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WO2015049641A1 - Composition, kit et procédé de production de mousse de latex - Google Patents

Composition, kit et procédé de production de mousse de latex Download PDF

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Publication number
WO2015049641A1
WO2015049641A1 PCT/IB2014/064983 IB2014064983W WO2015049641A1 WO 2015049641 A1 WO2015049641 A1 WO 2015049641A1 IB 2014064983 W IB2014064983 W IB 2014064983W WO 2015049641 A1 WO2015049641 A1 WO 2015049641A1
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WIPO (PCT)
Prior art keywords
composition
gelling agent
latex
latex foam
foam
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Ceased
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PCT/IB2014/064983
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English (en)
Inventor
Jean de Dieu HAKUZIMANA
Quintin Keil
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EOC BELGIUM NV
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EOC BELGIUM NV
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Publication date
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Priority to EP14802145.4A priority Critical patent/EP3052558A1/fr
Publication of WO2015049641A1 publication Critical patent/WO2015049641A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/30—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by mixing gases into liquid compositions or plastisols, e.g. frothing with air
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0004—Use of compounding ingredients, the chemical constitution of which is unknown, broadly defined, or irrelevant
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/022—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/026—Crosslinking before of after foaming
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/02—Foams characterised by their properties the finished foam itself being a gel or a gel being temporarily formed when processing the foamable composition
    • C08J2205/022—Hydrogel, i.e. a gel containing an aqueous composition
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2309/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
    • C08J2309/06—Copolymers with styrene
    • C08J2309/08—Latex
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2313/00—Characterised by the use of rubbers containing carboxyl groups
    • C08J2313/02—Latex

