AU593100B2 - Curable latex composition, films and foams formed therefrom and method for curing the composition - Google Patents

Description

593100 4

AUSTRALIA

Patents Act COMPLETE SPECIFICATION

(ORIGINAL)

Application Number: Lodged: -7 ;z10,47 Class Int. Class Complete Specification Lodged: Accepted: Published: Priority t A r r crI Related Art: St I This document contains the amendments made under Section 49 and is correct for printing.

"APPLICANT'S REFERENCE: 33,830-F Name(s) of Applicant(s): The Dow Chemical Company e** Address(es) of Applicant(s): eo 2030 Dow Center, Abbott Road, Midland, Michigan 48640, UNITED STATES OF AMERICA.

SAddress for Service is: PHILLIPS ORMONDE and FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne 3000 AUSTRALIA Complete Specification for the invention entitled: CURABLE LATEX COMPOSITION, FILMS AND FOAMS FORMED THEREFROM AND METHOD FOR CURING THE COMPOSITION Our Ref 52319 POF Code: 1037/1037 The following statement is a full description of this invention, including the best method of performing it known to applicant(s): 6003q/1 1 i'ill~--;-ili- :-71

A

-11- CURABLE LATEX COMPOSITION, FILMS AND FOAMS FORMED THEREFROM *o AND METHOD FOR CURING THE COMPOSITION o99a *,9 The present invention relates to a curable latex composition, films and foams formed therefrom and a method of curing said curable latex composition. The term "latex" is defined as a polymer or copolymer prepared from one or more monomers in an aqueous environment by emulsion polymerization technique.

S* It is known in the prior art that useful polymeric films may be formed from carboxylated latex compositions which have been subjected to a crosslinking step. Carboxylated latexes and their methods of preparation are generally taught in the art.

The carboxylation is introduced by utilizing as one of the comonomers in the preparation of the latex an unsaturated carboxylic acid monomer. Numerous crosslinking methods have been tried in the formation Sof such films. For example, the reaction between an available epoxy group and the carboxylic group on the latex is taught in U.S. Patent 4,028,294. As described in this patent, a self-crosslinking latex may be. formed by polymerizing epoxy-f tional groups into the by polymerizing epoxy-functional groups into the 33,830-F i t i _7 1rst~rLI I1Lm~uadi -2- Scarboxylic polymer. However such systems have the disadvantages that reaction may take place during the polymerization of the latex and during storage of the polymer dispersion.

In order to prepare polymeric films having improved physical properties and reduced sensitivity to water from an aqueous latex comprising a copolymer of styrene and butadiene containing an unsaturated monocarboxylic or dicarboxylic acid, it has been S, attempted to crosslink such latex with a post-added emulsion of an epoxy resin. However, there have been difficulties in preparing a stable epoxy resin emulsion. In particular, it is difficult to provide an emulsion having an adequate small particle size for use in crosslinking of the copolymer. Further difficulties relate to the sluggish nature of the reaction mechanism. The reaction requires high temperatures of, for example, greater than 180 0 C and also long oven dwell S" times.

S.Other attempts have been made to crosslink carboxylated latex films, such as, for example, by utilizing melamine formaldehyde resins and metallic S salt complexes and by hydrogen bonding, methylol substitution or ionic crosslinking, but all of these techniques suffer from one or more disadvantages such as sluggish reactivity, poor water resistance, high sensitivity to alkaline aqueous media, release of toxic volatiles during processing, short shelf life of the mixture and moderate crosslinking efficiency.

In view of the aforementioned deficiencies of the known latex compositions, it would be desirable to provide a curable latex composition which cures fast at 33,830-F -2- La -i -3relatively low temperatures, has improved shelf life, and provide plastic films or foams having improved physical properties and improved moisture resistance.

One indication of improved moisture resistance is improved wet strength.

Accordingly, in a first aspect, the present invention provides a curable latex composition comprising a carboxylated latex, an epoxy resin emulsion containing an organo-soluble or organo-miscible catalyst and a water-soluble catalytic curing agent.

0, The curable latex composition according to this aspect of the present invention is characterized in that the subsequent curing step may be achieved at v relatively low temperatures and relatively short dwell times. The curable latex composition according to this aspect of the present invention further provides a product of improved shelf life, improved physical properties and improved resistance to moisture.

25 2 The abo.ylat d latex p..c a oopol.y-....a.

a vinyl aromatic monomer and an unsaturated carbox c acid monomer. In a preferred form, the copo er may further comprise a diene monomer.

The vinyl aromatic romer may be selected from *tyrene, a-methylstyr a,r-methylstyrene, a,rethylstyrene, a- ,r-dimethylstyrene, a,r,a,rdimethyl Iene, a,r-t-butylstyrene, vinylnaphthalene, me ystyrene, cyanostyrene, acetylstyrene, -monoohlorostyrene, dihlorotyrene, -and ether 3 830-F -3- 1 La'1 The carboxylated latex comprises a copolymer of a vinyl aromatic monomer or a diene monomer and an ethylenically unsaturated carboxylic acid monomer. In a preferred form, the copolymer comprises a copolymer of an aromatic monomer, a diene monomer and an ethylenically unsaturated carboxylic acid monomer.

