BE1027044A1 - INTERNETABLE FUNCTIONAL LATEX CONTAINING ALUMINUM TRIHYDROXIDE - Google Patents

Abstract

The present invention relates to a crosslinkable functional latex comprising: 10.0 to 55.0% by weight of a crosslinkable latex polymer comprising at least one carboxy functional group in an amount of at least 0.05% by weight with respect to the total weight of said latex; optionally up to 15.0% by weight crosslinker; up to 15.0% by weight of a surfactant; and 40.0 to 70.0 weight% aluminum trihydroxide; supplemented with water to 100.0% by weight. In addition, the invention also relates to a method for preparing a cured latex foam compound, a cured latex foam compound obtained by such a method, a device comprising said cured latex foam composition and the use of a crosslinkable functional latex according to the present invention for the preparation. of a cured latex foam composition.

Description

CONNECTABLE FUNCTIONAL LATEX CONTAINING ALUMINUM TRIHYDROXIDE

TECHNICAL FIELD The present invention relates to a crosslinkable functional latex. The present invention relates in particular to a composition for making a cured latex foam composition, which is suitable for the automotive sector.

STATE OF THE ART Aqueous dispersions of polymers are also known under the name latex. A latex is used in coatings (for example latex paint) and adhesives because it hardens by coalescence of polymer particles as water evaporates and can therefore form films without releasing potentially toxic organic compounds into the environment. Another application of latex concerns the manufacture of latex foams. Aqueous dispersions of hydroxy or carboxy functional polymers are well known latex.

Within the automotive market, textile coverings (such as seat, headliner, door panel) are always equipped with a layer of polyurethane foam compound. Depending on the location in the car and the production process of the part, different types of polyurethane foam can be used. The bonding between textile and foam is in most cases done with the flame lamination technique. During flame lamination, the foam passes a flame, creating a melt in situ. Shortly afterwards, the textile is melted. The textile will stick to the foam by cooling the melt. This creates a bond between textile and foam. The reason why this has been a success to date is the cost of the process. It is perfectly possible to make a bond using adhesive film or hot melt, but this is much more expensive and therefore less interesting for the automotive sector.

A crosslinker is of great importance for curing latex into latex-based products, such as a latex film or a latex foam. Amino resins can be used to crosslink hydroxyl-functional latex; adipic dihydrazide can be used to cross link diacetone acrylamide latex. Latex compositions with hydroxy functional polymers and amino resins or polyisocyanates as crosslinkers are known in the art, as illustrated in WO 2017/006298, EP 698 638 and US 6,592,944.

WO 2017/006298 relates to a cross-linkable hydroxy functional latex, said latex comprising 10.0 to 65.0 weight% hydroxy functional latex; 0.1 to 25.0 weight% crosslinker; 0.1 to 10.0% by weight of a surfactant; and at least 20.0 weight% filler; supplemented with water to 100.0% by weight. Examples of suitable crosslinkers include aminoplasts comprising methylol and / or methylol ether groups and polyisocyanates or carbamates. The cured latex compound of WO 2017/006298 is suitable for various carpets and upholstery. The cured latex compound can be used as a textile carrier, the latex compound can be applied to the textile before drying and curing.

EP 0 698 638 discloses to this end a crosslinkable water-based dispersion of a hydroxy-functional polydiene polymer composition, comprising: (a) 10 to 65% by weight of a hydroxy-functional polydiene polymer, (b) 0.2 to 25% by weight of a suitable amino resin, (c) 0.1 up to 10% by weight of a surfactant which is ionic or anionic and has a volatile cation, and (d) the balance water. The technology of EP 0 698 638 also provides a water continuous process and an inversion process for making such dispersions. The problem that US 6,592,944 tries to solve relates to transparent cover layers suitable for multi-layer coatings. There is a need for clear coating formulations with an excellent balance of post-application performance characteristics, particularly with regard to scratch resistance at a high solids content and low application viscosity of the coating.

To this end US 6,592,944 describes a transparent coating composition which is suitable, inter alia, for use as a transparent covering layer in, inter alia, finishing layers in the automotive industry. The coating composition includes polyisocyanate, polyester polyol and melamine components, with more than half of the total solid-based composition comprising the polyisocyanate and melamine components.

WO 02/26873 concerns a composition for preparing a latex foam.

Such composition includes a latex, an epoxy silane crosslinker, and optionally various additives such as antioxidants and resilience enhancing additives.

WO 2017/006298, EP 698 638 and US 6,592,944 show the problem that the compositions comprise an excess of expensive functional chemical agents.

A more considered choice of the composition with attention to widely available ingredients would reduce dependence on suppliers and also mean considerable cost savings. In addition, there remains a need for improved compositions for preparing latex foam that can be used directly in the automotive industry without using flame lamination techniques or similar cost, time and energy saving techniques.

There remains a need in the art for an improved, water-based and more environmentally friendly foam composition for technical textiles.

Styrene butadiene rubber are widely used in the automotive sector, However, a common vulcanization with sulfur is preferably avoided for unpleasant odors and environmental problems, Thus there remains a need for a suitable replacement of styrene butadiene rubber with another more suitable polymer for the automotive industry The present invention aims to solve at least one of the above problems.

SUMMARY OF THE INVENTION A first aspect of the invention relates to a crosslinkable functional latex, comprising: - 10.0 to 55.0 weight% latex functional polymer comprising at least one carboxy functional group in an amount of 0.05 weight% with respect to the total weight of said latex; - optionally, up to 15.0% by weight crosslinker; - up to 15.0% by weight of a surfactant; and - 40.0 to 70.0 weight% aluminum trihydroxide; supplemented with water to 100.0% by weight.

The present invention relates to crosslinkable functional latex based on styrene and butadiene or similar monomers (90 to 99.5%). An overview of functional monomers and possible crosslinkers is presented as Table 1. Functional Monomers (0.5 to 10%) Possible Crosslinkers; Amino resins, blocked isocyanate, e Post additive of epoxysilanes e Epoxy resins s Metal complex ions (Zn (NH3) 42 *) ions: metal caroxylate: aluminum, Acid: (acrylic acid, methacrylic acid etc.) Mg, Ca, lactate> are made by Corbion bv, PURACAL, PURAMEX Al Aluminum-L-lactate, ezv, e Carbodiimides (eg, Desmodur xp 2802 from Bayer Diacetone acrylamide (DAAM) Adipic dihydrazide Epoxide (glycidyl methacrylate) (Poly) Amine crosslinkers Hybrid (carboxyl + hydroxyl), ( amide + carboxyl), (amide + hydroxyl), (diacetone acrylamide + carboxyl), (diacetone | With one or more suitable acrylamide + hydroxyl), (Amide + Diacetone crosslinkers possible depending on the acrylamide) .functional monomers Hybrid with more than 2 functional monomers are also possible.

The present invention concerns an aqueous formulation developed on the basis of the hydroxy and / or carboxy functional latex and the crosslinking techniques with various crosslinkers.

In a preferred embodiment, the present invention provides a crosslinkable carboxylated latex using epoxy silanes as integrated, post-additive crosslinkers.

In a further preferred embodiment, even in the case of carboxylated latex, metal complex ions of the filler would also perform as ionic crosslinkers.

In another embodiment, the present invention provides a crosslinkable hydroxy functional latex with amino resins, blocked isocyanate, carbamates and other aminoplasts.

In another embodiment, the present invention relates to a hybrid cross-linkable latex, with hydroxy- and carboxy-functional monomers each having one or 2 or more suitable crosslinkers, possibly depending on the said functional monomers. Aluminum trihydroxide has been added as a fire-retardant filler. This filler was moreover specifically used to optimize the material properties. The stated amount of aluminum trihydroxide of

40.0-70.0% by weight can be used to provide a fill to the crosslinkable functional latex and thus provide the desired material properties. Care must be taken here to ensure that the eventually cured latex retains a sufficiently high stability; that is, in which no filler or filler failure occurs.

