Thermoplastic elastomer

• US 20030212211A1
• Filed: 05/07/2002
• Published: 11/13/2003
• Est. Priority Date: 05/07/2002
• Status: Active Grant

• Current Assignee: AFI Licensing LLC (Armstrong World Industries Incorporated)
• Original Assignee: AWI Licensing Company
• Inventors: Winey, Rebecca L., Lenox, Ronald S., Ward, Harry D.
• Granted Patent: US 6,921,791 B2
• Time in Patent Office: Days
• US Class Current: 525/222
• CPC Class Codes: C08K 3/346 Clay
• CPC Class Codes: C08L 15/00 Compositions of rubber derivatives C08L11/00, C08L13/00 take precedence
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 23/0853 Vinylacetate
• CPC Class Codes: C08L 23/0876 Neutralised polymers, i.e. ionomers
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 29/14 Homopolymers or copolymers of acetals or ketals obtained by polymerisation of unsaturated acetals or ketals or by after-treatment of polymers of unsaturated alcohols
• CPC Class Codes: C08L 7/00 Compositions of natural rubber
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers

Abstract

Disclosed is a product and process for a substantially halogen-free thermoplastic elastomer. The thermoplastic elastomer can be incorporated into a decorative surface covering as a binder with the addition of an optional filler. The substantially halogen-free thermoplastic comprises the combination of a dynamically vulcanized blend of epoxidized natural rubber (ENR), ionomers and a diluent polymer such as ethylene vinyl acetate (EVA). The combination produces a pliable and flexible flooring product.

Claims

1. A thermoplastic elastomer comprising:

a dynamically vulcanized blend of an epoxidized elastomer and an ionomer; and

a diluent polymer.

2. The thermoplastic elastomer of claim 1, wherein the epoxidized elastomer comprises epoxidized natural rubber.

3. The thermoplastic elastomer of claim 2, wherein the thermoplastic elastomer comprises between about 2% to about 60% by weight epoxidized natural rubber.

4. The thermoplastic elastomer of claim 1, wherein the ionomer comprises a partially or totally neutralized copolymer of (meth)acrylic acid.

5. The thermoplastic elastomer of claim 4, wherein the (meth)acrylic acid is at least partially neutralized with metal ions selected from the group consisting of zinc ions, lithium ions, magnesium ions, calcium ions, potassium ions, sodium ions and combinations thereof.

6. The thermoplastic elastomer of claim 1, further comprising a filler.

7. The thermoplastic elastomer of claim 6, where the thermoplastic elastomer comprises up to about 90% by weight filler.

8. The thermoplastic elastomer of claim 6, wherein the filler is selected from the group consisting of limestone, clay, silicates, aluminum oxide, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers, and combinations thereof.

9. The thermoplastic elastomer of claim 1, wherein the diluent polymer is selected from the group consisting of ethylene vinyl acetate, polyvinyl butyral, polyesters, and combinations thereof.

10. The thermoplastic elastomer of claim 1, further comprising additives selected from the group consisting of plasticizers, stabilizers, antioxidants, fire retardants, processing aids, pigments, oils and combinations thereof.

11. The thermoplastic elastomer of claim 1, wherein the thermoplastic elastomer comprises between about 5% to about 80% by weight diluent polymer.

12. The thermoplastic elastomer of claim 1, wherein the thermoplastic elastomer comprises between about 2% to about 60% by weight ionomer.

13. The thermoplastic elastomer of claim 1, wherein the thermoplastic elastomer is rheologically stable for at least 30 minutes at 250°

F.

14. A method for making a thermoplastic elastomer comprising:

combining an epoxidized elastomer, an ionomer, and a diluent polymer to create the thermoplastic elastomer.

15. The method of claim 14, wherein the epoxidized elastomer comprises epoxidized natural rubber.

16. The method of claim 14, wherein the ionomer comprises an ethylene/(meth)acrylic acid copolymer which has been at least partially metal ion neutralized.

17. The method of claim 14, further comprising adding a filler to the thermoplastic elastomer.

18. The method of claim 17, wherein the filler is added in an amount comprising up to about 90% by weight of the thermoplastic elastomer.

19. The method of claim 17, wherein the filler is selected from the group consisting of limestone, clay, silicates, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers, and combinations thereof.

20. The method of claim 14, wherein the ionomer comprises a partially or totally neutralized copolymer of (meth)acrylic acid.

21. The method of claim 14, wherein the diluent polymer is selected from the group consisting of ethylene vinyl acetate, polyvinyl butyral, polyesters, and combinations thereof.

22. The method of claim 14, further comprising adding additives to the thermoplastic elastomer selected from the group consisting of plasticizers, stabilizers, antioxidants, fire retardants, processing aids, pigments, oils, and combinations thereof.

23. The method of claim 14, wherein the diluent polymer is combined in the thermoplastic elastomer in an amount comprising between about 5% to about 80% by weight of the thermoplastic elastomer.

24. The method of claim 14, wherein the epoxidized natural rubber is combined in the thermoplastic elastomer in an amount between about 2% to about 60% by weight of the thermoplastic elastomer.

25. The method of claim 14, wherein the ionomer is combined in the thermoplastic elastomer in amount between about 2% to about 60% by weight of the thermoplastic elastomer.

26. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises:

a dynamically vulcanized blend of an epoxidized elastomer and an ionomer; and

a diluent polymer.

27. The decorative surface covering of claim 26, wherein the epoxidized elastomer comprises epoxidized natural rubber.

28. The decorative surface covering of claim 26, wherein the decorative surface covering is in the form of a flooring tile.

29. The decorative surface covering of claim 26, wherein the decorative surface covering is in the form of a sheet.

30. The decorative surface covering of claim 26, further including a non-woven backing.

31. The decorative surface covering of claim 26, further including a wear layer.

32. The decorative surface covering of claim 26, wherein the ionomer comprises a partially or totally neutralized copolymer of (meth)acrylic acid.

33. The decorative surface covering of claim 26, where the thermoplastic elastomer comprises up to about 90% by weight filler.

34. The decorative surface covering of claim 26, wherein the filler is selected from the group consisting of limestone, clay, silicates, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers, and combinations thereof.

35. The decorative surface covering of claim 26, wherein the diluent polymer is selected from the group consisting of ethylene vinyl acetate, polyvinyl butyral, polyesters, and combinations thereof.

36. The decorative surface covering of claim 26, further comprising additives selected from the group consisting of stabilizers, antioxidants, pigments, oils, and combinations thereof.

37. The decorative surface covering of claim 26, wherein the thermoplastic elastomer comprises between about 5% to about 80% by weight diluent polymer.

38. The decorative surface covering of claim 26, wherein the thermoplastic elastomer comprises between about 2% to about 60% by weight epoxidized natural rubber.

39. The decorative surface covering of claim 26, wherein the thermoplastic elastomer comprises between about 2% to about 60% by weight ionomer.

40. The decorative surface covering of claim 26, wherein the thermoplastic elastomer has an Olsen stiffness of less than 0.5 inch-pound at 73°

F.