Foaming additives
An additive may be used to foam and/or otherwise alter the physical properties of a polymeric material. In particular, a foaming additive may be used to foam a polymeric composite material. The foaming additive may include a blowing agent and a surfactant. The surfactant may be an amphiphilic block copolymer.
1 . A foaming additive comprising:
a blowing agent; and
an amphiphilic polymer having a nonionic hydrophilic segment.
2 . The foaming additive of claim 1 wherein the blowing agent is inorganic.
3 . The foaming additive of claim 2 wherein the blowing agent includes a carbonate salt.
4 . The foaming additive of claim 3 wherein the blowing agent includes sodium bicarbonate and/or sodium carbonate.
5 . The foaming additive of claim 1 wherein the amphiphilic polymer is an amphiphilic block copolymer.
6 . The foaming additive of claim 1 wherein the amphiphilic polymer includes a polyolefin segment and a polyalkylene oxide segment.
7 . The foaming additive of claim 1 comprising at least about 5 wt % of the blowing agent.
8 . The foaming additive of claim 1 further comprising at least about 10 wt % of a polymeric carrier.
9 . The foaming additive of claim 1 further comprising a hydrophilic dispersion aid.
10 . The foaming additive of claim 9 wherein the hydrophilic dispersion aid includes water, polyalkylene glycol, polyvinyl alcohol, and/or glycerol.
11 . The foaming additive of claim 1 further comprising
a polymeric carrier;
wherein the foaming additive comprises
about 20 to 60 wt % of the polymeric carrier;
about 10 to 60 wt % of the blowing agent; and
no more than about 10 wt % of the amphiphilic polymer.
12 . A foamed material prepared using the foaming additive of claim 1 .
13 . A melt processable composition comprising the foaming additive of claim 1 and a thermoplastic polymeric component.
14 . A foaming additive comprising:
a blowing agent; and
an amphiphilic block copolymer.
15 . The foaming additive of claim 14 wherein the blowing agent is solid.
16 . The foaming additive of claim 14 wherein the blowing agent is inorganic.
17 . The foaming additive of claim 16 wherein the blowing agent includes a carbonate salt.
18 . The foaming additive of claim 17 wherein the blowing agent includes sodium bicarbonate and/or sodium carbonate.
19 . The foaming additive of claim 14 wherein the amphiphilic block copolymer includes a polyolefin block and a polyalkylene oxide block.
20 . The foaming additive of claim 14 comprising at least about 5 wt % of the blowing agent.
21 . The foaming additive of claim 14 further comprising at least about 10 wt % of a polymeric carrier.
22 . The foaming additive of claim 14 further comprising a hydrophilic dispersion aid.
23 . The foaming additive of claim 22 wherein the hydrophilic dispersion aid includes water, polyalkylene glycol, polyvinyl alcohol, and/or glycerol.
24 . The foaming additive of claim 14 further comprising
a polymeric carrier;
wherein the foaming additive comprises
about 20 to 60 wt % of the polymeric carrier;
about 10 to 60 wt % of the blowing agent; and
no more than about 10 wt % of the amphiphilic block copolymer.
25 . A foamed material prepared using the foaming additive of claim 14 .
26 . A melt processable composition comprising the foaming additive of claim 14 and a thermoplastic polymeric component.
27 . A foaming additive comprising:
a polymeric carrier;
one or more carbonate salts;
an amphiphilic block copolymer.
28 . The foaming additive of claim 27 wherein the polymeric carrier has a melting point of no more than about 150° C.
29 . The foaming additive of claim 27 wherein the one or more carbonate salts include sodium carbonate and/or sodium bicarbonate.
30 . The foaming additive of claim 27 wherein the amphiphilic block copolymer is nonionic.
31 . The foaming additive of claim 27 wherein the amphiphilic block copolymer includes a polyolefin block and a polyalkylene oxide block.
32 . The foaming additive of claim 27 comprising at least about 10 wt % of the one or more carbonate salts.
33 . The foaming additive of claim 27 comprising no more than 5 wt % of the amphiphilic block copolymer.
34 . The foaming additive of claim 27 further comprising at least about 20 wt % of the polymeric carrier.
35 . The foaming additive of claim 27 further comprising a hydrophilic dispersion aid.
36 . The foaming additive of claim 35 wherein the hydrophilic dispersion aid includes water, polyalkylene glycol, polyvinyl alcohol, and/or glycerol.
37 . The foaming additive of claim 35 wherein a weight ratio of the one or more carbonate salts to the hydrophilic dispersion aid is about 1 to 6.
38 . The foaming additive of claim 27 further comprising
a hydrophilic dispersion aid;
wherein the foaming additive comprises
about 30 to 55 wt % of the polymeric carrier;
about 15 to 50 wt % of the one or more carbonate salts; and
no more than about 5 wt % of the amphiphilic block copolymer; and
wherein a weight ratio of the one or more carbonate salts to the hydrophilic dispersion aid is about 0.6 to 10.
39 . A foamed material prepared using the foaming additive of claim 27 .
40 . The foamed material of claim 39 wherein the foamed material is a structural building member or an automotive component.
41 . A melt processable composition comprising the foaming additive of claim 27 and a thermoplastic polymeric component.
42 . A method of producing a foamed composite material comprising:
mixing a foaming additive, a filler, and a first thermoplastic polymeric component to provide a first blend;
activating the blowing agent to provide a foamed blend;
wherein the foaming additive includes a blowing agent and an amphiphilic block copolymer.
43 . A method of producing a foamed composite material comprising:
heating a first blend that includes a filler, a blowing agent, an amphiphilic block copolymer, and a thermoplastic polymeric component at a temperature sufficient to form a foamed blend.
44 . A foaming additive comprising:
a hydrophilic blowing agent; and
a hydrophilic dispersion aid;
wherein a weight ratio of the hydrophilic blowing agent to the hydrophilic dispersion aid is about 0.6 to 10.
45 . A foaming additive comprising:
a compatibilizer;
a hydrophilic blowing agent; and
a hydrophilic dispersion aid.
46 . A melt processable composition comprising:
a blowing agent; and
a polyolefin having a molecular weight of at least about 500,000 and/or a fluoropolymer.
47 . A foamed composite material comprising:
at least about 60 wt % filler; and
a thermoplastic polymeric component;
wherein the foamed composite material has a density of no more than 0.7 g/cm 3 and a flexural modulus of at least about 600 MPa.