Elastomeric latex foams
View Patent ↗The invention relates generally to a stable flexible latex foam. The latex foam will contain at least one polymer having a plurality of hard domains and a plurality of soft domains, a micelle forming agent, a hydrocarbon propellant substantially free of dimethyl ether, and an agent which is a solvent for said micelle forming agent and an emulsifier for said hydrocarbon propellant.
1. A latex foam composition derived from a water-based emulsion which comprises:
at least one polymer having a plurality of hard domains and a plurality of soft domains;
a hydrocarbon propellant to form gas bubbles within said at least one polymer, said propellant having no dimethyl ether;
a fatty alcohol micelle forming agent
said micelle forming agent present in an amount of at least 2% of said composition,
said micelle forming agent solidifying around said gas bubbles at said hydrocarbon propellant and water interface threby assisting in the prevention of bubble collapse due to coalescence of said bubbles at said interface; and
a polyether diol agent which is a solvent for said micelle forming agent and an emulsifier for said hydrocarbon propellant.
2. The foam of claim 1 wherein
said micelle forming agent comprises 16 carbon atoms and 18 carbon atoms.
3. The foam of claim 2 wherein
a critical micelle ratio of moles of micelle forming agent to moles of hydrocarbon propellant is at least approximately 5%.
4. The foam of claim 3 wherein
said critical micelle ratio is in excess of at least approximately 9%.
5. The foam of claim 4 wherein
said critical micelle ratio is in excess of at least approximately 13%.
6. The foam of claim 3 wherein
said micelle forming agent comprises at least two different micelle forming agents.
7. The foam of claim 6 wherein
said polymer is a thermoplastic elastomer;
said polyether diol comprises a 1,2-propanediol homopolymer;
said hydrocarbon propellant is a C 2 –C 4 alkane and mixtures thereof; and
said micelle forming agent comprises C 16 and C 18 monohydroxyl fatty alcohols.
8. The foam of claim 7 wherein
said thermoplastic elastomer is selected from the group consisting of polyurethanes and styrene-butadiene rubbers.
9. The foam of claim 8 wherein
said thermoplastic elastomer is a polyurethane.
10. The foam of claim 3 which further comprises
a surfactant selected from the group consisting of a cationic surfactant and a non-ionic surfactant.
11. The foam of claim 10 which further comprises
an alkylene glycol.
12. The foam of claim 3 wherein
said polymer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
13. The foam of claim 5 wherein
said polymer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
14. A latex foam composition derived from a water-based emulsion which comprises:
at least two polymers, at least one of said polymers being an emulsion having a first Tg, and at least one other of said polymers being an emulsion having a second Tg, at least one of said Tg's being above about 22° C.;
a hydrocarbon propellant to form gas bubbles within said at least two polymers, said propellant having no dimethyl ether;
a fatty alcohol micelle forming agent,
said micelle forming agent present in an amount of at least 2% of said composition;
said micelle forming agent solidifying around said gas bubbles at said hydrocarbon propellant and water interface thereby assisting in the prevention of bubble collapse due to coalescence of said bubbles at said interface; and
a polyether diol agent which is a solvent for said micelle forming agent and an emulsifier for said hydrocarbon propellant.
15. The foam of claim 14 wherein
said micelle forming agent comprises 16 carbon atoms and 18 carbon atoms.
16. The foam of claim 15 wherein
a critical micelle ratio of moles of micelle forming agent to moles of hydrocarbon propellant is at least approximately 5%.
17. The foam of claim 16 wherein
said critical micelle ratio is in excess of at least approximately 9%.
18. The foam of claim 17 wherein
said critical micelle ratio is in excess of at least approximately 13%.
19. The foam of claim 16 wherein
said micelle forming agent comprises at least two different micelle forming agents.
20. The foam of claim 19 wherein
said polymers forming hard domains comprising a multiplicity of areas with each arrangement of hard domains forming a center and said polymers forming soft domains are about a periphery of said hard domains thereby promoting chain entanglement;
said polyether diol comprises a 1,2-propanediol homopolymer;
said hydrocarbon propellant is a C 2 –C 4 alkane and mixtures thereof; and
said micelle forming agent comprises C 16 and C 18 monohydroxyl fatty alcohols.
21. The foam of claim 20 wherein
said polymers are styrene-butadiene rubbers.
22. The foam of claim 20 wherein
said polymers are polyurethanes.
23. The foam of claim 16 which further comprises
a surfactant selected from the group consisting of a cationic surfactant and nonionic surfactant.
