Water swellable coatings and method of making same

• US 5,817,713 A
• Filed: 01/19/1996
• Issued: 10/06/1998
• Est. Priority Date: 01/19/1996
• Status: Expired due to Term

• Current Assignee: Fiber-Line, Inc. (Avient Corp.)
• Original Assignee: Fiber-Line, Inc. (Avient Corp.)
• Inventors: Vitola, Louis A., Detwiler, Vernon Z., Pappas, Vincent J.
• Primary Examiner(s): REDDICK, MARIE L
• Application Number:
  US08/588,944
• Time in Patent Office: 991 Days
• Field of Search: 524/522, 524/523, 524/297, 524/521
• US Class Current: 524/521
• CPC Class Codes: A61L 15/225 Mixtures of macromolecular compounds
• CPC Class Codes: A61L 15/60 Liquid-swellable gel-forming materials, e.g. super-absorbents
• 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 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 33/02 Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C09D 127/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: D06M 15/248 containing chlorine
• CPC Class Codes: D06M 15/263 of unsaturated carboxylic acids; Salts or esters thereof
• CPC Class Codes: D06M 23/00 Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
• CPC Class Codes: D06M 23/08 Processes in which the treating agent is applied in powder or granular form adhesives for multi-layer textile fabrics D06M17/00
• CPC Class Codes: D06N 3/0056 characterised by the compounding ingredients of the macro-molecular coating D06N3/005 takes precedence
• CPC Class Codes: D06N 3/06 with polyvinylchloride or its copolymerisation products surface treatment or foaming for floor coverings D06N7/0007
• CPC Class Codes: G02B 6/44384 the means comprising water blocking or hydrophobic materials G02B6/4439, G02B6/4479 take precedence
• CPC Class Codes: Y02P 20/141 Feedstock
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter
• CPC Class Codes: Y10T 428/2929 Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2938 Coating on discrete and individual rods, strands or filaments
• CPC Class Codes: Y10T 428/2964 : Artificial fiber or filament
• CPC Class Codes: Y10T 428/2967 : Synthetic resin or polymer
• CPC Class Codes: Y10T 428/2969 : Polyamide, polyimide or polyester
• CPC Class Codes: Y10T 428/2971 : Impregnation
• CPC Class Codes: Y10T 428/2975 : Tubular or cellular
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31909 : Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31928 : Ester, halide or nitrile of addition polymer

Abstract

A method for forming a water swellable coating and a water swellable coating for forming a coated substrate are provided. The water swellable coatings are semi-gel dispersions of particulate superabsorbent polymer in a polyvinyl chloride plastisol. A dispersion is formed from the polymer and plastisol, then contacted with a substrate and heat cured to a semi-gel state. The coatings are capable of swelling in the presence of water to protect the substrates from water penetration, block water from penetrating the coatings to reach other substrates or to retain water to prevent leakage.

Claims

1. A water swellable coating, comprising a semi-gel dispersion of a particulate superabsorbent polymer which is hydrophilic and capable of absorbing and retaining a large quantity of water in a polyvinyl chloride plastisol.

2. The water swellable coating according to claim 1, wherein the particulate superabsorbent polymer is selected from the group consisting of at least partially cross-linked homopolymers and copolymers of sodium polyacrylate, and potassium polyacrylate.

3. The water swellable coating according to claim 2, wherein the particulate superabsorbent polymer is sodium polyacrylate homopolymer having an average particle size of from about 1 to about 500 microns.

4. The water swellable coating according to claim 3, wherein the particulate superabsorbent polymer is sodium polyacrylate homopolymer having an average particle size of from about 1 to about 100 microns.

5. The water swellable coating according to claim 2, wherein the particulate superabsorbent polymer is a potassium copolymer of polyacrylate and polyacrylamide having an average particle size of from about 1 to about 500 microns.

6. The water swellable coating according to claim 1, wherein the polyvinyl chloride plastisol comprises a polyvinyl chloride resin and a plasticizer, the weight percentage ratio of the resin to the plasticizer being from about 0.25:

1 to about 3;

1.

7. The water swellable coating according to claim 6, wherein the weight percentage ratio of the resin to the plasticizer is about 1:

1.

8. The water swellable coating according to claim 5, wherein the plastisol further comprises an additive selected from the group consisting of secondary plasticizers, flame retardants, stabilizers, fillers, colorants, viscosity modifiers, foaming agents and combinations thereof.

9. The water swellable coating according to claim 1, wherein the coating comprises from about 10 weight percent to about 50 weight percent superabsorbent polymer.

10. The water swellable coating according to claim 1, wherein the absorption capacity of the coating is at least about 34 g water/g coating after a 5 minute exposure of a 0.011 inch thick layer of the coating to distilled water.

11. The water swellable coating according to claim 10, wherein the absorption capacity of the coating is at least about 40 g water/g coating after a 5 minute exposure of a 0.011 inch thick layer of the coating to distilled water.