The vinyl aromatic monomer may be selected from styrene, a-methylstyrene, a, r-methylsty' Se, a, r-ethylstyrene, a-a, r-dimethylstyrene, a, r,a, r-dimethylstyrene, a,r-t-butylstyrene, vinylnaphthalene, methoxystyrene, cyanostyrene, acetylstyrene, monochlorostyrene, dichlorostyrene, and other e ti.

C C z t C 1i C* c Cr C C C 39 -3aw

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i: 1 -4halostyrenes, and mixtures thereof. The vinyl aromatic monomer may be present in any effective amount. The vinyl aromatic monomer may be present in amounts of from approximately 0 to 75% by weight, based on the total weight of the polymer resin. Preferably the vinyl aromatic monomer is present in amounts of from' approximately 35 to 70% by weight.

The ethylenically unsaturated carboxylic acid may.be a monocarboxylic acid, or a dicarboxylic acid or Sa polycarboxylic acid, such as, for example, acrylic i acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, derivatives thereof and mixtures thereof.

U. The ethylenically unsaturated carboxylic acid monomer may be present in amounts of from approximately to 25% by weight, based on the total weight of the polymeric resin. Preferably, the ethylenically 20 unsaturated acid monomer is present in amounts of from approximately 1 to 5% by weight and, more preferably, :front 3 to 5% by weight, based on the total weight of the copolymer.

C 25 The diene monomer, when present, may be selected from butadiene, isoprene, divinylbenzene, derivatives thereof and mixtures thereof. The 1,3butadiene monomer is preferred. The diene monomer may be present in amounts of from approximately 0 to 85% by weight, preferably from approximately 30 to 65% by weight, based on the total weight of the polymer resin.

The latex may comprise an additional ethylenically unsaturated monomeric component or components. Specific examples of such ethylenically 33,830-F -4unsaturated compounds include methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2ethylhexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacrylonitrile, ethylchloroacrylate, diethyl maleate, polyglycol maleate, vinyl chloride, vinyl bromide, vinylidene chloride, vinylidene bromide, vinyl methyl ketone, methyl isopropenyl ketone and vinyl ethylester. Derivatives thereof or mixtures thereof may be included.

a The latex may comprise a styrene/butadiene/acrylic acid copolymer or a styrene/butadiene/hydroxyethylacrylate/itaconic acid copolymer. The latex may also include a mixture of copolymers. A mixture of styrene/butadiene/acrylic acid and styrene/butadiene/a. hydroxyethylacrylate/itaconic acid polymers in approximately equal amounts by weight may be used.

Such monomers are copolymerized in an aqueous 81"20 emulsion containing surfactants and modifiers under S* conditions of time, temperature, pressure and agitation in accordance with well known principles of emulsion polymerization.

25 The latex component of the curable latex composition may further include an emulsifier or surfactant.

The surfactants used are conventional nonionic and/or anionic surface active agents. Suitable nonioni-c surfactants include the ethylene oxide derivatives of alkylphenols, such as octyl or nonylphenol containing from 10 to 60 moles of ethylene oxide per mole of the phenol, and long chain alcohols, such as dodecyl alcohol containing the same proportion 33,830-F 1 1 -i

I

-6of ethylene oxide. Suitable anionic surfactants include alkyl sulfates, such as lauryl sulfates, and diverse sulfonates, such as the esters of sulfonated dicarboxylic acids, especially succinic acid. The ethoxylated nonionic surfactants are preferred.

The emulsifier or surfactant may be present in amounts of from approximately 0.5 to 5% by weight, based on the dry weight of the copolymer.

*It has been found that the inclusion of an emulsifier or surfactant may improve the shelf life of the curable coating composition according to the present invention.

The epoxy resin component is suitably any compound which possesses more than one 1,2-epoxy group.

In general, the epoxy resin component is saturated or unsaturated aliphatic or cycloaliphatic, aromatic or heterocyclic and can be substituted or unsubstituted.

The epoxy resins may be selected from the polyglycidyl ethers of bisphenol compounds, the polyglycidyl ethers of a novolac resin, and the polyglycidyl ethers of a polyglycol. Mixtures of two or more epoxy resins may Salso be used.

The preferred epoxy resins are the polyglycidyl ethers of bisphenol compounds. The polyglycidyl ethers of bisphenol A or bisphenol F have been found to be suitable. The epoxy resins may be formed as the reaction products of epichlorohydrin and bisphenol A or bisphenol F or derivatives thereof.

The epoxy resin component of the curable latex 35 composition may further include an emulsifier or surfactant. An anionic or a nonionic surfactant may be 33,830-F -6- -7used. A nonionic surfactant is preferred. An ethoxylated nonionic surfactant is more preferred. An ethoxylated nonionic surfactant having an HLB of approximately 16 to 20 is most preferred. The nonionic surfactant sold under the trade designation "Capcure 65" and available from Diamond Shamrock Corporation has been found to be suitable. The emulsifying agent or surfactant may be present in amounts of from approximately 5 to 10% by weight, based on the weight of the epoxy resin. Preferably, the emulsifying agent or surfactant is present in amounts of from approximately at least 8% by weight. It has been found that where a nonionic surfactant or "15 emulsifying agent is included, the epoxy resin emulsion so formed provides a relatively reduced particle size.

