Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Reexamination Certificate
2003-02-28
2004-06-22
Foelak, Morton (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
C521S071000
Reexamination Certificate
active
06753355
ABSTRACT:
The invention relates to a novel composition containing latex and either a polynitrile oxide or an epoxy silane or a combination of the two, and a process using this composition in foam coating in the preparation of, for instance, flooring, wall covering, shoe lining, and non-woven materials.
Latex foam using high solids latex (HSL) crosslinked by sulfur vulcanization is well known. In certain applications, the latex is employed in the manufacture of flooring, wall covering, shoe lining and non-woven materials. The end user may add fillers to enhance desired properties prior to coating a given substrate with a foam layer made from the latex. New, improved latex compositions for foaming applications are highly sought, particularly compositions that provide crosslinking ability yet may be stored for extended periods of time, with crosslinking being initiated when desired.
The present invention provides a solution to one or more of the disadvantages and deficiencies described above.
In one broad respect, this invention is a composition comprising a carboxylated latex and either a polynitrile oxide or an epoxy silane, or a combination of the polynitrile oxide and epoxy silane, for crosslinking. In one embodiment, the latex is a carboxylated styrene-butadiene polymer. The latex may be bimodal. The composition may also contain various components to improve physical properties of the resulting foam. For example, the composition may include performance enhancing additives, such as paraffin wax and silicone detackifier. Advantageously, the latex composition may be supplied to the point of manufacture where inorganic or organic filler can be added to enhance desired properties. More advantageously, no additional curing pastes, gelling agents, accelerators or stabilizers are required in the practice of this invention. The emulsion, in one non-limiting embodiment, is stable for at least twelve months at ambient temperatures. During processing, the resulting foam will cross-link in the backing process to improve final end properties such that the product has sufficient strength. The present invention provides a simple means of preparing one-part coating systems that can be cured at room temperature without the release of by-products.
In another broad aspect, this invention is a process useful for forming an article of manufacture, comprising applying a foam to a substrate wherein the foam is formed from a composition comprising a latex and either a polynitrile oxide or an epoxy silane or a combination of the two. This process is particularly advantageous in applying a backing such as in the manufacture of flooring, wall covering, shoe lining, or non-woven material.
In another broad aspect, this invention is a structure that comprises a substrate attached to a latex foam that includes a polynitrile oxide, an epoxy silane, or a combination thereof. In one embodiment, this invention also encompasses an article of manufacture which comprises a substrate bonded to a latex foam, wherein the foam is also adhered to a second substrate to form a three-component structure, wherein the foam is made from the composition containing latex and either a dinitrile oxide or an epoxy silane or a combination of the two.
In another broad respect, this invention is a foam made by foaming a composition comprising latex and either polynitrile oxide or epoxy silane or a combination of the two.
A wide variety of latexes may be used in the practice of this invention. Representative monomers useful in preparing the latexes of this invention and methods for preparing the individual separate particles are well known, such as those described in U.S. Pat. Nos. 3,404,116 and 3,399,080, the teachings of which are incorporated herein by reference. Examples of suitable monomers for providing a carboxylate character include acrylic acid, methacrylic acid, itaconic acid, and fumaric acid. Examples of monomers suitable for preparing the latexes of this invention can include the olefins such as ethylene and propylene, vinyl acetate, alkyl acrylates, hydroxyalkyl acrylates, alkyl methacrylates, hydroxyalkyl methacrylates, acrylamide, n-methyloylacrylamides, as well as monomers such as vinyl chloride and vinylidene chloride. Especially preferred latexes include modified styrene/butadiene latexes such as, for example, styrene/butadiene/acrylic acid, styrene/butadiene/acrylic acid/itaconic acid, styrene/butadiene/vinylidene chloride, styrene/butadiene/beta-hydroxyethyl acrylate, styrene/butadiene/beta-hydroxyethylacrylate/acrylic acid, styrene
-butylacrylate/acrylic acid, methyl methacrylate
-butylacrylate/acrylic acid, vinyl acetate/acrylic acid, vinyl acetate
-butylacrylate/acrylic acid, and/or styrene
-butyl acrylate/butadiene/acrylic acid. Mixtures of carboxylic acids can be employed in the aforementioned latexes.
In the practice of this invention, one may employ carboxylated latex comprised of a copolymer of a vinyl aromatic monomer and an unsaturated carboxylic acid monomer. The copolymer may further comprise a diene monomer.
The vinyl aromatic monomer may be selected from styrene, alpha-methylstyrene, ethylstyrene, dimethylstyrene, t-butylstyrene, vinylnaphthalene, methoxystyrene, cyanostyrene, acetylstyrene, monochlorostyrene, dichlorostyrene, and other halostyrenes, and mixtures thereof. The vinyl aromatic monomer may be present in any effective amount. The vinyl aromatic monomer may be present in amounts of from approximately 0 to 75 percent by weight, based on the total weight of the polymer resin. In one embodiment, the vinyl aromatic monomer is present in amounts of from approximately 35 to 70 percent by weight. It is understood that the percentage of monomers in the final polymer will equal 100 percent.
The ethylenically unsaturated carboxylic acid may be a monocarboxylic acid, or a dicarboxylic acid or a polycarboxylic acid, such as, for example, acrylic acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, derivatives thereof, and mixtures thereof.
The ethylenically unsaturated carboxylic acid monomer may be present in amounts of from approximately 0.5 to 25 percent by weight, based on the total weight of the polymeric resin. In one embodiment, the ethylenically unsaturated acid monomer is present in amounts of from approximately 1 to 5 percent by weight and, in another embodiment, is from 3 to 5 percent by weight, based on the total weight of the copolymer.
The diene monomer, when present, may be selected from butadiene, isoprene, divinylbenzene, derivatives thereof and mixtures thereof. The 1,3-butadiene monomer is preferred. The diene monomer may be present in amounts of from 0 to 85 percent by weight, and in one embodiment is from 30 to 65 percent by weight, based on the total weight of the polymer resin.
The latex may comprise an additional ethylenically unsaturated monomeric component or components. Specific examples of such ethylenically unsaturated compounds include methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacrylonitrile, ethyl-chloroacrylate, diethyl maleate, polyglycol maleate, vinyl chloride, vinyl bromide, vinylidene chloride, vinylidene bromide, vinyl methyl ketone, methyl isopropenyl ketone, and vinyl ethyl ester. Derivatives thereof and/or mixtures thereof may be included.
The latex may comprise a styrene/butadiene/acrylic acid co polymer or a styrene/butadiene/hydroxy-ethylacrylate/itaconic acid copolymer. The latex may also include a mixture of copolymers. A mixture of styrene/butadiene/acrylic acid and styrene/butadiene/-hydroxyethylacrylate/itaconic acid polymers in approximately equal amounts by weight may be used.
Such monomers are copolymerized in an aqueous emulsion containing surfactants and modifiers under conditions of time, temperature, pressure, and agitation in accordance with well known principles of emulsion polymerization.
The bimodal latexes that can be used in this invention may be characterized as having two separate and distinct particle size distributions, hi
Kennedy James G.
Stollmaier Friederike
Dow Global Technologies Inc.
Foelak Morton
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