Extruded thermoplastic foams and uses in applications requiring strength and lightweight
Disclosed are extruded foam comprising an extruded thermoplastic, closed-cell foam having at least a first surface and comprising: (i) thermoplastic polymer cell walls formed by an extrusion step, with the walls being comprised of at least about 0.5% by weight of ethylene furanoate moieties and optionally one or more co-monomer moieties; (ii) blowing agent contained in at least a portion of said closed cells; and a material different than said thermoplastic, closed-cell foam attached to and/or integral with at least a portion of said first foam surface.
1 . A wind turbine blade comprising:
a. a blade shell; and
b. an extruded foam in the blade shell, said extruded foam having a foam density of from about 70 kg/m 3 to about 250 kg/m 3 and comprising a thermoplastic foam comprising:
(1) thermoplastic polymer cells comprising cell walls forming closed cells, wherein said thermoplastic polymer comprises ethylene furanoate moieties and optionally ethylene terephthalate moieties; and
(2) 1234ze(E) contained in the closed cells.
2 . The wind turbine blade of claim 1 wherein said thermoplastic polymer comprises from about 0.5 mole % to about 100 mole % of ethylene furanoate moieties.
3 . The wind turbine blade of claim 1 wherein said thermoplastic polymer further comprises at least about 0.5 mole % ethylene terephthalate moieties.
4 . The wind turbine blade of claim 1 wherein said thermoplastic polymer (i) comprises from about 0.5 mole % to about 99.5 mole % of ethylene furanoate moieties and from 0.5 mole % to about 99.5 mole % ethylene terephthalate moieties; and (ii) has a molecular weight of from about 25,000 kg/mole to about 140,000 kg/mole.
5 . The wind turbine blade of claim 1 wherein at least about 75% of the cells are closed cells.
6 . The wind turbine blade of claim 1 wherein said extruded foam has a foam density of from about kg/m 3 to about 150 kg/m 3 .
7 . A faced foam comprising:
a. an extruded thermoplastic foam core having a foam density of from about 70 kg/m 3 to about 250 kg/m 3 and comprising polymer cells comprising cell walls forming closed cells, wherein said thermoplastic polymer comprises ethylene furanoate moieties and 1234ze(E) contained in the closed cells; and
b. a facing attached to and/or integral with at least a portion of said foam core.
8 . An article of manufacture comprising the faced foam of claim 7 .
9 . An energy generating device comprising the faced foam of claim 7 .
10 . The energy generating device of claim 9 comprising a blade, foil or rotor located in a wind turbine electricity generator.
11 . A foam article comprising:
a. an extruded thermoplastic, closed-cell foam having at least a first foam surface; and
b. a material different than said thermoplastic, closed-cell foam attached to and/or integral with at least a portion of said first foam surface, wherein:
(i) said thermoplastic polymer cells comprise cell walls comprising at least about 0.5% by weight of ethylene furanoate moieties;
(ii) said closed cells contain 1234ze(E); and
(iii) said extruded foam has a foam density of from about 70 kg/m 3 to about 250 kg/m 3 .
12 . The foam article of claim 11 wherein said extruded foam has foam density of from about 70 kg/m 3 to about 150 kg/m 3 and a compressive strength of from about 2 MPa to about 8 MPa.
13 . The foam article of claim 11 wherein said thermoplastic polymer cells comprise cell walls comprising at least about 1% by weight of ethylene furanoate moieties.
14 . The foam article of claim 13 wherein at least about 75% of the cells are closed cells.
15 . The foam article of claim 14 wherein said thermoplastic polymer comprises from about 0.5 mole % to about 99.5 mole % of ethylene furanoate moieties and from 0.5 mole % to about 99.5 mole % ethylene terephthalate moieties.
16 . The foam article of claim 15 wherein said thermoplastic polymer has a molecular weight of from about 25,000 kg/mole to about 140,000 kg/mole.
17 . The foam article of claim 15 wherein said thermoplastic polymer has a molecular weight of from about 80,000 kg/mole to about 130,000 kg/mole.
18 . An article of manufacture comprising the foam article of claim 17 .
19 . An energy generating device comprising the foam article of claim 17 .
20 . The energy generating device of claim 19 comprising a blade, foil or rotor located in a wind turbine electricity generator.