Soft elastomeric composite composition

• US 6,025,067 A
• Filed: 06/14/1997
• Issued: 02/15/2000
• Est. Priority Date: 03/08/1995
• Status: Expired due to Fees

• Current Assignee: John Nicholas Fay
• Original Assignee: John Nicholas Fay
• Inventors: Fay, John Nicholas
• Primary Examiner(s): Chen, Vivian
• Application Number:
  US08/873,843
• Time in Patent Office: 976 Days
• Field of Search: 428/304.4, 428/314.4, 428/317.1, 428/317.3, 428/317.7, 428/423.1, 428/319.3, 428/319.9, 428/320.2, 428/424.2, 428/424.8, 428/515, 428/519 , 428/517, 525/92 C, 525/95, 525/96
• US Class Current: 428/314.4
• CPC Class Codes: B32B 2264/0221 Thermoplastic elastomer particles
• CPC Class Codes: B32B 2266/08 Closed cell foam
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 53/00 Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: Y10T 428/249976 Voids specified as closed
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/31573 Next to addition polymer of ethylenically unsaturated monomer
• CPC Class Codes: Y10T 428/31587 Hydrocarbon polymer [polyethylene, polybutadiene, etc.]
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31917 Next to polyene polymer
• CPC Class Codes: Y10T 428/31924 Including polyene monomers

Abstract

A composition comprising discrete particles of elastomeric triblock copolymer, the particles having a Shore A hardness of less than 30 suspended in a continuous phase matrix of noncellular elastomeric polyurethane polymer, in which the triblock copolymer has the configuration A-X-A in which block A is polystyrene and block X is a polymer of butadiene, isoprene or copolymer of ethylene and butylene; the final composition having a Shore A hardness of less than 20.

Claims

1. A composition comprising discrete particles of elastomeric triblock copolymer, the particles having a Shore A hardness of less than 30 suspended in a continuous phase matrix of noncellular elastomeric polyurethane polymer, in which the triblock copolymer has the configuration A-X-A in which block A is polystyrene and block X is a polymer of butadiene, isoprene or copolymer of ethylene and butylene;

the final composition having a Shore A hardness of less than 20.

2. The composition of claim 1 in which the particles of triblock copolymer are of a size of about 0.1 to 10 mm and comprise 10 to 80% by weight of the composition and have a Shore A hardness of less than about 15, and the elastomeric polyurethane has a Shore A hardness of less than about 10.

3. The composition of claim 2 in which the amount of particles of triblock copolymer have a shore A hardness at least 1 unit greater that that of the continuous phase polyurethane matrix.

4. The composition of claim 3 in which the amount of particles is from about 30 to about 55 percent by weight based on the total weight of the composition.

5. The composition of claim 2 in which the composition is formed into an article, a film or slab and is coated with a silicone coating from a dispersion of silicone rubber or a urethane coating.

6. The composition of claim 5 in which the composition is formed into an article, film or slab, is coated with a silicone coating from a dispersion of silicone rubber or a urethane coating and is adhered to a sheet of closed cell foam material.

7. The composition of claim 6 in which the composition is formed into an article, film or slab, is coated with a silicone coating from a dispersion of silicone rubber or a urethane coating and is adhered to a preformed sheet of a cross linked polyethylene by curing the particle containing polyurethane mixture in contact with a preformed sheet.

8. The composition of claim 1 in which the particles are an S-EB-S triblock copolymer in which S is polystyrene blocks and EB is a rubbery polymer block of ethylene and butylene.

9. The composition of claim 1 in which the particles of triblock copolymer are of a size of about 1 to 6 mm and comprise about 20 to about 60 percent by weight based on the total weight of the composition.

10. The composition of claim 9 in which the amount of particles is from about 30 to about 60 percent by weight based on the total weight of the composition.

11. The composition of claim 9 in which the amount of particles is from about 30 to about 55 percent by weight and the particles are harder than the polyurethane by at least 1 Shore A unit.

12. The composition of claim 11 in which the particles are harder than the polyurethane by at least 3 Shore A units.

13. A kit comprising components 1) and 2) wherein component 1) is a triblock copolymer particles wherein the copolymer has the configuration A-X-A in which block A is polystyrene and block X is a polymer of butadiene, isoprene or copolymer of ethylene and butylene, and which said triblock copolymer has a Shore A hardness of less than about 30 and component 2) is a polyurethane which has a Shore A hardness of less than about 20;

each component

     1) and

     2) being present in an amount sufficient to form a molded composition having discrete particles of component

     1) in a noncellular continuous phase matrix of component

     2) wherein said molded composition has a Shore A hardness of less than 20 and wherein the said composition is sufficient for a single use in a mold.

14. The kit of claim 13 in which component 1) is particles of 0.1 to 10 mm in size and present in an amount sufficient to form 20 to 80% of the total weight of the total composition.