Co-agglomerated latex polymer dispersions and methods of preparing and using same

Abstract

Co-agglomerated dispersions and methods for their preparation are described herein. The co-agglomerated dispersions are prepared by co-agglomerating an anionic polymer dispersion and inert particles. The polymers for use in the co-agglomerated dispersions are derived from one or more monomers including at least one conjugated diene monomer. The inert particles have a particle size of less than 2 μm. Also described herein is an aqueous dispersion including co-agglomerated particles formed from at least one polymer and at least one inert material. Further described herein are foamed polymers, latex-based adhesives, waterproofing membranes, sound absorbing coatings, and methods for their preparation and use.

1 - 25 . (canceled) 
     
     
         26 . An aqueous dispersion comprising co-agglomerated particles formed of at least one polymer and at least one inert material, said co-agglomerated particles having a particle size of 100 nm to 5 μm and said polymer derived from one or more monomers including at least one conjugated diene monomer. 
     
     
         27 . The aqueous dispersion of  claim 26 , having a surface tension of less than 45 mN/m. 
     
     
         28 . The aqueous dispersion of  claim 26 , wherein the solids content is greater than 50%. 
     
     
         29 . The aqueous dispersion of  claim 26 , wherein the solids content is greater than 60%. 
     
     
         30 . The aqueous dispersion of  claim 29 , wherein the viscosity is less than 1 Pa·s at 20° C. 
     
     
         31 . The aqueous dispersion of  claim 26 , wherein said at least one inert material includes at least one inorganic material. 
     
     
         32 . The aqueous dispersion of  claim 31 , wherein said inorganic material includes one or more clays. 
     
     
         33 . The aqueous dispersion of  claim 31 , wherein said inorganic material includes one or more particles having platelet structures. 
     
     
         34 . The aqueous dispersion of  claim 31 , wherein said inorganic material includes material selected from the group consisting of kaolin, mica, bentonite, natural and synthetic hectorite, ettringite, calcium phosphate, and mixtures thereof. 
     
     
         35 . The aqueous dispersion of  claim 34 , wherein said inorganic material includes kaolin. 
     
     
         36 . The aqueous dispersion of  claim 26 , wherein the inert material is present in the co-agglomerated particles in an amount of from 1% to 20% by weight based on the dry weight of the polymer in the co-agglomerated particles. 
     
     
         37 . The aqueous dispersion of  claim 26 , further comprising a cationic surfactant. 
     
     
         38 . The aqueous dispersion of  claim 26 , wherein the polymer is derived from one or more monomers, wherein at least 50% of the monomers comprise the at least one conjugated diene. 
     
     
         39 . The aqueous dispersion of  claim 38 , wherein the at least one conjugated diene monomer includes butadiene. 
     
     
         40 . The aqueous dispersion of  claim 26 , wherein the one or more monomers include at least one vinyl aromatic monomer. 
     
     
         41 . The aqueous dispersion of  claim 40 , wherein said at least one vinyl aromatic monomer includes styrene. 
     
     
         42 . The aqueous dispersion of  claim 41 , where said polymer is a styrene-butadiene-based copolymer. 
     
     
         43 . The aqueous dispersion of  claim 26 , wherein the one or more monomers include at least one (meth)acrylic acid ester. 
     
     
         44 . The aqueous dispersion of  claim 43 , wherein said at least one (meth)acrylic acid ester includes methyl methacry late. 
     
     
         45 . The aqueous dispersion of  claim 26 , wherein said polymer is polybutadiene. 
     
     
         46 . A foamed polymer comprising at least one polymer and at least one inert material wherein the inert material is substantially uniformly distributed throughout the foamed polymer, the foamed polymer produced from co-agglomerated particles formed of the at least one polymer and the at least one inert material having a particle size of 100 nm to 5 μm, wherein said at least one polymer is derived from one or more monomers including at least one conjugated diene monomer. 
     
     
         47 . The foamed polymer of  claim 46 , wherein said at least one inert material comprises at least one inorganic material. 
     
     
         48 . A method for producing a foamed polymer, comprising:
 co-agglomerating an anionic polymer dispersion, said polymer derived from one or more monomers including at least one conjugated diene monomer and in the presence of inert particles having a particle size of less than 2 μm to form a co-agglomerated dispersion comprising the anionic polymer and particles;   introducing air or other gases into the polymer dispersion to form a foamed dispersion;   molding the foam dispersion;   solidifying or setting the foam dispersion to form the polymer foam; and   cross-linking the co-agglomerated particles in the polymer foam.   
     
     
         49 . The method of  claim 48 , further comprising the step of adding a foaming agent to the co-agglomerated dispersion. 
     
     
         50 . The method of  claim 48 , further comprising the step of adding a gelling agent to the co-agglomerated dispersion. 
     
     
         51 . The method of  claim 48 , wherein said inert particles comprise inorganic particles. 
     
     
         52 . A latex-based adhesive, comprising co-agglomerated particles formed of at least one polymer and at least one inert material, said co-agglomerated particles having a particle size of 100 nm to 5 μm and said polymer derived from one or more monomers including at least one conjugated diene monomer. 
     
     
         53 . A method of adhering a substrate to a surface, comprising the steps of:
 applying to a surface a co-agglomerated dispersion comprising co-agglomerated particles formed of at least one polymer and at least one inert material, said co-agglomerated particles having a particle size of 100 nm to 5 μm and said polymer derived from one or more monomers including at least one conjugated diene monomer;   applying the substrate to the dispersion; and   removing water from the dispersion.   
     
     
         54 . The method of  claim 53 , further comprising the steps of:
 co-agglomerating an anionic polymer dispersion, said polymer derived from one or more monomers including at least one conjugated diene monomer and in the presence of inert particles having a particle size of less than 2 μm to form the co-agglomerated dispersion.   
     
     
         55 . The method of  claim 53 , further comprising the step of removing water from the co-agglomerated dispersion prior to applying it to the surface of the co-agglomerated dispersion. 
     
     
         56 . A modified asphalt composition, comprising an asphalt emulsion and a co-agglomerated dispersion comprising co-agglomerated particles formed of at least one polymer and at least one inert material, said co-agglomerated particles having a particle size of 100 nm to 5 μm and said polymer derived from one or more monomers including at least one conjugated diene monomer.