Thermoplastic elastomer
View Patent ↗Disclosed is a product and process for a substantially halogen-free thermoplastic elastomer. The thermoplastic elastomer can be incorporated into a decorative surface covering as a binder with the addition of an optional filler. The substantially halogen-free thermoplastic comprises the combination of a dynamically vulcanized blend of epoxidized natural rubber (ENR), ionomers and a diluent polymer such as ethylene vinyl acetate (EVA). The combination produces a pliable and flexible flooring product.
1. A composition comprising a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend consisting of (a) at least one epoxidized elastomer, (b) at least one ionomer and (c) a component selected from the group consisting of (i) a diluent polymer selected from the group consisting of ethylene vinyl acetate copolymer polyvinyl butyral and combinations thereof and (ii) a combination of the diluent polymer and an additive selected from the group consisting of plasticizers, stabilizers, antioxidants, fire retardants, pigments, oils, fillers and combinations thereof.
2. The composition of claim 1 , wherein the epoxidized elastomer is epoxidized natural rubber.
3. The composition of claim 2 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the epoxidized natural rubber.
4. The composition of claim 1 , wherein the ionomer is an at least partially neutralized copolymer of(meth)acrylic acid.
5. The composition of claim 4 , wherein the copolymer of (meth)acrylic acid is at least partially neutralized with metal ions selected from the group consisting of zinc ions, lithium ions, magnesium ions, calcium ions, potassium ions, sodium ions and combinations thereof.
6. The composition of claim 1 , further comprising a filler.
7. The composition of claim 6 , wherein the composition comprises up to about 90% by weight of the filler.
8. The composition of claim 6 , wherein the filler is selected from the group consisting of limestone, clay, silicates, aluminum oxide, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers and combinations thereof.
9. The composition of claim 1 , further comprising an additive selected from the group consisting of plasticizers, stabilizers, antioxidants, fire retardants, processing aids, pigments, oils and combinations thereof.
10. The composition of claim 1 , wherein the thermoplastic elastomer comprises between from about 5% to about 80% by weight of the diluent polymer.
11. The composition of claim 1 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the ionomer.
12. The composition of claim 1 , wherein the thermoplastic elastomer is rheologically stable for at least 30 minutes at 250° F.
13. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend consisting of (a) at least one epoxidized elastomer, (b) at least one ionomer and (c) a component selected from the group consisting of (i) a diluent polymer selected from the group consisting of ethylene vinyl acetate copolymer, polyvinyl butyral, polyesters and combinations thereof and (ii) a combination of the diluent polymer and an additive selected from the group consisting of plasticizers, stabilizers, antioxidants, fire retardants, pigments, oils, fillers and combinations thereof.
14. The decorative surface covering of claim 13 , wherein the epoxidized elastomer is epoxidized natural rubber.
15. The decorative surface covering of claim 14 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the epoxidized natural rubber.
16. The decorative surface covering of claim 13 , wherein the ionomer comprises an at least partially neutralized copolymer of (meth)acrylic acid.
17. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer composition comprises up to about 90% by weight of a filler.
18. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer composition comprises a filler selected from the group consisting of limestone, clay, silicates, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers and combinations thereof.
19. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer composition further comprises an additive selected from the group consisting of stabilizers, antioxidants, pigments, oils and combinations thereof.
20. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer comprises between from about 5% to about 80% by weight of the diluent polymer.
21. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the ionomer.
22. The decorative surface covering of claim 13 , wherein the thermoplastic elastomer composition has an Olsen stiffness of less than 0.5 inch-pound at 73° F.
23. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend comprising an epoxidized elastomer, an ionomer, and a diluent polymer, wherein the decorative surface covering is in the form of a flooring tile.
24. The decorative surface covering of claim 23 , wherein the epoxidized elastomer comprises epoxidized natural rubber.
25. The decorative surface covering of claim 24 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the epoxidized natural rubber.
26. The decorative surface covering of claim 23 , wherein the ionomer comprises an at least partially neutralized copolymer of (meth)acrylic acid.
27. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer comprises from about 2% to about 60% by weight of the ionomer.
28. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer comprises from about 5% to about 80% by weight of the diluent polymer.
29. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer composition comprises up to about 90% by weight of a filler.
30. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer composition comprises a filler selected from the group consisting of limestone, clay, silicates, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers and combinations thereof.
31. The decorative surface covering of claim 23 , wherein the blend comprises a filler selected from the group consisting of limestone, clay, silicates, glass powder, magnesium hydroxide, aluminum hydroxide, barite, organic fillers and combinations thereof.
32. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer composition comprises an additive selected from the group consisting of stabilizers, antioxidants, pigments, oils and combinations thereof.
33. The decorative surface covering of claim 23 , wherein the blend comprises an additive selected from the group consisting of stabilizers, antioxidants, pigments, oils and combinations thereof.
34. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer composition has an Olsen stiffness of less than 0.5 inch-pound at 73° F.
35. The decorative surface covering of claim 23 , wherein the thermoplastic elastomer is the reaction product of a dynamically vulcanized blend consisting of (a) epoxidized natural rubber, (b) at least partially neutralized copolymer of (meth)acrylic acid and (c) a component selected from the group consisting of (i) a diluent polymer selected from the group consisting of ethylene vinyl acetate copolymer polyvinyl butyral and combinations thereof and (ii) a combination of the diluent polymer and an additive selected from the group consisting of plasticizers, stabilizers, antioxidants fire retardants, pigments, oils, fillers and combinations thereof.
36. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend comprising an epoxidized elastomer, an ionomer, and a diluent polymer, wherein the decorative surface covering is in the form of a sheet.
37. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend comprising an epoxidized elastomer, an ionomer, and a diluent polymer, wherein the decorative surface covering further includes a non-woven backing.
38. A decorative surface covering comprising a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises a thermoplastic elastomer, the thermoplastic elastomer being the reaction product of a dynamically vulcanized blend comprising an epoxidized elastomer, an ionomer, and a diluent polymer, wherein the decorative surface covering further includes a wear layer.