are obtained using graphite oxide (GO) as a precursor. There are three methods for oxidizing graphite that are most widely used and described in Brodie B.C., Philos. Trans. R. Soc. London, 149, 249 (1859); Staudenmaier L., Ber. Dtsh. Chem. Ges, 31, 1481 (1898); Hummers W. et al, J. Am. Chem. Soc, 80, 1339 (1958), according to which oxidation occurs in an acidic environment (for example, sulfuric acid and nitric acid) in the presence of potassium salts. The graphite oxide produced is subjected to consecutive washing operations in aqueous solutions and filtrations to be finally vacuum dried.
[0030] The graphite oxide obtained according to one of the methods mentioned above is a material consisting of layers of graphite interspersed with: -oxy groups of covalently linked (ie, epoxy groups, hydroxyl groups and less extensive carbonyl and carboxylic groups) ); -water, not covalently bound (Stankovich et al, Carbon, 45, 1558-1565 (2007)).
[0031] Graphite oxide can be characterized by means of X-ray diffraction (XRD). The typical XRD spectrum of GO generally indicates an interplanar distance of about 0.71 nm (WO 2008/045778) consequently greater than the distance of 0.34 nm, typical of pristine graphite.
[0032] The functional groups of GO make this material highly hydrophilic and therefore easily exfoliable in aqueous solution. In particular, in patent application WO 2008/048295, sonic waves are used with a frequency of about 20 kHz, for example, to exfoliate graphite oxide in water, ultimately obtaining stable colloidal suspensions.
[0033] Graphite oxide is in general a material that is electrical insulating and optically very thick, has a very hydrophilic nature and, moreover, becomes incompatible with the most common organic polymers.
[0034] Surprisingly, the Applicants have now observed that graphite and / or graphite materials can also be functionalized with oxygen groups through unconventional physical treatments. According to the present invention, these treatments consist of thermal oxidations in a controlled atmosphere.
[0035] A first procedure provides that the oxidative heat treatment takes place in the presence of oxygen in a variable concentration, preferably with O2 contents that vary from 0.5 to 100% in volume with respect to the total, even more preferably from 1 to 30 % by volume in relation to the total. Nitrogen or other inert gases, such as helium or argon, can be used to dilute oxygen.
[0036] More specifically, oxidation is carried out in an oven consisting of a quartz tube, in which the graphite is placed for periods of less than 5 hours, preferably 1 to 3 hours, and at suitable temperatures, preferably less than 700 ° C, even more preferably from 350 ° C to 600 ° C.
[0037] A certain amount of water vapor can also be added to the oxidizing atmosphere. The water vapor concentration can vary from 0.5 to 50% by volume, preferably from 0.5 to 10% by volume, and even more preferably from 0.5 to 5% by volume.
[0038] The Applicants have surprisingly noted that graphite and / or graphite materials can also be functionalized with oxygen groups by means of ozone or an ozone-containing gas. The ozone, to which the present invention refers, can be generated, for example, according to one of the following procedures: -using a gas containing oxygen, which passes through a particular electrical discharge (crown effect) that is generated between two electrodes separated by a dielectric material and from the current discharge area; -using a UV lamp with a wavelength around 185 nm. An oxygen-containing gas, in the manner previously described, passes around the lamp and ozone is generated by means of ultraviolet radiation emitted from the lamp; -using cold plasma created by a dielectric barrier discharge.
[0039] The oxygen content in the gas can be variable. The higher levels generally provide a higher ozone yield. In particular cases, the gas can be air, which in this case oxygen is typically around 20%, or pure oxygen. Water vapor can be added to the gas stream before or after ozonation.
[0040] The functionalization of the graphite material is obtained by passing the gas flow containing ozone in the graphite material.
[0041] The ozone-containing gas passes through the graphite material for a period greater than 1 minute, preferably for a period greater than 1 hour.
[0042] The gas and / or graphite material can be brought to a temperature ranging from -200 ° C to 600 ° C, preferably from -20 ° C to 200 ° C.
[0043] A stream of water vapor, which can be saturated or overheated, can also be advantageously fed together with the ozone-containing gas.
[0044] The graphite used in the present invention can be natural or synthetic, it can have a particle diameter, measured as well as for carbon black, which varies from 0.5 to 50 pm, preferably from 1 to 15 pm, with an area 5-20 m2 / g. One example is Kropfmuhl's UF 2 product with a particle diameter equal to 4.5 micrometers.
[0045] The graphite material is intended to be that described by IUPAC (see "RECOMMENDED TERMINOLOGY FOR THE DESCRIPTION OF CARBON AS A SOLID", by IUPAC Recommendations, 1995).
[0046] Several methods, both physical and chemical, have been proposed in the literature, which, starting with graphite oxide as a precursor, allow graphene plates at the nanoscale to be obtained for potential use in polymeric nanocomposites, see, for example example, WO 2008/045778; Stankovich et al, Carbon, 45, 1558-1565 (2007); Tung et al, Nature Nanotech. 4, 25-29 (2008); WO 2008/048295; Si and Samulski, Nano Letters, 8, 1679-1682 (2008); WO 2009/018204; WO 2009/049375.
[0047] The rapid heating of GO, for example, can lead to volatilization of the intercalating agents with a consequent expansion and thermal exfoliation of the graphene sheets. In patent application WO 2008/045778, it is specified that the rapid heating (> 2,000 ° C / min) of GO (or also GO-water sludge), in an inert atmosphere (for example, nitrogen, argon or a mixture of the two), leads to an expansion / delamination of graphite oxide.
[0048] Graphene plates in nanoscale are thus obtained, more specifically of the functionalized FGS graphene type (with few epoxy, hydroxyl and carboxyl groups), electrical conductors and easily dispersible in the most common thermoplastic and elastomeric polymers. FGS materials with surface areas of around 1,500 m2 / g and an XRD spectrum, in which both the typical crystalline peak of pristine graphite and that typical of graphite oxide are absent, correspond to gradients in the order of 2,000 ° C / min .
[0049] Functionalized graphene (FGS) is different from expanded graphite. The latter has been proposed several times as a filler for plastic materials (USA 2008/0171824, USA 2008/0096988). In U.S. patent 6,444,714, for example, expanded graphite is used as a flame retardant additive for expandable styrene polymers.
[0050] Expanded graphites are partially exfoliated graphites, typically with a worm-like appearance (USA 2008/0171824 and WO 04/5778), produced by intercalating graphite with a volatile blowing agent, for example, sulfuric acid combined with acid nitric (USA 2008/0171824 and WO 04/5778). The interleaved material is then heated to a temperature sufficient to transform the blowing agent into a gas. The expansion of the gas causes a removal of the graphite layers and, therefore, an increase in the distance in the direction of the c axis (perpendicular to the layers). Although heating leads to a removal of the layers in the direction of the c-axis, the XRD spectrum of expanded graphite, however, generally shows the typical crystalline peak of pristine graphite (2G of about 26.5 ° for Cu-Ka radiation), associated with the distance between layers of about 0.34 nm. The presence of this peak and surface areas typically less than 200 m2 / g are indicative of a partial exfoliation of the graphite. Graphene plates at the nanoscale, which the present invention concerns, have an XRD spectrum without crystalline peaks typical of both pristine graphite and graphite oxide.
[0051] Nano-scale graphene plates can also be produced by chemical reduction of GO, dispersed in aqueous solution, with the use of hydrated hydrazine (H2N H2-H2O) or other reducing agents (StanKovich et al, Carbon, 45, 1558-1565 (2007)). As the reduction continues, the phenomenon of coalescence may arise, associated with the insolubility in aqueous environment of the reduced oxide with consequent partial regrafitization phenomenon.
[0052] Tung et al. (Nature Nanotech. 4, 25-29 (2008)) reduced GO in pure hydrazine, obtaining electrically conductive hydrazine graphene (HG), which can be dried and resuspended in organic solvents, such as dimethyl sulfoxide (DMSO) or N, -dimethylformamide .
[0053] In patent application WO 2008/048295, the reduction of GO is carried out in the presence of a polymeric material (for example, poly (sodium 4-styrene) sulfonate (PSS) used in a high concentration (weight ratio 10 : 1 = PSS: GO) This allows the production of graphene plates at the nanoscale grafted with polymeric groups (for example, PSS), thanks to the coalescence phenomena that are avoided during the reduction.
[0054] In an alternative procedure, graphite oxide can be functionalized by inserting isocyanate groups, as described in patent application WO 2008 / 048295.The isocyanate functionalized GO (iGO) has a reduced hydrophilic nature, with respect to to graphite oxide. IGO, therefore, can form stable dispersions in suitable aprotic organic solvents (for example N, N-dimethylformamide, dimethylsulfoxide, N-methylpyrrolidone), in which it is also possible to dissolve the polymer of interest.
[0055] Stankovich et al (WO 2008/048295; Nature, 442, 282-286 (2006)) proposed a method for the reduction of iGO, dispersed in a solution of N, - dimethylformamide and polystyrene, with dimethylhydrazine. This method allows conductive graphene plates on a nanometric scale to be obtained, avoiding their agglomeration phenomena at the same time during the reduction.
[0056] Si and Samulski (Nano Letters, 8, 1679-1682 (2008)) proposed a method for the preparation of graphene plates on a nanoscale, soluble both in water and in organic solvents (such as methanol, acetone, acetonitrile) . The method consists of three fundamental steps: a pre-reduction of graphite oxide with sodium borohydrate; a sulfonation by means of which the p-phenyl-SOsH groups are introduced into the GO; and finally a post-reduction with hydrazine.
[0057] Alternative synthesis methods for the production of graphene plates at the nanoscale can predict the exfoliation of graphite or its derivatives (US 2009/0026086; US 2008/0206124; US 2008/0258359; US 2009/0022649; Hernandez et al, Nat. Nanotechnol. 3, N. 9, pages 563-568, 2008; Hernandez et al, J. Am. Chem. Soc., 2009, 131 (10), pages 3611-3620; US 2009/0155578; Li et al, Science 319, 1229-1232 (2008); Li et al, Nature Nanotech. 3, 538-542 (2008)) using chemical and / or physical methods.
[0058] US patent application 2008/0206124, for example, describes a method for the production of graphene plates on a nanoscale, with a thickness less than 100 nm, starting from graphite or its derivatives (carbon fibers, highly oriented pyrolytic graphite, graphite nanofibers, pre-interleaved graphite, etc.). This method consists of two fundamental steps: 1. intercalation of graphite, or its derivatives, with the use of halogen molecules (bromine, iodine, etc.) in the vapor phase. The intercalation process is carried out at temperatures higher than the melting point or sublimation point of the said molecules; 2. exfoliation of the intercalated compound by means of two alternative procedures: the first comprises "heating the intercalated compound at temperatures above the boiling point of the halogen molecules, with consequent expansion of the latter and exfoliation of the graphite layers; further separation of the layers it can be obtained with subsequent mechanical treatment, for example, by grinding the thermally exfoliated product, the second provides for the liquid exfoliation of the compound intercalated in specific solvents combined with an ultrasound treatment.
[0059] Hernandez et al, "High-Yield Production of Graphene by Liquid-phase Exfoliation of Graphite", Nat. Nanotechnol. 3, N. 9, pages 563-568, 2008, describe a method for obtaining colloidal suspensions of unique high-quality graphene sheets by sonication and the consequent exfoliation of graphite in organic solvents, such as N-methyl pyrrolidone (NMP), N, N-dimethyl acetamide, y-butyrolactone, 1,3-dimethyl-2-imidazolidinone (DMEU).
