Solid surface materials derived from aqueous latex dispersions of thermoplastic polymers

Abstract

A thermoplastic solid surface material derived from a thermoplastic latex co-dispersion and downstream intermediates, including (a) aqueous thixotropic slips; (b) polymeric composite flakes; (c) composite powders; (d) composite pastes; and (e) preformed composite pieces

What is claimed is:  
     
         1 . An aqueous thixotropic slip composition comprising: 
 (a) about 20-60% by weight, based on the weight of solids, of at least one thermoplastic polymer having a T g  greater than about 60° C., the at least one thermoplastic polymer in the form of colloidal particles;    (b) about 20-80% by weight, based on the weight of solids, of mineral filler;    (c) up to about 5% by weight, based on the weight of solids, of decorative filler;    (d) up to about 50% by weight, based on the weight of solids, of polymeric particles selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof; and    (e) a thickening agent; wherein the thickening agent is present in an amount sufficient to form a thixotropic combination and wherein said composition is non-film-forming when dried at atmospheric pressure.    
     
     
         2 . The composition of  claim 1 , wherein the colloidal particles have an average latex particle size of less than about 2 microns.  
     
     
         3 . The composition of  claim 1 , wherein the colloidal particles have an average latex particle size of less than about 1 micron.  
     
     
         4 . The composition of  claim 1 , wherein the thermoplastic polymer is a homopolymer or copolymer of acrylic or methacrylic esters.  
     
     
         5 . The composition of  claim 1 , wherein the mineral filler is selected from alumina, silica, alumina trihydrate, calcium carbonate, aluminosilicates, borosilicates, and combinations thereof.  
     
     
         6 . The composition of  claim 1 , wherein the decorative particles are selected from pigments, colorants, reflective particles, and combinations thereof.  
     
     
         7 . The composition of  claim 1 , wherein the polymeric particles comprise the at least one thermoplastic polymer.  
     
     
         8 . The composition of  claim 1  wherein the thickening agent is a salt.  
     
     
         9 . The composition of  claim 8  wherein the salt is selected from ammonium acetate, ammonium carbonate, and combinations thereof.  
     
     
         10 . The composition of  claim 1 , comprising about 30-50 % by weight, based on the weight of solids, of the at least one thermoplastic polymer and about 50-75% by weight, based on the weight of solids, of the mineral filler.  
     
     
         11 . The composition of  claim 1 , wherein the at least one thermoplastic polymer has a weight average molecular weight of at least 300,000.  
     
     
         12 . A dry composite intermediate comprising: 
 (a) about 20-60% by weight, based on the weight of the intermediate, of at least one thermoplastic polymer having a T g  greater than 60° C., and a weight average molecular weight of greater than 300,000;    (b) about 20-80% by weight, based on the weight of the intermediate, of mineral filler particles; and    (c) up to about 5% by weight, based on the weight of the intermediate, of decorative filler particles;    (d) up to about 50 % by weight, based on the weight of the intermediate, selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         13 . The intermediate of  claim 12 , wherein the at least one thermoplastic polymer cannot be processed by a process selected from melt extrusion, injection molding, and combinations thereof.  
     
     
         14 . The intermediate of  claim 12 , wherein the thermoplastic polymer is a homopolymer or copolymer of acrylic or methacrylic esters.  
     
     
         15 . The intermediate of  claim 12 , wherein the at least one thermoplastic polymer is selected from amorphous polymers having an amorphous Tg, semi-crystalline polymers having a semi-crystalline Tm, and combinations thereof, wherein the intermediate is capable of coalescing to form a non-porous coherent object under the application of temperatures above a highest reference temperature selected from the amorphous T g . and semi-crystalline T m  of thermoplastic polymer and pressures greater than about 14 kg/cm 2 .  
     
     
         16 . The intermediate of  claim 12  in the form of composite flakes, wherein each of the composite flakes includes at least one layer of a distinct color.  
     
