Coating composition, coated fabric, method for producing coated fabric, and articles made from coated fabric.

Abstract

To provide a coating composition, a coated fabric, an article made from the coated fabric, and a method of making the coated fabric.SOLUTION: Provided is a coating composition, comprising: a first polymeric component which comprises a first polymeric dispersion, wherein polymers contained in the first polymeric dispersion have a surface free energy of equal to or greater than 28 mJ / m2 and a volume average particle size diameter of from 0.1 to 10 microns; a second polymeric component which comprises one or more second polymeric emulsions wherein polymers contained in the second polymeric emulsions have a surface free energy equal to or less than 26 mJ / m2 and a volume average particle size diameter from 0.005 to 1,000 microns; and one or more rheology modifiers is provided. An article coated with the coating composition and a method of making the coated article are also provided.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coating composition, a coated cloth, a method for producing a coated cloth, and an article made from a coated cloth. [Background technology]

[0002] Polymer coatings on fabrics, primarily polyester and nylon, are used in gas / pneumatic retention applications such as automotive airbags and aircraft emergency chutes. While silicone coatings dominate the market, organic coatings are gaining market share due to their lower cost. Known coatings have drawbacks including cost, blocking (the tendency for polymer-coated surfaces to stick together), flammability, high coat weight, and gas pressure drop over periods exceeding a few seconds. Pressure-retaining coatings that optimize all these factors are beneficial for such applications. [Overview of the project] [Problems that the invention aims to solve]

[0003] The present invention provides a coating composition, a coated cloth, a method for producing a coated cloth, and articles made from the coated cloth. The present invention further provides articles such as airbags and emergency chutes made from the coated cloth. [Means for solving the problem]

[0004] In one embodiment, the present invention provides a coating composition comprising (1) a first polymer component comprising a first polymer dispersion, wherein the polymer contained in the first polymer dispersion is 28 mJ / m 2 (1) A first polymer component having the above surface free energy and a volume-average particle size of 0.1 to 10 microns; and (2) a second polymer component comprising one or more second polymer emulsions, wherein the polymer contained in the second polymer emulsion has a surface free energy of 26 mJ / m³2 A second polymer component having the following surface free energy and a volume average particle size of 0.005 to 1,000 microns, (3) one or more rheology modifiers in an amount sufficient for the coating composition to have a viscosity of 100 to 2000 cP, and (4) optionally, a base sufficient for the first and second polymer components to remain stable, wherein the first polymer component is present in an amount such that the solids in the first polymer component are 50 to 99.9% by weight of the total solids of the coating composition, and the second polymer component is present in an amount such that the solids in the second polymer component are 0.1 to 50% by weight of the total solids of the coating composition.

[0005] In an alternative embodiment, the present invention provides a coated fabric for use in an airbag, which comprises (1) a woven or non-woven fabric substrate and (2) a coating derived from the coating composition of the present invention, wherein the coating is applied to at least one surface of the substrate with a total coating weight of 20 to 50 g / m 2 of the total coating weight.

[0006] In another alternative embodiment, the present invention provides an article comprising the coated fabric of the present invention.

[0007] In another alternative, the present invention provides a method for preparing a coated fabric, which comprises providing a woven or non-woven fabric substrate, applying a coating composition to at least one surface of the substrate by one or more coating methods selected from the group consisting of knife coating, roll coating, dip coating, flow coating, squeeze coating, and spray coating to produce a wet-coated substrate, and drying the wet-coated substrate to produce a coated fabric having a coating weight of 20 to 50 g / m 2 of the coating weight. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] [Figure 1]It is a schematic diagram of a typical melt extrusion apparatus used to prepare the dispersion used in the embodiments of the present invention.

Embodiments for Carrying out the Invention

[0009] The present invention provides a coating composition, a coated fabric, and an article made therefrom, as well as a method for producing a coated fabric.

[0010] Coating composition The coating composition according to the present invention contains (a) a first polymer component, (b) a second polymer component, (c) a rheology modifier, (d) optionally, a base, and (e) optionally, a solvent.

[0011] First polymer component The first polymer component includes a first polymer dispersion, and the polymer contained in the first polymer dispersion has a surface free energy of 28 mJ / m 2 or more and a volume average particle diameter of 0.1 to 10 microns. As used herein, the term "first polymer dispersion" generally includes polymers dispersed in a liquid known as a dispersion, as well as polymer emulsions such as acrylic latexes, and polymer suspensions. 28 mJ / m 2 All individual values and subranges of 28 mJ / m or more are included and disclosed herein. For example, the surface free energy of the polymer in the first polymer dispersion can be in the range from a lower limit of 28, 30, 32, or 34 mJ / m 2 For example, the surface free energy of the polymer in the first polymer dispersion is 28 to 60 mJ / m 2 or, in an alternative example, 28 to 42 mJ / m 2 or, in an alternative, 30 to 50 mJ / m 2 or, in an alternative example, 35 to 55 mJ / m 2The range may be as follows: All individual values ​​and subranges from 0.1 to 10 microns are included and disclosed herein, for example, the volume-average particle size of solids in the first polymer dispersion may range from a lower limit of 0.1, 0.5, 1, 3, or 5 microns to an upper limit of 1, 5, 7, 9, or 10 microns. For example, the volume-average particle size of solids in the first polymer dispersion may range from 0.1 to several microns, or alternatively, 0.1 to 5 microns, or alternatively, 0.5 to 6 microns, or alternatively, 1 to 8 microns.