The biggest advantage of the above-mentioned latex is that the textile manufacturer can apply the latex directly to the textile carrier material. This means no cutting waste is created and there is much less loss of raw materials. The burning off of residual material is completely eliminated here, which means that we have a less toxic process that entails less loss of raw materials. In addition, the proposed latex is completely water based and therefore more environmentally friendly.

A second aspect of the invention relates to a method wherein said latex foam composition, comprising a crosslinkable functional latex with a surfactant, aluminum trihydroxide in an amount of between 40.0 to 70.0% by weight with respect to the total weight of said latex foam composition, a thickener and optionally a crosslinker, a foam stabilizer and / or a foam booster, is applied directly to a textile backing and then cured.

A third aspect of the invention relates to a method for preparing a cured latex compound, comprising the steps of: - providing a crosslinkable functional latex polymer comprising at least one carboxy functional group in an amount of at least 0.05% by weight relative to the total weight of said latex; - mixing said crosslinkable functional latex with optionally a crosslinker, and further with a surfactant, a filler, a thickening agent and optionally a foam stabilizer and / or a foam booster, thereby obtaining a latex foam composition; - optionally, spreading said latex foam composition on a substrate; and - drying said latex foam composition, thereby obtaining a cured latex compound, wherein aluminum trihydroxide is mixed as a filler in an amount of between 40.0 to 70.0% by weight, based on the total weight of said latex foam composition.

A fourth aspect of the invention relates to a cured latex compound obtainable by a method according to the third aspect of the invention. In a fifth aspect, the present invention provides a device comprising a cured latex compound according to the third aspect of the invention, such as automotive interior textiles, such as car seat, car door and floor panel textiles. In a sixth aspect, the present invention provides use of a cross-linkable functional latex according to the first aspect of the invention for preparing a cured latex foam composition.

DETAILED DESCRIPTION A first aspect of the invention provides a cross-linkable functional latex comprising: - 10.0 to 55.0 weight% latex functional polymer comprising at least one carboxy functional group in an amount of at least 0.05 weight% with respect to the total weight of said latex; - optionally up to 15.0% by weight crosslinker; - up to 15.0% by weight of a surfactant; and - 40.0 to 70.0 weight% aluminum trihydroxide; supplemented with water to 100.0% by weight. Aluminum trihydroxide as a filler can be used to optimize the material properties of a composition. The stated amount of filler in the crosslinkable functional latex of between 40.0 wt.

% to 70.0% by weight, preferably more than 45.0% by weight, more than 50.0% by weight, more than 55.0% by weight, and even more than 60.0% by weight; and less than 70.0 wt.%, less than 67.0 wt.%, and even less than 65.0 wt.% aluminum trihydroxide can be used to provide a fill to the crosslinkable functional latex and thus carry the desired material properties.

It has unexpectedly been found that crosslinkable latex of the present invention offers satisfactory properties and resilience, even if no additional crosslinker was added to the blend.

Without being bound by mechanistic considerations, it is believed that this effect can be attributed to the use of aluminum trihydroxide through the formation of ionic bonds between aluminum and the lone pairs inherent in said latex, specifically with carboxylic acid functional groups present in said latex.

Al + ions may be responsible for this crosslinking behavior.

Aluminum trihydroxide thus exhibits crosslinking properties.

In addition, it has been found that aluminum hydroxide offers better properties in these than other fillers known in the prior art, such as for example chalk (CaCO3). Aluminum trinydroxide is especially suitable for the crosslinkable latex without conventional crosslinkers.

It has unexpectedly been found that aluminum trihydroxide can act as a crosslinker in latex of the invention.

Thus, the latex foam composition of the present invention has an improved characteristic, but a lower price because it does not include additional crosslinkers in the composition.

Aluminum hydroxide is non-carcinogenic, low toxic, halogen free and flame retardant.

In addition to those properties, aluminum hydroxide can form gels in water.

In fact, due to the formation of gels, aluminum hydroxide is occasionally used to purify waste water as the flocculating agent.

Since gel has a strong adsorption capacity, suspended solids can be adsorbed and precipitated.

The inventors have realized that this property can potentially be beneficial for latex crosslinking.

Indeed, experiments confirmed that aluminum trihydroxide has cross-linking properties, which contributes to good latex properties.

The properties of the resulting latex are mainly advantageous for automotive products.

Care must be taken to ensure that the final cured latex foam composition retains a sufficiently high stability and is suitable for textile manufacturers that can be applied directly to the textile; that is, in which no filler or filler failure occurs.

The percentages stated in this text are to be understood as percentages by weight and are abbreviated as "percent by weight".

A dispersion is a material comprising multiple phases wherein at least one phase consists of finely divided phase domains, often of the colloidal order of magnitude, which are dispersed in a continuous phase. Dispersions include emulsions, suspensions and smoke. An emulsion is a colloidal mixture of liquids, a suspension is a solid suspended in a liquid, and a smoke is a mixture of solid and / or liquid substances very finely divided in a gas. The term "aqueous dispersion" refers to a dispersion in which the continuous phase is water. The term "aqueous emulsion" refers to an emulsion where one of the liquids is water. A crosslinkable latex is an aqueous dispersion or emulsion of one or more hydroxy- or carboxy-functional polymers or a mixture thereof. The hydroxy- or carboxy-functional, or a mixture thereof, polymers are preferably polymerized in an aqueous emulsion with surfactants and regulators under a specified time, temperature, pressure and agitation in accordance with the known principles of the emulsion polymerization, to form a latex. . For the preparation of latex derivatives or cured latex compounds, it is important that the polymers of the latex are crosslinkable. The term “crosslinkable” refers to a chemical compound that can be crosslinked, “crosslinking” refers to the interconnection of chemical compounds. Crosslinking of a hydroxy or carboxy functional polymer according to the present invention will cause the latex to cure into a cured latex compound.

In a preferred embodiment, the crosslinkable latex of the present invention comprises a functional monomer in an amount between 0.05% by weight to

10.0 wt%, preferably more than 1.5 wt%, and even more than 2.0 wt%; and less than 5.0% by weight, and even less than 4.0% by weight with respect to the total weight of said crosslinkable latex.

In a preferred embodiment, the crosslinkable latex of the present invention comprises a latex polymer, said latex polymer comprising at least one carboxy functional group in an amount of 0.05% by weight to 15.0% by weight with respect to the total weight of said latex, preferably more than 0.1 wt% to 10.0 wt%, and less than 7.5 wt%, and even less than

5.0% by weight with respect to the total weight of said latex. More preferably, said latex polymer comprises 0.10, 0.15, 0.20, 0.25, 0.30, 0.40, 0.50,

0.60, 0.70, 0.80, 0.90, 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 3.00, 3.50 or 4.00% by weight of a monomer having a carboxy functional group, or any amount in between.

A "carboxy-functional polymer" or carboxylated latex is a polymer with one or more functional carboxyl groups. The carboxylic acid monomers useful in the production of the polymers of this invention are the olefinically unsaturated carboxylic acids containing at least one active olefinic carbon-carbon double bond, and at least one carboxyl group, i.e. an acid containing an olefinic double bond that is readily available in polymerization. functions. Examples include low molecular weight carboxylic acids having a number average molecular weight of less than about 500 Daltons, such as aliphatic, cycloaliphatic and aromatic acids, predominantly acids having 2 to 20 carbon atoms, preferably 2 to 10 carbon atoms. In a preferred embodiment, the present invention provides an acrylic or a metacrylic acid as a functional monomer in the crosslinkable functional latex of the present invention. Non-limiting examples include acrylic acid, methacrylic acid, ethacrylic acid, alpha chloroacrylic acid, alpha cyanoacrylic acid, beta hemethyl acrylic acid (crotonic acid), alpha phenylacrylic acid, beta acryloxypropionic acid, sorbic acid, alpha chloro sorbic acid, cinnamic acid, p-chloro cinnamic acid -styrylic acrylic acid (1-carboxy-4-phenylbutadiene-1,3), itaconic acid, citraconic acid, mesaconic acid, glutaconic acid, aconitic acid, maleic acid, fumaric acid, tricarboxyethylene and the like.