The reduced particle size provides an improvement in the stability of the epoxy resin and in turn in the curable latex composition.

Desirably, in the preparation of the epoxy resin emulsion, the epoxy resin and surfactant or emulsifier are homogenized by means of a suitable high shear blender. The particle size of the epoxy resin emulsion thus produced may be approximately two to five times that of the latex (for example approximately three times that of the latex (for example less than l 1000 High shear homogenization may continue during phase inversion in order to assist in achieving small particle size.

The level of epoxy resin employed will vary over a wide range depending upon the properties of the final product required, as well as the types of epoxy carboxylic acid used.

resin and carboxylic acid used.

33,830-F -7rar*raa;ra~i~nrp~s -8- Low viscosity resins are preferred as it is easier to produce a stable emulsion from them. Most preferred is the epoxy resin sold under the trade designation 351-A available from The Dow Chemical Company.

The epoxy resin emulsion component as described above comprises an organo-soluble or organo-miscible catalyst. Suitable organo-soluble or organo-miscible catalysts include the phosphonium salts, such as, for example, ethyltriphenyl phosphonium acid acetate and ethyltriphenyl phosphonium phosphate and the quaternary ammonium salts, such as, for example, alkylbenzyl dimethyl ammonium chloride, benzyltrimethyl ammonium chloride, methyltrioctyl ammonium chloride, tetraethyl *C ammonium bromide, N-dodecyl pyridinium chloride and tetraethyl ammonium iodide. The preferred organosoluble or organo-miscible catalysts are ethyltriphenyl 20 phosphonium acid acetate, ethyltriphenyl phosphonium S* phosphate and methyltrioctyl ammonium chloride.

Ethyltriphenyl phosphonium phosphate is not readily available but it can be manufactured from ethyltriphenyl phosphonium acetate by reaction with phosphoric acid.

The organo-soluble or organo-miscible catalyst Smay be present in an amount of from approximately 0.1

S

F to approximately 10.0%, preferably from 0.3 to by weight, based on the weight of the epoxy resin.

The water-soluble catalytic curing agent may be present in an amount of from approximately 0.1 .to approximately 15% by weight, based on the weight of the copolymer. Suitable catalytic curing agents include tridimethyl aminomethyl phenol, dimethyl aminomethyl 33,830-F -8-

:I:

r.s

I

-2 phenol, dicyanidiamide, polyamines such as, for example, ethylenediamine, diethylenetriamine, triethylene tetramine, tetraethylene pentamine and isophorone diamine.

The curable latex composition according to the present invention may further include standard compounding ingredients such as, for example, fillers, thickening agents, antioxidants, dispersants, pH modifiers and flame retarding agents.

Fillers, when present, may be selected from metals in powder or filamnent form, and non-metals such as carbon, silicates, asbestos, titanium dioxide, zinc *15 oxide, calcium carbonate, zinc sulphide, potassium titanate and titanate whiskers, glass flakes, clays, 0* kaolin and glass fibers. The fillers may be present in S amounts of from approximately 0 to 80% by weight, or higher, based on the total weight of the composition.

Where the curable latex composition is to be used in the preparation of a foam, calcium carbonate has been Sfound to be a suitable filler.

If a flame retarding agent is used, suitable 25 S agents may include chlorinated and brominated organic compounds and/or inorganic compounds such as antimonytrioxide and phosphorous compounds, such as phosphates and phosphites.

30 An adjustment of the pH of the mixture of the reactive latex and the coreactive material may be made, if desired, by the addition of usual acidifying or alkalizing agents such as, for example, acetic acid, citric acid, dilute mineral acids, ammonium hydroxide 41 -j 33,830-F -9and dilute aqueous solutions of alkali metal hydroxides.

In another aspect, the present invention provides a blend of a latex comprising a copolymer of a vinyl aromatic monomer, a diene monomer and an ethylenically unsaturated carboxylic acid monomer as described above, and an epoxy resin emulsion as described above and containing an organo-soluble or organo-miscible catalyst.

It has been found that the shelf life for the 15 blend of latex and epoxy resin emulsion is at least several weeks in the absence of the water-soluble Scatalytic curing agent.

20 The shelf life of the blend of latex and epoxy resin emulsion may be improved by selecting the pH oef the blend such that a substantial proportion of the carboxyl groups on the latex copolymer are protonine.d.

It has been found that if the pH is maintained in the .'25 range of approximately 6 to 6.5, extended shelf life may be achieved. The pH may be adjusted in any suitable manner. Addition of an approximate amount of ammonia has been found to be suitable for pH adjustment.

It will be understood that the various components of the curable latex compositions of the present invention may be maintained separately until shortly before use because of their ambient temperature curing properties. In some instances, two or more components which do not react with each other can be

I

33,830-F -11premixed. For example, the latex and the water-soluble catalytic curing agent may be provided as one component and the epoxy emulsion containing the organo-soluble or organo-miscible catalyst as the other component. The latex may also be combined with the epoxy emulsion containing the organo-soluble or organo-miscible catalyst and then the water-soluble catalytic curing agent may be added separately immediately prior to use.

