Multi-layered resin coated sand
A method of forming a multi-layer coated particulate material, the method including the steps of: mixing a first thermoplastic polymer with a particulate substrate to form a mixture at a temperature greater than a melting point of the first thermoplastic polymer; cooling the mixture to a temperature below the melting point of the first thermoplastic polymer; combining the cooled mixture with a second thermoplastic polymer, wherein a melting point of the second thermoplastic polymer is less than the temperature of the cooled mixture; and cooling the combined mixture to a temperature less than the melting point of the second polymer. In another aspect, embodiments disclosed herein relate to a particulate material having: a particulate substrate coated with a first layer comprising a first thermoplastic polymer and a second layer comprising a second thermoplastic polymer; wherein a melting point of the first thermoplastic polymer is greater than a melting point of the second thermoplastic polymer.
1 . A method of forming a coated particulate material, the method comprising:
mixing at least one thermoplastic polymer with a particulate substrate to form a mixture at a temperature greater than a melting point of the thermoplastic polymer;
cooling the mixture to a temperature below the melting point of the thermoplastic polymer:
wherein the mixing is at a temperature of less than 199° C.
2 . The method of claim 1 , comprising heating the particulate substrate to a temperature greater than the melting point of the thermoplastic polymer.
3 . The method of claim 1 , comprising heating the particulate substrate and the thermoplastic polymer to a temperature greater than the melting point of the thermoplastic polymer.
4 . The method of claim 1 , wherein the mixing is at a temperature of 180° C. or less.
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11 . The method of claim 1 , wherein the at least one thermoplastic polymer coats at least 50% of the surface of the particulate substrate.
12 . A method of forming a multi-layer coated particulate material, the method comprising:
mixing a first thermoplastic polymer with a particulate substrate to form a mixture at a temperature greater than a melting point of the first thermoplastic polymer;
cooling the mixture to a temperature below the melting point of the first thermoplastic polymer;
combining the cooled mixture with a second thermoplastic polymer, wherein a melting point of the second thermoplastic polymer is less than the temperature of the cooled mixture; and
cooling the combined mixture to a temperature less than the melting point of the second polymer.
13 . The method of claim 12 , comprising heating the particulate substrate to a temperature greater than a melting point of the first thermoplastic polymer.
14 . The method of claim 12 , comprising heating the first thermoplastic polymer and the particulate substrate to a temperature greater than the melting point of the thermoplastic polymer.
15 . The method of claim 12 , wherein the mixing is at a temperature from 140° C. to 350° C.
16 . The method of claim 12 , wherein the combining is at a temperature less than the melting point of the first thermoplastic polymer.
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22 . The method of claim 12 , wherein the melting point of the second thermoplastic polymer is 100° C. or less.
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24 . The method of claim 12 , wherein at least one of the cooling steps comprises indirect heat exchange.
25 . The method of claim 12 , further comprising heating the cooled mixture to a temperature greater than the melting point of the second thermoplastic polymer.
26 . The method of claim 12 , further comprising foaming at least one of the first thermoplastic polymer and the second thermoplastic polymer.
27 . The method of claim 12 , further comprising combining an adhesion promoter with the particulate substrate.
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37 . A particulate material comprising:
a particulate substrate coated with a first layer comprising a first thermoplastic polymer and a second layer comprising a second thermoplastic polymer;
wherein a melting point of the first thermoplastic polymer is greater than a melting point of the second thermoplastic polymer.
38 . The particulate material of claim 37 , wherein the first thermoplastic polymer is selected from the group consisting of: propylene-based homopolymers, copolymers, interpolymers, and multi-block interpolymers; ethylene-based homopolymers, copolymers, interpolymers, and multi-block interpolymers; and combinations thereof.
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40 . The particulate material of claim 37 , wherein the particulate substrate is selected from the group consisting of mineral grains, sands, and rubber particles.
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42 . The particulate material of claim 37 , wherein the second thermoplastic polymer is selected from the group consisting of: propylene-based homopolymers, copolymers, interpolymers, and multi-block interpolymers; ethylene-based homopolymers, copolymers, interpolymers, and multi-block interpolymers; and combinations thereof.
43 . The particulate material of claim 37 , wherein the melting point of the second thermoplastic polymer is 100° C. or less.
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46 . The particulate material of claim 37 , further comprising an adhesion promoter.
47 . The particulate material of claim 37 , wherein the particulate material comprises the first polymer in an amount ranging from 1 to 15 weight percent, and the second polymer in an amount ranging from 1 to 15 weight percent, based on the combined weight of the particulate substrate, the first thermoplastic polymer, and the second thermoplastic polymer.
48 . The particulate material of claim 37 , wherein the particulate material comprises an overall polymer content ranging from 1 to 20 weight percent, based upon the combined weight of the particulate substrate, the first thermoplastic polymer, and the second thermoplastic polymer.
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51 . The particulate material of claim 37 , wherein the first thermoplastic polymer has a melting point at least 5° C. higher than the melting point of the second polymer.
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56 . Artificial turf comprising the particulate material of claim 37 .