VINYL ACRYLIC COPOLYMERS AND METHODS OF MAKING AND USE THEREOF

Abstract

Described herein are compositions comprising a vinyl acrylic copolymer derived in the presence of maltodextrin. In some examples, the compositions comprise a copolymer derived from: vinyl acetate; an acrylate monomer having a T.sub.g of −30° C. or less; a carboxylic acid, a carboxylic acid anhydride, or a combination thereof; and an organosilane; in the presence of maltodextrin. The copolymer can be provided as an aqueous dispersion. In some examples, the aqueous dispersion can have an overall solids content of from 40% to 75%. Also disclosed herein are carpet tiles having a surface coated with the adhesive formulations disclosed herein. In some examples, the carpet tile with the adhesive formulation applied thereto can pass the British spill test. Also disclosed herein are methods of making the compositions disclosed herein.

Claims

1.-52. (canceled)

53. A composition comprising a copolymer derived from: vinyl acetate; an acrylate monomer having a glass transition temperature (T.sub.g) of −30° C. or less; a carboxylic acid, a carboxylic acid anhydride, or a combination thereof; and an organosilane; in the presence of maltodextrin.

54. The composition of claim 53, wherein the copolymer is derived from 30-90% by weight vinyl acetate based on the total monomer weight.

55. The composition of claim 53, wherein the copolymer is derived from 45-75% by weight vinyl acetate, based on the total monomer weight.

56. The composition of claim 53, wherein the acrylate monomer comprises butyl acrylate, 2-ethylhexyl acrylate, or a combination thereof.

57. The composition of claim 53, wherein the acrylate monomer comprises butyl acrylate.

58. The composition of claim 53, wherein the copolymer is derived from 20-70% by weight of the acrylate monomer, based on the total monomer weight.

59. The composition of claim 53, wherein the copolymer is derived from 30-60% by weight the acrylate monomer, based on the total monomer weight.

60. The composition of claim 53, wherein the carboxylic acid, carboxylic acid anhydride, or a combination thereof is derived from a monocarboxylic acid, a dicarboxylic acid, or a combination thereof.

61. The composition of claim 53, wherein the carboxylic acid, carboxylic acid anhydride, or combination thereof is selected from the group consisting of (meth)acrylic acid, itaconic acid, crotonic acid, fumaric acid, maleic acid, anhydrides thereof, and combinations thereof.

62. The composition of claim 53, wherein the carboxylic acid comprises acrylic acid.

63. The composition of claim 53 wherein the copolymer is derived from greater than 0% to 10% by weight of the carboxylic acid, based on the total monomer weight.

64. The composition of claim 53, wherein the copolymer is derived from 0.5-2% by weight of the carboxylic acid, based on the total monomer weight.

65. The composition of claim 53, wherein the organosilane comprises a vinyl silane.

66. The composition of a claim 53, wherein the organosilane comprises vinyltrimethoxysilane, vinyltriethoxysilane, vinyl tris(2-methoxyethoxysilane), vinyl triisopropoxysilane, gamma-methacryloxypropyltrimethoxy silane, or combinations thereof.

67. The composition of claim 53, wherein the organosilane comprises vinyltriethoxysilane.

68. The composition of claim 53, wherein the copolymer is derived from 0.05% to 2% by weight of the organosilane, based on the total monomer weight.

69. An aqueous dispersion comprising water and the copolymer of claim 53.

70. An adhesive formulation, comprising the aqueous dispersion of claim 69.

71. A carpet tile having a surface coated with the adhesive formulation of claim 70.

72. A method of making the composition of claim 53, the method comprising polymerizing monomers comprising: vinyl acetate; an acrylate monomer having a T.sub.g of −30° C. or less; a carboxylic acid, a carboxylic acid anhydride, or a combination thereof; and an organosilane; in the presence of maltodextrin.

Description

EXAMPLES

[0086] The following examples are set forth below to illustrate the methods and results according to the disclosed subject matter. These examples are not intended to be inclusive of all aspects of the subject matter disclosed herein, but rather to illustrate representative methods and results. These examples are not intended to exclude equivalents and variations of the present invention which are apparent to one skilled in the art.

[0087] Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in ° C. There are numerous variations and combinations of measurement conditions, e.g., component concentrations, temperatures, pressures and other measurement ranges and conditions that can be used to optimize the described process.

Example 1

[0088] An example of a carpet latex composition and the corresponding evaluation are described below.

[0089] A carpet formulation was prepared with the components shown in Table 1, where the pH was 7.01 (controlled using NaOH).

TABLE-US-00001 TABLE 1 Materials for the carpet formulation. TSC BASE 1 Latex Binder 52.58 100 Sodium Salt of Acrylic Polymer 41.6 0.4 other additive 50 1.35

[0090] Carpet formulations A, B, C, and D were prepared as shown in Table 2. The properties of carpet formulations A, B, C, and D are shown in Table 3.

TABLE-US-00002 TABLE 2 Materials for the carpet formulations A, B, C, and D. TSC A B C D Latex Binder of the 52.49 100 100 100 100 Invention ground calcium 100 200 250 300 350 carbonate anionic surfactant blend 30 0.25 0.25 0.25 0.25 starch dispersion 45 3 3 3 3 alkali-swellable 15.5 1 1 1 1 emulsion thickener

TABLE-US-00003 TABLE 3 Properties of carpet formulations A, B, C, and D. A B C D Predicted Solids, % 74.5 77.3 79 79 VISC SPEC 7000-9000 7000-9000 7000-9000 7000-9000 (RVT, #5, 20 rpm): cp cp cp cp V A F (viscosity after 1700 2000 1800 1400 filler) TD (Thickener Demand) 7.17 5.46 5.27 8.92 Initial Viscosity, cp 8400 8200 8400 8000 Froth Rate, % 52.01 60.98 74.91 68.11 Froth Viscosity, cp 13000 14100 17600 15500 Viscosity after 1 Day, cp 8000 7200 7400 8600 Tensile, psi 341 454.46 565.28 575.21 Elongation, % 36.96 19.43 11.13 7.88 Cup Coat Wt 67.81 68.89 69.45 68.11 Precoat only on Nylon 15.04 13.06 13.39 11.88 Loop carpet Tuft Bind Dry, psi Precoat only on Nylon 5 5 4.5 5 Loop carpet Velcro Rating Dry range (1 (poor) to 5 (no fuzzing)) Bundle Wrap % 99.5 99.3 99.4 99.4 Tuft Bind Dry, lb*force — — 11.43 10.33 Tuft Bind 1 min Wet, — — 10.52 7.97 units Tuft Bind 20 min Wet, — — 6.65 4.06 units Velcro Rating 20 min — — 3 2.5 Wet, units

[0091] Other advantages which are obvious and which are inherent to the invention will be evident to one skilled in the art. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

[0092] The methods of the appended claims are not limited in scope by the specific methods described herein, which are intended as illustrations of a few aspects of the claims and any methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative method steps disclosed herein are specifically described, other combinations of the method steps also are intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein or less, however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.