A "hydroxy functional polymer" is a polymer with one or more functional hydroxyl groups. Polymers with two functional hydroxyl groups, ie dicles, and polymers with more than two functional hydroxyl groups are referred to in this text as "polyols". Examples include low molecular weight polyols with a number average molecular weight less than about 500 Daltons, such as aliphatic, cycloaliphatic and aromatic polyols. mainly diols of 2 to 20 carbon atoms, preferably 2 to 10 carbon atoms and "macro glycols", i.e. polymeric polyols having molecular weights of at least 500 Daltons, more typically about 1000 to 6000 Daltons, or even 1000 to 10000 Daltons. such macroglycols include polyester polyols including alkyd resins, polyether polyols, polycarbonate polyols, polyhydroxy polyester amides, hydroxyl containing polycaprolactones, hydroxyl containing acrylic polymers, hydroxyl containing epoxides, polyhydroxy polycarbonates, polyhydroxy polyacetals, polyhydroxy polythoxyoethers, polysiloxy ethers, The polysiloxane polyols, polybutadiene polyols and hydrogenated polybutadiene polyols, polyisobutylene polyols, polyacrylate polyols, halogenated polyesters and polyethers, and the like and mixtures thereof. The latex may include an additional ethylenically unsaturated monomer component or components. Specific examples of such ethylenically unsaturated compounds include methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacrylonitrile, ethyl chloroacrylate, diethyl acrylate, methyl ethylene chloride, vinylyl ketone bromide, vinylyl ketidyl ether Derivatives thereof and / or mixtures thereof may be included.

Other acrylic or methacrylic acid derivatives are also suitable functional monomers of the present invention. In one embodiment, amides such as acrylamide, methacrylamide, diacetone acrylamide and the like are defined as functional monomers. In another embodiment, epoxides such as glycidyl methacrylate are used as functional polymers.

Hydroxy functional polymers which are useful in the context of this invention are hydroxy functional polydiene polymers. Hydroxy functional polydiene polymers suitable for the present invention are monohydric alcohols, diols and polyols of hydrogenated and non-hydrogenated low molecular weight diene homopolymers and copolymers with more than one diene and / or a vinyl aromatic hydrocarbon. Such copolymers are usually random copolymers or tapered block copolymers because it is difficult to make low molecular weight copolymers with a sharp separation between the blocks because the crossover reaction from one monomer to another is usually low compared to the progagation reaction. In a most suitable embodiment, said hydroxy functional latex comprises a styrene-butadiene polymer. Suitable polymers include monohydric alcohols, diols and low molecular weight polyols, polybutadiene and polyisoprene and their copolymers with styrene, either hydrogenated or non-hydrogenated.

Hydrogenated polybutadiene diols are preferred for use in this invention because they are easy to prepare, as they have a low glass transition temperature and excellent weather resistance. The diols,

dihydroxylated polybutadienes are synthesized by anionic polymerization of conjugated diene hydrocarbons with lithium initiators. Monohydric alcohols and polyols can also be synthesized in the same way. This method is known and described, for example, in US Patents Nos. US 4,039,593 and US RE 27,145. In accordance with the present invention, unsaturated linear or hydrogenated isoprene polymers with 1-2 terminal hydroxyl groups per molecule and also such polymers with other hydroxyl groups can also be used. Preferably, the isoprene polymers have greater than 80% 1,4 addition of the isoprene and hydrogenation of at least 90% of the polymerized isoprene. The polymers are preferably prepared by anionic polymerization in the absence of microstructure modifiers that increase 3,4 addition of the isoprene.

The hydroxy functional polydiene polymers have suitable molecular weights of 1000 to 3,000,000. Lower molecular weights require excessive crosslinking while higher molecular weights lead to very high viscosity making processing difficult Conjugated diolefins which can be anionically polymerized include those conjugated diolefins comprising 4 to 24 carbon atoms such as 1,3-butadiene, isoprene, piperylene, methylpentadiene, etc. phenyl butadiene, 3,4-dimethyl-1,3-hexadiene, 4,5-diethyl-1,3-octadiene and the like. Isoprene and butadiene are the preferred conjugated diene monomers for use in the present invention because of their low cost and easy availability. The conjugated diolefins that can be used in the present invention include isoprene (2-methyl-1,3-butadiene), 2-ethyl-1,3-butadiene, 2-propyl-1,3-butadiene, 2-butyl-1 , 3-butadiene, 2-pentyl-1,3-butadiene (2-amyl-1,3-butadiene), 2-hexyl-1,3-butadiene, 2-heptyl-1,3-butadiene, 2-octyl- 1,3-butadiene, 2-nonyl-1,3-butadiene, 2-decyl-1,3-butadiene, 2-dodecyl-1,3-butadiene, 2-tetradecyl-1,3-butadiene, 2-hexadecyl- 1,3-butadiene, 2-isoamyl-1,3-butadiene, 2-phenyl-1,3-butadiene, 2-methyl-1,3-pentadiene, 2-methyl-1,3-hexadiene, 2-methyl 1,3-heptadiene, 2-methyl-1,3-octadiene, 2-methyl-6-methylene-2,7-0ctadiene (myrcene), 2-methyl-1,3-nonyldiene, 2-methyl-1,3 -decyldiene and 2-methyl-1,3-dodecyldiene, as well as 2-ethyl, 2-propyl, 2-butyl, 2-pentyl, 2-hexyl, 2-heptyl, 2-octyl, 2-nonyl, 2-decyl , 2-dodecyl, 2-tetradecyl, 2-hexadecyl, 2-isoamyl and 2-phenyl versions of all of these dienes. Also included are 1,3-butadiene, piperylene, 4,5-diethyl-1,3-octadiene and the like. Di-substituted conjugated diolefins that can be used include 2,3-dialkyl-substituted conjugated diolefins such as 2,3-dimethyl-1,3-butadiene, 2,3-diethyl-1,3-pentadiene, 2,3-dimethyl 1,3-hexadiene, 2,3-diethyl-1,3-heptadiene, 2,3-dimethyl-1,3-octadiene and the like and 2,3-fluoro-substituted conjugated diolefins such as 2,3-difluoro-1,3 -butadiene, 2,3-difluoro-1,3-pentadiene, 2,3-difluoro-1,3-hexadiene, 2,3-difluoro-1,3-heptadiene, 2,3-fluoro-1,3-octadiene and such. Alkenyl aromatic hydrocarbons that can be copolymerized include vinyl aryl compounds such as styrene, various alkyl-substituted styrenes, alkoxy-substituted styrenes, vinyl naphthalene, alkyl-substituted vinyl naphthalenes, and the like. In one embodiment, the present invention provides a hybrid functional latex. A hybrid functional latex comprises at least two functional monomers. In another embodiment, hybrid latex of the present invention comprises more than two functional monomers. In a preferred embodiment, the crosslinkable hybrid latex comprises a hydroxy and a carboxy functional monomer. Preferably, the crosslinkable functional latex according to the first aspect of the invention comprises a hydroxy and / or carboxyl functional styrene / butadiene polymer, such as for example , but not limited to, a carboxylated styrene-butadiene-styrene tri-block copolymer, a hydroxylated styrene-butadiene-styrene tri-block copolymer, a carboxylated styrene-butadiene random copolymer, or a hydroxylated styrene-butadiene random copolymer. Both block copolymers and random or random copolymers are copolymers in which the mutual ratio of the monomer units changes along the polymer chain. In block copolymers, said mutual ratio changes abruptly, while in statistical or "random" copolymers said mutual ratio changes irregularly.