[0060] Alternatively, said dispersion of graphene sheets can be obtained by starting from the exfoliation of graphite in aqueous solution, with the use of suitable surfactants, such as sodium dodecylbenzene sulfonate (see for example Hernandez et al. "Liquid Phase Production of Graphene by Exfoliation of Graphite in Surfactant / Water Solutions ", J. Am. Chem. Soc., 2009, 131 (10), pages 3611-3620). As indicated in the articles by Hernandez et al. mentioned earlier, however, the performance of these processes is generally limited, and the authors indicate yields of 1-12%.
[0061] US patent application 2009/0155578 describes graphene plates in nanometer scale with high size / width ratios (greater than 3), obtained by the intercalation of carbon fibers or graphite fibers, and the subsequent exfoliation of the intercalated compound . Interleaving can be performed with the use of various interleaving agents (for example, sulfuric acid, nitric acid, carboxylic acid, halogen molecules in liquid or vapor phase, alkali metals, supercritical carbon dioxide, etc.). In an alternative procedure, intercalation is performed electrochemically. The intercalated product is obtained through an electrochemical reaction, in which an acid is used (formic, nitric or carboxylic acid) both as an electrolyte and an intercalating agent, and the carbon fibers or graphite fibers as an anode. The interleaved products, with one of the previous procedures, are then thermally exfoliated (at temperatures ranging from 300 to 1,100 ° C) and finally mechanically treated (for example, by grinding) to obtain graphene plates on a nanoscale with the desired dimensions.
[0062] US patent application 2009/0022649 describes ultra-thin nanometer-scale graphene plates, with a thickness of no more than 2 nm, obtained by re-intercalation and subsequent exfoliation of nanometer-scale plates (with thicknesses <10 nm) , obtained in turn by intercalating graphite or its derivatives, and subsequent exfoliation of the intercalated compound. Some examples of interleaving / exfoliation processes have been previously described (for example, pertaining to US patent 2009/0155578). Again, US patent application 2009/0022649 describes an alternative procedure for obtaining graphene plates at the nanoscale, with thicknesses of no more than 2 nm. This alternative procedure provides for the use of ultrasound, under appropriate conditions of time and energy level, to exfoliate graphite in solution, or possibly nanometer-scale plates with intermediate thicknesses (<10 nm) without going through the intercalation step.
[0063] Li et al, "Chemically Derived, Ultrasmooth Graphene Nanoribbon Semiconductors", Science 319, 1229-1232 (2008); Li et al, "Highly Conducting Graphene Sheets and Langmuir-Blodgett Films", Nature Nanotech. 3, 538-542 (2008) describe chemically modified graphene (CMG) obtained from the expandable / expanded graphite. According to a first procedure, the expanded graphite is sonicated in a solution of dichloroethane and poly (m-phenylenovinylene-co-2,5-dioctoxy-p-phenylenovinylene) (PmPV), from which a stable suspension of graphene " in nano tapes "is obtained (Li et al," Chemically Derived, Ultrasmooth Graphene Nanoribbon Semiconductors ", Science 319, 1229-1232 (2008)).
[0064] Another type of approach (Li et al, "Highly Conducting Graphene Sheets and Langmuir-Blodgett Films", Nature Nanotech. 3, 538-542 (2008)) is based on the re-intercalation of expanded graphite with oil and in the subsequent expansion of the latter by inserting tetrabutylammonium hydroxide between the graphite layers. The graphite thus re-intercalated is sonicated in N, N-dimethylformamide (DMF) in the presence of a polyethylene glycol phospholipid (DSPE-mPEG). The resulting final suspension consists of about 90% of single sheets of graphene with adsorbed polymer chains.
[0065] Osvath et al, (Carbon 45, 3022-3026, (2007)) describe a method for obtaining single layers of graphene by heat treatment in air, at an elevated temperature (450-550 ° C) of graphite commercial exfoliated (1 mg in 20 ml of benzene).
[0066] Graphene plates at the nanoscale were also sintered from precursors not associated with graphite (U.S. 2006/0216222; Stride et al, Nature Nanotech. 4, 30-33 (2009); WO 2009/029984). A first procedure (US 2006/0216222) is based on total graphitization (1,000-3,000 ° C) or partial graphitization (300-1,000 ° C) of a polymeric precursor (for example, polyacrylonitrile fibers and phenol-formaldehyde resins) or oil, or fossil carbon tar. The resulting product, with a carbon-like or graphite-like structure, is subjected to subsequent exfoliation by treatment in solution, in the presence of oxidizing or intercalating agents. The exfoliated particles are finally subjected to a mechanical treatment (for example, grinding) to further separate the graphene layers and obtain nanometric dimensions d and graphene particles (nanometer scale plates).
[0067] In an alternative procedure (Stride et al, Nature Nanotech. 4, 30-33 (2009); WO 2009/029984), quantities of graphene in the order of grams were produced from a reaction between metallic sodium (Na) and ethanol (EtOH). The synthesis method consists of reacting, at 220 ° C for 72 hours, 2 g of Na in 5 ml of EtOH (molar ratio 1: 1). The reaction generates a graphene precursor (a solvotherm such as, for example, a metal alkoxide) which is subsequently pyrolyzed to obtain graphene, which is then washed in deionized water, filtered and dried.
[0068] The graphene plates in nanometric scale described above can be incorporated into the polymeric composition, object of the present invention, as such or also in the form of basic concentrate.
[0069] A first method for the preparation of the basic concentrate is the solution process, in which the polymer is dissolved in a suitable solvent, for example, N, -dimethylformamide, N-methylpyrrolidone, tetrahydrofuran, etc. Graphene plates at the nanoscale are then added to the solution and dispersed, for example, using a sonic flow. In an alternative procedure, graphene plates at the nanoscale can be pre-dispersed in a portion of solvent, and said dispersion is subsequently mixed with the polymeric solution. In many cases, the solvent may have a low boiling point in order to be removed from the product by evaporation. When a high boiling solvent is used, the composite can be recovered by precipitation followed by filtration and / or centrifugation. Solution methods are particularly used when graphene plates at the nanoscale are synthesized directly as suitable suspensions in suitable solvents (Tung et al, Nature Nanotech. 4, 25-29 (2008); WO 2008/048295; Si and Samulski, Nano Letters, 8, 1679-1682 (2008); US 2008/0206124; Hernandez et al, Nat. Nanotechnol. 3, N. 9, pages 563-568, 2008); U.S. 2009/0022649; Li et al, Science 319, 1229-1232 (2008); Li et al, Nature Nanotech. 3, 538-542 (2008)).
[0070] A second method for the preparation of the basic concentrate is to mix in the molten state, in which the polymer is exposed to temperatures higher than the melting point or softening point, and then it is mixed with the graphene plates in scale nanometric. The nanometer-scale plates used for this purpose are preferably in powder form, such as those synthesized according to the procedures described in patent applications WO 2008/045778; U.S. 2008/0206124; U.S. 2009/0155578; U.S. 2009/0022649; U.S. 2006/0216222; WO 2009/029984. The mixing can be carried out with devices commonly used for the processing of plastic materials (twin screw extruder, Brabender mixer, etc.).
[0071] In an additional alternative procedure, the polymer in powder form and graphene plates in nanometer scale, also in powder form, can be pre-mixed by dry mixing or turbomixing and subsequently processed in mixers in the molten state. The premix ensures a better degree of dispersion of the nanocharge within the polymer matrix.
[0072] Another alternative method is represented by in-situ polymerization, in which graphene plates in nanometer scale are dispersed in a monomer that is subsequently polymerized. The monomer can also be dissolved in a suitable solvent, in such a way that low viscosities can guarantee a good degree of dispersion of the nanocharges. Polymerization can also be carried out under stirring conditions to ensure that the nanometer-scale plates remain dispersed during the process.
[0073] The nanometer-scale plates can possibly be functionalized before polymerization. In particular, they can be inserted in the vinyl groups. In this way, the nanometer-scale plates can be co-polymerized, thus preventing re-aggregation even if the polymer itself is exposed beyond the melting point.
[0074] The Claimants also found a method to produce said graphene plates on a nanometer scale during the polymerization itself. This method allows for an optimal dispersion of the nanometer-scale plates to be obtained.
[0075] In general, nanometer-scale plates do in fact naturally tend to become agglomerated, and consequently, for example, when graphite oxide is reduced in an aqueous environment, nanometer-scale plates tend to be separated from the solvent and become clustered. In order to avoid this phenomenon, they can be partially oxidized or functionalized. These modifications, however, induce a variation in the atomic structure that, in general, causes a reduction in the absorption capacity of infrared light and, consequently, a reduction in thermal and electrical conductivity. These variations are therefore generally undesirable.
[0076] The Applicants, however, have found a method to prevent agglomeration, while maintaining a low concentration of functionalizations in graphene.
[0077] This method comprises dispersing a nano-scale precursor of graphene plates, such as graphite oxide, in an aqueous suspension. The monomer is then added and the polymerization is subsequently carried out in suspension. At the same time, or before starting polymerization, but with the monomer already suspended in the aqueous solution, reducing agents are added in order to reduce the precursor of graphene plates on a nanometric scale.
[0078] In this case, it is preferable that most reducing agents are hydrophilic (for example, hydrazine), even if a quota of hydrophobic reducing agent (for example, methylhydrazine) can still be used.
[0079] Polymerization can be completed after the normal methods in use.
[0080] The present invention is fully described in the appended claims.
[0081] An object of the present invention, therefore, concerns compositions of expandable thermoplastic polymers, for example, in granules or beads, comprising: a) a thermoplastic polymer matrix produced by the polymerization of a base comprising one or more polymerizable monomers ; b) 1-10% by weight, calculated with respect to the polymer (a), of a blowing agent included in the polymeric matrix; c) 0.004-15% by weight, preferably 0.01-5%, even more preferably 0.05-2%, calculated with respect to the polymer (a), of an athermic charge comprising graphene plates on a nanoscale.
[0082] In particular, nano-scale graphene plates, which the present invention concerns, have a thickness (orthogonal to the graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, even more preferably, the thickness varies from 0.3 to 5 nm. Said nanometric scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably not more than 1 micrometer, even more preferably not more than 500 nm. The nano-scale graphene plates, which the present invention concerns, have a surface area> 50 m2 / g The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area ranges from 300 to 2,600 m2 / g.
[0083] An object of the present invention also concerns foams derived from the use of the expandable compositions described above, in which the blowing agent is therefore no longer contained in the composition or is contained in a lower percentage.
[0084] According to the present invention, polymerizable monomers are selected from vinyl monomers, such as ethylene or propylene, and aromatic vinyl monomers. Aromatic vinyl monomers are preferred, however.
[0085] In accordance with an alternative embodiment of the present invention, however, the athermic charge may comprise, in addition to said graphene plates on a nanometric scale, up to 6% by weight, calculated with respect to the polymer, for example, from 0.01 to 6% by weight, preferably from 0.05 to 4.5% by weight of additional athermic agents, such as graphite and / or carbon coke and / or carbon black, as synergists. Graphite can be natural or synthetic, and it can possibly be expandable or of the expanded type. Graphite, carbon coke or carbon black can have a particle diameter, measured by laser diffraction, which ranges from 0.5 to 50 pm.
[0086] The polymeric compositions, object of the present invention, can be prepared, with respect to the polymeric matrix and from the monomer, in the best way illustrated below, by means of: 1. a suspended process, which comprises the dissolution / dispersion of graphene plates on a nanoscale, and possible additives in the monomer, followed by polymerization in aqueous suspension and addition of the blowing agent; or 2. a suspension process comprising the suspension, for example, aqueous, of a preformed polymeric composition comprising said polymeric matrix and said graphene plates on a nanoscale, followed by the addition and incorporation of the blowing agent; or 3. a continuous mass process that includes the following steps, in series: -mixing a thermoplastic polymer in the form of granules or powder, or already in the molten state, with said graphene plates on a nanoscale (as such, or in the form of basic concentrate) and other possible additives; -possibly, if it is not already in the molten state, expose the thermoplastic polymer mixture to a temperature higher than the melting point of the polymer; -incorporate the blowing agent in the melted thermoplastic polymer, together with other possible additives, such as the flame retardant system described below; -mix the polymeric composition thus obtained by means of static or dynamic mixing elements; feeding the polymeric composition thus obtained to a die-cut mold (for example, according to the procedures described in U.S. Patent 7,320,585); 4. a direct extrusion process, that is, feeding a mixture of granules of thermoplastic polymer and graphene plates on a nanoscale (as such, or in the form of basic concentrate), directly into an extruder in which the blowing agent is also fed.