Definitions

  • the present invention concerns a composition, kit, and method for the production of latex foam.
  • the invention concerns a composition for the production of a latex foam, wherein the composition contains the following components: a latex, a cross- linker, and optionally, a gelling agent or latent gelling agent.
  • Latex foam is a soft form of latex having a light weight. Its most desirable properties are considered to be (i) that of gripping a substrate, or its anti-slip property with respect to two surfaces between which a latex foam is placed, and (ii) its cushioning properties. The most important application of latex foam is as an underlay for carpets in order to minimize slipping thereof. Other known applications of latex foam are gloves for goalkeepers in football or the use of latex foam in masks or facial prostheses. Latex foam is produced from a liquid latex base containing a variety of additives that is foamed and then poured or injected into a mould. Finally, the liquid latex foam is dried and/or cured in an oven.
  • WO 02/26873 describes a composition that is suitable for preparing latex foam.
  • the composition contains a latex and a polynitrile oxide such as 2,4,6-triethyl-l,3-DNile oxide or a latex and an epoxy silane, or a latex and a mixture of two of said curing agents.
  • the composition may also contain extra components such as fillers, surfactants, foam stabilizers, foam boosters, components for reducing viscosity and improving resilience, and antioxidants.
  • the composition is particularly well-suited for use in the production of floors, wall coverings, shoe soles, and non-woven materials. Nevertheless, new, improved compositions for the production of latex foam are needed.
  • the present invention provides a solution to at least one of the aforementioned problems by providing a composition, kit, and method for the production of latex foam as described in claims 1 to 19.
  • the present invention provides a composition for the production of a latex foam, comprising :
  • said latent gelling agent is convertible to a gelling agent.
  • the present invention provides a kit for the production of a latex foam, comprising a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent.
  • the present invention provides a method for the production of a latex foam using a kit according to the third embodiment of the invention, comprising the following steps:
  • the present invention provides a method for the production of a latex foam, comprising the steps of:
  • the present invention provides a method for the production of a latex foam, comprising the steps of:
  • composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent, thus obtaining an aqueous latex foam;
  • the present invention provides a latex foam that can be obtained by means of a method according to the fourth embodiment of the invention.
  • the present invention provides a latex foam that can be obtained by means of a method according to the fifth embodiment of the invention.
  • the present invention provides a product comprising a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as surgical gloves.
  • a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres,
  • the invention concerns a composition, kit, and method for the production of latex foam.
  • the present invention provides a composition for the production of a latex foam, comprising :
  • said latent gelling agent is convertible to a gelling agent.
  • Examples of monomers that are suitable for preparing the latex for application of this invention are olefins, such as - but not limited to - ethene, propene, vinyl acetate, alkyl acrylates, hydroxyalkyl acrylates, methyl alkyl acrylates, hydroxyalkyl methacrylates, acrylamide, n-methyl thyloylacrylamides, and monomers such as vinyl chloride and vinylidene chloride.
  • olefins such as - but not limited to - ethene, propene, vinyl acetate, alkyl acrylates, hydroxyalkyl acrylates, methyl alkyl acrylates, hydroxyalkyl methacrylates, acrylamide, n-methyl thyloylacrylamides, and monomers such as vinyl chloride and vinylidene chloride.
  • said latex comprises a modified styrene/butadiene unit such as, but not limited to, styrene/butadiene/acrylic acid, styrene/butadiene/acrylic acid/itaconic acid, styrene/butadiene/vinylidene chloride, styrene/butadiene/beta-hydroxyethyl acrylate, styrene/butadiene/beta-hydroxyethyl acrylate/acrylic acid, styrene/n-butyl acrylate/acrylic acid, methyl methacrylate/n-butyl acrylate/acrylic acid, vinyl acetate/acrylic acid, vinyl acetate/n-butyl acrylate/acrylic acid and/or styrene/n- butyl acrylate and butadiene/acrylic acid.
  • a modified styrene/butadiene unit such as, but
  • ком ⁇ онент can be used in the aforementioned latex.
  • a carboxylated latex obtained from a copolymer of a vinyl aromatic monomer and an unsaturated carboxylic acid monomer may be used.
  • the copolymer may also include a diene monomer.
  • Said vinyl aromatic monomer may be selected from the group comprising styrene, alpha-methyl styrene, ethyl styrene, dimethyl styrene, t-butyl styrene, vinyl naphthalene, methoxy styrene, cyanostyrene, acetyl styrene, monochlorostyrene, dichlorostyrene and other halostyrenes or mixtures thereof.
  • the vinyl aromatic monomer may be contained in any effective amount.
  • the vinyl aromatic monomer may be contained in an amount of approximately 0 to 75% by wt. based on the total weight of the polymer.
  • said vinyl aromatic monomer is contained in an amount of approximately 25 to 60% by wt. based on the total weight of the polymer.
  • Said unsaturated carboxylic acid monomer may contain a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid such as, but not limited to, acrylic acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, and derivatives of the aforementioned acids and mixtures thereof.
  • the aforementioned unsaturated carboxylic acid monomer may be contained in an amount of 0.5 to 25.0% by wt. based on the total weight of the polymer. More preferably, said unsaturated carboxylic acid monomer is contained in an amount of approximately 1 to 5% by wt., and most preferably in an amount of 2 to 4% by wt. based on the total weight of the polymer.
  • said diene monomer may be selected for example from the group comprising, but not limited to butadiene, isoprene, divinyl benzene, derivatives thereof, and mixtures thereof. Most preferably, said diene monomer is 1,3- butadiene.
  • the aforementioned diene monomer may be present in an amount of 0 to 85% by wt., and more preferably 40 to 75% by wt. based on the total weight of the polymer.
  • a latex may also contain an extra ethene-unsaturated monomer component or components.
  • ethylene-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, vinyl bromide, vinylmethyl ketone, methyl isopropenyl ketone, and vinyl ethyl ester.