A latex as defined in the present invention may also be a multimodal latex characterized by two or more latexes of different mean particle size and / or particle size distripution; solids content and / or rheology parameters.

The term "crosslinker" should be understood as a synonym for the term "curing agent", "curing agent", "curing agent", "curing agent",

"Hardener", "Crosslinker", "Crosslinking Agent" or "Crosslinking Agent" and includes substances or mixtures of substances that are added to a polymer composition to promote or control the curing reaction, either the crosslinking or the crosslinking or the crosslinking.

Preferably the term 'crosslinker' refers to a reactive curing agent or hardener which is provided with at least two functional groups which can react with functional groups of functional monomers or can make an ionic, coordinative or covalent chemical bond and in this way is suitable to effect curing of a polymer.

A suitable crosslinker in the context of the present invention is a crosslinker having at least two functional groups that are reactive with hydroxyl groups.

Examples of suitable crosslinkers include epoxy silanes as an integrated crosslinker in the carboxylated latex of the present invention.

Various epoxy resins are suitable crosslinkers in the carboxylated latex of the present invention.

Preferably, various metal complex ions such as, but not limited to aluminum, magnesium, zinc, calcium lactate, Zn (NHz3) 4? * (E.g., Puracal, Puramex AL Aluminum-L-lactate from Corbion) are suitable crosslinkers. in carboxylated latex of the present invention.

Another example of suitable crosslinkers in carboxylated latex are carbodiimides (e.g.

Desmodur xp 2802 from Bayer). Any mineral known in the art, used as a filler or other purpose, can represent a source of multivalent cations.

In one embodiment, clay can be used as a source of multivalent cations.

In another embodiment, hard water is used as a source of multivalent cations.

In a preferred embodiment, the present invention provides that said crosslinkable latex is a carboxylated latex, said carboxylated latex comprising ZnO as an ionic crosslinker.

Without being bound by mechanistic considerations, it is possible that in the presence of NH: ZnO forms a multivalent, complex cation [Zn (NH 3) 4] 22+, Preferably the hydroxy functional crosslinkable latex comprises aminoplasts.

These aminoplasts include methylol and / or methylol ether groups and polyisocyanates.

Aminoplasts are obtained from the reaction of formaldehyde with an amine or amide.

The most common amines or amides are melamine, urea or benzoguanamine, and are preferred.

Still, condensates with other amines or amides can be used; for example aldehyde condensates of glycoluril,

yielding a high melting crystalline product useful in powder coatings. Although the aldehyde used is mostly formaldehyde, other aldehydes such as acetaldehyde, crotonaldehyde and benzaldehyde can be used. Preferably formaldehyde scavenger can be used to collect the released formaldehyde. The aminoplast contains methylol groups and preferably at least a portion of these groups are etherified with an alcohol to modify the curing response. Any monohydric alcohol can be used for this purpose, including methanol, ethanol, butanol, isobutanol and hexanol. Preferably, the aminoplasts used are melamine, urea or benzoguanamine formaldehyde condensates etherified with an alcohol having one to four carbon atoms.

In an embodiment where amides are used as functional monomers in the latex, amino resins are preferably used as crosslinkers. In another embodiment, where diacetone acrylamide is used as a functional monomer in the latex of the invention, adipic dihydrazide is used as a crosslinker. In another embodiment, where epoxide (e.g. gycidyl methacrylate) is used as a functional monomer in the latex of the invention, polyamine is used as a crosslinker. A surfactant is also referred to as a surfactant or a surfactant. A surfactant normally includes a hydrophobic and a hydrophilic portion. The hydrophobic part here has a chain length of 4 to 20 carbon atoms, preferably 6 to 19 carbon atoms and even more preferably 8 to 18 carbon atoms. Preferably the surfactant used will be selected from the group of anionic, cationic or non-ionic surfactants. Preferably, said crosslinkable functional latex comprises a surfactant in an amount of

0.1 to 15.0% by weight, relative to the total weight of the crosslinkable latex, and more preferably in an amount of 0.5 to 12.0% by weight, and more preferably from 5.0 to 11.0% by weight. Most preferably, said aqueous composition comprises a surfactant in an amount of 5.0, 6.0, 7.0,

8.0, 9.0, 10.0 or 11.0% by weight, or any value in between. Anionic surfactants include saponified fatty acids and derivatives of fatty acids with carboxyl groups such as sodium lauryl sulfate, sodium dodecyl benzene sulfonate, sulfates and sulfonates and abietic acid. Examples of anionic surfacates are also: carboxylates, sulfonates, sulfo-fatty acids, methyl esters, sulfates, phosphates. The anionic surfactants are preferably added as a salt. Salts are, for example, alkali metal salts such as sodium, potassium, lithium, ammonium, hydroxyethyl ammonium, di (hydroxyethyl) ammonium and tri (hydroxyethyl) ammonium salts or alkanolamine salts. Most preferably, said surfactants include sodium dicyclohexyl sulfosuccinate, diarium mono- and diodecyl diphenyl oxid sulfones and sodium alkylbenzene sulfonate or a combination of the foregoing. Non-limiting examples are Eurovet CH® (EOC Surfactant), Aerrosol DPOS-45® (CYTEC), Marlon A 375 (SASOL). Mixtures of disodium mono- and didodecyl diphenyl oxide sulfone and sodium alkyl benzene sulfonate are preferred as these ingredients do not contribute to the total VOCs of the coating. Cationic surfactants include dialkyl benzene, alkyl ammonium chloride, alkylbenzyl methyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide, benzalkonium chloride, cetyl pyridinium bromide, Clz, Cis, or C17 trimethyl ammonium bromides, halide salts of quaternized polyoxyethylalkylamines, dodecyl benzyl triethyl ammonium chloride and benzalkonium chloride. Examples of cationic surfactants are also: quaternary ammonium compounds. A quaternary ammonium compound is a compound which includes at least one RaN * group in its molecule. A betaine surfactant is a compound which, under conditions of use, comprises at least one positive charge and at least one negative charge. An alkyl betaine is a betaine surfactant comprising at least one alkyl unit per molecule. Nonionic surfactants include polyvinyl alcohol, polyacrylic acid, methalose, methyl cellulose, ethyl cellulose, propyl cellulose, hydroxy ethyl cellulose, carboxymethyl cellulose, natural gums, polyoxyethylene cetyl ether , polyoxyethylene lauryl ether, polyoxyethylene octyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitan monolaurate, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether and dialkylphenoxy poly (ethyleneoxy) ethanol. Nonionic surfactants have a neutral, polar and hydrophilic head, which make nonionic surfactants water soluble. Such surfactants adsorb to surfaces and aggregate into micelles above a critical micelle concentration. According to the nature of the head, different surfactants can be distinguished, such as (oligo) oxyalkylene groups, and in particular (oligo) oxyethylene groups, (polyethylene) glycol groups and carbohydrate groups, such as alkyl polyglucosides and fatty acid N-methylglucamides. Alcohol phenol alkoxylates are surfactants which can be produced by addition of alkylene oxide, preferably ethylene oxide, to alkyl phenols. Non-limiting examples are: Norfox® OP-102, Surfonic® OP-120, T-Det® O-12.