[0012] The polymers contained in the first polymer dispersion are, but are not limited to, nylon and aramid (generally about 40-67 mJ / m³). 2 (Having a surface free energy), epoxy (generally about 45 mJ / m³) 2 Cellulose (generally has a surface free energy of approximately 30-40 mJ / m³) 2 Acrylates (generally with a surface free energy of approximately 28-60 mJ / m³) 2 Polyolefins (generally with a surface free energy of approximately 30-34 mJ / m³) 2 Polystyrene (generally has a surface free energy of approximately 38 mJ / m³) 2 (Having a surface free energy of approximately 37 mJ / m³), as well as polyurethane (generally about 37 mJ / m³). 2 It may include (having a surface free energy of )

[0013] In certain embodiments, one or more polymers in the first polymer dispersion may include, for example, polyester. Polyester refers to a thermoplastic resin that may include polymers containing at least one ester bond. For example, polyester polyols can be prepared via conventional esterification processes using molar excess aliphatic diols or glycols in relation to alkanedioic acids. Examples of glycols that can be used to prepare polyesters include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,4-butanediol and other butanediols, 1,5-pentanediol and other pentanediols, hexanediol, decanediol, and dodecanediol. In some embodiments, the aliphatic glycol may contain 2 to about 8 carbon atoms. Examples of diacids that can be used to prepare polyesters include maleic acid, malonic acid, succinic acid, glutaric acid, adipic acid, 2-methyl-1,6-hexanoic acid, pimelic acid, suberic acid, and dodecanediol. In some embodiments, the alkanediic acid may contain 4 to 12 carbon atoms. Examples of polyester polyols include poly(hexanediol adipate), poly(butylene glycol adipate), poly(ethylene glycol adipate), poly(diethylene glycol adipate), poly(hexanediol oxalate), and poly(ethylene glycol sebecate). Another embodiment of the present invention uses a polyester resin containing an aliphatic diol, such as UNOXOL (a mixture of cis and trans-1,3- and 1,4-cyclohexanedimethanol), available from The Dow Chemical Company (Midland, Michigan).

[0014] In certain embodiments, one or more polymers in the first polymer dispersion may include, for example, a thermosetting material comprising an epoxy resin. An epoxy resin refers to a composition having one or more adjacent epoxy groups per molecule, i.e., at least one 1,2-epoxy group per molecule. Generally, such compounds are saturated or unsaturated aliphatic, alicyclic, aromatic, or heterocyclic compounds having at least one 1,2-epoxy group. Such compounds may be optionally substituted with one or more non-interfering substituents, such as halogen atoms, hydroxyl groups, ether radicals, or lower alkyl groups.

[0015] Exemplary epoxys are described in the Handbook of Epoxy Resins by HELee and K. Neville, published in 1967 by McGraw-Hill, New York, and U.S. Patent No. 4,066,628, incorporated herein by reference.

[0016] A particularly useful compound that can be used in the practical application of the present invention is an epoxy resin having the following formula: [ka] In the formula, n has a mean value of 0 or greater.

[0017] Epoxy resins useful in the present invention may include, for example, glycidyl polyethers of polyhydric phenols and polyhydric alcohols. Examples of known epoxy resins that can be used in the present invention include, for example, resorcinol, catechol, hydroquinone, bisphenol, bisphenol A, bisphenol AP (1,1-bis(4-hydroxylphenyl)-1-phenylethane), bisphenol F, bisphenol K, tetrabromobisphenol A, phenol-formaldehyde novolac resin, alkyl-substituted phenol-formaldehyde resin, phenol-hydroxybenzaldehyde resin, cresol-hydroxybenzaldehyde resin, dicyclopentadiene-phenol resin, dicyclopentadiene-substituted phenol resin, tetramethylbiphenol, tetramethyl-tetrabromoviphenol, tetramethyltribromoviphenol, diglycidyl ether of tetrachlorobisphenol A, and any combination thereof.

[0018] Examples of diepoxides particularly useful in the present invention include diglycidyl ether of 2,2-bis(4-hydroxyphenyl)propane (commonly known as bisphenol A) and diglycidyl ether of 2,2-bis(3,5-dibromo-4-)hydroxyphenyl)propane (commonly known as tetrabromobisphenol A). Mixtures of any two or more polyepoxides can also be used in the practice of the present invention.