[0087] Alternatively, in the case of an aromatic vinyl polymer, it may already be in the molten state from a polymerization plant, subsequently adding the athermic charge. The blowing agent is then added and the related product is then cooled and passed through a mold for granulation, or also for the direct preparation (direct extrusion) of sheets, tubes, expanded sheets, etc.
[0088] The term "vinyl aromatic monomer", as used in the present description and claims, essentially means a product that corresponds to the following general formula:
where R is a hydrogen or a methyl group, n is zero or an integer ranging from 1 to 5 and Y is a halogen, such as chlorine or bromine, or an alkyl or alkoxy radical with 1 to 4 carbon atoms.
[0089] Examples of aromatic vinyl monomers with the general formula identified above are: styrene, α-methylstyrene, methyl styrene, ethyl styrene, butyl styrene, dimethyl styrene, mono, di, tri, tetra and penta-chlor styrene, bromo-styrene, methoxy styrene, aceto , etc. The preferred aromatic vinyl monomers are styrene and α-methylstyrene.
[0090] Aromatic vinyl monomers that correspond to the general formula (I) can be used alone or in a mixture up to 50% by weight with other polymerizable comonomers. Examples of said monomers are (meth) acrylic acid, C1-C4 alkyl esters of (meth) acrylic acid such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, isopropyl acrylate, butyl acrylate, amides and (meth) acrylic acid nitriles such as acrylamide, methacrylamide, acrylonitrile, methacrylonitrile, butadiene, ethylene, divinyl benzene, maleic anhydride, etc. The preferred polymerizable co-monomers are acrylonitrile, methyl methacrylate.
[0091] Any blowing agent capable of being included in the thermoplastic polymer matrix can be used in combination with the expandable polymers, object of the present invention. Typical examples are aliphatic hydrocarbons, freon, carbon dioxide, alcohols such as ethyl alcohol, water, etc.
[0092] Conventional additives, generally used with traditional materials, such as pigments, stabilizing agents, nucleating agents, flame retardant systems, anti-static agents, release agents, etc., can be added to thermoplastic polymer compositions expandable, object of the present invention. In particular, a flame retardant system can be added to the present composition, comprising from 0.1 to 8%, with respect to the polymer (a), of a self-extinguishing brominated additive containing at least 30% by weight of bromine, and from 0.05 to 2% by weight, again with respect to the polymer (a), of a synergistic product containing at least a weak CC or OO bond, as described below.
[0093] At the end of the addition of the athermic filler, the blowing agent and possible additives, an expandable thermoplastic polymer is obtained in granules or beads, which can be transformed to produce expandable articles with a density ranging from 5 to 50 g / L, preferably from 10 to 25 g / L. For direct extrusion, on the other hand, densities of 20 to 40 g / L are used.
[0094] These expandable articles have an excellent thermal insulation capacity, expressed by a thermal conductivity ranging from 25 to 50 mW / mK, preferably from 29 to 45 mW / mK, which is in general even more than 10% lower with compared to that of equivalent expandable articles obtained from unfilled materials currently on the market, for example EXTIR A-5000 from Polimeri Europa SpA.
[0095] Thanks to these characteristics of the expandable thermoplastic polymers, objective of the present invention, it is possible to prepare thermal insulation articles with significant material savings or, for example, to prepare sheets with a thickness less than those prepared with traditional unloaded polymers, with consequent savings in space and product.
[0096] Extruded and expanded sheets of thermoplastic polymers comprising a cellular matrix, for example, of a vinyl or aromatic vinyl polymer, such as polyethylene or polystyrene, with a density ranging from 10 to 200 are included in the definition of expandable articles. g / L, an average cell size ranging from 0.01 to 1.00 mm and containing from 0.004 to 15% by weight, preferably from 0.01 to 5%, more preferably from 0.05 to 2%, calculated with in relation to the thermoplastic polymer, of said athermic charge comprising said graphene plates on a nanoscale with a thickness (orthogonal to the graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, the thickness even more preferably ranges from 0.3 to 5 nm. Said nanometric scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably not more than 1 micrometer, even more preferably not more than 500 nm. Said nano-scale graphene plates have a surface area> 50 m2 / g. The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area varies from 300 to 2,600 m2 / g.
[0097] The athermic charge, added to the thermoplastic polymer of the extruded expanded sheet, in addition to comprising the said plates on a nanoscale, can comprise up to 6% by weight, calculated with respect to the polymer, for example, from 0.01 to 6% by weight, preferably from 0.05 to 4.5%, respectively, of said additional athermic additives, such as graphite and / or carbon coke and / or carbon black, as synergists.
[0098] Said extruded and expanded sheets may also contain conventional additives normally used with traditional materials, such as pigments, stabilizers, nucleating agents, flame retardant systems, anti-static agents, release agents, etc.
[0099] An additional objective of the present invention concerns processes for the preparation of said compositions based on expandable thermoplastic polymers, for example, in beads or granules, with a better thermal insulation capacity and a lower density, after expansion, than 50 g / L.
In particular, an additional object of the present invention concerns a process for preparing aromatic expandable polymers of vinyl, in beads or granules, which comprises polymerizing in aqueous suspension one or more aromatic vinyl monomers, possibly together with at least one polymerizable co-monomer in quantities of up to 50% by weight, in the presence of said athermic charge comprising: -these graphene plates in nanometer scale with a thickness (orthogonal to the graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, the thickness even more preferably ranges from 0.3 to 5 nm. Said nanometric scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably not more than 1 micrometer, even more preferably not more than 500 nm. Said nano-scale graphene plates have a surface area> 50 m2 / g. The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area ranges from 300 to 2,600 m2 / g; -a peroxide radical initiator system, and -a blowing agent added before, during or at the end of polymerization.
[00101] The athermic charge, in addition to comprising the said nanometer scale plates, can also comprise up to 6% by weight, calculated with respect to the polymer, for example, from 0.01 to 6% by weight, preferably from 0.05 to 4.5% by weight, respectively, of said additional athermic additives, such as graphite and / or carbon coke and / or carbon black, as synergists.
[00102] Polymerization is carried out in an aqueous suspension with inorganic salts of phosphoric acid, for example, tri-calcium phosphate or magnesium phosphate. These salts can be added to the polymerization mixture either already finely divided or synthesized in situ by reaction, for example, between sodium pyrophosphate and magnesium sulfate.
[00103] Said inorganic salts are aided in their action of suspension by active agents on an anionic surface, for example, sodium dodecyl benzene sulfonate or its precursors, such as sodium metabisulfite, in the manner described in U.S. patent 3,631,014.
[00104] Polymerization can also be carried out in the presence of organic suspending agents such as polyvinylpyrrolidone, polyvinyl alcohol, etc.
[00105] The initial system generally comprises two peroxides, the first with a period reduced by half an hour at 85-95 ° C and the other with a period reduced by half an hour at 110-120 ° C. Examples of such initiators are tert-butylperoxy-2-ethylhexanoate and tert-butylperbenzoate.
[00106] The aromatic vinyl polymer or copolymer that is obtained has an average molecular weight Mw ranging from 50,000 to 300,000, preferably from 70,000 to 200,000. In general, more details on the procedures for the preparation of aromatic expandable polymers of vinyl in aqueous solution or, more generally, polymerization in suspension, can be found in Journal of Macromolecular Science, revised in Macromolecular Chemistry and Physics C31 (263) 215- 299 (1991).
[00107] To improve the stability of the suspension, it is possible to increase the viscosity of the vinyl aromatic monomer reagent solution, to be suspended in water, by dissolving the vinyl aromatic polymer in it, to a concentration of 1 to 30% by weight , preferably from 5 to 20%, calculated with respect to the monomers. The solution can be obtained by dissolving a preformed polymer in the reagent mixture (for example, fresh polymer or waste products from previous polymerizations and / or expansions), or by a prepolymerization of the monomer, or mixture of monomers, until that the previously mentioned concentrations are obtained, and subsequently continuing the polymerization in aqueous suspension in the presence of the remaining additives.
[00108] During suspension polymerization, polymerization additives are used, according to methods well known to those skilled in the art, which are typically those to produce aromatic expandable vinyl polymers, such as suspension stabilizing agents, transfer agents chain, expansion aids, nucleating agents, plasticizers, etc. In particular, during polymerization, it is preferable to add a flame retardant system comprising flame retardants, in an amount ranging from 0.1 to 8%, and synergistic products in quantities ranging from 0.05 to 2%, with respect to the resulting weight of the polymer. The flame retardants particularly suitable for the aromatic expandable vinyl polymers, object of the present invention, are aliphatic, cycloaliphatic compounds, brominated aromatic compounds, such as hexabromocyclododecane, pentabromo-monochlorocyclohexane and pentabromophenyl allyl ether. The synergistic products that can be used are dicumyl peroxide, cumene hydroperoxide, 3,4-dimethyl-3, -diphenylhexane, 3, -dimethyl-3, -diphenyl butane, 3,6,9-triethyl-3, 6,9-trimethyl-1, 4,7-triperoxy-nonane.
[00109] The blowing agents are preferably added during the polymerization phase, or subsequently by means of resuspension technology. In particular, it comprises the phases of: -polymerizing in aqueous suspension one or more aromatic vinyl monomers, at least in the presence of the athermic charge; - separate the beads or granules thus obtained; -re-suspend the beads or granules in water and heat until their spherical shape is obtained; -adding the expansion agents in the suspension and keeping the beads in contact with them until impregnation; and -re-separate the accounts.
[00110] The blowing agents are selected from aliphatic or cycloaliphatic hydrocarbons containing from 3 to 6 carbon atoms, such as n-pentane, isopentane, cyclopentane or mixtures thereof, halogenated derivatives of aliphatic hydrocarbons containing from 1 to 3 atoms of carbon such as, for example, dichlorodifluoromethane, 1,2,2-trifluor-ethane, 1,1,2-trifluorethane, carbon dioxide, water and ethyl alcohol.
[00111] At the end of the polymerization, whether in suspension or resuspension, the substantially spherical beads / granules of expandable polymer are obtained, with an average diameter ranging from 0.2 to 2 mm, preferably from 1 to 1.5 mm, in which said athermic charge and said other possible additives are dispersed in a homogeneous manner.
The granules are then discarded from the polymerization reactor and washed, either continuously or in batches, with non-ionic surfactants or, alternatively, with acids, in the manner described in U.S. Patent 5,041,465. The polymer granules can subsequently be heat treated with hot air ranging from 30 to 60 ° C.