24. The foam of claim 23 which further comprises
an alkylene glycol.
25. The foam of claim 16 wherein
said polymer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
26. The foam of claim 18 wherein
said polymer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
27. A latex foam composition derived from a water-based emulsion which comprises:
a thermoplastic elastomer having a plurality of hard domains and a plurality of soft domains;
a hydrocarbon propellant to form gas bubbles within said at least one thermoplastic elastomer, said propellant having no dimethyl ether;
a fatty alcohol micelle forming agent,
said micelle forming agent present in an amount of at least 2% of said composition,
said micelle forming agent solidifying around said gas bubbles at said hydrocarbon propellant and water interface thereby assisting in the prevention of bubble collapse due to coalescence of said bubbles at said interface; and
a polyether diol agent which is a solvent for said micelle forming agent and an emulsifier for said hydrocarbon propellant.
28. The foam of claim 27 wherein
said micelle forming agent comprises 16 carbon atoms and 18 carbon atoms.
29. The foam of claim 28 wherein
a critical micelle ratio of moles of micelle forming agent to moles of hydrocarbon propellant is at least approximately 5%.
30. The foam of claim 29 wherein
said critical micelle ratio is in excess of at least approximately 9%.
31. The foam of claim 30 wherein
said critical micelle ratio is in excess of at least approximately 13%.
32. The foam of claim 29 wherein
said micelle forming agent comprises at least two different micelle forming agents.
33. The foam of claim 32 wherein
said thermoplastic elastomer is a polyurethane;
said polyether diol comprises a 1,2-propanediol homopolymer;
said hydrocarbon propellant is a C 2 –C 4 alkane and mixtures thereof; and
said micelle forming agent comprises C 16 and C 18 monohydroxyl fatty alcohols.
34. The foam of claim 33 wherein
said polyurethane is an isophthalic acid polymer with adipic acid, hexanediol, dimethylolpropanoic acid and 1,1′-methylbis(isocyanatocyclohexane).
35. The foam of claim 29 which further comprises
a surfactant selected from the group consisting of a cationic surfactant and nonionic surfactant.
36. The foam of claim 35 which further comprises
an alkylene glycol.
37. The foam of claim 29 wherein
said thermoplastic elastomer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
38. The foam of claim 31 wherein
said thermoplastic elastomer comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.
39. A latex foam composition derived from a water-based emulsion which comprises:
at least one polymer having a plurality of hard domains and a plurality of soft domains;
a hydrocarbon propellant to form gas bubbles within said at least one polymer, said propellant having no dimethyl ether;
a fatty alcohol blend micelle forming agent,
said fatty alcohol blend present in an amount of at least 2% of said composition,
said fatty alcohol blend solidifying around said gas bubbles at said hydrocarbon propellant and water interface thereby assisting in the prevent of bubble collapse due to coalescence of said bubbles at said interface; and
a polyether diol agent which is a solvent for said fatty alcohol blend and an emulsifier for said hydrocarbon propellant.
40. The foam of claim 39 wherein
said micelle forming agent is a blend which comprises C 16 and C 18 monohydroxyl fatty alcohols.
41. The foam of claim 40 wherein
a critical micelle ratio of moles of micelle forming agent to moles of hydrocarbon propellant is at least approximately 5%.
42. The foam of claim 41 wherein
said critical micelle ratio is in excess of at least approximately 9%.
43. The foam of claim 42 wherein
said critical micelle ratio is in excess of at least approximately 13%.
44. The foam of claim 43 wherein
said micelle forming agent is at least two different micelle forming agents.
45. The foam of claim 44 wherein
said at least one polymer comprises a thermoplastic elastomer;
said polyether diol agent has a propyl ether repeating unit of about 2 to 5;
said hydrocarbon propellant is a C 2 –C 4 alkane and mixtures thereof; and
said micelle forming agent comprises cetyl alcohol and stearyl alcohols.
46. The foam of claim 45 wherein
said thermoplastic elastomer is selected from the group consisting of polyurethanes and styrene-butadiene rubbers.
47. The foam of claim 46 wherein
said thermoplastic elastomer is a polyurethane.
48. The foam of claim 47 which further comprises
a surfactant selected from the group consisting of a cationic surfactant and nonionic surfactant.
49. The foam of claim 48 which further comprises
an alkylene glycol.
50. The foam of claim 49 wherein
said polyurethane comprises particles having a particle size of between about 0.05 microns to about 3.5 microns.