[0019] Other exemplary diepoxides include diglycidyl ethers of divalent phenols, such as those described in U.S. Patents No. 5,246,751, 5,115,075, 5,089,588, 4,480,082, and 4,438,254, all of which are incorporated herein by reference, or diglycidyl esters of dicarboxylic acids, such as those described in U.S. Patent No. 5,171,820. Other exemplary diepoxides include, for example, αω-diglycidyloxyisopropylidene-bisphenol epoxy resins (commercially known as DER® 300 and 600 series epoxy resins, products of The Dow Chemical Company, Midland, Michigan).

[0020] The epoxy resins that can be used in practice of the present invention also include epoxy resins prepared by either the reaction of a diglycidyl ether of a divalent phenol with a divalent phenol, or by the reaction of a divalent phenol with epichlorohydrin (also known as "taffy resin").

[0021] Exemplary epoxy resins include, for example, diglycidyl ethers of bisphenol A, 4,4'-sulfonyldiphenol, 4,4-oxydiphenol, 4,4'-dihydroxybenzophenone, resorcinol, hydroquinone, 9,9'-bis(4-hydroxyphenyl)fluorene, 4,4'-dihydroxybiphenyl or 4,4'-dihydroxy-α-methylstilbene, and diglycidyl esters of dicarboxylic acids.

[0022] Other useful epoxide compounds include alicyclic epoxides. Alicyclic epoxides consist of saturated carbon rings having epoxy oxygen bonded to two adjacent atoms in the carbon ring, as shown in the following general formula, for example: [ka] In the formula, R is optionally a hydrocarbon group containing one or more heteroatoms (but not limited to Cl, Br, and S) or atoms or groups of atoms that form a stable bond with carbon (but not limited to Si, P, and B), and n is 1 or more.

[0023] Alicyclic epoxides may be monoepoxides, diepoxides, polyepoxides, or mixtures thereof. For example, any of the alicyclic epoxides described in U.S. Patent No. 3,686,359, incorporated herein by reference, may be used in the present invention. Examples of alicyclic epoxides that may be used in the present invention include, for example, (3,4-epoxycyclohexyl-methyl)-3,4-epoxy-cyclohexanecarboxylate, bis-(3,4-epoxycyclohexyl)adipate, vinylcyclohexene monoxide, and mixtures thereof.

[0024] In certain embodiments, one or more polymers in the first polymer dispersion may include thermoplastic polyurethane polymers. Such thermoplastic polyurethane polymers are generally known and are further described, for example, in International Publication 2008 / 057878, which is incorporated herein by reference to the extent that it describes thermoplastic polyurethane polymers. Exemplary polyurethanes include PELLETHANE thermoplastic polyurethane elastomers available from Lubrizol Advanced Materials, Inc., ESTANE thermoplastic polyurethanes, TECOFLEX thermoplastic polyurethanes, CARBOTHANE thermoplastic polyurethanes, TECOPHILIC thermoplastic polyurethanes, TECOPLAST thermoplastic polyurethanes, and TECOTHANE thermoplastic polyurethanes, all available from Noveon, ELASTOLLAN thermoplastic polyurethanes and other thermoplastic polyurethanes available from BASF, and commercially available thermoplastic polyurethanes available from Bayer, Huntsman, and Merquinsa.

[0025] In yet another embodiment, the first polymer dispersion may contain one or more emulsion polymer latexes comprising one or more acrylate or methacrylate polymers ("(meth)acrylate"). Examples of preferred (meth)acrylates include methyl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate and isooctyl acrylate, n-decyl acrylate, isodecyl acrylate, tert-butyl acrylate, methyl methacrylate, butyl methacrylate, hexyl methacrylate, isobutyl methacrylate, isopropyl methacrylate, and 2-hydroxyethyl acrylate and acrylamide. Preferred (meth)acrylates are methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, isooctyl acrylate, methyl methacrylate and butyl methacrylate. Other suitable monomers include lower alkyl acrylates and methacrylates containing acrylic acid and methacrylic acid ester monomers, and include methyl acrylate, ethyl acrylate, n-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, isobornyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, cyclohexyl methacrylate, isodecyl methacrylate, isobornyl methacrylate, t-butylaminoethyl methacrylate, stearyl methacrylate, glycidyl methacrylate, dicyclopentenyl methacrylate, and phenyl methacrylate.

[0026] In one embodiment, the first polymer dispersion is (a) 50 to 98% by weight of one or more olefin-based polymers based on the total solid weight of the dispersion, wherein one or more olefin-based polymers have a concentration of 28 mJ / m³ 2The mixture comprises one or more olefin-based polymers exhibiting the above surface free energy, (b) one or more dispersants in an amount of 2 to 40% by weight based on the total solids weight of the dispersion, (c) one or more compatibilizers in an amount of 0 to 15% by weight based on the total solids weight of the dispersion, (d) water, and (e) optionally, a neutralizing agent sufficient to neutralize one or more dispersants to one or more dispersants having an acid value of 100 to 140%, wherein the dispersion exhibits a volume-average particle size of 1 micron or less and a solids content of 1 to 60% by weight.