[00113] An additional objective of the present invention concerns a process for preparing, in continuous mass, compositions based on expandable thermoplastic polymers, in granules or beads, comprising the following series steps: i. Mixing a thermoplastic polymer in the form of granules / pellets or in powder, or already in the molten state, with an average molecular weight Mw ranging from 50,000 to 300,000, preferably from 70,000 to 200,000, with said athermic charge comprising said graphene plates in nanometer scale with a thickness (orthogonal to the graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, even more preferably the thickness ranges from 0.3 to 5 nm. Said nanometric scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably not more than 1 micrometer, even more preferably not more than 500 nm. Said nano-scale graphene plates have a surface area> 50 m2 / g. The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area varies from 300 to 2,600 m2 / g. The athermic charge, in addition to said graphene plates on a nanoscale, can comprise up to 6% by weight, calculated with respect to the polymer, for example, from 0.01 to 6% by weight, preferably from 0.05 to 4.5 %, respectively, of said additional athermic additives, such as graphite and / or carbon coke and / or carbon black, as synergists. Other possible additives, already described, including pigments, stabilizers, nucleating agents, said flame retardant system, anti-static agents, release agents, etc., can also be added in this step either totally or partially; ii. optionally, if it is no longer in the molten state, expose the polymer mixture to a temperature greater than the melting point of the thermoplastic polymer; iii.incorporating said blowing agent and possibly the remaining amount, part or all, of said other additives in the molten polymer; iv.mix the polymeric composition thus obtained by means of static or dynamic mixing elements; and v. granulating the composition thus obtained in a device comprising a mold, a cutting chamber and a cutting system.
[00114] At the end of the granulation, the granules / beads of expandable thermoplastic polymer can be obtained with a substantially spherical shape, with an average diameter ranging from 0.2 to 2.3 mm, preferably from 1 to 1.5 mm, within which said athermic charge, said possible additional synergistic athermic additives and said other additional additives, are dispersed homogeneously, with the naked eye.
[00115] According to the present invention, step (i) can be carried out by feeding the already formed polymeric granule, possibly mixed with residual processing products in an extruder. The unique components of the composition, object of the present invention, are mixed here, the polymeric part is subsequently melted and a blowing agent and other possible additives are then added.
[00116] Alternatively, in the case of aromatic vinyl polymers, the polymer can be used already in the molten state, originating directly from the solution polymerization installation, in particular from the relative devolatization unit, according to a process known to those skilled in the art. in technique as "continuous mass process". The molten polymer is fed into suitable devices, for example, a dynamic mixer or a static mixer, where it is mixed with the additives, for example, with the athermic filler and the blowing agent, and is subsequently extruded to supply the product in expandable beads / beads, purpose of the present invention. The granules (or beads) of the thermoplastic polymer composition can be re-fired, for example, at a temperature less than or equal to the glass transition temperature (Tg) or slightly higher, for example, the Tg increased by up to 8 ° C, possibly under pressure. A detailed method for preparing aromatic vinyl polymers in continuous mass is described in international patent application WO 03/53651.
[00117] In general, it is possible to incorporate at least said athermic charge in a basic concentrate, preferably based on a thermoplastic polymer compatible with that of the polymer matrix (a), with an average molecular weight Mw ranging from 50,000 to 300,000 , preferably from 70,000 to 200,000, to facilitate its mixing with the polymeric stream and to simplify the administration of the installation. In the basic concentrate, the athermic charge content, comprising said graphene plates in nanometer scale and the possible graphite and / or carbon coke and / or carbon black, varies from 15 to 60% by weight.
[00118] In particular, in the case of aqueous suspension polymerization, the basic pellet concentrate can be dissolved in the aromatic vinyl monomer. In the case of mass polymerization, on the other hand, the basic concentrate in the form of pellets can be mixed with the thermoplastic polymer granule or with the aromatic vinyl polymer in the molten state, which originates from solution polymerization.
[00119] Even more specifically, in the case of continuous mass polymerization of aromatic vinyl polymers, the basic pellet concentrate can be dissolved in the aromatic vinyl monomer / solvent mixture before being fed into the solution polymerization reactor.
[00120] At the end of the polymerization of aromatic vinyl polymers, whether in suspension, or mass, or continuous mass, the expandable beads or granules obtained can be subjected to the pre-treatment that is generally applied to conventional expandable compositions and which consists essentially in: 1. covering the beads or granules with a liquid antistatic agent selected from amines, ethoxylated tertiary alkylamines, ethylene oxide / propylene oxide copolymers, etc. The said agent allows the coating to adhere and facilitates the selection of accounts prepared in suspension; 2. applying the coating to said beads or granules, said coating consisting essentially of a mixture of glycerin mono, di and tri-esters (or other alcohols) with fatty acids, and metal stearates such as zinc stearate and / or magnesium, possibly also mixed with carbon black.
[00121] An additional object of the present invention concerns a process for the production of extruded and expanded sheets of thermoplastic polymers comprising: a1. mixing a thermoplastic polymer in the form of pellets or granules or beads, selected from a vinyl or aromatic vinyl polymer, such as polyethylene or polystyrene, and at least said athermic charge comprising said graphene plates in nanometer scale with a thickness (orthogonal graphene sheet) of no more than 150 nm. The thickness is preferably less than 50 nm, even more preferably the thickness ranges from 0.3 to 5 nm. Said nanometric scale plates also have an average dimension (length, width or diameter) of no more than 10 micrometers, preferably not more than 1 micrometer, even more preferably not more than 500 nm. Said nano-scale graphene plates have a surface area> 50 m2 / g. The surface area preferably ranges from 100 to 2,600 m2 / g, even more preferably the surface area varies from 300 to 2,600 m2 / g. b1. heat the mixture (a1) at a temperature ranging from 180 to 250 ° C, in order to obtain a polymeric fusion that is subjected to homogenization; c1. d. adding at least one blowing agent in the polymeric melt, and possibly said other additives, for example, said flame retardant system; d1. homogenize the polymeric fusion that includes at least the blowing agent; e1. homogeneously cooling the molten polymer (d1) to a temperature of not more than 200 ° C and not less than the Tg of the resulting polymeric composition; f1. extrude the polymer melt through a mold in order to obtain an expanded polymer sheet.
[00122] According to a modality of the process for the production of extruded and expanded sheets, which is an additional objective of the present invention, the athermic charge added to the thermoplastic polymer, in addition to the said graphene plates in nanometer scale, can also comprise up to 6% by weight, calculated with respect to the polymer, for example, from 0.01 to 6% by weight, preferably from 0.05 to 4.5%, respectively, of said additional athermic additives, such as graphite and / or coke carbon and / or carbon black as synergists.
[00123] According to an alternative method of the process for the production of extruded and expanded sheets, the objective of the present invention, the thermoplastic polymer in the form of pellets is either totally or partially replaced by vinyl compositions or aromatic vinyl thermoplastic polymers in beads / granules, described or prepared according to one of the processes described above.
[00124] Also in the process for the production of extruded and expanded sheets based on vinyl or thermoplastic vinyl aromatic polymers, said athermic charge can be used by means of said basic concentrate.
[00125] More details on the processes for preparing extruded and expanded sheets of thermoplastic polymers can be found in the international patent application WO 06/128656.
[00126] Some illustrative and non-limiting examples are provided below for a better understanding of the present invention and for its modality.
[00127] EXAMPLE 1
[00128] PART A - Preparation of graphene plates in nanometer scale by liquid exfoliation of graphite
[00129] 20 parts of graphite "UF1 98.5", produced by Kropfmuhl, are dispersed in 880 parts of N-methyl pyrrolidone (Sigma Aldrich) with a magnetic anchor stirrer. An ultrasonic field is applied, in agitation, by means of a sonotrode calibrated at 20 kHz and with a specific powder, calculated based on the absorbed powder of the generator, equal to about 100 W / liter. After about 2 hours, the product thus obtained is subjected to centrifugation. The supernatant product is collected and then again stirred, this time by means of a mechanical stirrer (Silverson Machines). 100 parts of polystyrene of EDISTIR type N1782 (polystyrene with an Mw equal to 130,000 g / mol, Mw / Mn = 2.3, MFI (200 ° C, 5kg) equal to 25 g / 10 ', produced by Polimeri Europa) are sprayed and then poured slowly, keeping the solution under continuous agitation. The temperature is maintained at about 120 ° C for the entire processing cycle.
[00130] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00131] 900 parts of EDISTIR polystyrene type N2982 (polystyrene with an Mw equal to 180,000 g / mol, Mw / Mn = 2.3, MFI (200 ° C, 5kg) equal to 7.5 g / 10 ', produced Polimeri Europa) are cast in a single screw extruder.
[00132] 66 parts of N1782 polystyrene produced by Polimer Europa; 2 parts of ethylene-bis-wstereamide; 10 parts of Saytex HP900 (hexabromo-cyclododecane sold by Alberarle); 2 parts of Perkdadox 30 (2,3-dimethyl-2,3-diphenylbutane, sold by Akzo Nobel) are mixed in a twin screw extruder. 20 parts of the first solution produced in part A are fed into the twin screw extruder through a side inlet.
[00133] 50 parts of a mixture of n-pentane (75%) and isopentane (25%) and the current that leaves the twin screw extruder are added to the polymeric fusion that leaves the single screw extruder. The mixture thus obtained is homogenized by means of a series of static mixing elements. A gear pump increases the pressure of the mixture thus obtained to 200 barg. The mixture is then cooled to about 170 ° C by means of a mixing exchanger. (SMR).
[00134] The composition is then distributed in the mold, where it is extruded through numerous holes with a diameter of 0.5 mm, immediately cooled with a jet of water and cut with a series of rotating knives (according to the method described in US patent 7,320,585).
[00135] The pressure in the granulation chamber is 5 bar and the shear rate is selected in order to obtain granules with an average diameter of 1.2 mm. Water is used as a liquid cooling spray and nitrogen is used as the carrier gas.
[00136] The resulting granules are dried with a centrifugal dryer and then covered with a coating. The coating is prepared by adding to the granules 3 parts of glyceryl monostearate, 1 part of zinc stearate and 0.2 part of glycerin per 1,000 parts of dry granules. The coating additives are mixed with the granulate using a continuous screw mixer.
[00137] The product is pre-expanded to 17 g / L with steam at a temperature of 100 ° C, left to age for 1 day and is used for molding the blocks (with dimensions of 1,040 x 1,030 x 550 mm).
[00138] The blocks were then cut to prepare flat sheets, in which the thermal conductivity is measured. The thermal conductivity proved to be 33.8 mW / mK.
[00139] Some of the leaves, obtained from the same blocks, are placed in an oven at 70 ° C for 2 days. The test samples are then placed (9cm x 19cm x 2cm) to test the fire behavior, according to DIN 4102. The test samples were approved.
[00140] EXAMPLE 2
[00141] PART A - Preparation of the concentrate
[00142] The product obtained according to example 1, part A, is placed under vacuum and temperature and exposed to about 170 ° C, for 3 hours, in continuous agitation and with a slight nitrogen bubble. 500 parts of solvent are thus evaporated and recondensed in a separate container for possible reuse.
[00143] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00144] 89.8 parts of ethylbenzene, 730.0 parts of styrene, 56.2 parts of α-methylstyrene and 0.2 parts of divinylbenzene are fed into a stirred reactor.
[00145] 123.8 parts of the preparation obtained in part A are fed into a reactor and dissolved (total: 1,000 parts). The reaction is then carried out at 125 ° C with an average residence time of 2 hours. The fluid composition at the outlet is then fed into a second reactor, where the reaction is completed at 135 ° C with an average residence period of 2 hours.
[00146] The resulting composition, which is hereinafter referred to as "composition (a)", with a conversion of 72%, is heated to 240 ° C and subsequently fed to the devolatilizer to remove the solvents and residual monomer. It is characterized by a molecular weight Mw of 200,000 g / mol and an Mw / Mn ratio of 2.8, where Mw is the weight of the average molecular weight and Mn is the number of the average molecular weight.
[00147] The composition (a) is fed from the devolatilizer in a heat exchanger, to decrease its temperature to 170 ° C.