Fatty acids ethoxylates are fatty acid ester surfactants which have been treated with varying amounts of ethylene oxide. Triglycerides are esters of glycerols (glycerides), in which all three hydroxyl groups are esterified with fatty acids. These can be modified with alkylene oxides. Fatty acid alcohol amides include at least one amide group with an alkyl group and one or two alkoxyl groups. Alkyl polygiycosides are mixtures of alkyl monoglucosides (alkyl-α-D- and -B-D-glucopyranoside with a small amount of glucofuranoside), alkyl diglucosides (-isomaltosides, -maltosides and others) and alkyl oligoglucosides (-maltotriosides and others). Alkyl polyglycosides can be synthesized non-limitingly by an acid catalyzed reaction (Fisher reaction) of glucose (or starch) or n-butyl glycosides with fatty alcohols. Furthermore, alkyl polyglycosides can also be used as a non-ionic surfactant. A non-limiting example is Lutensol® GD70. In addition, non-ionic N-alkylated, preferably N-methylated, fatty acid amides can also be used as surfactants. Alcohol alkoxylates, comprise a hydrophobic portion with a chain length of 4 to 20 C atoms, preferably 6 to 19 C atoms and more preferably 8 to 18 carbon atoms, wherein the alcohol can be linear or branched, and a hydrophilic portion which can contain alkoxylate units, such as ethylene oxide, propylene oxide and / or butylene oxide, with 2 to 30 recurring units. Non-limiting examples are: Lutensol® XP, Lutensol® XL, Lutensol® ON, Lutensol® AT, Lutensol® A, Lutensol® AO, Lutensol® TO.

It has been found that the incorporation of a surfactant can improve the shelf life of the curable or crosslinkable functional latex of the present invention.

By the term "filler" as used herein, it is meant a component that can improve the material properties of a composition by, for example, improving its texture or structure, providing dimensional stability and reduced elasticity, providing fire resistance properties and / or by reducing the total cost of the composition. These functional characteristics of a filler indicate the advantage of using a certain amount of filler in the crosslinkable functional latex of the present invention.

Aluminum trihydroxide is used as a filler in an amount of between 40.0% by weight to 70.0% by weight, preferably greater than 45.0% by weight, greater than

50.0 wt%, more than 55.0 wt%, and even more than 60.0 wt%; and less than 70.0 wt.%, less than 67.0 wt.%, and even less than 65.0 wt.% aluminum trihydroxide. In a preferred embodiment, further fillers can be used. Examples of fillers include, but are not limited to, chalk, talc, limestone, barium sulfate, kaolin, silica, aluminum trioxide, magnesium hydroxide, clay, melamine, or a combination of the foregoing. In a preferred embodiment, chalk and melamine are used as additional fillers. The filler can be recycled from any source and can be in any physical form that allows it to be blended or mixed with the other ingredients of a composition.

As mentioned above, a filler is a component that can improve the material properties of a composition by, for example, improving its texture or structure, providing dimensional stability and reduced elasticity, providing fire resistance properties and / or lowering the overall cost of the composition. The stated amount of aluminum trihydroxide in the cross-linkable functional latex of at least 40.0% by weight can be used to obtain a cross-linkable functional latex with desirable, improved and advantageous material properties obtained by the use of a filler.

In a preferred embodiment, the present invention provides a crosslinkable functional latex according to the first aspect of the invention, wherein said filler is comprised in an amount of 40.0 to 85.0% by weight.

Too high amounts of filler in a crosslinkable functional latex according to the present invention cause negative effects, including failure problems of filler in curing the crosslinkable functional latex, too much reduced elasticity, non-optimal compression properties, and a non-optimal optimal wear resistance of a cured product. Filler "loss" refers to a portion of filler that does not bond with the remainder of the crosslinkable functional latex upon curing. In addition, too low an amount of a filler leads to a more expensive product, requires a manufacturer to add other more expensive and less available ingredients in larger amounts, and results in an inefficient utilization of the above-mentioned improved properties obtainable by a filler.

It has unexpectedly been found that the high content of filler and in particular aluminum trihydroxide as filler contributes to an improved fire resistance of the latex of the present invention.

The stated amount of filler in the crosslinkable functional latex from 40.0 to

85.0% by weight gives rise to a crosslinkable functional latex with highly desirable, improved and advantageous properties obtained by the use of a filler, while negative effects due to an excessively high filler content are avoided.

In a preferred embodiment, the present invention provides a crosslinkable functional latex according to the first aspect of the invention, wherein aluminum trinhydroxide is included in an amount of between 40.0% by weight to

70.0% by weight, preferably more than 45.0% by weight, more than 50.0% by weight, more than 55.0% by weight, and even more than 60.0% by weight; and less than

70.0% by weight, less than 67.0% by weight, and even less than 65.0% by weight of aluminum trihydroxide relative to the total weight of the latex foam composition of the present invention. The stated amount of aluminum trihydroxide in the cross-linkable functional latex gives rise to a cross-linkable functional latex with the most desirable, improved and advantageous properties obtained by using a filler, while negative effects due to a too high filler content are avoided. In a most preferred embodiment, the present invention provides a crosslinkable functional latex according to the first aspect of the invention, wherein aluminum trihydroxide is included in an amount of at least 60.0% by weight to 65.0% by weight based on the total weight of the latex foam composition according to the present invention.

In one embodiment, the present invention provides a crosslinkable functional latex according to the first aspect of the invention, wherein said additional fillers are preferably chalk and melamine. Chalk or chalk rock is a sedimentary rock that consists almost entirely of the calcareous skeletons of algae and other fauna, the so-called coccolites. It is a limestone, and thus consists of CaCO :. Chalk is widely available and is not harmful to the environment. In addition, chalk is known as a cheap filler. These properties illustrate why chalk is preferred as a filler in the crosslinkable functional latex of the present invention.

Use of one or more of these additional fillers in the crosslinkable functional latex according to the present invention allows a great freedom of choice of fillers depending on technical considerations. For example, filler types and amounts can be selected to obtain or optimize desired material properties, such as texture and fire resistance.

In a preferred embodiment, the present invention provides a crosslinkable carboxylated latex according to the first aspect of the invention, wherein the crosslinker is an epoxy silane crosslinker.

An epoxy silane crosslinker is an integrated, functional crosslinker is a crosslinker that can be used for crosslinking or crosslinking. Use of epoxy silane functional crosslinkers in a crosslinkable functional latex according to the present invention offers the advantage that cured products obtained from the crosslinkable latex exhibit highly desirable hardness properties as well as highly desirable acid, base, solvent, and detergent resistance properties.

The epoxy silanes used as integrated crosslinkers in the latex of the invention can generally be described as epoxy-terminated silanes.

These compounds are well known in the literature and are commercially available.

These compounds have polymerizable (preferably terminal) epoxy groups and terminal polymerizable silane groups.

The epoxy and silane groups may be linked by non-hydrolyzable aliphatic, aromatic or aliphatic and aromatic divalent hydrocarbon linkages where linkages may have nitrogen and / or oxygen atoms in the divalent group.

For example, the oxygen atoms are preferably in the chain as ether linkages.

These linking chains may generally be substituted, as is well known in the art, because these substituents on the chain do not greatly affect the reactivity of the epoxy-terminated silanes.

Representative examples of such substituents include -NO2, alkyl, alkoxy, halogen, etc.

A representative representation of said epoxy silanes BC CHR SOR an 47 is: O wherein R is a divalent hydrocarbon group having less than 20 carbon atoms which may include one or more substituents (e.g. 2 or more ether linkages); R 'is an aliphatic hydrocarbon radical with less than 10 carbon atoms or a hydrocarbon radical of formula (CH2CH2O) .Z where k is an integer of at least 1 and Z is an aliphatic hydrocarbon radical, where m is 1, 2 or 3 and typically being 3 Another representative formula {HR C-CR "ICE SKOR hais: 9 wherein R, R 'and m are as described above, and wherein R" and R "together form a cyclic structure such as a six-membered hydrocarbon ring.