[0027] The first polymer dispersion comprises 50 to 98 weight percent of a base polymer(s) based on the total weight of the solids content of the dispersion. All individual values ​​and subranges of 50 to 98 weight percent are included and disclosed herein, for example, the weight percent may range from the lower limit of 50, 55, 60, 65, 70, 75, 80, 82, 90, or 92 weight percent to the upper limit of 65, 74, 83, 87, 90, 95, or 98 weight percent. For example, the dispersion may comprise 50 to 98, or in an alternative example 75 to 95, or in an alternative example 60 to 85 weight percent of a base polymer(s) based on the total weight of the solids content of the dispersion. The dispersion comprises at least one olefin-based polymer. The olefin-based polymer can be selected from, for example, the group consisting of thermoplastics and thermosettings. The one or more base polymers comprise one or more olefin-based polymers.

[0028] Examples of thermoplastic materials include homopolymers and copolymers (including elastomers) of alpha-olefins such as polyethylene, polypropylene, poly-1-butene, poly-3-methyl-1-butene, poly-3-methyl-1-pentene, poly-4-methyl-1-pentene, ethylene-propylene copolymer, ethylene-1-butene copolymer, and propylene-1-butene copolymer, as typically represented by polyethylene, polypropylene, poly-1-butene, poly-3-methyl-1-butene, poly-3-methyl-1-pentene, poly-4-methyl-1-pentene, ethylene-propylene copolymer, ethylene-1-butene copolymer, and propylene-1-butene copolymer; ethylene-butene copolymer. Examples include, but are not limited to, polyolefins (including elastomers) such as alpha-olefin copolymers with conjugated or unconjugated dienes, typically represented by diene copolymers and ethylene-ethylidene norbornene copolymers; and polyolefins (including elastomers) with two or more alpha-olefin copolymers with conjugated or unconjugated dienes, typically represented by ethylene-propylene-butadiene copolymer, ethylene-propylene-dicyclopentadiene copolymer, ethylene-propylene-1,5-hexadiene copolymer, and ethylene-propylene-ethylidene norbornene copolymer.

[0029] In the selected embodiment, the olefin-based polymer comprises a polyolefin selected from the group consisting of ethylene-alpha-olefin copolymers and propylene-alpha-olefin copolymers. In particular, in the selected embodiment, the base polymer comprises one or more non-polar polyolefins.

[0030] In some embodiments, preferred olefin polymers include homogeneous polymers as described in U.S. Patent No. 3,645,992; high-density polyethylene (HDPE) as described in U.S. Patent No. 4,076,698; heterogeneously branched linear low-density polyethylene (LLDPE), which can be prepared by processes disclosed in, for example, U.S. Patents No. 5,272,236 and No. 5,278,272, the disclosures of which are incorporated herein by reference; heterogeneously branched ultra-low linear-density polyethylene (ULDPE); homogeneously branched linear ethylene / alpha-olefin copolymers; homogeneously branched, substantially linear ethylene / alpha-olefin polymers; and high-pressure free-radical polymerized ethylene polymers and copolymers such as low-density polyethylene (LDPE).

[0031] In one embodiment, the polymer in the first polymer dispersion is a propylene copolymer or interpolymer. In some specific embodiments, the propylene / ethylene copolymer or interpolymer is characterized by having a substantially isotactic propylene sequence. The term “substantially isotactic propylene sequence” and similar terms mean that the sequence has an isotactic triad (mm) greater than about 0.85, preferably greater than about 0.90, more preferably greater than about 0.92, and most preferably greater than about 0.93, as measured by 13C NMR. The isotactic triad is known in the art and is described, for example, in U.S. Patent No. 5,504,172 and WO00 / 01745. 13This refers to the isotactic sequence of triad units in the copolymer molecular chain as measured by 13C NMR spectroscopy. Such propylene copolymers are further described in U.S. Patents 6,960,635 and 6,525,157, which are incorporated herein by reference. Such propylene / alpha-olefin copolymers are commercially available from The Dow Chemical Company under the trade name VERSIFY® or from ExxonMobil Chemical Company under the trade name VISTAMAXX®.

[0032] In other embodiments, the base polymer may be an ethylene-methyl acrylate (EMA) polymer. In other specific embodiments, the ethylene-alphaolefin copolymer may be an ethylene-butene, ethylene-hexene, or ethylene-octene copolymer or interpolymer. In other specific embodiments, the propylene-alphaolefin copolymer may be a propylene-ethylene or propylene-ethylene-butene copolymer or interpolymer.