[00148] 130.9 parts of N2982 polystyrene produced by Polimeri Europa, 14.0 parts of Saytex HP900 (hexabromo-cyclododecane sold by Alberarle) and 5.1 parts of Perkadox 30® (2,3-dimethyl-2,3- diphenylbutane, sold by Akzo Nobel) for a total of 150 parts, are fed into a second twin screw extruder. A gear pump increases the feed pressure of this molten additive to 260 barg. 50 parts of a mixture of n-pentane (75%) and iso-pentane (25%) are then pressurized and injected into the additive feed. The mixing is completed with the use of static mixers, at a temperature of about 190 ° C. The composition thus obtained is described below as "composition (B)".
[00149] Composition (B) is added to 850 parts of composition (A) originated from the heat exchanger. The ingredients are then mixed by means of static mixing elements for a calculated average residence time of 7 minutes. The composition is then distributed in the mold, where it is extruded, granulated, expanded and molded in the manner indicated in example 1, part B. The test samples are obtained from the block, expanded and molded at 17 g / L for the measurement of thermal conductivity and fire behavior test, completely following the procedure described in example 1, part B.
[00150] The test samples passed the DIN 4102 fire behavior test. The thermal conductivity proved to be 30.8 mW / mK.
[00151] The test samples are also collected for an evaluation of the compression force according to EN ISO 844. The stress at 10% of compression proved to be 130 kPa.
[00152] A thermogravimetric analysis (TGA) is performed on a sample obtained from the same blocks, in order to define the percentage of carbonaceous material present. The following procedure was adopted: a temperature increase of 20 degrees per minute is used, up to 600 ° C, in nitrogen. Weight loss is then recorded. The air supply is started and the temperature is exposed to 800 ° C. The difference in weight loss between the value recorded at 600 ° C in nitrogen and 800 ° C in air is considered to be equal to the carbonaceous material present. The analysis is repeated three times. The content of carbonaceous material refers to the average of the values obtained from simple analyzes.
[00153] The content of carbonaceous material in the test samples proved to be equal to 0.4% by weight.
[00154] EXAMPLE 3
[00155] PART A - Preparation of graphene plate concentrate on a nanoscale
[00156] Example 1, part A, is repeated, but using N, N-dimethylformamide (DMF) instead of N-methyl pyrrolidone as the solvent. 100 parts of the product thus obtained are poured dropwise into a container containing 2,000 parts of methanol. The operation is carried out keeping the container in vigorous agitation. The coagulated composite powder is recovered by filtration, washed with methanol and dried at 120 ° C for 12 hours.
[00157] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00158] A mixture is loaded into a closed and stirred container, consisting of 150 parts by weight of water, 0.2 parts of sodium pyrophosphate, 99 parts of styrene, 0.25 parts of tert-butylperoxy-2-ethyl -hexanoate, 0.25 parts of tert-butyl perbenzoate and 1 part of the preparation synthesized in part A. The mixture is heated with stirring at 90 ° C.
[00159] After about 2 hours at 90 ° C, 4 parts of a 10% polyvinylpyrrolidone solution are added. The mixture is heated to 100 ° C, still stirring, for another 2 hours, 7 parts of a 70/30 mixture of n-pentane and i-pentane are added, the complete mixture is heated for another 4 hours at 125 ° C , and then it is cooled and the batch is discarded.
[00160] The expandable polymer granules thus produced are subsequently recovered and washed with demineralized water, containing 0.05% of a non-ionic surfactant consisting of a fatty alcohol condensed with ethylene oxide and propylene oxide, sold by Huntsman, with the trade name of Empilan 2638. The granules are then dried in a stream of heated air, 0.02% of a nonionic surfactant is added, which consists of a condensate of ethylene oxide and propylene oxide in a base glycerin, sold by Dow (Voranol CP 755), and are subsequently selected to obtain a fraction with a diameter ranging from 1 to 1.5 mm.
[00161] 0.2% glyceryl monostearate and 0.1% zinc stearate are then added to this fraction.
[00162] The product is expanded with steam and molded according to what is described in example 1, part B. The test samples are collected to measure the thermal conductivity according to what is specified in the same example. The thermal conductivity was 33.2 mW / mK, while the carbon concentration, calculated according to the same procedure indicated in example 2, part B, proved to be 0.2% by weight.
[00163] The test samples are collected from said sheet for an evaluation of the compressive strength, according to EN ISO 844. The stress at 10% of compression proved to be 110 kPa.
[00164] EXAMPLE 4
[00165] PART A - Preparation of the concentrate
[00166] The concentrate is prepared according to example 3, part A. The product obtained is washed in deionized water, filtered and dried. The product is subsequently micronized by means of a jet mill.
[00167] PART B - Preparation of expanded polystyrene sheets containing graphene plates in nanometer scale
[00168] A mixture consisting of 97 parts of N1782 polystyrene and 3 parts of the product prepared in example 3, part A, is fed continuously in a system of two series extruders.
[00169] The temperature inside the first extruder is 220 ° C, in order to melt the polystyrene and mix it with the additives.
[00170] 2 parts of ethyl alcohol are fed into the mixture thus obtained together with 4 parts of carbon dioxide, as a blowing agent, for 100 parts of the mixture.
[00171] The polymeric fusion comprising the expansion system is homogenized and cooled to 120 ° C, and then it is extruded by means of a mold with a cross section, rectangular, with dimensions of 300 mm x 1.5 mm.
[00172] A continuous sheet with a thickness of 120 mm is obtained. The density of the sheet is 35 g / L, the average cell size (substantially spherical) within the sheet is about 400 pm. The thermal conductivity proved to be 34 mW / mK.
[00173] The test samples are obtained from said sheet to evaluate the compression resistance according to EN ISO 844. The stress at 10% of compression proved to be 550 kPa.
[00174] EXAMPLE 5 (comparative)
[00175] Preparation of expanded polystyrene sheets not containing graphene plates on a nanometric scale.
[00176] 100 parts of N1782 polystyrene are fed continuously in a system of two extruders in series.
[00177] The temperature inside the first extruder is 220 ° C, in order to melt the polystyrene.
[00178] 2 parts of ethyl alcohol are fed into the polystyrene together with 4 parts of carbon dioxide, as a blowing agent, for 100 parts of the mixture (a).
[00179] The polymeric fusion, comprising the expansion system, is homogenized and cooled to 120 ° C, and subsequently extruded by means of a mold with a rectangular cross section, with dimensions of 300 mm x 1.5 mm.
[00180] A continuous sheet with a thickness of 120 mm is obtained. The density of the sheet is 35 g / L, the average cell size (substantially spherical) within the sheet is about 500 pm.
[00181] The test samples are obtained from said sheet, in order to evaluate the compression strength according to EN ISO 844. The stress at 10% of compression proved to be 420 kPa.
[00182] EXAMPLE 6
[00183] Preparation of expandable polystyrene containing graphene plates in nanometer scale.
[00184] 0.4 parts of sodium dodecylbenzene sulfonate are dispersed in 1,000 parts of deionized water while stirring with a magnetic anchor.
[00185] 5 parts of graphite "UF1 98.5", produced by Kropfmuhl, are then added to the solution, keeping it in constant agitation. An ultrasonic field is applied, still in continuous agitation, by means of a sonotrode calibrated at 20 kHz, with a specific powder, calculated on the basis of the powder absorbed by the generator, equal to about 100 W / liter. After about 2 hours, the product thus obtained is subjected to centrifugation.
[00186] 150 parts of the supernatant are collected and loaded into an agitated and closed container. 0.2 parts of sodium pyrophosphate, 100 parts of styrene, 0.25 parts of tert-butyl peroxy-2-ethylhexanoate, 0.25 parts of tert-butylperbenzoate, are then added.
[00187] The mixture thus obtained is subjected to the same steps and process conditions, as described in example 3. The granules are expanded and molded under the same conditions.
[00188] The conductivity measured at 17 g / L was 31.7 mW / mK.
[00189] The carbon content was equal to 0.2% by weight and the stress at 10% compression was 120 kPa.
[00190] EXAMPLE 7
[00191] PART A - Preparation of the concentrate
[00192] 68 parts of N1782 polystyrene, produced by Polimeri Europa, are mixed in a twin screw extruder; 2 parts of ethylene-bis-stereamide are added together with 30 parts of the composition obtained in example 3, part A.
[00193] The extruded product is used as a basic concentrate.
[00194] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale.
[00195] 89.8 parts of ethylbenzene, 730.0 parts of styrene and 56.4 parts of α-methyl-styrene are fed into a stirred reactor.
[00196] 123.8 parts of the basic concentrate, prepared in the previous way, are fed into a reactor and dissolved (total: 1,000 parts). The reaction is carried out at 125 ° C with an average residence time of 2 hours. The fluid composition at the outlet is fed into a second reactor, where the reaction is terminated at 135 ° C with an average residence time of 2 hours.
[00197] The resulting composition, hereinafter referred to as "composition (a)", with a conversion of 72%, is heated to 240 ° C and subsequently fed to the devolatilizer to remove the solvent and residual monomer. It is characterized by a molecular weight Mw of 200,000 g / mol and an Mw / Mn ratio of 2.8, where Mw is the weight of the average molecular weight and Mn is the number of the average molecular weight.
[00198] The composition (a) is fed from the devolatilizer in a heat exchanger to reduce its temperature to 170 ° C.
[00199] 130.7 parts of N2982 polystyrene produced by Polimeri Europa, 14.2 parts of stabilized EBCD (Saytex HP900SG, sold by Chemtura) and 5.1 parts of Perkadox 30® (2,3-dimethyl-2,3- diphenylbutane, sold by Akzo Nobel), for a total of 150 parts, are fed into a second twin screw extruder.
[00200] A gear pump increases the feed pressure of this molten additive to 260 barg. 47 parts of a mixture of n-pentane (75%) and isopentane (25%) are then pressurized and injected into the additive feed. The mixing is completed by static mixers, at a temperature of about 190 ° C. The composition thus obtained is hereinafter described as "composition (B)".
[00201] The composition (B) is added in 850 parts of the composition (a) originated with heat exchanger. The ingredients are then mixed by static mixing elements for an average residence time of 7 minutes.
[00202] The composition is then distributed in the mold, where it is extruded, granulated, expanded and molded, as indicated in example 1, part B. The test samples are collected from the block, expanded and molded at 17 g / L to the measurement of thermal conductivity and fire behavior test, again following what is indicated in example 1, part B.
[00203] The test samples passed the DIN 4102 fire behavior test. The thermal conductivity proved to be 29.8 mW / mK.
[00204] The thermogravimetric analysis (TGA) and compressive strength, measured according to what is indicated in example 2, part B, show respectively a carbon content equal to 0.7% by weight and a stress at 10% of compression equal to 140 kPa.
[00205] EXAMPLE 8
[00206] PART A - Preparation of the concentrate
[00207] The dispersion of graphene plates on a nanometric scale in polystyrene is carried out following example 3 of WO 2008/048295. The TGA analysis for carbon content, performed in the manner described in example 1, part B of the present invention, proved to be equal to 2.5% by weight.
[00208] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale.
[00209] 945 parts of N1782 polystyrene, 40 parts of the dispersion prepared in part A, 2 parts of Perkadox 30 and 13 parts of stabilized EBCD Saytex HP900SG, sold by Albemarle (total: 1,000 parts), are fed into a double screw extruder .
[00210] The mixture thus obtained is subjected to a pressure of 250 bar by means of a gear pump.
[00211] 100 parts of the molten composition thus obtained are mixed with 5 parts of a mixture of n-pentane (75%) and iso-pentane (25%), injected into the molten mixture by means of a high pressure membrane pump.
[00212] The resulting product is exposed to a temperature of 160 ° C. It is then granulated, dried and covered with a coating, as in the conditions mentioned in example 1, part B. The granules thus obtained are then expanded and molded to form a block, again following the procedure of example 1, part B.
[00213] The test samples are collected for the measurement of the fire behavior and thermal conductivity test, again following the procedure of example 1, part B. The thermal conductivity proved to be 32.7 mW / mK at 17 g / L. The test samples passed the fire behavior test.