  • derivatives of the aforementioned compounds and/or mixtures thereof may be included.
  • the aforementioned monomers are preferably polymerized in an aqueous emulsion with surfactants and regulators under specific conditions of time, temperature, pressure, and agitation in accordance with the known principles of emulsion polymerization.
  • cross-linker' is to be understood as a synonym for terms such as 'curing means,' 'curing agent,' 'hardening means,' 'hardening agent,' 'hardener', 'cross- linking additive,' 'cross-linking means,' or 'cross-linking agent' and includes substances or mixtures of substances that are added to a polymer composition in order to promote or control the curing reaction.
  • the term 'cross-linker' preferably refers to a reactive hardening agent or curing agent that is provided with at least two functional groups that can react with a carboxylic acid group or form an ionic, coordinate, or covalent chemical bond and are therefore suitable for curing a polymer.
  • said catalyst is selected from the group including ethyltriphenyl phosphonium acetate, ethyltriphenyl phosphonium bromide, and methyltrioctyl ammonium chloride, most preferably ethyltriphenyl phosphonium bromide.
  • the aforementioned catalyst may be present in an amount of approximately 0.1 to approximately 10.0% by wt., preferably 0.3 to 2.0% by wt. based on the total weight of the cross-linker composition.
  • the advantage of using a latent gelling agent is that the composition can be stored under normal storage conditions such as room temperature and normal air pressure without causing premature gelling due to the latex composition .
  • the gelling takes place only after said latent gelling agent is activated.
  • a latent gelling agent makes it possible to achieve favourable mixing of the latex composition and therefore ensure a homogenous composition . After activation, said latent gelling agent is converted to a gelling agent, wherein the gelling of the latex leads to high- quality and uniform properties of the latex foam thus obtained.
  • said composition for the production of latex foam may be stored without visible gelling for a period of at least 5 days.
  • said composition may be stored without visible gelling for a period of between 50 days and 5000 days, more preferably between 100 days and 1000 days, most preferably 150, 200, 300, 400, 500, 600, 700, 800 or 900 days, or any value in between.
  • the present invention provides a composition according to the first embodiment of the invention, comprising 70.0 to 98.9% by wt. of latex with optional additives, 1.0 to 25.0% by wt. of a cross-linker with optional additives, and 0.1 to 5.0% by wt. of a latent gelling agent, relative to the total weight of said composition.
  • the present invention provides a composition according to the first embodiment of the invention, comprising 80.0 to 94.9% by wt. of latex with optional additives, 5.0 to 15.0% by wt. of a cross-linker, and 0.1 to 5.0% by wt. of a latent gelling agent, relative to the total weight of said composition.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 100°C.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 50°C.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is at least 50% converted to a gelling agent after 1 hour at a temperature of 25°C.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is converted to a gelling agent after reacting with an acid.
  • said latent gelling agent should be understood as a base that is converted to a gelling agent after reacting with an acid .
  • the aforementioned latent gelling agent may be either a neutral base B, such as in reaction ( 1), or a negatively charged base B " , such as in reaction (2) :
  • BH + and BH represent a positively charged gelling agent and a neutral gelling agent respectively. It should be noted in this connection that said gelling agent may be a mono-, di-, tri-, tetra-, penta-, hexa-, hepta-, octa-, nona-, or decavalent acid, or a polyvalent acid or polyacid.
  • bases that give rise to a gelling agent after reaction with a proton H + include, but are not limited to, amine oxide and suiphoxide and/or phosphoxide compounds.
  • said base is an amine oxide, suiphoxide, and/or phosphoxide compound with one or more alkyl groups.
  • the present invention provides a composition according to the first embodiment of the invention wherein said acid is hydrogen halide.
  • said acid is hydrogen fluoride, hydrogen chloride, hydrogen bromide, or hydrogen iodide.
  • said acid is hydrogen fluoride or hydrogen chloride.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said acid is formed from an acid precursor.
  • 'acid precursor' refers to a molecule that under the effect of temperature T, such as shown in reaction (3), or by a chemical reaction such as that with water shown in reaction (4), releases an acid HX.
  • a first example of suitable acid precursors are ammonium salts such as, but not limited to, NH 4 + c , which at high temperature split into NH 3 and HCI. This reaction is well known in the art. Analogous ammonium salts release an acid in a similar manner.
  • a second example of suitable acid precursors are main group metal and transition metal salts, preferably halides that, on reaction with water in an aqueous medium, hydrolyze to a metal hydroxide or a metal oxide, releasing an acid in the process, preferably a hydrogen halide.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride.
  • said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride.
  • said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride.
  • the above paragraph is further clarified by means of hydrolysis of sodium silicon fluoride.
  • the aforementioned silicon fluoride undergoes hydrolysis in an aqueous medium accompanied by the release of hydrogen fluoride.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.
  • said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.
  • Amine oxides are known surface-active substances having cationic characteristics at low and neutral pH and non-ionic characteristics at alkaline pH.
  • Amine oxides preferred for use in the present invention are in accordance with the following formula :
  • Rl, R2 and R3, independently of one another, may be an alkyl group or a functionalized or substituted alkyl group, preferably selected from the group comprising a CI, C2, C3, C4, C5, C6, C7, C8, C9, CIO, Cl l, C12, C13, C14, C15, C16, C17, C18, C19, or C20 group.
  • a composition for the production of latex foam comprising a carboxylated latex and a cross-linker or an alkyl dimethyl amine oxide as a latent gelling agent. The composition is thoroughly stirred in order to obtain a homogeneous mixture. This composition causes little or no gelling of the latex composition.
  • Na 2 SiF 6 NSF