     
         17 . The intermediate of  claim 12 , comprising about 30-50 % by weight, based on the weight of solids, of the at least one thermoplastic polymer and about 50-75% by weight, based on the weight of solids, of the mineral filler particles.  
     
     
         18 . A process for forming polymeric composite flakes, said process comprising: 
 (1) providing the aqueous thixotropic slip composition of  claim 1;     (2) applying the composition to a surface;    (3) drying the composition to form flakes.    
     
     
         19 . A process for forming a thermoplastic material, said process comprising: 
 (1) providing the dry latex-derived intermediate in accordance to the process of  claim 12 , wherein the at least one thermoplastic polymer is selected from amorphous polymers having an amorphous Tg, semi-crystalline polymers having a semi-crystalline Tm, and combinations thereof;    (2) providing the dry composite intermediate in a container; and    (3) applying pressure to the container including the dry intermediate to form a shaped material, at a temperature above a greatest reference temperature selected from the amorphous T g  and the semi-crystalline T m .    
     
     
         20 . The process of  claim 19 , wherein step (3) is carried out at a pressure of at least about 14 kg/cm 2 .  
     
     
         21 . The process of  claim 19 , wherein step (3) is carried out at a pressure of less Man about 7 kg/cm 2 .  
     
     
         22 . The process of  claim 21 , further comprising the step of (4) extracting preformed porous pieces from portions of the shaped material.  
     
     
         23 . The process of  claim 22 , wherein extracting step is carried out by chiselling, milling, routing, boring, cutting or machining.  
     
     
         24 . The process of  claim 19 , wherein step (3) is carried out by compression molding.  
     
     
         25 . The process of  claim 19 , wherein step (3) is carried out by ram extrusion.  
     
     
         26 . A decorative pattern in a solid surface material derived from at least one thermoplastic latex co-dispersion and containing no plasticizers, the decorative pattern selected from veined patterns, tessellated patterns, geometric inclusions, patterns of stratified domains, and combinations thereof.  
     
     
         27 . The decorative pattern of  claim 26 , wherein the at least one thermoplastic latex co-dispersion comprises about 20-60% by weight, based on the weight of solids, of at least one thermoplastic polymer having a T g  greater than 60° C., and a weight average molecular weight of greater than 300,000.  
     
     
         28 . The decorative pattern of  claim 27 , wherein the latex co-dispersion comprises: 
 (a) about 30-50% by weight, based on the weight of solids, of the at least one thermoplastic polymer;    (b) about 50-75% by weight, based on the weight of solids, of the mineral filler. the at least one thermoplastic polymer in the form of colloidal particles;    (c) up to about 5% by weight, based on the weight of solids, of decorative filler particles;    (d) up to about 50% by weight, based on the weight of solids, of polymeric particles selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         29 . The decorative pattern of  claim 26 , wherein the solid surface material has a discrete thickness, the decorative pattern disposed throughout the discrete thickness, such that the solid surface material is polishable without disturbing the integrity of the decorative pattern.  
     
     
         30 . A solid surface material having at least a first surface having a first pattern, at least a second surface having a second pattern, the first pattern being visibly different from the second pattern, a plurality of first planes parallel to the first surface, a plurality of second planes parallel to the second surface, wherein the first pattern is reproduced in the first planes, the second pattern is reproduced in the second planes, such that the first pattern and the second pattern are retainable after the structure undergoes machining, grinding, polishing, cutting, and combinations thereof, wherein the solid surface material is derived at least one thermoplastic latex co-dispersion.  
     
     
         31 . The structure of  claim 30 , wherein the thermoplastic material is derived from polymeric latex co-dispersion comprising: 
 (a) about 20-60% by weight, based on the weight of solids, of at least one thermoplastic polymer having a T g  greater than about 60° C., the at least one thermoplastic polymer in the form of colloidal particles;    (b) about 20-80% by weight, based on the weight of solids, of mineral filler particles;    (c) up to about 5% by weight, based on the weight of solids, of decorative filler particles;    (d) up to about 50% by weight, based on the weight of solids, of polymeric particles selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         32 . The structure of  claim 31 , wherein the polymeric latex co-dispersion comprises about 30-50% by weight, based on the weight of solids, of the at least one thermoplastic polymer and about 50-75% by weight, based on the weight of solids, of the mineral filler.  
     
