Polymer mixture, multilayer article containing the same, and process of preparing the multilayer article

• US 10,793,709 B2
• Filed: 10/11/2013
• Issued: 10/06/2020
• Est. Priority Date: 10/11/2013
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Zhang, Liang, Jiang, Jingui, Chen, Yongchun, Li, Yan, Li, Wei
• Primary Examiner(s): Sawdon, Alicia J
• Application Number:
  US15/027,329
• Publication Number:
  US 20160251507A1
• Time in Patent Office: 2,552 Days
• Field of Search: 472 92, 524031, 523021, 404 28, 404 17, 404 82
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B05D 7/50 Multilayers
• CPC Class Codes: C04B 18/22 Rubber , e.g. ground waste tires
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/48 Macromolecular compounds
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/71 at least one coating being an organic material
• CPC Class Codes: C08K 5/34924 containing cyanurate groups; Tautomers thereof
• CPC Class Codes: C08K 5/42 Sulfonic acids; Derivatives thereof
• CPC Class Codes: C08K 5/5435 containing oxygen in a ring
• CPC Class Codes: C08L 19/003 Precrosslinked rubber; Scrap rubber; Used vulcanised rubber
• CPC Class Codes: C08L 23/16 Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
• CPC Class Codes: C08L 2312/08 by silane
• CPC Class Codes: C08L 33/00 Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 33/06 of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08L 43/04 Homopolymers or copolymers of monomers containing silicon
• CPC Class Codes: C09J 133/04 Homopolymers or copolymers of esters C09J143/04 takes precedence
• CPC Class Codes: E01C 13/065 : at least one in situ layer consisting of or including bitumen, rubber or plastics
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A novel polymer mixture having fast drying time, a multilayer article comprising at least two layers of the dried polymer mixture and having good mechanical properties, water resistance and weatherability, and a method of preparing the multilayer article.

Claims

1. A synthetic sports surface comprising a polymer mixture, wherein the polymer mixture comprises an aqueous binder composition and vulcanized or crosslinked rubber, wherein the aqueous binder composition comprises:

(a) a first acrylic emulsion (co)polymer having a glass transition temperature of −

45°

C. to −

5°

C.,

(b) a second acrylic emulsion (co)polymer having a glass transition temperature of at least 15°

C., and

(c) a crosslinking agent comprising a water-dispersible isocyanate composition;

wherein the crosslinking agent further comprises an epoxy silane, said epoxy silane being a functional silane having at least one epoxy group and said epoxy silane having the structure of Formula (V);

2. The synthetic sports surface of claim 1, wherein the water-dispersible isocyanate composition comprises an isocyanate compound, a modified isocyanate compound having an anionic group, and a modified isocyanate compound having a polyethylene oxide segment.

3. The synthetic sports surface of claim 1, wherein the crosslinking agent is present in an amount of from 1 to 10 wt %, based on the total weight of the acrylic emulsion (co)polymers.

4. The synthetic sports surface of claim 1, wherein the aqueous binder composition comprises from 5 to 95 wt % of the first acrylic emulsion (co)polymer, and from 5 to 95 wt % of the second acrylic emulsion (co)polymer, based on the total weight of the acrylic emulsion (co)polymers.

5. The synthetic sports surface of claim 1, wherein the first acrylic emulsion (co)polymer and the second acrylic emulsion (co)polymer each comprises as polymerized units, at least one ethylenically unsaturated nonionic monomer, and at least one ethylenically unsaturated monomer having at least one functional group selected from carbonyl, acetoacetate, alkoxysilane, carboxyl, ureido, amide, imide or amino group, or mixtures thereof.

6. A multilayer synthetic sports surface comprising at least two layers made from the polymer mixture of claim 1:

(i) a base layer of dried polymer mixture, wherein the weight ratio of total acrylic emulsion (co)polymers to the vulcanized or crosslinked rubber is from 1;

6 to 1;

12; and

(ii) a top layer of dried polymer mixture, wherein the weight ratio of total acrylic emulsion (co)polymers to the vulcanized or crosslinked rubber is from 1;

2 to 1;

4.

7. The multilayer synthetic sports surface of claim 6, wherein the vulcanized or crosslinked rubber in the base layer has a sieve particle size of from 1 to 6 mm, and the vulcanized or crosslinked rubber in the top layer has a sieve particle size of from 0.1 to 6 mm.

8. The multilayer synthetic sports surface of claim 6, wherein the multilayer synthetic sports surface has a thickness of at least 10 mm, the volume ratio of the base layer to the multilayer synthetic sports surface is from 40 to 95%, and the volume ratio of the top layer to the multilayer synthetic sports surface is from 5 to 60%.

9. The multilayer synthetic sports surface of claim 6, wherein the multilayer synthetic sports surface has a force reduction of from 35 to 50%, a vertical deformation of from 0.6 to 2.5 mm, a slide resistance value of at least 47 (BPN, 20°

C.), a tensile strength of at least 0.4 MPa, an elongation at break of at least 40%, and a fire retardation grade of I, according to the GB/T 14833-2011 standard.

10. A method of preparing a multilayer synthetic sports surface from a first polymer mixture and a second polymer mixture as claimed in claim 1, comprising:

(1) providing the first polymer mixture, wherein the weight ratio of total acrylic emulsion (co)polymers to the vulcanized or crosslinked rubber is from 1;

6 to 1;

12;

(2) applying the first polymer mixture to a substrate;

(3) drying and curing the polymer mixture to form a base layer;

(4) providing the second polymer mixture, wherein the weight ratio of total acrylic emulsion (co)polymers to the vulcanized or crosslinked rubber is from 1;

2 to 1;

4;

(5) applying the second polymer mixture to the base layer; and

(6) drying and curing the second polymer mixture to form a top layer, such that the base layer resides between the substrate and the top layer.