[00214] The test samples are collected from the same block for the evaluation of the compressive strength, following example 5 (comparative). Stress at 10% compression proved to be equal to 115 kPa.
[00215] EXAMPLE 9 (comparative)
[00216] PART A -Preparing the concentrate
[00217] 975 parts of N1782 polystyrene, and 25 parts of graphite UF2-96 / 97, produced by Kropfmuhl, are fed into a twin screw extruder. The product is then mixed and extruded, and subsequently granulated.
[00218] PART B - Preparation of expandable polystyrene containing graphite.
[00219] Example 8 of part B is repeated, but using the granule produced in part A of example 9, instead of 40 parts of the dispersion of graphene plates in nanometer scale.
[00220] The conductivity in the resulting test samples, at 17 g / L, proved to be equal to 34.2 mW / m, while the stress at 10% compression proved to be equal to 95 kPa.
[00221] EXAMPLE 10
[00222] PART A - Preparation of the concentrate
[00223] Graphene plates at the nanoscale are obtained from graphite oxide, according to example 2 of WO 2008/045778.
[00224] 900 parts of EDISTIR N1782 polystyrene (polystyrene with an Mw of 180,000 g / mol, Mw / Mn = 2.3, MFI (200 ° C, 5kg) equal to 7.5 g / 10 ', produced by Polimeri Europa ) are micronized in a mill.
[00225] 100 parts of graphene plates on a nanoscale are mixed for 30 seconds at 2,000 rpm in a high shear powder mixer (Plasmec TRL 10 mixer), along with 900 parts of micronized polystyrene.
[00226] The mixture thus obtained is fed into a twin screw extruder, where it is melted and mixed. The polymeric fusion is granulated by cutting into spaghetti. A degassing section is present in the extruder, where the volatile components are removed by vacuum suction.
[00227] Part B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00228] Example 8 part B is repeated, but replacing the 40 parts of the graphene plates in nanometer scale of example 8 part A, with a mixture of 6 parts of the granules obtained in part A of example 10, and 34 parts of polystyrene in N1782 granules.
[00229] The material obtained is expanded and molded, again following the indicated procedure, obtaining a density of 17 g / L. A rate of the beads, after expansion, is left to age for 24 hours and is then expanded again using the same procedure. The material obtained, after an additional 24-hour aging, is shaped into blocks with a density of 12.5 g / L.
[00230] The TGA, again performed according to example 2, part B, indicated a carbon content equal to 0.6% by weight.
[00231] The conductivity proved to be 30.2 mW / mK at 12.5 g / L. The test samples passed the fire behavior test.
[00232] The test samples were obtained from the same block for an evaluation of the compressive strength, following example 5 (comparative). Stress at 10% compression proved to be equal to 85 kPa.
[00233] EXAMPLE 11 (comparative)
[00234] Example 9 (comparative) is repeated, but replacing 25 parts of graphite with an equal amount of N1782 polystyrene.
[00235] The beads thus obtained are expanded and molded following example 10, obtaining blocks at 12.5 g / L.
[00236] The conductivity proved to be 38 mW / mK at 12.5 g / L. The compressive strength is assessed following example 5 (comparative). Stress at 10% compression proved to be equal to 60 kPa.
[00237] EXAMPLE 12
[00238] PART A - Preparation of the concentrate
[00239] A graphene plate concentrate on a nanoscale is prepared based on the disclosures contained in patent application WO 2009/029984. 20 g of metallic sodium are reacted and 220 0 for 72 hours in 50 ml of EtOH (molar ratio 1: 1). The reaction generates a precursor to graphene (a solvothermal product, such as, for example, a metal alkoxide). This precursor is pyrolyzed in a Lindberg tube oven, in an argon atmosphere. The oven is preheated to 1,100 °. A quartz tube containing the precursor, in an argon atmosphere, is quickly inserted into the oven and extracted after one minute. The product thus obtained is subsequently washed in deionized water, filtered and dried, and is then micronized by means of a jet mill. Graphene plates at the nanoscale are thus obtained.
[00240] The sample is analyzed by TGA, again following the procedure indicated in example 2, part B. the measurement indicated a carbon content equal to 80% by weight.
[00241] The particle diameter is evaluated by means of a laser diffraction granulometer. The average particle diameter proved to be 5 pm.
[00242] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00243] 89.8 parts of ethylbenzene, 853.8 parts of styrene, 56.4 parts of α-methylstyrene (total: 1,000 parts) are fed into a stirred reactor. The reaction is carried out at 125 ° C with an average residence time of 2 hours. The fluid composition at the outlet is then fed into a second reactor, where the reaction is terminated at 135 ° C with an average residence time of 2 hours.
[00244] The resulting composition, hereinafter referred to as "composition (a)", with a conversion of 72%, is heated to 240 ° C and subsequently fed to the devolatilizer to remove the solvent and the residual monomer. It is characterized by a melt flow index (MFI) at 200 ° C, 5 kg, of 8 g / 10 ', a molecular weight Mw of 200,000 g / mol and a Mw / Mn ratio of 2.8, where Mw is the weight of the average molecular weight and Mn is the number of the average molecular weight.
[00245] The composition (a) is fed from the devolatilizer in a heat exchanger to reduce its temperature to 170 ° C.
[00246] 123.7 parts of N2982 polystyrene, produced by Polimeri Europa, 10.0 parts of the sample obtained in part A of the present example, 14.2 parts of stabilized EBCD (Saytex HP900SG, sold by Chemtura) and 2.1 parts Perkadox 30® (2,3-dimethyl-2,3-diphenylbutane, sold by Akzo Nobel), for a total of 150 parts, are fed into a second twin screw extruder.
[00247] A gear pump increases the supply pressure of this molten additive to 260 barg. The composition thus obtained is hereinafter described as "composition (B)".
[00248] Composition (B) is added in 850 parts of composition (a), originated from the heat exchanger, and in 50 parts of a mixture of n-pentane (75%) and iso-pentane (25%). The mixing is completed by means of static mixers, at a temperature of about 190 ° C.
[00249] The ingredients are then mixed and granulated in the manner described in example 2.
[00250] The expansion of the granules and molding were carried out as in example 10. The TGA analysis carried out as in example 1, part B, of the present invention, proved to be equal to 0.8% by weight. Thermal conductivity proved to be 30.6 mW / mK at 12.5 g / L.
[00251] EXAMPLE 13
[00252] PART A - Preparation of the concentrate
[00253] Nano-scale graphene plates are produced following and example 2 of U.S. patent application 2008/0206124.
[00254] The product thus obtained is washed in deionized water, filtered and dried. The product is then micronized by means of a jet mill. Graphene plates at the nanoscale are thus obtained.
[00255] The sample is analyzed by TGA, again following the procedure indicated in example 2 part B. The measurement indicated a carbon content equal to 90% by weight.
[00256] The particle diameter is evaluated by means of a laser diffraction granulometer. The average size proved to be 6 pm.
[00257] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00258] Example 12 part B is repeated, but replacing the 10 parts of graphene plates in nanometer scale obtained according to example 12, part A, with those obtained in part A of the present example.
[00259] The TGA analysis carried out according to example 1, part B, proved to be equal to 0.9% by weight.
[00260] Thermal conductivity proved to be 30.8 mW / mK at 12.5 g / L.
[00261] EXAMPLE 14
[00262] PART A - Preparation of the concentrate
[00263] 70 parts of linear low density polyethylene of the type Flexirene FG 30, produced by Polimeri Europa (density 0.925 g / L, MFI 190 °, 2.16 kg equal to 1.0 g / 10 ') and 30 parts of composition obtained in example 3, part A, are mixed in a twin screw extruder. The extruded product is used as a basic concentrate.
[00264] PART B - Preparation of expanded polyethylene sheets containing graphene plates in nanometer scale
[00265] A mixture consisting of 80 parts of linear low density polyethylene of the type Flexirene FG 30 and 20 parts of the basic concentrate, prepared in part A of the present example, are fed continuously in a system of two extruders in series .
[00266] The temperature inside the first extruder is 220 ° C in order to melt the polyethylene and mix it with the additives.
[00267] 2 parts of ethyl alcohol are fed into the mixture thus obtained, together with 4 parts of carbon dioxide as a blowing agent per 100 parts of the mixture.
[00268] The polymeric fusion comprising the expansion system is homogenized and cooled to 130 ° C, and then extruded by means of a mold with a rectangular cross section with dimensions of 200 mm x 1.5 mm.
[00269] A continuous sheet is obtained with a thickness of 90 mm. the density of the sheet is 50 g / L, the average cell dimension (substantially spherical) within the sheet is about 400 µm.
[00270] The test samples are obtained from this sheet to assess the compressive strength in accordance with EN ISO 844. The stress at 10% compression proved to be 250 kPa.
[00271] EXAMPLE 15
[00272] PART A - Preparation of the basic concentrate
[00273] Graphene plates at the nanoscale are prepared according to example 1 of U.S. patent application 2009/0155578. The second step of reinterleaving is not evaluated.
[00274] 900 parts of polystyrene type EDISTIR N1782 (polystyrene with an Mw equal to 180,000 g / mol, Mw / Mn = 2.3, MFI (200 ° C, 5 kg) equal to 7.5 g / 10 ', produced by Polimeri Europa) are micronized in a mill.
[00275] 100 parts of the graphene plates on the previous nanometer scale are mixed for 30 seconds at 2,000 rpm in a high shear powder mixer (Plasmec TRL 10 mixer) with 900 parts of micronized polystyrene.
[00276] The mixture thus obtained is fed into a twin screw extruder, where it is melted and mixed. The polymeric fusion is granulated by cutting into spaghetti. A degassing section is present in the extruder, where the volatile components are removed by means of vacuum suction.
[00277] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00278] 61 parts of polystyrene N 1782 produced by Polimeri Europa, 2 parts of ethylene-bis-stereamide; 20 parts of Saytex HP 900 (hexabromo-cyclododecane sold by Alberarle), 5 parts of Perkadox 30 (2,3-dimethyl-2,3-diphenyl butane, sold by Akzo Nobel) and 12 parts of the basic concentrate, produced in part A in this example, they are mixed in a twin screw extruder.
[00279] 50 parts of a mixture of n-pentane (75%) and iso-pentane (25%) are added to the polymeric melt at the outlet of the single screw extruder. The mixture thus obtained is mixed using a series of static mixing elements. A gear pump increases the pressure of the mixture thus obtained to 200 barg. The mixture is then cooled to about 170 ° C by means of a mixing exchanger. (SMR).
[00280] The composition is then distributed in the mold, granulated, expanded and molded according to what is indicated in example 1, part B.
[00281] The blocks are obtained in 17 g / L in a first expansion, and in 12.5 g / L in a second expansion, as indicated in example 10, part B.
[00282] The analysis of the coal content by means of the TGA analysis, performed in the manner indicated in example 1, part B, proved to be equal to 1.2% by weight. Thermal conductivity proved to be 29.5 mW / mK at 12.5 g / L. The stress at 10% compression, performed in the manner indicated in example 2, part B, proved to be 160 kPa at 17 g / L.
[00283] EXAMPLE 16
[00284] PART A - Preparation of the basic concentrate
[00285] Nano-scale graphene plates are prepared according to example 1 of U.S. patent application 2009/0155578. The second step of reinterleaving is performed in the manner indicated in the example cited.
[00286] 980 parts of polystyrene type EDISTIR N1782 (polystyrene with an Mw equal to 180,000 g / mol, w / Mn = 2.3, MFI (200 ° C, 5 kg) equal to 7.5 g / 10 ', produced by Polimeri Europa) are micronized in a mill.
[00287] 20 parts of the graphene plates on the previous nanometer scale are mixed, for 30 seconds at 2,000 rpm, in a high shear powder mixer (Plasmec TRL 10 mixer) with 900 parts of micronized polystyrene.