     
         33 . The structure of  claim 30 , having a discrete thickness and at least one decorative pattern disposed throughout the discrete thickness, the at least one decorative pattern selected from disordered/natural vein patterns, tessellated patterns, geometric inclusions, superimposed/predetermined vein patterns, patterns of stratified domains and combinations thereof.  
     
     
         34 . A thermoplastic solid surface material derived from a thermoplastic latex co-dispersion composition comprising: 
 (a) about 20-60% by weight, based on the weight of solids, of at least one thermoplastic polymer having a Tg greater than about 60° C., the at least one thermoplastic polymer in the form of colloidal particles;    (b) about 20-80% by weight, based on the weight of solids, of mineral filler particles;    (c) up to about 5% by weight, based on the weight of solids, of decorative filler particles;    (d) up to about 50% by weight, based on the weight of solids, of polymeric particles selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         35 . A composite intermediate derived from a thermoplastic latex co-dispersion composition comprising: 
 (a) about 20-60% by weight, based on the weight of solids, of at least one thermoplastic polymer having a Tg greater than about 60° C., the at least one thermoplastic polymer in the form of colloidal particles;    (b) about 20-80% by weight, based on the weight of solids, of mineral filler particles;    (c) up to about 5% by weight, based on the weight of solids, of decorative filler particles;    (d) up to about 50% by weight, based on the weight of solids, of polymeric particles selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         36 . The intermediate of  claim 35 , having a physical form selected from composite powders, composite flakes, preformed aqueous composite intermediate porous composite pieces, and combinations thereof.  
     
     
         37 . The intermediate of  claim 35 , comprising a solids content of at least 70 weight percent, based on the weight of the intermediate.  
     
     
         38 . The intermediate of  claim 35  having a physical form selected from composite paste, aqueous thixotropic slip, and combination thereof.  
     
     
         39 . The intermediate of  claim 36 , having a density of from about 50% to about 99% of fill density.  
     
     
         40 . A process for forming the preformed composite piece of  claim 39 , the process comprising: 
 (1) placing in a container a wet intermediate selected from composite paste, aqueous thixotropic slip and combinations thereof; and    (2) drying the wet intermediate.    
     
     
         41 . A process for forming the preformed composite piece of  claim 36 , the process comprising: 
 (1) extruding onto a surface a wet intermediate selected from composite paste, aqueous thixotropic slip and combinations thereof; and    (2) drying the wet intermediate.    
     
     
         42 . A dry composite intermediate comprising: 
 (a) about 20-60% by weight, based on the weight of the intermediate, of at least one thermoplastic polymer having a T g  greater than 60° C., wherein the at least one thermoplastic polymer cannot be processed by a process selected from melt extrusion, injection molding, and combinations thereof;    (b) about 20-80% by weight, based on the weight of the intermediate, of mineral filler particles; and    (c) up to about 5% by weight, based on the weight of the intermediate, of decorative filler particles;    (d) up to about 50% by weight, based on the weight of the intermediate, selected from filled polymeric particles, unfilled polymeric particles, and combinations thereof.    
     
     
         43 . The composition of  claim 43 , wherein the thermoplastic polymer is a homopolymer or copolymer of acrylic or methacrylic esters.  
     
     
         44 . A thermoplastic solid surface material comprising about 20-60% by weight, based on the weight of the material, of at least one thermoplastic polymer having a T g  greater than 60° C., and a weight average molecular weight of greater than 300,000.  
     
     
         45 . The composition of  claim 44 , wherein the thermoplastic polymer is a homopolymer or copolymer of acrylic or methacrylic esters.