Once combined, the composition may be used directly or may be further diluted with water depending on the solids level desired for the particular method of application to be. employed. The composition is applied in conventional manner, such as, for example, by 15 brushing, spraying and roll coating.

.In another aspect, the present invention relates to a process for preparing a curable latex composition which comprises blending a carboxylated latex, an epoxy resin emulsion containing an organo-soluble or organo-miscible Scatalyst and a water soluble catalytic curing agent.

S '25 In a further aspect of the present invention, there is provided a method for preparing a crosslinked latex product whicn method comprises the steps of tr a providing a curable latex composition comprising a latex comprising a copolymer of a vinyl aromatic monomer and/or a diene monomer and an ethylenically unsaturated carboxylic acid monomer, 33,830-F -11- 'i j -12an epoxy resin emulsion containing an organo-soluble or organo-miscible S+ catalyst, and a water-soluble catalytic curing agent and heating the curable latex composition at a temperature and for a time sufficient to cure the product.

The curing temperature may be any suitable temperature above ambient temperature. Indeed, some curing may occur at ambient temperature, but since the reaction time is extremely slow, such a temperature is 15 1 impractical.

The preferred temperature range is from .s approximately 120 to 180°C. The residence time is variable. Factors influencing residence time include temperature, film thickness, water content and the ;components of the curable coating composition. With temperatures in that range, a total residence time of approximately five to ten minutes has been found to be oi..25 suitable.

Whilst the generality of the invention should not in any way be restricted by theory based on the results of our experiments it can be postulated that the water-soluble catalytic curing agent will to some extent be transferred into the epoxy resin phase upon drying, and promote polymerization of the epoxy resin, as well as carboxyl-epoxy reaction,. It also makes the latex more miscible with the epoxy resin. The organic soluble catalyst had shown reasonable activity for the acid-epoxy reaction only, hence resin emulsions 33,830-F -12- A r -13precatalyzed with the organo-soluble catalyst yield a long shelf life. The organic soluble catalyst also makes the carboxylated latex polymer more miscible with the epoxy resin. It is therefore reasonable to assume, that the latex particles are crosslinked with a builtin network of homopolymerized epoxy resin.

If the crosslinked latex product to be formed is a film, the method of preparing a latex product may include the further steps of (ia) casting a film onto a suitable support and 99 (iaa) drying the film so formed.

A film of the latex blend may be cast onto a foil support. A polyester foil support, for example, of the "Mylar" type may be used.

.9 The film thickness is variable but a film of a thickness of from approximately 500 to 1000 micrometers, preferably 750 micrometers has been found to be suitable.

It is preferred that the film is air dried at 25 ambient temperature initially and drying completed at elevated temperature. For example, the film may be n odried at a temperature of approximately 50 to 70C0 for Sapproximately twenty to thirty minutes. It has been found that the initial air drying avoids shrinkage cracking of the film.

If the latex product to be formed is a foam product, the method of preparing the latex product comprises the further step of 33,830-F -13-

I

ii~iiiili i Iii I -14subjecting the blend so formed to a foaming step prior to curing.

The foaming step may be undertaken in any suitable manner.

A foam or froth may be generated by methods well known in the art, for example by releasing a noncoagulating gas such as nitrogen, or by causing the decomposition of a gas-liberating material to -chemically react with an ingredient in the mixture with the liberation of a non-coagulable gas as a reaction product. The mixture of the reactive latex and the coreactive material is also foamed by whipping or by use of apparatus having commercially available foam heads. Known foaming aids, such as sodium lauryl sulfate, or foam stabilizers, such as potassium oleate, h may be added if desired. Preferably, such added materials should be non-reactive with the reactive group in the latex polymer or in the coreactive f material and thus the preference may vary with the .composition of the mixture. Other soaps, emulsifiers, w tting agents, and surfactants, however, may be used, '1 5 even though they may be reactive to a limited extent.

The frothed mixture may be poured into molds, spread on a flat tray or belt, or coated onto substrates. For the purpose of this specificatidn, the term "substrate" is defined as any material such as cloth, fabric, leather, wood, glass or metal or any form of backing to which the frothed mixture will adhere when applied and after it is cured.

In a preferred embodiment in which the foam is used as a textile backing, the foam may be applied to 3 f 33,830-F -14r s 4t tr E aI

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8'9O #9 i 4* 4 C Q

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4 9( C4l .4 *I 0 'p ti I t It te the textile prior to drying and curing. A typical froth formed from the continuous foam will have a density in the range of from approximately 200 to 400 grams per litre in its wet state, preferably approximately 350 grams per litre. The foam may be -applied to the substrate utilizing a doctor blade.

Once formed, the foam may be dried and cured at a temperature of approximately 110 to 150 C. The drying and curing may be undertaken in a forced air circulation oven. The internal temperature of the oven should be maintained preferably at or above approximately 120 0

C.

15 The present invention will now be more fully described with reference to the accompanying examples.

It should be understood, however, that the following examples are illustrative only and should not be taken in any way as a restriction on the generality of the invention as described above.

