PLASTISOL FOR SPRAY-MOLDED PLASTIC ARTICLES

• US 20130244017A1
• Filed: 11/30/2011
• Published: 09/19/2013
• Est. Priority Date: 12/03/2010
• Status: Abandoned Application

• Current Assignee: Polyone Corporation (Avient Corp.)
• Original Assignee: Polyone Corporation (Avient Corp.)
• Inventors: Cassata, Brent, Horton, Stephen D., Tresino, John
• Application Number:
  US13/990,969
• Publication Number:
  US 20130244017A1
• Time in Patent Office: Days
• US Class Current: 428/220
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/18 Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
• CPC Class Codes: C08K 5/0016 Plasticisers
• CPC Class Codes: C08K 5/12 of cyclic polycarboxylic acids
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C09D 127/06 Homopolymers or copolymers of vinyl chloride

Abstract

A plastisol is disclosed comprising poly(vinyl halide) and a trimellitate plasticizer and a second plasticizer, with the trimellitate plasticizer comprising between about 60 and about 90 weight percent of the total plasticizer content. The plastisol can be made into a polymeric skin using spray molding techniques. The plastisol can be sprayed on a slush mold surface.

Claims

1. A spray molded plastic article comprising:

plastisol liquid fused into a solid after being sprayed into a thin layer on to a surface of a female form mold,

wherein the plastisol comprises poly(vinyl halide), a trimellitate plasticizer, and a second plasticizer,

wherein the trimellitate plasticizer comprises between about 60 and about 90 weight percent of total plasticizer in the article.

2. The article of claim 1, wherein the poly(vinyl halide) comprises poly(vinyl chloride).

3. The article of claim 1, wherein the poly(vinyl halide) is copolymerized with a co-monomer present in an amount ranging from about 0.1 to 15 percent by weight and selected from the group consisting of acrylonitrile, 2-ethylhexyl acrylate, vinylidene chloride, and isobutyl ether.

4. The article of claim 1, wherein the poly(vinyl halide) has a K-value of from about 50 to about 90 as measured using 0.2 grams of poly(vinyl halide) in 100 ml of cyclohexanone at 30°

C.

5. The article of claim 1, wherein the trimellitate plasticizer is selected from the group consisting of trimellitate plasticizers include trimethyl trimellitate, Tri-(n-octyl, n-decyl) trimellitate, Tri-(heptyl,nonyl) trimellitate, n-octyl trimellitate (NOTM), Tri-(2-ethylhexyl) trimellitate (TOTM), and combinations thereof.

6. The article of claim 1, wherein the second plasticizer is a sebacate plasticizer, an azelate plasticizer, or an adipate plasticizer, and wherein the trimellitate plasticizer comprises between about 62 and about 88 weight percent of total plasticizer in the article.

7. The article of claim 6, wherein the trimellitate plasticizer comprises between about 67 and about 83 weight percent of total plasticizer in the article.

8. The article of claim 7, wherein the trimellitate plasticizer comprises between about 75 weight percent of total plasticizer in the article.

9. The article of claim 1, further comprising adhesion promoters;

biocides (antibacterials, fungicides, and mildewcides), anti-fogging agents;

anti-static agents;

bonding, blowing and foaming agents;

dispersants;

fillers and extenders;

fire and flame retardants and smoke suppressants;

impact modifiers;

initiators;

lubricants;

micas;

pigments, colorants and dyes;

processing aids;

release agents;

silanes, titanates and zirconates;

slip and anti-blocking agents;

stabilizers;

stearates;

ultraviolet light absorbers;

viscosity regulators;

waxes;

or combinations of them.

10. A method of making the article of claim 1, comprising the steps of:

(a) spraying a surface of a female form mold cavity with plastisol to obtain a layer of plastisol which adheres to the surface of the mold;

(b) heating a mold to a temperature of about 160°

C. to about 230°

C. to gel and fuse the plastisol to form a polymeric skin on the mold

(c) cooling the mold with suitable cooling means; and

(d) removing the formed polymeric skin from the mold.

11. The process of claim 10, wherein the poly(vinyl halide) comprises poly(vinyl chloride) and wherein the female form mold is a cold nickel slush mold.

12. The process of claim 10, wherein the poly(vinyl halide) is copolymerized with a co-monomer present in an amount ranging from about 0.1 to 15 percent by weight and selected from the group consisting of acrylonitrile, 2-ethylhexyl acrylate, vinylidene chloride, and isobutyl ether.

13. The process of claim 10, wherein the poly(vinyl halide) has a K-value of from about 50 to about 90 as measured using 0.2 grams of poly(vinyl halide) in 100 ml of cyclohexanone at 30°

C.

14. The process of claim 10, wherein the trimellitate plasticizer is selected from the group consisting of trimellitate plasticizers include trimethyl trimellitate, Tri-(n-octyl, n-decyl) trimellitate, Tri-(heptyl,nonyl) trimellitate, n-octyl trimellitate (NOTM), Tri-(2-ethylhexyl) trimellitate (TOTM), and combinations thereof.

15. The process of claim 10, wherein the second plasticizer is a sebacate plasticizer, an azelate plasticizer, or an adipate plasticizer, and wherein the trimellitate plasticizer comprises between about 62 and about 88 weight percent of total plasticizer in the article.

16. The process of claim 15, wherein the trimellitate plasticizer comprises between about 67 and about 83 weight percent of total plasticizer in the article.

17. The process of claim 16, wherein the trimellitate plasticizer comprises between about 75 weight percent of total plasticizer in the article.

18. The process of claim 10, further comprising adhesion promoters;

biocides (antibacterials, fungicides, and mildewcides), anti-fogging agents;

anti-static agents;

bonding, blowing and foaming agents;

dispersants;

fillers and extenders;

fire and flame retardants and smoke suppressants;

impact modifiers;

initiators;

lubricants;

micas;

pigments, colorants and dyes;

processing aids;

release agents;

silanes, titanates and zirconates;

slip and anti-blocking agents;

stabilizers;

stearates;

ultraviolet light absorbers;

viscosity regulators;

waxes;

or combinations of them.

19. A polymeric skin made by the process of claim 10, wherein the thickness of the polymeric skin ranges from about 0.06 cm to about 0.30 cm.

20. A polymeric skin comprising the article of claim 1, wherein the thickness of the polymeric skin ranges from about 0.04 cm to about 0.30 cm.