  • hydrogen fluoride is released after hydrolysis of Na 2 SiF 6 in the water present in the latex composition.
  • the aforementioned hydrogen fluoride then reacts with said alkyl dimethyl amine oxide to form a gelling agent.
  • the hydrolysis reaction causes protonation of the amine oxide to occur relatively slowly compared to use of other acids such as HCI, resulting in a smaller pH shock and better distribution of the acid in the latex. This relatively slow reaction causes coagulation to occur.
  • the pH drops from 7-8 to approximately 5.
  • the pH may decrease to approximately 4 due to the release of volatile bases (such as NH 3 ).
  • the advantage of this is that the gelling agent is generated homogeneously, simultaneously, and to an identical degree throughout the liquid, aqueous latex composition, which results in homogeneous gelling properties. This is reflected in the homogeneous physical properties of the latex foam obtained as a final product.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latent gelling agent is a salt comprising a metal and an alkyl carboxylate.
  • said latent gelling agent is a salt comprising a metal and an alkyl carboxylate.
  • the term 'alkyl carboxylate' refers to a chemical compound comprising an alkyl group and a carboxylate group.
  • the term 'alkyl' refers to both linear and branched alkyl groups, and by extension to unsaturated hydrocarbons such as alkenyl- and alkynyl groups as well as alkyl groups having functional groups such as, but not limited to, halogens, aldehydes, ketones, ethers, esters, and amides.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said alkyl carboxylate is selected from the group comprising lactate, citrate, and acetyl acetonate, or any combination of one or more of the aforementioned carboxylates.
  • the invention also provides improved gelling by using a metal cross-linker such as Al 3+ , Mg 2+ , or Ca 2+ .
  • a metal cross-linker such as Al 3+ , Mg 2+ , or Ca 2+ .
  • a lactate salt such as calcium lactate is used rather than a chloride salt such as calcium chloride, because the former gradually releases the Ca 2+ ions in solution, thus preventing coagulation of the latex.
  • the Ca 2+ ions bring about gelling of the latex and simultaneously give rise to cross-linking of the carboxylated polymer in the latex by means of ionic interaction.
  • lactates As an alternative to lactates, one may also use other organic anions such as, but not limited to, citrate, acetyl acetonate and propionate.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latex contains 35 to 60% by wt. of water.
  • the present invention provides a composition according to the first embodiment of the invention, wherein said latex contains 45 to 50% by wt. of water.
  • the choice of the cross-linker may also be determined based on the reaction rate. Specifically, substituents may affect the hydrolysis rate of e.g. silane groups and/or the reactivity of the epoxide compound.
  • Suitable epoxy silanes that may be used in implementing this invention can generally be described as epoxy-terminated silanes. These compounds are generally known in the literature and are commercially available. These compounds have reactive, preferably terminal, epoxy groups and terminal, reactive silane groups.
  • the epoxy- and silane groups may be compounds derived from non- hydrolyzable aliphatic, aromatic or aliphatic and aromatic carbon-based compounds that may possibly include nitrogen and/or oxygen atoms, such as ether bonds. These carbon-based compounds may generally be substituted as known in the art so that they will not exert any major effect on the reactivity of the epoxy- terminated silanes.
  • Suitable epoxy resins are all compounds containing more than one 1,2-epoxy group.
  • said epoxy resin is a saturated or unsaturated aliphatic, cyclo-aliphatic, aromatic or heterocyclic compound and may be substituted or unsubstituted.
  • said epoxy resins are selected from the group comprising polyglycidyl ethers of bisphenol compounds, polyglycidyl ethers of novolac resins, and polyglycidyl ethers of polyglycol, or mixtures of two or more epoxy resins.
  • composition for the production of latex foam may also contain surfactants or tensioactive or surface-active substances.
  • a surfactant normally contains a hydrophobic and hydrophilic portion.
  • the hydrophobic portion has a chain length of 4 to 20 carbon atoms, preferably 6 to 19 carbon atoms, and even more preferably 8 to 18 carbon atoms.
  • the surfactant used is selected from the group of anionic, cationic or non-ionic surface-active substances.
  • Anionic surface-active substances include saponified fatty acids and derivatives of fatty acids with carboxyl groups such as sodium dodecyl sulphate (SDS), sodium dodecyl benzene sulphonate, sulphates and sulphonates, and abietinic acid.
  • carboxyl groups such as sodium dodecyl sulphate (SDS), sodium dodecyl benzene sulphonate, sulphates and sulphonates, and abietinic acid.
  • anionic surfactants also include carboxylates, sulphonates, sulphofatty acid methyl esters, sulphates, and phosphates. The anionic surfactants are preferably added as salts.
  • salts include alkali metal salts such as sodium, potassium, lithium, ammonium, hydroxyethyl ammonium, di(hydroxyethyl) ammonium, and tri(hydroxyethyl) ammonium salts or alkanolamine salts.
  • Cationic surface-active substances include dialkyl benzene alkyl ammonium chloride, alkylbenzyl methyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide, benzalkonium chloride, cetyl pyridinium bromide, C 12 , C 15 , or C 17 trimethyl ammonium bromides, halide salts, or quaternized polyoxyethyl alkylamines, dodecyl benzyl triethyl ammonium chloride, and benzalkonium chloride.
  • Examples of cationic surfactants also include quaternary ammonium compounds.
  • a quaternary ammonium compound is a compound that contains at least one R 4 N + - group in its molecule.
  • a betaine surfactant is a compound that under application conditions contains at least one positive charge and at least one negative charge.
  • An alkyl betaine is a betaine surfactant that contains at least one alkyl unit per molecule.
  • Non-ionic surfactants include polyvinyl alcohol, polyacrylic acid, methalose, methyl cellulose, ethyl cellulose, propyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, natural rubbers, polyoxyethylene cetyl ether, polyoxyethylene lauryl ether, polyoxyethylene octyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitan monolaurate, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, and dialkylphenoxy poly(ethyleneoxy) ethanol.
  • Fatty acid ethoxylates are fatty acid ester surface-active substances that are treated with various amounts of ethylene oxide.
  • Triglycerides are esters of glycerols (glycerides) in which all three of the hydroxyl groups are esterified with fatty acids. These may be modified with alkylene oxides.