Following is a description of materials and test procedures employed in the examples and comparative runs.

Materials employed V Epoxy Resin A Epoxy Resin B a diglycidyl ether of bisphenol A supplied by The Dow Chemical Company a diglycidyl ether of bisphenol A supplied by The Dow Chemical Company 33,830-F ~aum~ a -16-

S.

0

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15 0@ 4, 0 S S a 050 Epoxy Resin C Epoxy Resin D Catalyst A .Catalyst

B

Catalyst C CapcureT 65 Latex A -a 50/5O blend of' Epoxy Resin B and Epoxy Resin D a diglycidyl ether of, bisphenol F supplied by The Dow Chemical Company Ethyl triphenyl phosphonium acid acetate Ethyl triphenyl phosphonium phosphate Diethylene triamine Ethoxylated nonionic surf'actant supplied by Diamond Shamrock 58% styrene/39% butadiene/3% itaconic acid 28% Styrene/34% butadiene/36% vinylidene chloride/2% itaconic acid A copolymer of' 32 wt. styrene, 65 wt. butadiene and 3 wt. acrylic acid supplied by The Dow Chemical Company A carboxylated styrene/butadiene latex supplied by Dow Chemical (Australia) Ltd.

S

S..

OS

0 0 0~ Latex B -"-25 0016 a Latex C tC tC-£C e v r Latex D 33,830-F

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-17- Catalyst D Antioxidant A Poly Resin 55B 4t 44 o a, o r o to af 4.44 r 0 44t a.

C

44; ft t a 4 «r *1 6 t 4 10 L.ankropol

ODS/LS

CalgonTM T 15 MobilcerT' RV 20 IrgaliteTM SPV-1 CalciteTH C 'T5-c Tridimethyl aminomethyl phenol supplied by Rhom Haas 2'2'-methylene-bis[6-(methylcyclohexyl)-para-cresol)] A polyacrylate thickener solids) supplied by Revertex Industries (Australia) N-octadecyl sulphosuccinamate supplied by Diamond Shamrock A polyphosphate dispersant supplied by Albright and Wilson Company A paraffin wax emulsion supplied by Mobil Oil Company A carbon black dispersion supplied by Ciba -A CaCO 3 filler with suitable particle size distribution supplied by A.C.I. Minerals An acrylic thickener supplied by Allied Colloids LTD.

A melamine formaldehyde resin supplied by.Hoechst A propylene glycol methyl ether supplied by The Dow Chemical Company :,25 mar a, e F e ViscalexT M HV-30 CassuritTM MT DowanolTH PM 33,830-F -17i 1

I:

:i a -18- Surfynol T M EG-75 Drew Defoamer XZS 86857.00 A surfactant, tertiary acetylenic glycol in ethylene glycol supplied by Air Products and Chemicals, Inc.

-A defoamer supplied by Drew Ameroid Australasia Pty. LTD.

-An antioxidant dispersion supplied by Dow Chemical Europe -Precatalyzed epoxy resin emulsion supplied by Dow Chemical Australia -Trioctyl methyl ammonium chloride supplied by Henkel Corporation Epoxy Resin E 0el q 15

CR

04,4 6 0#0

C

Catalyst E Swell and Gel Tests Procedure Add approximately 0.5 g (weighed accurately) of polymer film to a centrifuge tube. Add 35cc of tetrahydrofuran (THF). Shake for 1.5 hours.

,25 Centrifuge 1 hour at 19,000 rpm. Drain the THF, weigh, dry (minimum of 5 hours) at and reweigh.

1 3 Swell Index Weight of Polymer Gel 100 x original film weight Wt of THF imbibed Final Dry Final dry weight of polymer 33,830-F -18-

I

i !1 1

I

Icu--j i l S" i i -19- Example 1 Preparation of Organo-Soluble or Organo- Miscible Catalyst mm il Final Catalyst Composition: S 30.0% Catalyst B 9.3 acetic acid 10.7% water 50.0% methanol Procedure: Charge 1000 grams (70% solids) Catalyst A to container.

Mix 193 grams phosphoric acid, 15 210.5 grams water and 804.7 grams methanol together.

While stirring, add mixture to Catlyst A over a five minute period.

Stir for one hour.

*9 It has been discovered that adding water and S" the mixing of the phosphoric acid, water, and methanol prior to the addition to catalyst A were advantageous in preventing precipitation of the phosphate catalyst with time.

4- e Example 2 Preparation of Epoxy Resin Emulsion A fine particle, stable oil-in-water emulsion of epoxy resin was prepared in accordance with the formulation and method outlined below.

33,830-F -19i i r~ 1.~ Formulation: Parts Dry Wet Epoxy Resin C Catalyst B (30%) Capcure 65 (65%) Water 100 15.4 79.6 200 111.5 Total Solids Content Epoxy Resin Content 55.75% 50.00% *e 9* 9 9*~ 0r 9S C4

C+

Procedure: Warm up epoxy resin to 60 0

C

Using an agitator, mix in Catalyst B and Capcure 20 Add water incrementally with high shear mixing Homogenize mix by means of a suitable homogenizer for at least five minutes Example 3 Preparation of A Curable Latex Composition 1 Using a Dow latex having a polymer composition of styrene/butadiene/acrylic acid in ratio 32/65/3, a blend was prepared in accordance with the following procedure and using the ingredients listed below.