For example, in these formulas, R can be divalent hydrocarbon radicals such as methylene, ethylene, decalene, phenylene, cyclohexylene, cyclopentylene, methylcyclohexylene, 2-ethylbutylene and alone or an ether radical such as -CH2-CH2-O-CH2-CH2-, - (CH2-CH2 -O) 2-CH2-CH2-, -X-O-CH2-CH2- and -CH2O- (CH2) 3- where X is a divalent cyclohexane moiety.

R 'can be any aliphatic hydrocarbon radical with less than 10 carbon atoms such as methyl, ethyl, isopropyl, butyl, vinyl, alkyl or any acyl radical with less than 10 carbon atoms such as formyl, acetyl, propionyl or any radical of the formula (CH2CH2O) kZ wherein k is an integer of at least 1, for example 2, 5 and 8 and Z is hydrogen or an aliphatic hydrocarbon residue with less than 10 carbon atoms, such as methyl,

ethyl, isopropyl, butyl, vinyl and allyl.

Epoxy functional silane oligomers are particularly suitable for use as a coupling agent, adhesion promoter and crosslinker for waterborne coatings with acrylic, styrene acrylic, vinyl acrylic, polyurethane dispersions, epoxy dispersion and other anionic or cationic binders. Epoxy silane oligomers comprise a polyfunctional structure bearing gamma-glycidoxy groups, which has a reduced emission of methanol upon hydrolysis of the material as compared to typical monomeric epoxy silanes. Said epoxy functional silane oligomers lead to improvement of abrasion and scrub resistance, improved adhesion to concrete, glass, textiles and metals, improved chemical and corrosion resistance, improved hardness and the like. Representative examples of epoxy silanes currently commercially available include the Silquest "" epoxy silanes and CoatOsil epoxysilane such as CoatOsil 2287 and CoatOsil MP200 available from Momentive Performance Materials. In a preferred embodiment, Coatosil MP200 is used when it has more epoxide rings on a molecule and this increases the crosslinking efficiency with a carboxyl latex. Another advantage is that Coatosil MP200 also means less alcohol is released by the hydrolysis reaction of the alcoxy-silane groups.

In a preferred embodiment, the present invention provides a crosslinkable carboxylated latex according to the first aspect of the invention no crosslinker is used. One of skill in the art should recognize that metal complex ions of filler or other added additives can perform as crosslinkers in carboxylated latex. In a further preferred embodiment, carboxylated latex is crosslinked with zinc oxide as an ionic crosslinker.

According to another embodiment of the present invention, nitrogen functional crosslinkers are crosslinkable hydroxy functional latex. Non-limiting examples of said crosslinkers are amines, preferably compounds comprising two nitrogen groups for crosslinking or crosslinking, such as diamines. Examples of suitable crosslinkers include various maleimides, various diisocyanates such as toluene diisocyanate, various isocyanate-terminated polyester prepolymers, melamine formaldehyde resins, polyisocyanates, blocked polyisocyanates, and various polyamines such as methylenedianiline. In addition, various epoxides such as the diglycidyl ether of bisphenol-A, etc., can be used. The term "blocked" when used in combination with a polymer, as used in this text for blocked polyisocyanates, refers to a polymer of which one or more terminal or terminal functional groups are blocked with one or more chemical compounds that act as blocking agents.

In a preferred embodiment, the present invention provides a hybrid crosslinkable hydroxy and carboxy functional latex according to the first aspect of the invention, wherein said hybrid latex is crosslinked with epoxysilanes, epoxy resins, metal complex ions, carbodiimides, amino resins or any combination thereof.

In a preferred embodiment, the present invention provides a crosslinkable hydroxy functional latex according to the first aspect of the invention, wherein the nitrogen functional crosslinker is a melamine formaldehyde resin.

In a preferred embodiment, the present invention provides a cross-linkable functional latex according to the first aspect of the invention, wherein the cross-linkable functional latex comprises one or more additives selected from the group comprising salts, catalysts, water softeners, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, ammonia, agents capable of binding volatile organic compounds such as aldehyde-binding agents or oxygen-binding agents, or a combination thereof.

In this text, “catalysts” specifically refers to catalysts that can catalyze or accelerate the curing of the crosslinkable functional latex.

Said agents that can bind volatile organic compounds are also called "scavengers". Aldehyde-binding agents or aldehyde scavengers can be selected from the group consisting of tetraethylene pentamine, propionamide, caprolactam, ammonium hydroxide, sodium bisulfate, sodium metabisulfite, ammonium phosphate, diammonium phosphate, a combination of ammonium phosphate and diammonium phosphate, a sulfium ammonium phosphate combination, ammonium phosphate and diammonium phosphate combination, ammonium hydroxide, ; adipic dihydrazide and a combination of a polyvinyl alcohol and adipic dihydrazide.

Zinc oxide is a non-limiting example of a suitable catalyst. Antimicrobial agents are agents that are effective against microorganisms. Examples of antimicrobial agents are bactericides and fungicides. One or more of the listed additives can be selected as part of the cross-linkable latex in function of desired functionalization of products obtained through the curing of the cross-linkable functional latex of the present invention.

Adjustment of the pH of the mixture of the reactive latex and the co-reactive material can be made, if desired, by the addition of conventional acidifying or alkalizing agents such as, for example, acetic acid, citric acid, dilute mineral acids, ammonium hydroxide and dilute aqueous solutions. of alkali metal hydroxides. In a preferred embodiment of the present invention, ammonium hydroxide is used to adjust a pH of the latex composition.

In a preferred embodiment, the present invention provides a crosslinkable latex according to the first aspect of the invention, wherein the crosslinkable latex comprises a foam booster and / or a foam stabilizer. Foaming of the crosslinkable latex of the present invention can be carried out in any suitable or conventional manner according to the art. A foam can be produced by methods well known in the art, for example, by releasing a non-coagulating gas such as nitrogen, or by causing the decomposition of a gas-releasing chemical after chemically reacting with an ingredient in the product. mixture, releasing a non-coagulable gas as a reaction product. When foaming the cross-linkable latex, the use of foam boosters and / or foam stabilizers is desirable. Known foaming aids or foam boosters, such as sodium lauryl sulfate or foam stabilizers, such as potassium oleate, sulfosuccinamate soaps such as - but not limited to - disodium tallow sulfosuccinamate soap, can be added if desired. Preferably, such additives should be relatively non-reactive with the reactive group in the hydroxy or carboxy functional polymer or optionally in the co-reactive material and therefore the preferred composition may vary according to the composition of the mixture. As an alternative to disodium tallow sulfosuccinamate, use can also be made of betaine soap, sodium silicate and ethyl vinyl acetate latex. However, other soaps, emulsifiers, wetting agents and / or surfactants can be used, although they may be reactive to a limited extent.

In a preferred embodiment, the present invention provides a crosslinkable functional latex according to the first aspect of the invention, wherein the crosslinkable functional latex comprises a thickener.

