Method to make an elastomeric polyolefin skin

Patent metadata

Field	Value
Publication number	US-10875050-B2
Application number	US-201615554910-A
Country	US
Kind code	B2
Filing date	Mar 1, 2016
Priority date	Mar 18, 2015
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

The present invention relates to method to make a spray skin from an aqueous polyolefin dispersion composition comprising a an olefin block copolymer, a dispersing agent, preferably an ethylene acrylic acid, and water, wherein said aqueous dispersion preferably has a pH less than 12 and is derived from the melt blending. The method comprises the steps of spraying the aqueous polyolefin dispersion onto a heated mold forming the skin and then allowing it to dry.

First claim

What is claimed is:

1. A process for making a spray skin comprising the steps of:
(i) spraying an aqueous polyolefin dispersion onto a heated mold forming a sprayed skin having a first surface and a second surface, and
(ii) allowing the sprayed skin to dry,
wherein the aqueous polyolefin dispersion is derived from the melt blending of (A) a polyolefin composition comprising an olefin block copolymer in the presence of (B) at least one dispersing agent which is a polar polymer and (C) water and wherein the aqueous polyolefin dispersion consists essentially of the olefin block copolymer, the dispersing agent, water, and optionally one or more of dye, a pigment, an organic filler, an inorganic filler, a plasticizer, a stabilizer, a surfactant, an anti-static agent, a tackifier, an oil extender, a chemical blowing agent, an anti-microbial agent, a thickening agent, an age resister, an aqueous acrylic dispersion, or an aqueous polyurethane dispersion.

2. The process of claim 1 wherein (A) the polyolefin composition comprising the olefin block copolymer further comprises one or more of a random olefin copolymer, a polyethylene, a propylene, a propylene, ethylene, α-olefin, a non-conjugated dienes based copolymers, an ethylene-vinyl acetate, an ethylene-vinyl alcohol, a chlorinated polyethylene, an alcohol functionalized polyolefin, an amine functional polyolefin, or a silane grafted polyolefin.

3. The process of claim 1 wherein (B) the dispersing agent comprises a polymer selected from the group consisting of ethylene acrylic acid (EAA), ethylene-methacrylic acid (EMA), ethylene ethyl acrylate (EEA), ethylene methyl methacrylate (EMMA), or ethylene butyl acrylate (EBA).

4. The process of claim 1 wherein the aqueous polyolefin dispersion is derived from the melt blending of (A) an olefin block copolymer in the presence of (b) an ethylene acrylic acid as a dispersing agent and (C) water.

5. The process of claim 1 wherein the polyolefin composition comprises one or more of a dye, a pigment, an organic filler, an inorganic filler, a plasticizer, a stabilizer, a surfactant, an anti-static agent, a tackifier, an oil extender, a crosslinking agent, a chemical blowing agent, an anti-microbial agent, a thickening agent, or an age resister.

6. The process of claim 1 wherein the mold is heated to equal to or greater than 50° C.

7. The process of claim 1 further comprising the step of (iii) applying a paint layer to the first surface of the spray skin.

8. The process of claim 1 further comprising the step of (iv) providing a foam backing to the second surface of the spray skin.

9. The process of claim 1 further comprising the step of (iii) applying a paint layer to the first surface of the spray skin and the step of (iv) providing a foam backing to the second surface of the spray skin.

10. The process of claim 1 wherein the aqueous polyolefin dispersion is blended with an aqueous colorant.

11. The process of claim 1 further comprising bonding the skin to another structure.

12. The process of claim 11 wherein the bonding comprises laminating.

13. The process of claim 7 which forms an automotive interior article.

14. The process of claim 8 which forms an automotive interior article.

15. The process of claim 11 which forms an automotive interior article.

16. The process of claim 1 wherein the aqueous polyolefin dispersion consists of the olefin block copolymer, the dispersing agent, water, and optionally one or more of dye, a pigment, an organic filler, an inorganic filler, a plasticizer, a stabilizer, a surfactant, an anti-static agent, a tackifier, an oil extender, a chemical blowing agent, an anti-microbial agent, a thickening agent, an age resister, an aqueous acrylic dispersion, or an aqueous polyurethane dispersion.

Assignees

• Dow Global Technologies Llc
• Dow Global Technlogies LLC

Inventors

• Walia Parvinder S
• Chaudhary Amit K
• Klumb George A

Classifications

• C09D153/00 Primary

  Coating compositions based on block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers · CPC title

• B05D1/02 Primary

  performed by spraying · CPC title

• C09D153/005 Primary

  Modified block copolymers · CPC title

• C09D123/0815

  Copolymers of ethene with aliphatic 1-olefins · CPC title

• C09D7/40

  Additives · CPC title