Spray dried polyolefin elastomer powder for rotational molding processes

Patent metadata

Field	Value
Publication number	US-2018044536-A1
Application number	US-201615554902-A
Country	US
Kind code	A1
Filing date	Mar 1, 2016
Priority date	Mar 31, 2015
Publication date	Feb 15, 2018
Grant date	—

Abstract

The present invention relates to a method to make a rotational molded skin from a powdered polyolefin elastomer composition derived from spray drying an aqueous polyolefin dispersion composition wherein the aqueous polyolefin dispersion composition is derived from melt blending a polyolefin composition comprising an olefin block copolymer, a dispersing agent, and water, wherein said aqueous dispersion preferably has a pH less than 12.

First claim

What is claimed is:

1 . A process for making a rotational molded skin comprising the steps of:
(i) forming an aqueous polyolefin dispersion by melt blending
(A) a polyolefin composition comprising an olefin block coploymer in the presence of
(B) at least one dispersing agent and
(C) water,
(ii) spray drying said dispersion forming a powdered polyolefin composition having an average particle size equal to or less than 350 microns, and (iii) rotational molding said powdered polyolefin composition into a skin wherein the skin has a first surface and a second surface.

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 is ethylene acrylic acid (EAA), ethylene-methacrylic acid (EMA), ethylene ethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA), or ethylene butyl acrylate (EBA).

4 . The process of claim 1 wherein (B) the dispersing agent is a long chain fatty acid having from 12 to 60 carbon atoms or a fatty acid salt having from 12 to 60 carbon atoms.

5 . 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) a long chain fatty acid having from 12 to 60 carbon atoms or a fatty acid salt having from 12 to 60 carbon atoms a dispersing agent and (C) water.

6 . 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.

7 . The process of claim 1 further comprising the step of (iii) applying a paint or lacquer layer to the first surface of the rotational molded 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 or lacquer 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.

Assignees

• Dow Global Technologies Llc

Inventors

• Walia Parvinder S
• Hong Liang
• Jones Mary Ann
• Malotky David L
• Sekharan Manesh Nadupparambil

Classifications

• C09D7/69

  Particle size larger than 1000 nm · CPC title

• C09D153/005

  Modified block copolymers · CPC title

• C09D5/031 Primary

  characterised by particle size or shape · CPC title

• B29C41/18

  Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off · CPC title

• C09D5/03

  Powdery paints · CPC title