  • Fatty acid alcohol amides include at least one amide group with an alkyl group and one or two alkoxyl groups.
  • Alkyl polyglycosides are mixtures of alkylmonoglycosides (alkyl-a-D- and - ⁇ -D- glucopyranoside with a small amount of -glucofuranoside), alkyl diglycosides (-isomaltosides, -maltosides, etc.) and alkyl oligoglycosides (-maltotriosides, -tetraosides, etc.).
  • Alkyl polyglycosides may be synthesized in a non-limiting manner by means of an acid-catalyzed reaction (Fisher reaction) of glucose (or starch) or n-butyl glycosides with fatty acid alcohols.
  • alkyl polyglycosides may also be used as non-ionic surfactants.
  • a non-limiting example is Lutensol® GD70.
  • non-ionic N-alkylated, and preferably N-methylated fatty acid amides may be used as surfactants.
  • Alcohol alkoxylates contain a hydrophobic portion with a chain length of 4 to 20 C atoms, preferably 6 to 19 C atoms and more preferably 8 to 18 C atoms, wherein the alcohol may be in linear or branched form, and a hydrophilic portion that may contain alkoxylate units, such as ethylene oxide, propylene oxide and/or butylene oxide, with 2 to 30 repeating units.
  • alkoxylate units such as ethylene oxide, propylene oxide and/or butylene oxide, with 2 to 30 repeating units.
  • Non-limiting examples include Lutensol® XP, Lutensol® XL, Lutensol® ON, Lutensol® AT, Lutensol® A, Lutensol® AO, and Lutensol® TO.
  • the aforementioned surfactant or surface-active substance may be present in amounts of approximately 0.5 to 5% by wt., and preferably 1 to 3% by wt., based on the dry weight of the copolymer. It has been found that inclusion of a surfactant can improve the shelf life of the curable composition according to the present invention.
  • the present invention provides a composition according to the first embodiment of the invention, comprising a foam booster and/or a foam stabilizer.
  • the foams of the composition for the production of a latex foam may be produced by any suitable or commonly-used method of prior art.
  • a foam can be produced by methods known in the art, for example by releasing a non-coagulating gas such as nitrogen, or by causing decomposition of a gas-releasing chemical compound after a chemical reaction with an ingredient of the mixture, resulting in the release of a non-coagulable gas as a reaction product.
  • the mixture of the reactive latex and the co-reactive material is also foamed by means of whipping, if applicable by means of a device that is commercially available and suitable for this purpose according to the art.
  • Foaming auxiliaries such as sodium lauryl sulphate or foam stabilizers such as potassium oleate, or sulphosuccinimate soaps such as - but not limited to - disodium tallow sulphosuccinimate soap, may be added as desired.
  • such additives should be fairly non-reactive with the reactive group in the latex polymer of the co-reactive material, the composition of the mixture in the preferred composition may therefore be varied as necessary.
  • disodium tallow sulphosuccinimate one may also use betaine soap, sodium silicate, or ethyl vinyl acetate (EVA) latex.
  • EVA ethyl vinyl acetate
  • other soaps, emulsifiers, moisturizing agents and/or surface-active substances may also be used, even though they may be reactive to a certain degree.
  • the present invention provides a composition according to the first embodiment of the invention, comprising one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more of such additives.
  • a composition according to the present invention for the production of a latex foam may also include components such as, but not limited to, fillers, thickeners, antioxidants, dispersing agents, colorants, acidity regulators and flame retarding agents.
  • accelerators such as, but not limited to, zinc (II) oxide (ZnO) may also be preferred.
  • ZnO zinc oxide
  • ammonium salts are present in the aqueous latex composition, on dissolving in water, ZnO will form Zn 2+ ions, which in turn may form complexes with ammonia derived from the reaction of ammonium salts with ZnO.
  • the zinc-amine complexes formed in this manner then act as a gelling agent for the polymer particles.
  • additives and fillers may be selected from metals in powder form or filament form and non-metals such as carbon, silicates, titanium dioxide, zinc oxide, chalk or calcium carbonate, zinc sulphide, potassium titanate and titanate fibres, carbon fibres, clay, kaolins, and glass fibres.
  • the fillers may be present in amounts of approximately 0 to 80% by wt. or more with respect to the total weight of the composition.
  • a water softener, antioxidants, bactericides, and/or ammonia may also be added.
  • a flame retardant may also be added to the composition.
  • flame retardant refers to any substances that can cause one or more of the following effects:
  • a suitable flame retarding agent may preferably be selected from the group comprising nitrogen- and phosphorus-based flame retardants.
  • the present invention provides a kit for the production of a latex foam, comprising a composition (A) according to the first embodiment of the invention; and a composition (B) comprising at least an acid or acid precursor for converting said latent gelling agent to a gelling agent.
  • said latent gelling agent should be understood as a base that is converted to a gelling agent after reacting with an acid.
  • the aforementioned latent gelling agent may be either a neutral base B, such as in reaction (1), or a negatively charged base B " , such as in reaction (2) :
  • said base is an amine oxide, sulphoxide, and/or phosphoxide compound with one or more alkyl groups.
  • the aforementioned proton H + from reaction (1) and reaction (2) may be derived from a compound having the general formula H + X " , wherein X " may be an organic and/or an inorganic molecule or anion.
  • said proton H + is derived from an inorganic acid.
  • the present invention provides a kit according to the second embodiment of the invention, wherein said salt is a hydrogen halide, preferably hydrogen fluoride, hydrogen chloride, hydrogen bromide and/or hydrogen iodide. Most preferably, said salt is hydrogen fluoride or hydrogen chloride.
  • the present invention provides a kit according to the second embodiment of the invention, wherein said acid is formed from an acid precursor.
  • the term 'acid precursor' refers to a molecule that under the effect of temperature T, such as shown in reaction (3), or by a chemical reaction such as that with water shown in reaction (4), releases an acid HX.
  • a first example of suitable acid precursors are ammonium salts such as, but not limited to, l ⁇ IH + CI " , which at high temperature split into NH 3 and HCI. This reaction is well known in the art. Analogous ammonium salts release an acid in a similar manner.
