Heat-resistant foamed polyesters

Claim 1

A process for preparing a thermoformed, foamed, crystalline, high molecular weight linear polyester sheet, said process comprising the steps of: (i) reacting a homogeneous mixture consisting essentially of: (a) a high molecular weight linear polyester, which is a polycondensation product of an aromatic dicarboxylic acid and a glycol; and (b) a high molecular weight linear aromatic polycarbonate represented by the repeating structural unit of the formula: ##STR9## wherein X is a divalent hydrocarbon radical with a total of from 2 up to about 9 carbon atoms selected from the group consisting of ##STR10## in which R 1 represents a member selected from the group consisting of hydrogen and lower alkyl and R 2 represents a member selected from the group consisting of phenyl and alkyl of 1 to 7 carbon atoms, in a weight ratio of (a):(b) of about 20:1 to 1:20, at a temperature and for a period of time sufficient to form the mixture into a softened foamable mass and to release carbon dioxide from said polycarbonate for foaming said mass; (ii) extruding said foamable mass of step (i) into a sheet at a pressure sufficient to cause the released carbon dioxide to expand and reduce the density of the extruded sheet; (iii) cooling said sheet of step (ii) on a chill roll at a temperature from about 70° F. to about 120° F. to inhibit crystallization whereby the average crystallinity of said sheet is in the range from about 0% to about 18%; (iv) contacting said sheet of step (iii) with a mold which is at a temperature in the range of from about 240°-350° F.; (v) applying forces comprising a differential in applied pressure to said sheet of step (iv) so as to make said sheet conform to said mold, whereby a thermoformed sheet is made; (vi) allowing said thermoformed sheet of step (v) to remain in contact with said mold until an average crystallinity of at least about 20% is achieved; and (vii) removing said thermoformed sheet of step (vi) from said mold.