[0033] In one embodiment, the olefin-based polymer may have a density of 0.86 to 0.96 g / cc and a melt index I2 of 1 to 50 g / 10 min.

[0034] In certain embodiments, the base polymer may be a propylene-ethylene copolymer or interpolymer having an ethylene content of 5 to 20 weight percent and a melt flow rate of 0.5 to 300 g / 10 min (230°C, 2.16 kg). In other embodiments, the propylene-ethylene copolymer or interpolymer may have an ethylene content of 9 to 12 weight percent and a melt flow rate of 1 to 100 g / 10 min (230°C, 2.16 kg).

[0035] In other embodiments, the base polymer may have a crystallinity of less than 50 percent. In other embodiments, the crystallinity of the base polymer may be between 5 and 35 percent. In other embodiments, the crystallinity may be in the range of 7 to 20 percent.

[0036] In certain other embodiments, the base polymer is a semi-crystalline polymer and may have a melting point below 110°C. In some embodiments, the melting point may be between 25 and 100°C. In yet another embodiment, the melting point may be between 40 and 85°C.

[0037] In other selected embodiments, olefin block copolymers, such as ethylene multiblock copolymers described in U.S. Patent Application No. 11 / 376,835, can be used as the base polymer. Non-limiting examples of suitable ethylene / α-olefin multiblock copolymers are disclosed in U.S. Patent No. 7,608,668, which is incorporated herein by reference. In one embodiment, the ethylene / α-olefin multiblock copolymer is an ethylene / octene multiblock copolymer. The ethylene / octene multiblock copolymer is available from The Dow Chemical Company under the trade name INFUSE®. Such an olefin block copolymer may be an ethylene / α-olefin interpolymer, which is, (a) M w / M n , at least one melting point T in Celsius m , and has a density d in grams / cubic centimeter, T m The numerical values ​​of and d correspond to the following relationships: T m >-2002.9+4538.5(d)-2422.2(d) 2 ,or (b) M of approximately 1.7 to 3.5 w / M nIt has the following characteristics: the heat of fusion ΔH in J / g, and the delta amount ΔT in Celsius, which is defined as the temperature difference between the highest DSC peak and the highest CRYSTAF peak, and the values ​​of ΔT and ΔH have the following relationship: If ΔH is greater than zero and the maximum is 130 J / g, then ΔT > -0.1299(ΔH) + 62.81. If ΔH exceeds 130 J / g, then ΔT ≥ 48℃. If the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30°C, or (c) A compression-molded film of ethylene / α-olefin interpolymer is characterized by a strain of 300% and an elastic recovery rate Re in percent over one cycle, having a density d in grams / cubic centimeter, and if the ethylene / α-olefin interpolymer substantially has no crosslinking phase, the values ​​of Re and d satisfy the following relationship: Re>1481-1629(d), or (d) Having a molecular weight that elutes at 40°C to 130°C when fractionated using TREF, characterized in that the fraction has a molar comonomer content at least 5 percent higher than the molar comonomer content of a comparable random ethylene interpolymer fraction that elutes at the same temperature, wherein the comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content of 10 percent or less (based on the entire polymer) of the ethylene / α-olefin interpolymer, or (e) It has a storage modulus G'(25°C) at 25°C and a storage modulus G'(100°C) at 100°C, with the ratio of G'(25°C) to G'(100°C) being in the range of approximately 1:1 to approximately 9:1.

[0038] Ethylene / α-olefin interpolymers are also (a) When fractionated using TREF, the fraction has a molecular weight that elutes at 40°C to 130°C, and the fraction has a block index of at least 0.5 and a maximum of about 1 and a molecular weight distribution greater than about 1.3 M w / M n A feature having, or (b) A mean block index greater than 0 and with a maximum of approximately 1.0 and a molecular weight distribution greater than approximately 1.3 w / M n It has.

[0039] In certain embodiments, the olefin-based polymer includes a polar polymer having a polar group as either a comonomer or a grafted monomer. In exemplary embodiments, the olefin-based polymer includes one or more polar polyolefins having a polar group as either a comonomer or a grafted monomer. Exemplary polar polyolefins include, but are not limited to, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, available under trade names such as PRIMACOR® from The Dow Chemical Company, NUCREL® from EIDuPont de Nemours, and ESCOR® from ExxonMobil Chemical Company, and described in U.S. Patents 4,599,392, 4,988,781, and 5,938,437, each incorporated herein by reference in whole. Other exemplary olefin-based polymers include, but are not limited to, ethylene ethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA) copolymer, and ethylene butyl acrylate (EBA) copolymer.

[0040] In one embodiment, the olefin polymer includes a polar polyolefin selected from the group consisting of ethylene-acrylic acid (EAA) copolymer, ethylene-methacrylic acid copolymer, and combinations thereof.

[0041] Those skilled in the art will recognize that the above list is a non-exclusive list of exemplary base polymers. It will be understood that the scope of the present invention is limited only by the claims.