[00288] The previous powder mixture is extruded and granulated following the same procedures indicated in example 15, part A.
[00289] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00290] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanoscale, as obtained in part A of the present example.
[00291] The blocks at 12.5 g / L are prepared, continuing with a second expansion as shown in example 10, part B.
[00292] The analysis of the coal content by means of the TGA analysis, performed in the manner indicated in example 1, part B, of the present invention, proved to be equal to 0.2%. Thermal conductivity proved to be 31.9 mW / mK at 12.5 g / L. The 10% compression stress, performed in the manner indicated in example 2 part B, proved to be 80 kPa.
[00293] EXAMPLE 17
[00294] PART A - Preparation of the basic concentrate
[00295] Example 16 part A is repeated, but using an equal amount of graphene plates on a nanoscale, prepared according to example 4 of U.S. patent application 2009/0155578.
[00296] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00297] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanometric scale as obtained in part A of the present example.
[00298] The blocks at 12.5 g / L are prepared, continuing with a second expansion as shown in example 10, part B.
[00299] Thermal conductivity proved to be 32.0 mW / mK at 12.5 g / L.
[00300] EXAMPLE 18
[00301] PART A - Preparation of the basic concentrate
[00302] Example 16 part A is repeated, but using an equal amount of graphene plates on a nanoscale, prepared according to example 2 of U.S. patent application 2009/0026086.
[00303] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00304] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanoscale, as obtained in part A of the present example.
[00305] The blocks at 12.5 g / L are prepared, continuing with a second expansion, as indicated in example 10, part B.
[00306] Thermal conductivity proved to be 32.1 mW / mK at 12.5 g / L. The 10% compression stress, performed in the manner indicated in example 2, part B, proved to be 75 kPa.
[00307] EXAMPLE 19
[00308] PART A - Preparation of graphene plate concentrate on a nanometer scale.
[00309] Graphite powder type UF2-96 / 97, produced by ropfmuhl, is inserted into an aluminum oxide tube. The tube is inserted in a refrigerator to maintain a temperature of -18 ° C.
[00310] A series of ozone generators are used, of the Microlab type, produced by the Biaccabi company, powered by an oxygen cylinder. The ozone thus produced is cooled to -18 ° C and is then stained with graphite for 24 hours.
[00311] 97.5 parts of polystyrene are dissolved in N, N-dimethylformamide. 2.5 parts of graphite functionalized with oxygen groups (FOG) are collected from the aluminum oxide tube and dispersed in the solution with the aid of an ultrasound sonotrode immersed in the solution. This is heated to 90 ° C, the dimethylhydrazine is then added and left to act for 24 hours. The solution is fed dropwise into a container loaded with methanol, and kept under vigorous stirring. The compost, separated by centrifugation, is washed, dried and a pestle is used to reduce it to a powder.
[00312] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00313] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanoscale, as obtained in part A of the present example. The blocks are produced at 17 g / L.
[00314] The carbon content, measured in the manner indicated in example 2, proved to be equal to 0.2% by weight.
[00315] Thermal conductivity proved to be 31.7 mW / mK at 17 g / L. The stress at 10% compression, performed in the manner indicated in example 2 part B, proved to be 110 kPa.
[00316] EXAMPLE 20
[00317] PART A1 - Preparation of graphene plates in nanometer scale
[00318] Graphite powder type UF2-96 / 97, produced by Kropfmuhl, is inserted into an aluminum oxide tube.
[00319] A series of ozone generators is used, of the Microlab type, produced by the Biaccabi company, this time powered by dry air. The ozone thus produced is mixed with a stream of superheated water vapor. The mixture thus obtained is then stained with graphite for 12 hours.
[00320] The aluminum oxide tube containing the functionalized graphite (FOG) is stained for a few minutes in argon, then it is quickly inserted into a Lindberg tube oven, kept in an argon atmosphere. The oven is preheated to 1,100 ° C. After 30 seconds, the tube is extracted from the oven and allowed to cool still in an argon flow.
[00321] PART A2 - Preparation of graphene plate concentrate on a nanoscale
[00322] 980 parts of EDISTIR N1782 polystyrene (polystyrene with an Mw equal to 180,000 g / mol, Mw / Mn = 2.3, MFI (200 ° C, 5 kg) equal to 7.5 g / 10 ', produced by Polimeri Europa) are micronized in a mill.
[00323] 20 parts of the graphene plates on the previous nanometer scale are mixed, for 30 seconds at 2,000 rpm, in a high shear powder mixer (Plasmec mixer TRL 10) together with the 900 parts of micronized polystyrene.
[00324] The previous powder mixture is extruded and granulated following the same procedure as in example 15 part A.
[00325] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00326] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanoscale, as obtained in part A2 of the present example. The blocks are produced at 17 g / L.
[00327] The carbon content, measured in the manner indicated in example 2, proved to be equal to 0.2% by weight.
[00328] The thermal conductivity proved to be 31.5 mW / mK at 17 g / L. The stress at 10% compression, performed in the manner indicated in example 2 part B, proved to be 110 kPa.
[00329] EXAMPLE 21
[00330] PART A1 - Preparation of graphene plates in nanometer scale
[00331] Graphite powder UF2-96 / 97, produced by Kropfmuhl, is inserted into an aluminum oxide tube.
[00332] The tube is introduced into a muffle furnace, in an atmosphere of nitrogen preheated to 550 ° C. A mixture of 10 parts of air, 40 parts of nitrogen and 50 parts of water vapor is heated by passing it in a cooled tube located inside said muffle furnace, and is then fed into the tube containing the graphite. After 4 hours at 550 ° C, the muffle is eliminated, maintaining the color. The graphite functionalized with oxygen groups (FOG) is fed into a Lindberg tube oven in the manner indicated in part A1 of example 20.
[00333] PART A2 - Preparation of graphene plate concentrate on a nanoscale
[00334] The basic concentrate is prepared using the same procedure indicated in part A2 of example 20, but using the nanometer scale plates produced in part Al of the present example.
[00335] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00336] Example 15 part B is repeated, but using the basic concentrate of graphene plates on a nanoscale as obtained in part A2 of the present example. The blocks are produced at 17 g / L.
[00337] The carbon content, measured in the manner indicated in example 2, proved to be equal to 0.2% by weight.
[00338] Thermal conductivity proved to be 32.0 mW / mK at 17 g / L. The stress at 10% compression, performed in the manner indicated in example 2 part B, proved to be 105 kPa.
[00339] EXAMPLE 22
[00340] Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00341] Graphite powder UF2-96 / 97, produced by ropfmuhl, is oxidized following the method of Hummers. A part of the product thus obtained is dispersed in 100 parts of deionized water by sonication.
[00342] The product thus obtained is loaded into a closed and stirred container. A mixture of 50 parts by weight of water, 0.2 parts of sodium pyrophosphate, 100 parts of styrene, 0.25 parts of tert-butylperoxide-2-ethylhexanoate, 0.25 parts of tert-butylperbenzoate is added. 20 parts of a 10% hydrazine solution are added with stirring and the mixture is heated to 90 ° C.
[00343] After about 2 hours at 90 ° C, 4 parts of a 10% polyvinylpyrrolidone solution are added. The mixture is heated, still stirring at 100 ° C for an additional 2 hours, 7 parts of a 70/30 mixture of n-pentane and i-pentane are added, the mixture is heated for an additional 4 hours at 125 ° C, and it is then cooled and the batch is discarded.
[00344] The expandable polymer granules thus produced are subsequently treated with the same procedure as in example 3, part B.
[00345] The product is expanded with steam and molded according to what is indicated in example 10 of part B. The thermal conductivity was 30.2 mW / mK at 12.5 g / L, whereas the carbon concentration , calculated following the same procedure as in example 2, part B, proved to be equal to 0.8% by weight.
[00346] The test samples are prepared at 17 g / L to assess the compressive strength in accordance with EN ISO 844. The stress at 10% compression proved to be equal to 130 kPa.
[00347] EXAMPLE 23
[00348] PART A - Preparation of graphene plate concentrate on a nanoscale
[00349] Graphene plates at the nanoscale are prepared according to example 2 of U.S. patent application 2009/0026086.
[00350] 10 parts of the nanometer scale plates thus produced are dispersed in 200 parts of tetrahydrofuran (THF) by sonication, performed with a sonotrode immersed in the solution.
[00351] 300 parts of polystyrene type N1782, produced by Polimeri Europa, are dissolved in a stirred tank containing 3,000 parts of tetrahydrofuran. The solution of graphene plates at the nanoscale is then poured into the polystyrene solution, under continuous stirring, and the solution thus obtained is left under stirring for 4 hours. The superheated steam is blown into the solution, evaporating the THF. The concentrate thus obtained is dried in a vacuum muffle furnace.
[00352] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00353] Example 15 part B is repeated, but using graphene plate concentrate on a nanometer scale as obtained in part A of the present example. The blocks are produced at 12.5 g / L. The carbon content, measured in the manner indicated in example 2, proved to be 0.4%.
[00354] Thermal conductivity proved to be 30.0 mW / mK at 12.5 g / L. The stress at 10% compression, performed in the manner indicated in example 2 part B, proved to be 120 kPa.
[00355] EXAMPLE 24
[00356] Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00357] Example 15 part A is repeated. 150 parts of N1782 polystyrene, produced by Polimeri Europa, 20 parts of ethylene-bis-stereamide; 25 parts of Saytex HP 900 (hexabromo-cyclododecane sold by Alberarle); 5 parts of Perkadox 30 (2,3-dimethyl-2,3-diphenyl butane, sold by Akzo Nobel) and 800 parts of the basic concentrate, produced in part A of this example, are mixed in a twin screw extruder.
[00358] 50 parts of a mixture of n-pentane (75%) and iso-pentane (25%) are added to the polymeric melt at the outlet of the single screw extruder. The mixture thus obtained is mixed using a series of static mixing elements. A gear pump increases the pressure of the mixture thus obtained to 200 barg. The mixture is then cooled to about 170 ° C by means of a mixing exchanger. (SMR).
[00359] The composition is then distributed in the mold, granulated, expanded and molded according to what is indicated in example 1, part B.
[00360] The blocks are obtained in 20 g / L in a first expansion, and in 12.5 g / L in a second expansion, as indicated in example 10, part B.
[00361] The analysis of the carbon content by means of the TGA analysis, carried out in the manner indicated in example 1, part B, of the present invention, proved to be equal to 2.6% by weight. Thermal conductivity proved to be 30.8 m / m at 12.5 g / L. The stress at 10% compression, performed in the manner indicated in example 2, part B, proved to be 210 kPa at 20 g / L.
[00362] The measurement of electrical conductivity was performed on the final product at 20 g / L, using the four-point method. Conductivity was shown to be 0.0001 Siemens cm2.
[00363] EXAMPLE 25
[00364] PART A - Preparation of graphene plate concentrate on a nanoscale
[00365] A polystyrene-TEMPO was produced according to the methods indicated in the literature (Georges et al, Macromolecules, 26, 5316 (1993) and Hawkar et al, Macromolecules, 28, 2993 (1995)), using styrene and m- Xylene (Polimeri Europa), TEMPO (2,2,6,6-tetramethyl-1-piperidinyloxy) supplied by Aldrich Chemical Co., benzoyl peroxide (AKZO NOBEL).
[00366] Graphene plates at the nanoscale are prepared according to example 2 of U.S. patent application 2009/0026086.
[00367] 100 parts of said graphene plates on a nanoscale, 1,000 parts of polystyrene-TEMPO and 5,000 parts of m-xylene are mixed in a tank.