33,830-F 7,V* rl, 1 6: 3;.

-21- Parts Ingredients Dry Wet Latex C 100 177.9 Catalyst D 1 3.3 Antioxidant A 2.2 4.4 'Epoxy Resin Emulsion 11.5 Poly Resin 55B 0.28 2.3 Ammonia to pH 9 15 The ingredients were added with stirring in sequence listed above. The mixture was then filtered through a 100 micron Nylon mesh and centrifuged at 3000 rpm to remove all entrained air.

A film was cast to a wet thickness of 750 micrometers on a "Mylar" polyester foil. To prevent Sshrinkage cracking-, the film was air-dried at 23 0

C

S followed by 10 minutes drying at 65°C. Finally, the 2 film was cured in a forced air circulation oven for r 25 minutes at 130 0

C.

Upon cooling, the film was removed from the substrate and cut into dumbell shaped specimen to test physical properties and tested on an Instron tensile tester for tensile strength, energy and elongation.

The results are shown in Table 1.

33,830-F -21i.

F

-22- TABLE 1 Properties Tensile Stength N.cm" 2 Elongation Energy J Latex Without Latex With Epoxy Cure Epoxy Cure System System 2160 11030 457 542 0.43 1.93 Example 4 Preparation of Latex Foam 4 44 c p4 *44r 4.4, 04d ft ,4 4 *4 A stable no-gel foam was prepared in accordance with the following formulation and procedure.

Formulation: Parts SDry t Latex C 100 4 XZS 86854.01 A.O. Dispersion 2.2 Catalyst D 0.75 25 Epoxy Resin C Emulsion 10 Lankropol ODS/LS 5 Calgon T 1 Mobilcer RV 4 Irgalite SPV-1 0.1 Calcite C 75-c 180 Viscalex HV-30 0.15 Ammonia to pH Total Solids Content pH Wet 178.2 4.4 18.1 14.3 3.3 8 0.27 180 1 specified 73.9% 8.9 33,830-F -22c~ r

"I

-23- The ingredients were mixed with agitation in sequence as listed above.

The mixture was passed through a continuous foamer and the resulting froth with a density of 350 g.l was doctored onto a precoated tufted carpet at a thickness of approximately 3.5 mm. The foam was then dried and cured to a lowest internal temperature of 120°C in a forced air circulation oven.

After cooling and conditioning at 23 0 the foam was sliced off the carpet and the physical properties were measured. The results are S shown below.

Properties *4 Sr t* ttt 4i c Foam dry density Tensile strength Elongation Delamination Strength Gauge Retent on unaged/aged (at 2 40 g.l' wet density) 0.243 g.cm 3 10.5 N.cm- 2 185% 6.2 N.2.5cm 1 103/92.8% V C- 2 Example 5 And Comparative Runs A and B I t C

F

For purposes of demonstrating the superiority of the products of the present invention to the products made with known latexes, a latex with a polymer composition of styrene butadiene/acrylic acid in ratio 32/65/3 was reacted with various crosslinkers and physical properties of the films cured at 135°C for minutes were determined before and after hot water 33,830-F -23- -24treatment. The results: are shown in Table 2. The film formed in Example 5 was prepared in a similar manner to Example 1.

4 04 00 0 4 *4 044 .4.4 4. 0 .44, 09 0 4 4* 4 44 0 4,4 4 *4# 04 0 0 0e S4 0 t t &E 33,830-F if 9 4~9 4 4, 9 a- S S .4 9~S~ a a S aSS S a I SaSS I 59 a 'a 944 4 S *a'a a55 3 a 5 4 59 aa, a S S

(A)

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0 III TABLE 2 Properties Comparative Run A (Typical melamine formaldehyde resin) Methylated Melamine Resin (Cassurit MT) phis Example 5 Epoxy Resin A Emulsion 2% Catalyst A 5 phls Comparative Run B (Typical Ionic Crosslinking Complex) Zirconium Ammonium Carbonate (Bacote 4 phls Tensile N.cm- 2 Elongation Energy Ncm.cm- 3 Tensile Modulus N.cm- 2 minutes in boiling 306/257* 472/416 962/730 1063/743 465/452 694/642 1423/1292 376 /350 593/490 1244/1015 133/159 268 /273 water, re-dried at 110 0

C

7 -26- Examples 6 to 11 and Comparative Runs C, D and E Further experiments were carried out to optimize catalyst levels and demonstrate the synergistic effect of the two-catalyst system. The results are shown in Table 3.

Catalyst B levels 0.5/1.0/1.5 parts per 100 parts Epoxy Resin C

V,,

C 3 r It 4 Catalyst D levels 0/5/10 parts per 100 parts Epoxy Resin C Latex Styrene/Butadiene/Acrylic Acid 32/65/3.