[0042] Dispersants and neutralizing agents In some embodiments, particularly those in which the polymer(s) are olefins, the first polymer dispersion comprises one or more dispersants in an amount of 2 to 40 weight percent, based on the total weight of the solids content of the dispersion. All individual values ​​and partial ranges of 2 to 40 weight percent are included and disclosed herein, for example, the dispersant may range from a lower limit of 2, 7, 12, 17, 22, or 25 weight percent to an upper limit of 15, 20, 25, 30, or 40 weight percent. For example, the dispersion may comprise one or more dispersants in an amount of 2 to 40, or in an alternative example 5 to 30, or in an alternative example 10 to 34, or in an alternative example 15 to 40 weight percent, based on the total weight of the solids content of the dispersion.

[0043] The dispersant may preferably be an external stabilizer. In selected embodiments, the dispersant may be a surfactant, a polymer, or a mixture thereof. In certain embodiments, the dispersant may be a polar polymer having a polar group as either a comonomer or a grafted monomer. In exemplary embodiments, the dispersant comprises one or more polar polyolefins having a polar group as either a comonomer or a grafted monomer or a functional group. In one embodiment, the dispersant is an acrylic dispersant. An "acrylic dispersant" is an acrylic monomer-containing material that facilitates the formation and stabilization of a dispersion. Non-limiting examples of suitable acrylic monomers for use in acrylic dispersants include alkyl (meth)acrylates, ethylhexyl acrylate (2-EHA), and combinations thereof. Non-limiting examples of suitable monomers include nonionic copolymer monoethylene unsaturated monomers, such as (meth)acrylic acid ester monomers, methyl (meth)acrylate (MMA), ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, decyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, ureidofunctional (meth)acrylate and acetacetate, acetamide or cyanoacetate of (meth)acrylic acid; styrene or substituted styrene; vinyltoluene; monoethylene unsaturated acetophenone or benzophenone derivatives; vinyl acetate or other vinyl esters; vinyl monomers such as vinyl chloride, vinylidene chloride, N-vinylpyrrolidone; and (meth)acrylonitrile. The term "(meth)" followed by another term, such as (meth)acrylate, refers to both acrylate and methacrylate. In one embodiment, the acrylic dispersant contains at least one acrylic monomer and a carboxylic acid comonomer. Non-limiting examples of suitable carboxylic acid comonomers include acrylic acid, methacrylic acid, crotonic acid, itaconic acid, fumaric acid, maleic acid, monomethyl itaconic acid, monomethyl fumarate, monobutyl fumarate, and maleic anhydride.In one embodiment, the acrylic dispersant is an alkyl (meth)acrylate / carboxylic acid interpolymer. In a further embodiment, the acrylic dispersant is a 2-EHA / alkyl (meth)acrylate / carboxylic acid terpolymer.

[0044] Examples of acrylic dispersants include, but are not limited to, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, available under trade names such as PRIMACOR (commercially available from The Dow Chemical Company), NUCREL (commercially available from EIDuPont de Nemours), and ESCOR (commercially available from ExxonMobil Chemical Company), as described in U.S. Patents 4,599,392, 4,988,781, and 5,938,437, which are incorporated herein by reference in their entirety. Other examples of polymer dispersants include, but are not limited to, ethylene ethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA), and ethylene butyl acrylate (EBA). Other ethylene-carboxylic acid copolymers may also be used. Those skilled in the art will recognize that several other useful polymers may also be used.

[0045] In one embodiment, the acrylic dispersant does not contain ethylene.

[0046] In another embodiment, the acrylic dispersant is an ethylhexyl acrylate / methyl methacrylate (MMA) / methacrylate terpolymer.

[0047] Other dispersants that can be used include, but are not limited to, long-chain fatty acids, fatty acid salts, or fatty acid alkyl esters having 12 to 60 carbon atoms. In other embodiments, the long-chain fatty acids or fatty acid salts may have 12 to 40 carbon atoms.

[0048] Dispersants can be partially or completely neutralized with a neutralizing agent. In certain embodiments, the neutralization of dispersants such as long-chain fatty acids or EAAs may be 100–140 percent molarly, or 100–120 percent molarly in alternative examples. For example, in the case of EAAs, the neutralizing agent may be a base such as ammonium hydroxide or potassium hydroxide. Other neutralizing agents may include, for example, lithium hydroxide or sodium hydroxide. In another alternative example, the neutralizing agent may be, for example, a carbonate. In yet another alternative example, the neutralizing agent may be any amine such as monoethanolamine or 2-amino-2-methyl-1-propanol (AMP). Amines useful in the embodiments disclosed herein may include monoethanolamine, diethanolamine, triethanolamine, and TRIS AMINO (each available from Angus), NEUTROL TE (available from BASF), as well as triisopropanolamine, diisopropanolamine, and N,N-dimethylethanolamine (each available from The Dow Chemical Company in Midland, Michigan). Other useful amines may include ammonia, monomethylamine, dimethylamine, trimethylamine, monoethylamine, diethylamine, triethylamine, mono-n-propylamine, dimethyl-n-propylamine, N-methanolamine, N-aminoethylethanolamine, N-methyldiethanolamine, monoisopropanolamine, N,N-dimethylpropanolamine, 2-amino-2-methyl-1-propanol, tris(hydroxymethyl)-aminomethane, and N,N,N'N'-tetrakis(2-hydroxypropyl)ethylenediamine. In some embodiments, mixtures of amines or mixtures of amines and surfactants can be used. Those skilled in the art will recognize that the selection of a suitable neutralizing agent may depend on the specific composition being formulated, and that such selection is within the scope of knowledge of those skilled in the art.