  • a second example of suitable acid precursors are main group metal and transition metal salts, preferably halides that, on reaction with water in an aqueous medium, hydrolyze to a metal hydroxide or a metal oxide, releasing an acid in the process, preferably a hydrogen halide.
  • the present invention provides a kit according to the second embodiment of the invention, wherein said acid precursor is an alkali- or alkaline earth metal silicon fluoride, preferably sodium silicon fluoride.
  • the above paragraph is further clarified by means of the hydrolysis reaction of sodium silicon fluoride.
  • the aforementioned silicon fluoride undergoes hydrolysis in an aqueous medium accompanied by the release of hydrogen fluoride.
  • the present invention provides a kit according to the second embodiment of the invention, wherein said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.
  • said latent gelling agent is an amine oxide, preferably a trialkyl amine oxide, and more preferably an alkyl dimethyl amine oxide.
  • Amine oxides are known surface-active substances having cationic characteristics at low and neutral pH and non-ionic characteristics at alkaline pH.
  • Amine oxides preferred for use in the present invention are in accordance with the following formula :
  • Rl, R2 and R3, independently of one another, may be an alkyl group or a functionalized or substituted alkyl group, preferably selected from the group comprising a CI, C2, C3, C4, C5, C6, C7, C8, C9, CIO, Cll, C12, C13, C14, C15, C16, C17, C18, C19, or C20 group.
  • the present invention provides a kit according to the second embodiment of the invention, wherein composition (A) contains an alkyl dimethyl amine oxide as a latent gelling agent.
  • composition (A) contains an alkyl dimethyl amine oxide as a latent gelling agent.
  • the composition is thoroughly stirred in order to obtain a homogeneous mixture.
  • This composition causes little or no gelling of the latex composition.
  • Na 2 SiF 6 (NSF) to the composition, hydrogen fluoride is released after hydrolysis of Na 2 SiF 6 in the water present in the latex composition.
  • the aforementioned hydrogen fluoride then reacts with said alkyl dimethyl amine oxide to form a gelling agent.
  • the hydrolysis reaction causes protonation of the amine oxide to occur relatively slowly compared to use of other acids such as HCI, resulting in a smaller pH shock and better distribution of the acid in the latex. This relatively slow reaction causes coagulation to occur.
  • the pH drops from 7-8 to approximately 5.
  • the pH may decrease to approximately 4 due to the release of volatile bases (such as NH 3 ).
  • composition (A) and/or composition (B) also contain a foam booster and/or a foam stabilizer.
  • composition (A) and/or composition (B) also contain one or more additives selected from the group of fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.
  • composition (A) and/or composition (B) also contain acidifying or acidifying or alkalizing agents such as, but not limited to, acetic acid, citric acid, dilute inorganic acids, ammonium hydroxide, and dilute aqueous solutions of alkali metal hydroxides.
  • acidifying or acidifying or alkalizing agents such as, but not limited to, acetic acid, citric acid, dilute inorganic acids, ammonium hydroxide, and dilute aqueous solutions of alkali metal hydroxides.
  • composition (A) and/or composition (B) also include other additives and fillers selected from metals in powder form or filament form and non-metals such as carbon, silicates, titanium dioxide, zinc oxide, chalk or calcium carbonate, zinc sulphide, potassium titanate and titanate fibres, carbon fibres, clay, kaolins, and glass fibres.
  • the fillers may be present in amounts of approximately 0 to 80% by wt. or more with respect to the total weight of the composition.
  • a water softener, antioxidants, bactericides, and/or ammonia may also be added.
  • a flame retardant may also be added to the composition.
  • a suitable flame retarding agent may preferably be selected from the group comprising nitrogen- and phosphorus-based flame retardants.
  • the present invention provides a kit for the production of a latex foam, comprising :
  • kit provides an application-friendly packaging form for the user of latex foam, thus ensuring a constant composition for the production of latex foam.
  • This in turn leads to an improved and more uniform composition of the latex foam obtained as a final product and thus to better product properties.
  • the present invention provides a kit according to the third embodiment of the invention, wherein both compositions are further provided with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.
  • the present invention provides a method for the production of a latex foam using a kit according to the third embodiment of the invention, comprising the steps of:
  • Mixing of the composition may be carried out using agents such as those known in the art. Drying and curing may be carried out at a suitable temperature above ambient temperature.
  • the present invention provides a method for the production of a latex foam, wherein said latex foam is a non-gel latex foam, comprising the steps of:
  • aqueous latex foam onto a substrate such as the underside of a carpet
  • said cross-linker may also fulfil the function of a latent gelling agent.
  • the present invention provides a method for the production of a latex foam wherein said latex foam is a gel latex foam, comprising the steps of:
  • aqueous latex foam onto a substrate such as the underside of a carpet
  • the present invention provides a method for the production of a latex foam, comprising the steps of:
  • said latent gelling agent is converted in solution to a gelling agent.
  • the foam in an embodiment of this invention wherein the foam is used as a textile carrier, the foam can be applied to the textile prior to drying and curing.
  • a typical foam formed from the aqueous latex foam has a density during this process of approximately 100 to 1000 g/L when wet, preferably 200 to 600 g/L, and more preferably 200, 250, 300, 350 of 400 g/L or any value in between.
  • the foam can be applied to the substrate using a scraper.
  • the present invention provides a method according to the fifth embodiment of the invention, comprising the step of mixing said aqueous latex foam with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.
  • said aqueous latex foam is dried at a temperature of between 60°C and 100°C, more preferably at a temperature of between 70°C and 90°C, and most preferably at a temperature of 71, 72, 73, 74, 75, 76, 77, 78, 79, 80°C, or any temperature in between.
