Extruded thermoplastic foams and uses in applications requiring strength and lightweight

Patent metadata

Field	Value
Publication number	US-2025154929-A1
Application number	US-202418946114-A
Country	US
Kind code	A1
Filing date	Nov 13, 2024
Priority date	Nov 13, 2023
Publication date	May 15, 2025
Grant date	—

Abstract

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.

First claim

What is claimed is:

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 125 kg/m 3 to about 425 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
(b) 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 to about 140,000.

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 130 kg/m 3 to about 400 kg/m 3 .

7 . A faced foam comprising:
a. an extruded thermoplastic foam core having a foam density of from about 125 kg/m 3 to about 425 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 first foam.

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 130 kg/m 3 to about 425 kg/m 3 .

12 . The foam article of claim 11 wherein said extruded foam has foam density of from about 130 kg/m 3 to about 400 kg/m 3 and a compressive strength of from about 1 MPa to about 14 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 to about 140,000.

17 . The foam article of claim 15 wherein said thermoplastic polymer has a molecular weight of from about 80,000 to about 130,000.

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.

Assignees

• Honeywell Int Inc

Inventors

• Abrevaya Hayim
• Lehuta Keith
• Martins Susie

Classifications

• F03D1/0682 Primary

  incorporated into the shell structure · CPC title

• F05B2230/24

  by extrusion · CPC title

• F05B2280/4011

  Organic materials not otherwise provided for · CPC title

• F05B2280/6012

  Foam · CPC title

• F05B2280/4007

  Thermoplastics · CPC title