A thickener, also known as a thickener or thickener, refers to a substance that is added to a liquid composition to thicken it and reduce its flowability. The use of a thickener in the composition of the cross-linkable latex of the present invention is advantageous for the foam stability of a foamed product obtained from this cross-linkable latex. Other additives known to those of skill in the art for use in latex synthesis, such as radical initiators, chain transfer agents, latex seeds, and the like, can be used in the synthesis of the latex without departing from the scope of the invention. A second aspect of the invention relates to a method wherein said latex foam composition, comprising a crosslinkable latex with a surfactant, contains aluminum trihydroxide in an amount of between 40.0% by weight to 70.0% by weight, preferably more than 45.0% by weight, more than 50.0% by weight, more than 55.0% by weight, and even more than 60.0% by weight; and less than 70.0 wt.%, less than 67.0 wt.%, and even less than 65.0 wt.% aluminum trinydroxide with respect to the total weight of said latex foam composition, a thickening agent and optionally a crosslinker, a foam stabilizer and / or a foam booster, applied directly to a textile backing and then cured. A third aspect of the invention relates to a method wherein said latex foam composition, comprising a crosslinkable latex with a surfactant, aluminum trihydroxide in an amount of between 40.0 to 70.0% by weight with respect to the total weight of said latex foam composition, a thickener and optionally a crosslinker. , a foam stabilizer and / or a foam booster, is applied directly to a textile backing, and then cured. It is clear to those skilled in the art that any of the additional components mentioned in the first aspect of the present invention can be used as components of the present latex composition. The non-limiting examples of the above additives are: salts, catalysts, water softeners, antioxidants, antimicrobial agents, hydrophobic additives, ammonia, oleophobic additives, agents that can bind volatile organic compounds such as aldehyde-binding agents or oxygen-binding agents, or a combination of these . Components such as radical initiators, chain transfer agents, latex seeds and the like can also be added to the latex composition without departing from the scope of the invention. A third aspect of the invention relates to a method for preparing a cured latex compound, comprising the steps of - providing a crosslinkable latex polymer comprising at least one carboxy functional group in an amount of 0.05% by weight with respect to the total weight of said latex; - mixing said crosslinkable latex with optionally a crosslinker, further a surfactant, a filler, a thickener and optionally a foam stabilizer and / or a foam booster, thereby obtaining a latex foam composition; - optionally, spreading said latex foam composition on a substrate; and - drying said latex compound, thereby obtaining a cured latex compound, wherein aluminum trihydroxide filler is mixed in an amount of 40.0 to 70.0% by weight, based on the total weight of said latex foam composition.

The use of a deliberate amount of aluminum trihydroxide as a filler as part of a crosslinkable functional latex to make a cured latex foam composition is ideally suited to improve material properties, such as texture and fire resistance, of the resulting cured latex compound. automotive industry.

Mixing of the composition in the method according to the third aspect of the invention can be done by means as known in the art. Drying can be done at any suitable temperature above ambient for a given residence time.

The residence time is variable and depends on factors such as temperature, layer thickness, foam density, water content and the components of the curable composition. The typical residence time is between 1 and 20 minutes, preferably between 1 and 10 minutes. Drying can be performed in an air circulation oven. The internal temperature of the oven is preferably maintained at or above 120 ° C. It is to be understood by those skilled in the art that any type of oven commonly used for curing / drying latex compositions can be used herein without departing from the scope of the invention; In a preferred embodiment, the present invention provides a method for preparing a cured latex foam composition according to the third aspect of the invention, comprising the step of mixing said crosslinkable latex or latex compound with one or more additives selected from the group comprising: salts, catalysts, water softeners, antioxidants, antimicrobial agents, hydrophobic additives, ammonia, oleophobic additives, agents capable of binding volatile organic compounds such as aldehyde-binding agents or oxygen-binding agents, or a combination thereof.

The latex foam composition can be poured into molds, spread on a flat plate or belt, or coated on substrates. For the purposes of this specification, the term "substrate" is defined as any material, such as fabric, leather, wood, glass or metal or any form of support such as for carpet and shoe soles, wall coverings, to which the latex compound will adhere when applied and after it has hardened.

In one embodiment of this invention in which the cured latex foam composition is used as a textile support, the latex compound can be applied to the textile before drying and curing. A typical latex foam, formed from the latex compound as cured latex foam composition, has a density in the range of about 100 to 1000 grams per liter in the wet state, preferably 100 to 600 grams per liter, and more preferably 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220 or 230 grams per liter or any value in between. The latex foam can be applied to the substrate using a squeegee.

In a preferred embodiment, the present invention provides a method for preparing a cured latex foam composition according to the third aspect of the invention, wherein said latex compound is dried by heating to a temperature between 50 ° C and 200 ° C.

Preferably, said latex foam composition is dried at a temperature between 60 ° C and 180 ° C, more preferably at a temperature between 125 ° C and 160 ° C. In a preferred embodiment, the present invention provides a method for preparing a cured latex foam composition according to the third aspect of the invention, wherein said latex compound is treated with the aid of an infrared lamp.

In another preferred embodiment, the present invention provides a method for preparing a cured latex foam composition according to the third aspect of the invention, wherein said latex compound is dried in a hot air oven. The temperature of the convection oven is preferably set to 50 ° C to 80 ° C for this purpose.

In a preferred embodiment, the present invention provides a method of making a cured latex foam composition according to the third aspect of the invention, wherein said cured latex foam composition is post-treated mechanically, such as by pressing, printing or pressing.

In another embodiment, the present invention provides a method for preparing a cured latex foam composition according to the third aspect of the invention, wherein said cured latex compound is thermally post-treated, such as, for example, by curing at a temperature between 100 ° C and 200 ° C .

Preferably, said cured latex foam composition is thermally post-treated in an oven at a temperature between 125 ° C and 180 ° C, more preferably at a temperature between 125 ° C and 160 ° C. A fourth aspect of the invention relates to a cured latex foam composition obtainable according to a method according to the third aspect of the invention.

In a fifth aspect, the present invention provides a device comprising a cured latex foam composition according to the third aspect of the invention, such as, for example, an automotive interior textile, such as for car seat, car door and floor panel textiles. In another preferred embodiment, a cured latex foam composition is used as a covering for technical textiles, especially as a mattress cover, duvets, curtain fabric, and the like. The cured latex foam composition according to the third aspect of the invention can be used as an anti-slip coating, a tufted carpet, a woven carpet, artificial grass, an automotive carpet, a needle felt carpet, tiles, needle felting, rubber granulate, upholstery, a domestic carpet. use as for example in a drawing room or bathroom, a carpet for stairs, a carpet for use in hospitals, furniture, mattresses, car tires, shoe soles and for use in medical or hygienic applications, such as used in surgical gloves.

In a sixth aspect, the present invention provides a use of a crosslinkable latex according to the first aspect of the invention for preparing a cured latex foam composition.

EXAMPLES The examples described below relate to a preparation of a cured latex compound and in particular of a latex foam, and the composition of crosslinkable latex to obtain this latex foam.

The general methods for preparing a crosslinkable latex and for making a latex foam are described below, and the various examples of resulting crosslinkable latex compositions are illustrated in Example 1 and Example 2.

A first step is to mix the ingredients of a crosslinkable functional latex, water (A) and optionally a crosslinker (B) to obtain a composition (A + B). Also, a filler such as aluminum trinydroxide, or the mixture of aluminum trihydroxide with chalk and melamine (C) in the above composition (A + B) is mixed at room temperature. A crosslinkable latex compound (A + B + C) is thus obtained. In addition, other substances are mixed with said cross-linkable latex such as additives and a foam booster and stabilizer. Optionally, a thickening agent is added as a final addition. In a second step, the crosslinkable latex is intensively mixed to obtain an hydrous latex foam. When the hydrous latex foam has obtained a good foam quality, it is applied to a substrate. For example, the substrate can be the back of a carpet. Good contact is thereby ensured between the aqueous latex foam and the substrate, for example by pressing by means of roller rollers. Subsequently, in a third step, the aqueous latex foam is treated by means of an infrared lamp to a temperature of 120 ° C. Alternatively, the aqueous latex foam can be heated in a convection oven at a temperature of 80 ° C. In a final step, the at least partially dried latex foam is cured and further dried. In this way, crosslinking of the crosslinkable latex is accomplished. Optionally, this thermal treatment is followed by a mechanical treatment, such as, for example, pressing, and a thermal post-treatment before curing in an oven at a temperature of about 150 ° C. The various cross-linkable functional latex compositions of Examples 1-3 are shown respectively on using Table 2-4. Table 6 shows a latex foam composition of the invention, using the latex obtained in Examples 1-3.