  • the present invention provides a method according to the fifth embodiment of the invention, wherein said aqueous latex foam is treated using an infrared lamp.
  • the present invention provides a method according to the sixth embodiment of the invention, comprising the step of mixing said aqueous latex foam with one or more additives selected from the group comprising : fillers, salts, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, or a combination of one or more additives.
  • the present invention provides a method according to the sixth embodiment of the invention, wherein said aqueous latex foam is dried by heating to a temperature of between 50°C and 150°C.
  • said aqueous latex foam is dried at a temperature of between 60°C and 100°C, more preferably at a temperature of between 70°C and 90°C, and most preferably at a temperature of 71, 72, 73, 74, 75, 76, 77, 78, 79, 80°C, or any temperature in between.
  • the present invention provides a method according to the sixth embodiment of the invention, wherein said aqueous latex foam is treated using an infrared lamp.
  • the present invention provides a method according to the sixth embodiment of the invention, wherein said latex foam is subjected to mechanical post-treatment such as compression, printing, or pressing.
  • the present invention provides a method according to the sixth embodiment of the invention, wherein said latex foam is thermally post- treated, e.g. by curing at a temperature of between 100°C and 200°C.
  • said latex is thermally post-treated in an oven at a temperature of between 125°C and 175°C, more preferably at a temperature of between 140°C and 160°C, and most preferably at a temperature of 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155°C, or any temperature in between.
  • the present invention provides a latex foam that can be obtained by means of a method according to the fourth embodiment of the invention.
  • the present invention provides a latex foam that can be obtained by means of a method according to the fifth embodiment of the invention.
  • the present invention provides a product comprising a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as in surgical gloves.
  • a latex foam according to the seventh embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres
  • the present invention provides a product comprising a latex foam according to the eighth embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres, or shoe soles, and in medical or sanitary applications such as in surgical gloves.
  • a latex foam according to the eighth embodiment of the invention such as an anti-slip covering, a tufted carpet, a woven carpet, artificial turf, a carpet for use in the automotive sector, a needle felt carpet, tiles, needle felts, rubber granules, upholstering, a carpet for household use such as in the living room or bathroom, a carpet for stairways, a carpet for use in hospitals, furniture, mattresses, automobile tyres
  • the present invention provides an application of a composition according to the first embodiment of the invention for the production of a latex foam.
  • compositions for the production of a latex foam and for production of said latex foam are described below, after which the various examples of the compositions obtained are presented in Examples 1 to 15.
  • the compositions may also be obtained by first combining two or more separate compositions that can be stored in the form of a kit and then reactively mixed in order to produce the desired latex.
  • a latex (A) and a cross-linker (B) are mixed to obtain a composition (A+B).
  • a latent gelling agent (C) is also mixed into the aforementioned composition (A+B) at room temperature.
  • a latex composition (A+B+C) is obtained in this manner.
  • other substances may be mixed into the aforementioned latex composition, such as additives and a foam booster and -stabilizer.
  • said latent gelling agent is activated and converted to a gelling agent.
  • the latex composition is intensively mixed in order to obtain an aqueous latex foam.
  • the aqueous latex foam shows favourable foam quality
  • it is applied to a substrate.
  • the substrate may be the underside of a carpet.
  • favourable contact is provided between the aqueous latex foam and the substrate, for example by applying pressure using a rolling mill.
  • the aqueous latex foam is treated by means of an infrared lamp at a temperature of 70 to 80°C.
  • the at least partially dried latex foam is cured and further dried. In this manner, cross-linking of the latex composition takes place. If applicable, this thermal treatment is followed by a mechanical treatment such as compression, printing, or pressing and thermal post-treatment for curing in an oven at a temperature of approximately 150°C.
  • Table 1 Composition for the production of a latex foam according to example 1 of the present invention.
  • Table 2 Composition for the production of a latex foam according to example 2 of the present invention.
  • Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane
  • Table 3 Composition for the production of a latex foam according to example 3 of the present invention.
  • Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane
  • Table 4 Composition for the production of a latex foam according to example 4 of the present invention.
  • Table 5 Composition for the production of a latex foam according to example 5 of the present invention.
  • Acrylic acid functional latex post-functionalized 100 190 with 1.5% epoxy silane
  • Disodium tallow sulphosuccinimate soap 1 2.8 Betaine soap 0.5 1.4
  • Table 7 Composition for the production of a latex foam according to example 7 of the present invention.
  • Acrylic acid functional latex 100 190
  • Table 8 Composition for the production of a latex foam according to example 8 of the present invention.
  • Sodium silicofluoride 10 20 Table 9: Composition for the production of a latex foam according to example 9 of the present invention.
  • Acrylic acid functional latex 100 190
  • Table 10 Composition for the production of a latex foam according to example 10 of the present invention.
  • Acrylic acid functional latex 100 190
  • Table 11 Composition for the production of a latex foam according to example 11 of the present invention.
  • Table 12 Composition for the production of a latex foam according to example 12 of the present invention.
  • Acrylic acid functional latex 100 190
  • Table 13 Composition for the production of a latex foam according to example 13 of the present invention.
  • Acrylic acid functional latex 100 190
  • Table 14 Composition for the production of a latex foam according to example 14 of the present invention.
  • Table 15 Composition for the production of a latex foam according to example 15 of the present invention.
  • Acrylic acid functional latex 100 190

