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Polystyrene blends and a method of making sameRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Natural Rubber Compositions Having Nonreactive Materials (dnrm) Other Than: Carbon, Silicon Dioxide, Glass Titanium Dioxide, Water, Hydrocarbon, Halohydrocarbon, Ethylenically Unsaturated Reactant Admixed With A Preformed Reaction Product Derived From: (a) At Least One Polycarboxylic Acid, Ester, Or Anhydride; (b) At Least One Polyhydroxy Compound; And (c) At Least One Fatty Acid Glycerol Ester, Or A Fatty Acid Or Salt Derived From A Naturally Occurring Glyceride, Tall Oil, Or A Tall Oil Fatty Acid, At Least One Solid Polymer Derived From Ethylenic Reactants Only, Polymer Mixture Of Two Or More Solid Polymers Derived From Ethylenically Unsaturated Reactants Only; Or Mixtures Of Said Polymer Mixture With A Chemical Treating Agent; Or Products Or Processes Of Preparing Any Of The Above Mixtures, Solid Polymer Derived From Ethylene Or PropylenePolystyrene blends and a method of making same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060281869, Polystyrene blends and a method of making same. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates polystyrene blends. The present invention particularly relates to polystyrene blends prepared using a solution blend process. [0003] 2. Background of the Art [0004] Polystyrene is one of the largest volume thermoplastic resins in commercial production today. Unmodified polystyrene is well suited to applications where its brittleness is acceptable. Engineering plastics have been used in applications where less brittleness is required, but such polymers are often expensive or have properties other than less brittleness that make them less than optimum selections. Thus, styrene-based copolymers, and particularly polystyrene resins that are modified with organic rubber particles, have been investigated for use in applications requiring less brittleness. The modification of polystyrene to reduce brittleness is often referred to increasing its impact properties and thus the modified polystyrene is said to have higher impact. [0005] These high-impact polystyrene blends, commonly referred to by the acronym HIPS, are known to be useful in the art of preparing articles with polymers wherein the application for the articles requires less brittleness than unmodified polystyrene. For example, U.S. Defensive Publication T59,011 to Smith discloses that a high impact resin can be prepared by blending from 15 to 50 parts of an impact modifier with from 85 to 50 parts of a clear crystal polystyrene. Such materials are disclosed to be useful for packaging applications. [0006] Another method of making HIPS is to first dissolve a rubber in styrene monomer and then polymerize the monomer. Such polymers are disclosed in U.S. Pat. No. 6,569,941 to Sosa, et al. Therein, it is disclosed that styrene monomer containing a dissolved polybutadiene rubber is flowed into an elongated upflow stirred reactor containing three reaction zones, wherein the styrene monomer is polymerized to form a HIPS. [0007] It is also known to blend polystyrene with other materials. For example, U.S. Pat. No. 5,194,525, to Miura et al, discloses a continuous process for making polystyrene from styrene monomer and a polymerizable unsaturated fatty acid. The inclusion of the unsaturated fatty acid is disclosed to improve the heat resistance and moldability of the blend, making the modified polystyrene desirable for injection molding applications. [0008] In HIPS, desirably the polystyrene is a continuous phase including a discontinuous phase of rubber particles. The size and distribution of the rubber particles in the continuous polystyrene phase can affect the properties of the HIPS. In blends of polystyrene with other materials, the distribution of the noncontinuous phase in the continuous polystyrene phase is often similarly important. SUMMARY OF THE INVENTION [0009] In one aspect, the present invention is a polystyrene blend wherein the blend is a blend of polystyrene and a polymer selected from the group consisting of syndiotactic polypropylene, ethylene propylene copolymer, and mixtures thereof, and the blend is prepared by solution polymerization. [0010] In another aspect, the present invention is a polystyrene blend wherein the blend is a blend of polystyrene, rubber, and a polymer selected from the group consisting of syndiotactic polypropylene, ethylene propylene copolymer, hydrogenated styrene butadiene copolymers, and mixtures thereof, and the blend is prepared by solution polymerization. [0011] In still another aspect, the present invention is a process for preparing a polystyrene blend, the process including admixing styrene and a polymer selected from the group consisting of syndiotactic polypropylene, ethylene propylene copolymer, and mixtures thereof to form a solution, and then polymerizing the styrene monomer. BRIEF DESCRIPTION OF THE DRAWINGS [0012] For a detailed understanding and better appreciation of the present invention, reference should be made to the following detailed description of the invention and the preferred embodiments, taken in conjunction with the accompanying drawings, wherein: [0013] FIG. 1 is a photomicrograph made using transmission electron microscopy (TEM) techniques of a polystyrene blend including 5 percent syndiotactic polystyrene and 6 percent rubber. [0014] FIG. 2 is a TEM photomicrograph of a polystyrene blend including 10 percent syndiotactic polystyrene and 6 percent rubber. [0015] FIG. 3 is a TEM photomicrograph of a polystyrene blend including 10 percent syndiotactic polystyrene and no rubber. [0016] FIG. 4 is a TEM photomicrograph of a polystyrene blend including 10 percent ethylene propylene copolymer and no rubber. [0017] FIG. 5 is a TEM photomicrograph of a polystyrene blend including 5 percent isotactic polystyrene and 4% polybutadiene. [0018] FIG. 6 is a TEM photomicrograph of a polystyrene blend including 10 percent isotactic polystyrene and 4% polybutadiene. [0019] It will be appreciated that the figures are not necessarily to scale and the proportions of certain features are exaggerated to show detail. DETAILED DESCRIPTION OF INVENTION [0020] In one embodiment, the present invention is a blend of polystyrene and a polymer selected from the group consisting of syndiotactic polypropylene, ethylene propylene copolymer, styrene-butadiene-styrene copolymers, and mixtures thereof. In another embodiment the blend additionally includes a rubber. 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