[00368] The mixture is exposed to 125 ° C and kept under constant stirring. After 8 hours, the reagent mixture is poured dropwise into a second container containing an excess of methanol kept under vigorous stirring. The precipitate is filtered on filter paper, washed with methanol and dried in an oven at 80 ° C in a stream of nitrogen for 24 hours.
[00369] PART B - Preparation of expandable polystyrene containing graphene plates in nanometer scale
[00370] Example 15 part B is repeated, but using graphene plate concentrate on a nanoscale, as obtained in part A of the present example. The blocks are produced at 12.5 g / L. The carbon content, measured in the manner indicated in example 2, proved to be equal to 1.2% by weight.
[00371] Thermal conductivity proved to be 29.6 mW / mK at 12.5 g / L. The stress at 10% compression, performed in the manner indicated in example 2 part B, proved to be 140 kPa at 17 g / L.
[00372] Throughout this document, the term "part" implicitly refers to "part by weight", unless otherwise specified. The same applies to percentage values.
[00373] The examples can be considered to be illustrative, but not limiting, of the objective of the present invention.
[00374] The invention has been described in detail with particular reference to its preferred modalities, but it is understood that variations and modifications can be carried out in the spirit and scope of the invention. While it is evident that the exemplary embodiments of the present invention described herein satisfy the objectives specified above, it is understood that various modifications and other modalities can be devised by those skilled in the art.
[00375] Therefore, it is understood that the specific claims cover all these modifications and modalities, which form part of the spirit and objective of the present invention.
[00376] All the conditions indicated in the description can be considered as preferred conditions, if not expressly specified.

权利要求:
Claims (34)
[0001]
1. Nanocomposite compositions based on expandable thermoplastic polymers, characterized by the fact that they comprise: a) a polymeric matrix produced by polymerization of a base that comprises one or more polymerizable monomers; b) 1-10% by weight, calculated with respect to the polymer (a), of a blowing agent inserted in the polymer matrix; c) 0,004-15% by weight, calculated with respect to the polymer (a), of an athermic charge comprising graphene plates in nanometer scale with a thickness (orthogonal to the graphene sheet) of no more than 150 nm, an average dimension ( length, width or diameter) of no more than 10 micrometers and a surface area> 50 m2 / g.
[0002]
2. Nanocomposite compositions according to claim 1, characterized by the fact that polymerizable monomers are selected from vinyl monomers and aromatic vinyl monomers.
[0003]
3. Nanocomposite compositions according to claim 2, characterized by the fact that the polymerizable monomers are selected from aromatic vinyl monomers.
[0004]
4. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the athermic charge comprises up to 6% of graphite and / or carbon and / or carbon black as synergistic products.
[0005]
5. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the thickness (orthogonal to the graphene sheet) of the graphene plates in nanometer scale is less than 50 nm.
[0006]
6. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the thickness (orthogonal to the graphene sheet) of the graphene plates in nanometer scale varies from 0.3 to 5 nm.
[0007]
7. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the average dimension (length, width or diameter) of graphene plates in nanometer scale is no more than 1 micron.
[0008]
8. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the average dimension (length, width or diameter) of graphene plates in nanometer scale is no more than 500 nm.
[0009]
9. Nanocomposite compositions according to any one of the preceding claims, characterized by the fact that the surface area of graphene plates on a nanometer scale varies from 100 to 2,600 m2 / g.
[0010]
10. Nanocomposite compositions according to any of the preceding claims, characterized by the fact that the surface area of graphene plates on a nanometer scale varies from 300 to 2,600 m2 / g.
[0011]
11. Expandable articles characterized by the fact that they are obtained from the nanocomposite compositions as defined in any of the preceding claims, presenting a density ranging from 5 to 50 g / L and a thermal conductivity ranging from 25 to 50 mW / mK.
[0012]
12. Expanded extruded sheets of thermoplastic polymers, characterized by the fact that they comprise a cell matrix with a density ranging from 10 to 200 g / L, an average cell dimension ranging from 0.01 to 1.00 mm and containing from 0.004 at 15% by weight, calculated with respect to the thermoplastic polymer, of said athermic charge comprising said nanometer-scale graphene plates with a thickness (orthogonal to the graphene sheet) of no more than 150 nm, an average dimension (length, width or diameter) of no more than 10 micrometers and a surface area> 50 m2 / g.
[0013]
13. Extruded sheets according to claim 12, characterized by the fact that the thermoplastic polymer is selected from a vinyl polymer and an aromatic vinyl polymer.
[0014]
14. Extruded sheets according to claim 13, characterized by the fact that the thermoplastic polymer is an aromatic vinyl polymer.
[0015]
15. Extruded sheets, according to claim 12, 13 or 14, characterized by the fact that said athermic charge comprises, in addition to said nanometer-scale graphene plates, up to 6% by weight, calculated with respect to the polymer, of the said additional athermic additives respectively, such as graphite and / or carbon coke and / or carbon black as synergistic products.
[0016]
16. Process for preparing expandable aromatic vinyl polymer compositions, in beads or granules, as defined in any of claims 1 to 10, characterized in that it comprises polymerizing in aqueous suspension one or more aromatic vinyl monomers, possibly together with at least one polymerizable comonomer in an amount of up to 50% by weight, in the presence of said athermic charge comprising said nanometer-scale graphene plates with a thickness (orthogonal to the graphene sheet) of no more than 150 nm, an average dimension (length, width or diameter) of no more than 10 micrometres and a surface area> 50 m2 / g, and at least in the presence of a peroxide radical initiator system and an expanding agent added before, during or at the end polymerization.
[0017]
17. Process according to claim 16, characterized by the fact that the athermic charge comprises, in addition to said graphene plates in nanometer scale up to 6% by weight, calculated with respect to the polymer, of said additional athermic additives respectively, such as graphite and / or carbon coke and / or carbon black as synergistic products.
[0018]
18. Process according to claim 16 or 17, characterized by the fact that the viscosity of the aromatic vinyl monomer reagent solution, to be suspended in water, is increased by dissolving the aromatic vinyl polymer in said solution, up to a concentration ranging from 1 to 30% by weight, with respect to the weight of the monomers.
[0019]
19. Process according to claim 16 or 17, characterized by the fact that the viscosity of the aromatic vinyl monomer reagent solution, to be suspended in water, is increased by prepolymerizing the monomer in bulk, or the mixture of monomers, until a polymer concentration ranging from 1 to 30% by weight is obtained.
[0020]
20. Process according to any one of claims 16 to 19, characterized by the fact that at the end of the polymerization the beads / granules of substantially spherical expandable polymer are obtained with an average diameter ranging from 0.2 to 2 mm, in that said athermic charge and said possible additional athermic additives are dispersed homogeneously.
[0021]
21. Process for mass preparing the expandable thermoplastic polymer compositions, in granules or beads, as defined in any one of claims 1 to 10, characterized in that it comprises the following series steps: i. Mixing a thermoplastic polymer in the in the form of granules / pellets or in powder, or already in the molten state, with an average molecular weight MW ranging from 50,000 to 300,000, with said athermic charge comprising said graphene plates in nanometer scale with a thickness (orthogonal to the sheet of graphene) of no more than 150 nm, an average dimension (length, width or diameter) of no more than 10 micrometers, and a surface area> 50 m2 / g, and with all or a part of other possible additives; ii. optionally, if it is no longer in the molten state, subject the polymer mixture to a temperature higher than the melting point of the thermoplastic polymer; iii.incorporating in said molten polymer said blowing agent and possibly the remaining portion or all of said other additives; iv.mix the polymeric composition thus obtained by means of static or dynamic mixing elements; and v. granulating the composition thus obtained in a device comprising a mold, a cutting chamber and a cutting system.
[0022]
22. Process according to claim 21, characterized by the fact that the athermic charge comprises, in addition to said graphene plates on a nanometric scale, up to 6% by weight, calculated with respect to the polymer, of said additional athermic additives respectively, such as graphite and / or carbon coke and / or carbon black as synergistic products.
[0023]
23. Process according to claim 21 or 22, characterized by the fact that at the end of the granulation the granules / beads of substantially spherical thermoplastic expandable polymer are obtained, with an average diameter ranging from 0.2 to 2.3 mm , in which said athermic charge and said possible additional athermic additives are dispersed homogeneously.
[0024]
24. Process according to claim 21, 22 or 23, characterized by the fact that the thermoplastic polymer is an aromatic vinyl polymer in the molten state, in continuous feed from the solution polymerization plant.
[0025]
25. Process according to any one of claims 16 to 24, characterized in that said athermic additives are incorporated into a standard mixture comprising a thermoplastic polymer with an average molecular weight MW ranging from 50,000 to 300,000.
[0026]
26. Process according to claim 25, characterized by the fact that the athermic charge content, comprising said graphene plates on a nanoscale and possibly said graphite and / or carbon and / or carbon black coke, varies from 15 to 60% by weight.
[0027]
27. Process according to any one of claims 16 to 20, characterized by the fact that the standard pellet mixture is dissolved in the aromatic vinyl monomer.
[0028]
28. Process according to claim 24, characterized by the fact that the standard pellet mixture is dissolved in the aromatic vinyl monomer / solvent mixture before being fed into the solution polymerization reactor.
[0029]
29. Process for the production of expanded extruded sheets of thermoplastic polymers, as defined in any of claims 12-15, characterized by the fact that it comprises: a1. mixing a thermoplastic polymer into pellets, or granules or beads, and at least said athermic charge comprising said graphene plates on a nanoscale with a thickness (orthogonal to the graphene sheet) of no more than 150 nm, an average dimension (length , width or diameter) of no more than 10 micrometers and a surface area> 50 m2 / g; b1. heat the mixture (a1) at a temperature ranging from 180 to 250 ° C, in order to obtain a molten polymer that is subjected to homogenization; c1. adding to the polymeric melting at least one blowing agent and possibly said additional additives, for example, said flame retardant system; d1. homogenize the polymeric fusion that includes at least the blowing agent; e1. homogeneously cool the polymeric fusion (d1) to a temperature of not more than 200 ° C and not less than the Tg of the resulting polymeric composition; f1. extrude the polymeric melt through a mold in order to obtain an expanded polymeric sheet.
[0030]
30. Process according to claim 29, characterized by the fact that the thermoplastic polymer is selected from a vinyl or aromatic vinyl polymer.
[0031]
31. Process according to claim 29, characterized by the fact that the vinyl polymer is polyethylene and the aromatic vinyl polymer is polystyrene.
[0032]
32. Process according to any one of claims 29 to 31, characterized in that said athermic charge added to the aromatic vinyl polymer comprises up to 6% by weight, calculated with respect to the polymer, of said additional athermic additives respectively, such as graphite and / or carbon coke and / or carbon black as synergistic products.
[0033]
33. Process according to any one of claims 29 to 32, characterized in that the thermoplastic polymer in pellets, or granules, or beads, and said athermic charge are replaced, both completely and partially, by thermoplastic polymer compositions. in beads / granules described or prepared as defined in any one of claims 1 to 28.
[0034]
34. Process according to any of claims 29 to 33, characterized in that said athermic charge is used as a standard mixture.

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法律状态:
2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2019-11-05| B25D| Requested change of name of applicant approved|Owner name: VERSALIS S.P.A. (IT) |

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2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

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2020-05-19| B09A| Decision: intention to grant|

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2020-07-07| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 06/10/2010, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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ITMI2009A001715A|IT1396193B1|2009-10-07|2009-10-07|EXPANDABLE THERMOPLASTIC NANOCOMPOSITE POLYMER COMPOSITIONS WITH IMPROVED THERMAL INSULATION CAPACITY.|

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ITMI2009A001715|2009-10-07|

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PCT/IB2010/002547|WO2011042800A1|2009-10-07|2010-10-06|Expandable thermoplastic nanocomposite polymeric compositions with an improved thermal insulation capacity|

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