Polymer mixture, multilayer article containing the same, and process of preparing the multilayer article

Patent metadata

Field	Value
Publication number	US-11098219-B2
Application number	US-201415537565-A
Country	US
Kind code	B2
Filing date	Dec 22, 2014
Priority date	Dec 22, 2014
Publication date	Aug 24, 2021
Grant date	Aug 24, 2021

Abstract

A novel polymer mixture having fast drying time, a multilayer article comprising at least one layer of the dried polymer mixture and having good mechanical properties, and a method of preparing the multilayer article.

First claim

What is claimed is:

1. A polymer mixture for a multilayer article, wherein the polymer mixture comprises an aqueous binder composition and vulcanized or crosslinked rubber, wherein the aqueous binder composition comprises:
(a) an acrylic emulsion (co)polymer;
(b) a crosslinking agent comprising a water-dispersible isocyanate composition; and
(c) a foaming agent; and
wherein the crosslinking agent further comprises an epoxy silane,
wherein the vulcanized or crosslinked rubber comprises rubber powder having a sieve particle size less than 0.5 mm; and the weight ratio of the total solids weight of the acrylic emulsion (co)polymer to the total weight of the vulcanized or crosslinked rubber is from 1:4 to 1:0.5.

2. The polymer mixture of claim 1 , wherein the crosslinking agent is present in an amount of from 2 to 40 wt %, based on the total solids weight of the acrylic emulsion (co)polymer.

3. The polymer mixture of claim 1 , wherein the foaming agent is selected from sodium oleate, sodium alkylsulfonate, sodium alkylbenzenesulfonate, or mixtures thereof.

4. The polymer mixture of claim 1 , wherein the aqueous binder composition comprises, based on the total solids weight of the acrylic emulsion (co)polymer, from 5 to 95 wt % of a first acrylic emulsion (co)polymer having a glass transition temperature of −5° C. or less, and from 5 to 95 wt % of a second acrylic emulsion (co)polymer having a glass transition temperature of at least 15° C.

5. The polymer mixture of claim 1 , wherein the acrylic emulsion (co)polymer comprises as polymerized units, at least one ethylenically unsaturated nonionic monomer, and at least one ethylenically unsaturated monomer having at least one functional group selected from carbonyl, acetoacetate, alkoxysilane, carboxyl, ureido, amide, imide or amino group, or mixtures thereof.

6. The polymer mixture of claim 1 , wherein the vulcanized or crosslinked rubber further comprises rubber particles having a sieve particle size of 0.5 to 6 mm.

7. The polymer mixture of claim 1 , wherein the aqueous binder composition further comprises a foaming stabilizer, a silicone dispersion, or mixtures thereof.

8. A multilayer article comprising:
(i) a base layer of a dried polymer mixture, wherein the polymer mixture comprises an aqueous binder composition and vulcanized or crosslinked rubber, wherein the aqueous binder composition comprises:
(a) an acrylic emulsion (co)polymer;
(b) a crosslinking agent comprising a water-dispersible isocyanate composition; and
(c) a foaming agent; and
wherein the crosslinking agent further comprises an epoxy silane,
wherein the vulcanized or crosslinked rubber comprises rubber powder having a sieve particle size less than 0.5 mm; and the weight ratio of the total solids weight of the acrylic emulsion (co)polymer to the total weight of the vulcanized or crosslinked rubber is from 1:4 to 1:0.5; and
(ii) a top layer made from an aqueous top coating composition comprising an acrylic emulsion (co)polymer and vulcanized or crosslinked rubber.

9. The multilayer article of claim 8 , wherein the top coating composition comprises:
a first acrylic emulsion (co)polymer having a glass transition temperature of −5° C. or less,
a second acrylic emulsion (co)polymer having a glass transition temperature of at least 15° C.,
a crosslinking agent comprising a water-dispersible isocyanate composition, and the vulcanized or crosslinked rubber.

10. The multilayer article of claim 8 , wherein the vulcanized or crosslinked rubber in the top coating composition are rubber particles having a sieve particle size of from 0.5 to 6 mm and the weight ratio of total solids weight of the acrylic emulsion (co)polymer to the weight of the vulcanized or crosslinked rubber particles is from 1:2 to 1:4.

11. The multilayer article of claim 8 , wherein the multilayer has a thickness of at least 10 mm, the volume ratio of the base layer to the multilayer article is from 40 to 95%, and the volume ratio of the top layer to the multilayer article is from 5 to 60%.

12. The multilayer article of claim 8 , wherein the multilayer article has a tensile strength of at least 0.5 MPa and an elongation at break of at least 50%, according to the GB/T 14833-2011 standard.

13. The multilayer article of claim 8 , wherein the crosslinking agent is present in an amount of from 2 to 40 wt %, based on the total solids weight of the acrylic emulsion (co)polymer.

14. The multilayer article of claim 8 , wherein the foaming agent is selected from sodium oleate, sodium alkylsulfonate, sodium alkylbenzenesulfonate, or mixtures thereof.

15. The multilayer article of claim 8 , wherein the aqueous binder composition comprises, based on the total solids weight of the acrylic emulsion (co)polymer, from 5 to 95 wt % of a first acrylic emulsion (co)polymer having a glass transition temperature of −5° C. or less, and from 5 to 95 wt % of a second acrylic emulsion (co)polymer having a glass transition temperature of at least 15° C.

16. The multilayer article of claim 8 , wherein the acrylic emulsion (co)polymer comprises as polymerized units, at least one ethylenically unsaturated nonionic monomer, and at least one ethylenically unsaturated monomer having at least one functional group selected from carbonyl, acetoacetate, alkoxysilane, carboxyl, ureido, amide, imide or amino group, or mixtures thereof.

17. The multilayer article of claim 8 , wherein the vulcanized or crosslinked rubber further comprises rubber particles having a sieve particle size of 0.5 to 6 mm.

18. The multilayer article of claim 8 , wherein the aqueous binder composition further comprises a foaming stabilizer, a silicone dispersion, or mixtures thereof.

19. A method of preparing the multilayer article of claim 8 , comprising:
(1) providing a polymer mixture, wherein the polymer mixture comprises an aqueous binder composition and vulcanized or crosslinked rubber, wherein the aqueous binder composition comprises:
(a) an acrylic emulsion (co)polymer;
(b) a crosslinking agent comprising a water-dispersible isocyanate composition; and
(c) a foaming agent; and
wherein the crosslinking agent further comprises an epoxy silane,
wherein the vulcanized or crosslinked rubber comprises rubber powder having a sieve particle size less than 0.5 mm; and the weight ratio of the total solids weight of the acrylic emulsion (co)polymer to the total weight of the vulcanized or crosslinked rubber is from 1:4 to 1:0.5;
(2) applying the polymer mixture to a substrate;
(3) drying and curing the polymer mixture to form a base layer;
(4) providing the aqueous top coating composition;
(5) applying the top coating composition to the base layer; and
(6) drying and curing the top coating composition to form a top layer, such that the base layer resides between the substrate and the top layer.

Assignees

• Dow Global Technologies Llc

Inventors

• Zhang Liang
• Li Wei
• Jiang Jingui

Classifications

• C08J2201/0504

  the liquid phase being aqueous · CPC title

• C08J9/0023

  containing oxygen · CPC title

• C08J9/30

  by mixing gases into liquid compositions or plastisols, e.g. frothing with air · CPC title

• C08G18/003

  with epoxy compounds having no active hydrogen (with epoxy resins containing active hydrogen C08G18/58) · CPC title

• C08J2201/026

  Crosslinking before of after foaming · CPC title