Table 2: Composition of a carboxylated latex according to Example 1 of the present invention. Material function Material Drying parts _ Monomers Styrene 400 Butadiene 54.45 Itaconic acid 0.55 Acrylic acid 3

Acrylonitrile 2 "Add water to a dry matter of 50-55% weight% 0" Crosslinker (in post addition) Epoxysilanes variable, from 0.1. up to 5.0% dry weight% on wet weight latex (optimum concentration is 1 to 3.0%) Table 3: Composition of a hydroxy functional latex according to Example 2 of the present invention.

Material function Material Drying parts Monomers Styrene 5245 Butadiene 42.0 Itaconic acid 0.55 Hydroxylethyl acrylate 3 Acrylonitrile 2 _ Add water to a dry matter of 50-55% weight% 0 Crosslinker (in post-Blocked polyisocyanate or a variable, from 0.1. Addition) other suitable crosslinker * which is reactive up to 10.0%, with optimal hydroxyl group concentration is 4 to 6.0%) * other suitable crosslinkers are shown in table 1. 8

Table 4: Composition of a hybrid hydroxy and carboxy functional latex according to Example 3 of the present invention.

Material function Material Drying parts Monomers Styrene 520 Butadiene 41.45 Itaconic acid 0.55 Hydroxylethyl acrylate 2 Acrylic acid 3 Acrylonitrile 2 _ Add water to a dry matter of 50-55% weight% 0

(in post-addition) * Crosslinkers suitable for this latex are those that can react with hydroxyl groups (blocked isocyanates, amino resins, etc.) or that can react with carboxyl groups (epoxysilanes, etc.) or a combination of both type of crosslinkers.

Table 5: A list of polymerization surfactants used. polymerization __Surfactant ss 1 Amount of surfactant dry / 100 dry polymer Sodium dicyclohexyl sulfosuccinate 1 Mixture of disodium mono- and didodecyl 1 diphenyl oxide sulfone Sodium alkylbenzene sulfonate 1 Note: Mixture of disodium mono- and didodecyl diphenyl oxide sulfone and Sodium alkylbenzene sulfonate are preferred these ingredients do not contribute to the total VOCs of the coating.

Table 6: The latex foam composition of the present invention.

Ingredient Dd 'Latex of Example 1,2 0f3 1000 Sodium hexametaphosphate 1.0 Tetrapotassium pyrophosphate 2.0 Sodium lauryl sulfate 1.5 Sulfosuccinamate soap 6.0 Antioxidant (Wingstay L) 1.5 Zinc oxide à 20 Ammonia OZ “Aluminum trihydroxide 2100 Water to dry matter of 60-80% Polyacrylating agent, Polyacrylate, CM , to the required viscosity, e.g. such) Brookfield RVF3 / 4 = 10-30

Claims (24)

CONCLUSIONS A cross-linkable functional latex, comprising: - 10.0 to 55.0% by weight of a cross-linkable latex polymer comprising at least one carboxy functional group in an amount of at least 0.05% by weight with respect to the total weight of said latex; - optionally up to 15.0% by weight crosslinker; - up to 15.0% by weight of a surfactant; and - 40.0 to 70.0 weight% aluminum trihydroxide; supplemented with water to 100.0% by weight. A crosslinkable functional latex according to claim 1, wherein said latex is a hydroxy or a carboxy functional monomer or both. A crosslinkable functional latex according to claims 1 or 2, wherein said functional latex does not include a crosslinker. Crosslinkable functional latex according to at least one of claims 1 to 3, wherein said functional latex is a carboxylated latex. Crosslinkable functional latex according to at least one of claims 1 to 4, wherein said latex comprises at least acrylic or methacrylic acid as functional monomer. A crosslinkable functional latex according to at least one of claims 1 to 5, wherein said latex is modified with epoxysilane. A crosslinkable functional latex according to at least one of claims 1 to 6, wherein said crosslinkable latex comprises zinc oxide. The crosslinkable functional latex of claim 2, wherein said functional latex is a hybrid hydroxy and carboxy functional latex. The crosslinkable functional latex of claim 8, wherein said functional latex comprises at least one crosslinker. The crosslinkable functional latex of claim 1, wherein said latex comprising functional monomers selected from the group comprising hydroxyl ethyl acrylate, acrylic acid, methacrylic acid, acrylamide, methacrylamide, diacetone acrylamide, glycidyl methacrylate, or a hybrid comprising a mixture thereof. The extensible functional latex of at least one of claims 1 to 10, wherein said latex comprises one or more additional fillers selected from the group consisting of chalk and melamine, or a combination thereof. The crosslinkable functional latex according to at least one of claims 1 to 11, wherein the crosslinkable latex comprises one or more additives selected from the group consisting of salts, catalysts, water softeners, antioxidants, antimicrobial agents, hydrophobic additives, oleophobic additives, ammonia, agents containing volatile organic substances such as aldehyde-binding agents or oxygen-binding agents, or a combination thereof. Crosslinkable functional latex according to at least one of claims 1 to 12, wherein the crosslinkable latex comprises a foam booster and / or a foam stabilizer. The crosslinkable functional latex of at least one of claims 1 to 13, wherein the crosslinkable latex comprises a thickener. A method wherein a latex foam composition comprising a crosslinkable functional latex with a surfactant, aluminum trihydroxide in an amount between 40.0 to 70.0% by weight with respect to the total weight of said latex foam composition, a thickener and optionally a crosslinker, a foam stabilizer and / or a foam booster, is applied directly to a textile backing, and then cured. A method for preparing a cured latex foam composition, comprising the steps of: - providing a crosslinkable functional latex polymer comprising at least one carboxy functional group in an amount of at least 0.05% by weight with respect to the total weight of said latex; - mixing said functional latex with optionally a crosslinker, and further with a surfactant, a filler, a thickener and optionally a foam stabilizer and / or a foam booster, thereby obtaining a latex foam composition; - optionally, spreading said latex foam composition on a substrate; and - drying said latex foam composition, thereby obtaining a cured latex compound, characterized in that aluminum trihydroxide in an amount between 40.0-70.0% by weight, based on the total weight of said latex foam composition, is mixed. A method according to claim 16, comprising the step of mixing said cross-linkable functional latex or latex foam composition with one or more additives selected from the group comprising: salts, catalysts, water softeners, antioxidants, antimicrobial agents, hydrophobic additives, ammonia, oleophobic additives, agents capable of binding volatile organic compounds such as aldehyde binding agents or oxygen binding agents, or a combination of these. A method according to claim 16 or 17, wherein said latex compound is dried by heating to a temperature between 50 ° C and 200 ° C, A method according to claim 18, wherein said latex compound is treated with the aid of an infrared lamp. A method according to at least one of claims 16 to 19, wherein said cured latex foam composition is thermally post-treated, such as, for example, by curing at a temperature between 100 ° C and 200 ° C. 21. Cured latex foam composition obtainable by a method according to at least one of claims 16 to 20. Automotive interior textiles, such as for car seat, car door and floor panel textiles, comprising a cured latex foam composition according to claim 21. 23. Covering for technical textiles, such as mattress, duvet and curtain fabric ticking comprising a cured latex foam composition according to claim 21. Use of a crosslinkable hydroxy functional latex according to at least one of claims 1 to 14 for preparing a cured latex foam composition.