33,830-F -26t :1"1 co 00

(A

C)

Catalyst B Catalyst D Tensile N.cm-2 Elongation Energy J Catalyst B Catalyst D Tensile N.m-2 Elongation Energy J Energy J r 1 i-i it n n n cr, 1 h C rn -rn r FI TABLE 3 Comp. Run C 0.5 0 2766 606 0.64 Comp. Run D 1.0 0 3136 622 0.73 Comp. Run E 1.5 0 2960 610 0.63 Ex. 6 0.5 5 5110 523 0.91 Ex. 11 11030 542 1.93 Ex. 7 6620 635 1.42 Ex. 8 1.5 5 5190 567 0.98 Ex. 9 0.5 10 6600 402 1.00 Ex. 10 1.0 10 7680 461 1.38 Curing conditions: 5 minutes at 130 0

C

-28- Example 12 Other two-catalyst systems were evaluated as in Example 6. The results of these tests showed that Catalyst E can be substituted for Catalyst A and obtain equivalent tensile properties. The results also showed that Catalyst C can be substituted for Catalyst D.

Example 13 Effect of Dual Catalyst System on Crosslinking Efficiency of Epoxy Resin In this example, several carboxylated latexes S containing either a single catalyst or a combination of two catalysts and up to 10% by weight of epoxy resin emulsion were evaluated to determine the effect of a 15 dual catalyst system on the crosslinking efficiency of S: the epoxy resin.

The swell and gel data shown in Table 4 indicate that crosslinking indeed occurred in the curable latex composition of the present invention. As more epoxy resin was added to either Latex A or Latex B, the swelling index decreased and the gel increased, both indicating increased crosslinking. The data in Table 5 show the effect on Latex B polymer swell and gel, of adding epoxy with no catalyst, or the "I single catalyst, Catalyst E. With no catalyst, no significant change in the swell index or gel was seen, indicating little crosslinking. Addition of 6% Catalyst E but only with room temperature drying also resulted in no significant crosslinking. With the use of 6% Catalyst E with 10 minute cure at 130 0 C, some decrease in the swell index and increase in gel was 33,830-F -28- ~raRIII~ ~.aruw~a~ bSYHb rRx.nnr'~' -29seen indicating crosslinking. However, the magnitude of the change was not as great as in the case of the dual catalyst system.

TABLE 4 Effect of Dual Catalyst as Indicated by Swell Index and Gel Parts Epoxy Latex Resin C Swell Index Gel A 0 8.6 73 A 3 7.4 77 0 ,A 6 6.8 81 A 10 5.6 B 0 16.3 59 B 3 13.4 67, B 6 9.4 71 B 10 8.0 73 It C Cr 33,830-F -29p earn i~ a C a p p ae* S a w a a S C C C a a a cc a a S P S *44 *aa S S C S 5~4 S.C a a a Table Effeet of' Catal_ st and Cure as Indicated by Gel and Swell Index Parts Epoxy Resin B Catalyst E Latex

B

B

B

B

B

Cured None None None Yes Yes Yes Yes Yes Swell Index 10..0 9.7 9.8 Gel 76 7.8 79 8.9 8.8 8.3 8.2 8.7 t7I None 6% 6% ;77 0

AO

iJ -31- Example 14 A latex compound containing a catalyst combination and an epoxy resin emulsion as well as an inorganic filler as listed below was prepared as in Example 4 and used as the backing material for "Synthetic turf" which is essentially a tufted floor covering made from polypropylene fibers.

r r 15 t The latex compound was applied to the carpet in -a conventional lick roll/pan situation and dried and cured in a forced air circulated dryer or by means of heat radiators e.g. electric or gas infrared.

The adequately cured backing exhibited a high initial tuft lock and little or no loss in physical properties after rigorous water treatment, which indicated very good moisture resistance.

t r, 33,830-F -31- Jt

I,

-32- Parts Formulation: Latex D Dowanol PM Surfynol EG-75 Drew Defoamer Irgalite SPV-i XZS 86857.00 Ammonia Catalyst D (30%) Calcite C 75-c Fly Ash Epoxy Resin E Viscalex HV-30 (15%) Total Solids Content .9 .9%viscosity pH Dry 100 0.5 0.05 0.8 1.5 0.3 70 20 3 Wet 200 0.67 0.1 2.2 0.8 5.145 0.65 4.3 62 614% *6,000-8,000 mPa'S 8 -9 Test Results: Coatifig Weight: Initial Tuft retention: After water treatment"*: 401 g.m- 2 dry 36 .7 N*1 41.7 N Tested in accordance with AS 2111.15, mean of pulls a Subjected to boiling water for 2 minutes, subsequent-- drying at 140*C.

33,830-F -32- Ah r 37 -33- Finally, it is to be understood that various other modifications and/or alterations may be made without departing from the Spirit of' the present invention as outlined herein.

e9 9 ~k9 4,.

9 44 C 49 99 9 C C 9.

0* *94, 9.