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
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Abstract

La présente invention concerne une composition pour la production d'une mousse de latex, cette composition comprenant (i) un latex ; (ii) un agent de réticulation et (iii) un agent gélifiant latent qui peut être converti en un agent gélifiant. Ceci permet une meilleure gélification de ladite composition. En outre, l'invention concerne également un kit et un procédé de production d'une mousse de latex.
PCT/IB2014/064983 2013-10-02 2014-10-01 Composition, kit et procédé de production de mousse de latex Ceased WO2015049641A1 (fr)

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BE2013/0657A BE1021038B1 (nl) 2013-10-02 2013-10-02 Samenstelling, kit en werkwijze voor het aanmaken van latexschuim.
BEBE2013/0657 2013-10-02

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WO2015049641A1 true WO2015049641A1 (fr) 2015-04-09

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020165740A1 (fr) * 2019-02-11 2020-08-20 Eoc Belgium Nv Latex fonctionnel réticulable comprenant un trihydroxyde d'aluminium

Citations (8)

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Publication number Priority date Publication date Assignee Title
US3399080A (en) 1966-11-02 1968-08-27 Dow Chemical Co Paper coated with an interpolymer of a monoethylenically unsaturated acid, an open-chain aliphatic conjugated diolefin and an alkenyl aromatic monomer
US3404116A (en) 1965-01-05 1968-10-01 Dow Chemical Co Latices of butadiene copolymers with monomers having hydroxyl and carboxyl groups
US4098944A (en) * 1974-12-19 1978-07-04 Borg-Warner Corporation Surface spray coating of latex foams
GB1528813A (en) * 1974-11-21 1978-10-18 Doverstrand Ltd Method for embossing foam latex compositions
GB2013687A (en) * 1977-12-14 1979-08-15 Albright & Wilson Sulphosuccinamates and rubber latex compounds
EP0245021A2 (fr) 1986-05-02 1987-11-11 The Dow Chemical Company Composition durcissable de latex, feuilles et mousses qui en sont préparées et procédé de durcissement de cette composition
EP0747134A2 (fr) * 1995-06-07 1996-12-11 Rohm And Haas Company Revêtement de substrates en bois aggloméré et liants latex moussable
WO2002026873A2 (fr) 2000-09-28 2002-04-04 Dow Global Technologies Inc Reticulation de latex avec des oxydes de nitrile ou des silanes epoxydes sequences

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3404116A (en) 1965-01-05 1968-10-01 Dow Chemical Co Latices of butadiene copolymers with monomers having hydroxyl and carboxyl groups
US3399080A (en) 1966-11-02 1968-08-27 Dow Chemical Co Paper coated with an interpolymer of a monoethylenically unsaturated acid, an open-chain aliphatic conjugated diolefin and an alkenyl aromatic monomer
GB1528813A (en) * 1974-11-21 1978-10-18 Doverstrand Ltd Method for embossing foam latex compositions
US4098944A (en) * 1974-12-19 1978-07-04 Borg-Warner Corporation Surface spray coating of latex foams
GB2013687A (en) * 1977-12-14 1979-08-15 Albright & Wilson Sulphosuccinamates and rubber latex compounds
EP0245021A2 (fr) 1986-05-02 1987-11-11 The Dow Chemical Company Composition durcissable de latex, feuilles et mousses qui en sont préparées et procédé de durcissement de cette composition
EP0747134A2 (fr) * 1995-06-07 1996-12-11 Rohm And Haas Company Revêtement de substrates en bois aggloméré et liants latex moussable
WO2002026873A2 (fr) 2000-09-28 2002-04-04 Dow Global Technologies Inc Reticulation de latex avec des oxydes de nitrile ou des silanes epoxydes sequences

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020165740A1 (fr) * 2019-02-11 2020-08-20 Eoc Belgium Nv Latex fonctionnel réticulable comprenant un trihydroxyde d'aluminium
BE1027044B1 (nl) * 2019-02-11 2020-09-07 Eoc Belgium Nv Vernetbare functionele latex omvattende aluminium trihydroxide

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BE1021038B1 (nl) 2015-02-11

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