[0049] Additional dispersants that may be useful in the practice of the present invention include, but are not limited to, cationic surfactants, anionic surfactants, or nonionic surfactants. Examples of anionic surfactants include, but are not limited to, sulfonates, carboxylates, and phosphates. Examples of cationic surfactants include, but are not limited to, quaternary amines. Examples of nonionic surfactants include, but are not limited to, ethylene oxide-containing block copolymers and silicone surfactants. Dispersants useful in the practice of the present invention may be either external surfactants or internal surfactants. External surfactants are surfactants that do not chemically react with the base polymer during the preparation of the dispersion. Examples of external surfactants useful herein include, but are not limited to, salts of dodecylbenzenesulfonic acid and lauryl sulfonates. Internal surfactants are surfactants that chemically react with the base polymer during the preparation of the dispersion. Examples of internal surfactants useful herein include 2,2-dimethylolpropionic acid and its salts. Additional surfactants that may be useful in the practice of the present invention include cationic surfactants, anionic surfactants, nonionic surfactants, or combinations thereof.

[0050] In the embodiments disclosed herein, various commercially available surfactants can be used as dispersants, including OP-100 (sodium stearate), OPK-1000 (potassium stearate), and OPK-181 (potassium oleate) available from RTD Hallstar; UNICID350 available from Baker Petrolite; DISPONIL FES77-IS and DISPONIL TA-430 available from Cognis, respectively; RHODAPEX CO-436, SOPROPHOR 4D384, 3D-33, and 796 / P, RHODACAL BX-78 and LDS-22, RHODAFAC RE-610- and RM-710 available from Rhodia, respectively, as well as SUPRAGIL MNS / 90; and TRITON® QS-15, TRITON® W-30, DOWFAX 2A1, DOWFAX available from The Dow Chemical Company in Midland, Michigan, respectively. Includes 3B2, DOWFAX 8390, DOWFAX C6L, TRITON® X-200, TRITON® XN-45S, TRITON® H-55, TRITON® GR-5M, TRITON® BG-10, and TRITON® CG-110.

[0051] The aforementioned additional components are not present in all embodiments of the first polymer dispersion. For example, acrylic latex emulsions typically do not contain the aforementioned dispersants and neutralizing agents. Any method known in the art for forming such emulsions can be used in embodiments of the present invention.

[0052] Additional components of the first polymer dispersion The first polymer dispersion further contains water. The first polymer dispersion of the present invention contains 35 to 90 volume percent of water based on the total volume of the first polymer dispersion. In certain embodiments, the water content may range from 35 to 90, or in alternative examples 35 to 65, or in alternative examples 45 to 55, or in alternative examples 50 to 90 volume percent, based on the total volume of the first polymer dispersion. The water content of the first polymer dispersion can preferably be controlled so that the solids content is about 1 to about 74 volume percent. In certain embodiments, the solids range may be about 10 to about 70 volume percent. In other certain embodiments, the solids range is about 20 to about 60 volume percent. In certain other embodiments, the solids range is about 30 to about 55 volume percent.

[0053] The first polymer dispersion may optionally further contain other additives. For example, additives may include compatibilizers, wetting agents, surfactants (added after the dispersion is formed), antistatic agents, defoamers, antiblocking agents, wax dispersion pigments, neutralizing agents, flame retardants, thickeners, whitening agents, rheology modifiers, biocides, bactericides, shear stabilizers, UV stabilizers, friction coefficient modifiers, and other additives known to those skilled in the art. While optional for the purposes of the present invention, other components may be very beneficial for the stability of the product during and after the manufacturing process.

[0054] The compatibilizer may include those previously described in the art, such as maleated waxes, and may be present in an amount of 0 to 15% by weight of the dispersion, based on the total solid weight of the first polymer dispersion.

[0055] The first polymer dispersion used in the present invention exhibits a volume-average particle size of 1 micron or less. All individual particle sizes of 1 micron or less are included and disclosed herein. For example, the volume-average particle size of the dispersion may have an upper limit of 1, 0.5, 0.25, or 0.1 microns. For example, the volume-average particle size may be in the range of 0.1 to 1 micron, or alternatively, 0.5 to 1 micron, or alternatively, 0.5 to 1 micron.

