Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
1998-12-16
2001-02-13
Nutter, Nathan M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S213000, C525S214000, C525S217000, C525S222000, C525S227000, C525S232000, C525S233000, C525S235000, C525S240000
Reexamination Certificate
active
06187865
ABSTRACT:
TECHNICAL FIELD
This invention relates to rubber compositions and laminates thereof. The laminates bring together materials not easily bonded to each other.
BACKGROUND ART
An example of a product where materials are not easily bonded together is a shelf liner. Usually vinyl foams or vinyl solid films are laminated to a non-slip pad or a waterproof layer. The composite of layers produces a protective film covering for a shelf or the bottom of a drawer. This protective laminate stays in place by virtue of a pressure sensitive adhesive or a foam non-slip pad either separate or attached to the under side of the waterproof surface. The products on the market as of this time represent foam layers of vinyl in many geometric conformities from solid to open mesh products either by themselves or laminated to a solid polymeric film. The open mesh product has a plurality of open cells extending through the pad from the top side to the bottom side. Another currently found product is a pre-printed vinyl film of assorted designs and colors adhesively laminated to a layer of open cell latex foam cast and cured to a fabric substrate, prior to lamination. Many inherent problems are found in this product emanating from the laminating heats involved in the formation of the composite, as well as the differential expansion and contraction characteristics of the multiple layers involved. In addition, the multiple processes involved in all of these increase the cost above the value of the product.
DISCLOSURE OF THE INVENTION
Compositions of the invention comprise rubber and a resin component containing at least one ethylene-vinyl acetate copolymer (EVA). My compositions are formulations of a foam energy absorbent pad of a suitable thickness that is formulated to a sufficient degree of surface tack to stay in place and cling to a wide variety of smooth horizontal planes, as well as vertical planes.
The pads can be cast and cured directly on polyvinyl, polypropylene, polyester and olefinic films with excellent adhesion to these films without the use of adhesives, or transition layers of any kind. The product is further formulated to possess effective flex modulus, as well as sufficient resistance to distortion, such that the resulting composite is readily converted into a compact wrinkle free roll that can be wound and unwound without sticking to itself, wrinkling or distorting. Commonly used foams and vinyl films that are found in this type application require the incorporation of a scrim into the composite for sufficient web firmness to permit ease of handling, as well as forming a transition layer between the backing and the top layer. Commonly used foams and films found in this type of application usually require the addition of a pressure sensitive adhesive to stay in place.
In addition, industry has not been able to cast curable foams on a thin thermoplastic web. The type of equipment and conditions that are found in the industry do not produce commercially cost competitive finished products in a continuous production line. The thermoplastic membrane softens and sags or melt flows off of restraining and tensioning and stretching conveyors. Casting of the material on a belt is equally unsatisfactory by virtue of the thermal expansion nature of all thermoplastics resulting in permanent creasing of the composite.
The invention further selects materials that are compatible in such a manner that ingredients from one polymer will not migrate or transfer to the other. The invention further results in a unique copolymer matrix of compatibles that will not migrate and transfer plasticizers or any other compounding ingredients to surface finishes, strains and common acrylic, alkyd or urethane paints or blends thereof.
BEST MODE OF CARRYING OUT INVENTION
Compositions of the invention comprise rubber and a resin component containing at least one ethylene-vinyl acetate copolymer (EVA). Ethylene vinyl acetate copolymers useful in the invention contain at least 15% by weight vinyl acetate. The resin component may contain only ethylene vinyl acetate copolymer or a mixture of EVA copolymers.
The rubbers, latexes or elastomers of this invention may vary widely. Examples of such elastomers include neoprene, EPDM, i.e., ethylene-propylene-diene terpolymer, SBR, i.e., styrene-butadiene rubber, nitrile rubber, and chlorinated polyethylene. Other eligible examples of rubbers include chlorosulfonated polyethylene, chlorinated polyethylene, ethylene-propylene rubber, isoprene-isobutylene rubber, chlorinated or brominated butyl rubber, and nitrile-butadiene rubber.
The compositions may also comprise conventional additives such as reinforcing fillers, pigments such as carbon black, and TiO
2
dyes, ultraviolet stabilizers, plasticizers, fungicides, extenders, waxes, antioxidants, and the like, in amounts known to those skilled in the art.
Other useful fillers include fumed silica, calcium and magnesium carbonates, calcium and barium sulfates, aluminum silicates, and the like, which may be included in small amounts such that they do not interfere with the physical properties required.
This invention is a unique combination of laminated foams and solid plastomeric materials that produce decorative, non-slip, non-marring, protective, shock absorbing coverings for a variety of purposes. These laminates have the ability to adhere to horizontal and vertical smooth and semi smooth surfaces of any kind without the need for adhesives of any kind.
This invention brings together polymers not generally considered capable of easily being bonded or joined to each other. Vinyl, polyethylene and olefin films are considered difficult to bond to most other type elastomeric films such that adhesives, transition layers, or mechanical means have to be resorted to for simple laminations of unlike polymeric materials.
Weight percent as used herein is based on the total weight of the composition being 100 percent. Molecular weight as used herein means weight average molecular weight. Parts as used herein is are based on weight. Parts are expressed as parts per 100 parts of rubber (PHR). Regarding, the amount of additives and fillers present, the expression “up to” is used herein. The expression is intended to mean effective amounts for the intended purpose which are greater than zero.
The present insertion will be better understood by reference to the following examples.
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Emch, Schaffer, Schaub & Porcello & Co., L.P.A.
Ludlow Composites Corporation
Nutter Nathan M.
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