6 Ct S C

CC

9 CC C C 33,830-F -33-

Claims (9)

1. A curable latex composition comprising a carboxylated latex an epoxy resin emulsion containing an organo-soluble or organo-miscible catalyst and #4 6 4A 0* a water-soluble catalytic curing agent. :06 4

2. A curable latex composition as claimed in Claim 1, wherein said carboxylated latex comprises a copolymer of a vinyl aromatic monomer, a diene monomer or mixture thereof, and an ethylenically unsaturated carboxylic acid monomer; said epoxy resin is a chemical compound containing more thanK1,2-epoxy groups; and said organo-soluble or organo-miscible catalyst is a catalyst selected from phosphonium salts and quatenary 15 ammonium salts. 4 B #46I t 4 #41 I S 4E A curable latex composition as claimed in Claim 1, wherein said carboxylated latex comprises a copolymer of from 0 to 75% by weight of a vinyl aromatic monomer, from 0 to 85% by weight of a diene monomer and from 0.5 to 25% by weight of an. ethylenically unsaturated carboxylic acid monomer, all weight percentages based on the total weight of the copolymer. -34- I-~r i x i

4. A curable latex composition as claimed in Claim 2 or Claim 3, wherein said vinyl aromatic monomer is selected from styrene, a-methylstyrene, a,r-methyl- styrene, a,r-ethylstyrene, a-a,r-dimethylstyrene, a,r,a,r-dimethylstyrene, a,r-t-butylstyrene, vinyl- naphthalene, methoxystyrene, cyanostyrene, acetyl- styrene, monochlorostyrene and mixtures thereof, said diene monomer is selected from butadiene, isoprene, divinylbenzene, derivatives thereof, and mixtures thereof, and said ethylenically unsaturated carboxylic acid is selected from acrylic acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, derivatives $og thereof and mixtures thereof. 15

5. A curable latex composition as claimed in o any one of Claims 2 to 4, wherein said carboxylated :o latex further comprises an ethylenically unsaturated monomeric compound selected from methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethyl hexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacrylonitrile, ethyl-chloroacrylate, diethyl maleate, polyglycol maleate, vinyl chloride, Po. vinyl bromide, vinylidene chloride, vinylidene bromide, vinyl methyl ketone, methyl isopropenyl ketone and vinyl ethylester. 9

6. A curable latex composition as claimed in any one of the preceding claims wherein said epoxy resin is selected from the polyglycidyl ethers of bisphenol compounds, the polyglycidyl ethers of a novolac resin and the polyglycidyl ethers of a polyglycol.

7. A curable latex composition as claimed in any one of the preceding claims wherein said epoxy 33,830-F -36- resin is a polyglycidyl ether of bisphenol A, a polyglycidyl ether of bisphenol F, or mixtures thereof.

8. A curable latex composition as claimed in any one of the preceding claims wherein said organo- soluble or organo-miscible catalyst is selected from ethyltriphenyl phosphonium acid acetate, ethyltriphenyl phosphonium phosphate, methyltrioctyl ammonium chloride, alkylbenzyl dimethyl ammonium chloride, benzyl trimethyl ammonium chloride, tetraethyl ammonium bromide, N-dodecyl pyridinium chloride and tetrabutyl o G. ammonium iodide; and said water-soluble catalytic ,curing agent is selected from tridimethyl aminomethyl phenol, dimethyl aminomethyl phenol, dicyanidiamide, 15 S. 1 ethylenediamine, diethylenetriamine, triethylene tetramine, tetraethylene pentamine and isophorone diamine; said organo-soluble or organo-miscible catalyst is present in an amount of from 0.1 to 10% by 20 weight, based on the weight of the epoxy resin and said water-soluble catalytic curing agent is present in an S amount of from0.1to 15% by weight, based on the weight 641' t of the copolymer.

9. A curable latex composition as claimed in any one of the preceding claims wherein said carboxylated latex and said epoxy resin emulsion further comprises a surfactant. A process for preparing a curable latex composition which comprises blending a carboxylated latex, an epoxy resin emulsion containing an organo-soluble or organo-miscible catalyst and a water-soluble catalytic curing agent, or blending a carboxylated latex comprising a copolymer of a vinyl aromatic monomer, a 33,830-F -36- I 1-1- 1.1-1 "4 S-37- diene monomer or mixture thereof, and an ethylenically unsaturated carboxylic acid monomer, an epoxy resin selected from a polyglycidyl ether of bisphenol A and polyglycidyl ether of bisphenol F and mixtures thereof, and containing an organo-soluble or organo-miscible catalyst selected from ethyltriphenyl phosphonium acid acetate, ethyltriphenyl phosphonium phosphate, methyltrioctyl ammonium chloride, benzyl trimethyl c>« l 4 a a 9 9 99 4 «4 1 4., 4 i: r r ammonium chloride, tetraethyl ammonium bromide, N- dodecyl pyridinium chloride and tetrabutyl ammonium iodide and a water-soluble catalytic curing agent selected from tridimethyl aminomethyl phenol, dimethyl aminomethyl phenol, dicyanidiamide, ethylenediamine, 1 diethylenetriamine, triethylene tetramine, tetraethylene pentamine and isophorone diamine.

11. A curable latex composition substantially as hereinbefore particularly described with reference to any one of the examples. 20 12. A process for preparing a curable latex composition substantially as hereinbefore particularly described with reference to any one of the examples. DATED: 30th April, 1987 PHILLIPS ORMONDE FITZPATRICK 25 Attorneys for: THE DOW CHEMICAL COMPANY q 33,830-F -37- II 10 I