[0056] The dispersions used in the present invention have a solids content of 1 to 60% by weight. All individual values ​​and partial ranges of 1 to 60% by weight are included and disclosed herein. For example, the solids content of the first polymer dispersion may be in the range of 1 to 60% by weight, or alternatively, 30 to 65% by weight, or alternatively, 25 to 60% by weight.

[0057] In some embodiments, the first polymer dispersion used in the present invention exhibits a pH of 8 or higher. All values ​​of 8 or higher are included and disclosed herein. For example, the pH of the dispersion may be 8 to 10, or in alternative examples, 8 to 11.

[0058] Formation of the first polymer dispersion In some embodiments, the first polymer dispersion can be prepared by an extrusion process, for example, as described in U.S. Patent No. 8,318,257, the disclosure of which is incorporated herein by reference.

[0059] Any melt-kneading means known in the art can be used. In some embodiments, a kneader, a Banbury mixer, a single-screw extruder, or a multi-screw extruder is used. The process for producing the dispersion according to the present invention is not particularly limited. One preferred process is, for example, a process comprising melt-kneading the above components according to U.S. Patent Nos. 5,756,659 and 6,455,636.

[0060] Figure 1 shows an exemplary schematic diagram of an extruder for producing an aqueous polymer dispersant, as used in the present invention. The extruder 30, such as a twin-screw extruder, may be connected to a control valve 32 to control the discharge pressure of the extruder. In some embodiments, the control valve 32 may be a V-ball control valve. In other embodiments, the control valve 32 may be a micronotch V-ball control valve. A neutralizing agent reservoir 34 and an initial dispersion medium reservoir 36, each including a pump (not shown), may also be provided. Desired amounts of the neutralizing agent and the initial dispersion medium, which is water as herein, are supplied from the neutralizing agent reservoir 34 and the initial water reservoir 36, respectively.

[0061] For example, a polymer resin(s) in the form of pellets, powder, or flakes may be supplied from the feeder 37 to the inlet 38 of the extruder 30. The dispersant is typically added to the extruder via and together with the resin, but may be supplied separately to the twin-screw extruder 30. The polymer and dispersant are then melted, mixed, and conveyed by the screw 40 in the mixing and conveying zone 42. Alternatively, the dispersant may be delivered in liquid form via any suitable liquid injector or pump.

[0062] Next, the molten resin is delivered from the mixture and conveying zone to the high internal emulsion formation zone 43 of the extruder (referred to herein as the "HIPE zone"). In the HIPE zone, initial amounts of water and neutralizing agent from reservoirs 34 and 36 are added via the inlet 44.

[0063] In the HIPE zone 43, the dispersed particle size is formed based on the distribution and dispersion mixing provided by the screw 40, which includes the interfacial chemistry of the mixture components, mass transfer of the neutralizing agent, and stress, strain, and passage frequency.

[0064] The emulsified mixture may be further diluted with additional water from reservoir 50 in the dilution zone 52 of the extruder 30 through one or more of the inlets 46, 47, and 48. Typically, the dispersion is diluted with at least 30 weight percent water in the dilution zone 52. In the dilution zone 52, the specific mass deviation of the dispersed particles and the viscosity of the mixture decrease. For example, the viscosity decreases to about 10 6 From about 10 2 The size can be reduced to centipoise ("cP").

[0065] The cooling zone 54 may be located towards the end of the screw 40, near the outlet of the extruder 30. Using the cooling zone 54, which provides heat exchange between the dispersion mixture and a cooling medium (not shown), the dispersion mixture can be cooled to a temperature below the boiling point of the dispersion medium. For example, if the dispersion medium is water, the dispersion mixture may be cooled to a temperature below about 100°C. The reduction in the temperature of the dispersion mixture may allow for further processing of the mixture without the undesirable loss of the dispersion medium due to evaporation.

[0066] Next, the cooled dispersion can exit the extruder 30 through outlet 56. Outlet 56 may be connected to control valve 32 as described above to maintain the discharge pressure control of the extruder.

[0067] With respect to the inside of the screw 40 and the extruder 30, one or more rotation-limiting orifices 58 may be located along the screw 40 in some embodiments. In addition to the control valve 32, the rotation-limiting orifices 58 can improve the stability of the dispersion formation process. In other embodiments, non-rotation-limiting orifices (not shown) may be used.

[0068] The screw 40 may also include a high-mixing disc 60 in some embodiments. In addition to the high-mixing disc 60 described above, embodiments of the extruder disclosed herein may also include a low-free-volume kneading disc 62 that can minimize the volume-weighted particle size distribution of the dispersion formed using the extruder 30.

[0069] In other embodiments of the extruder, the reverse element can be removed to prevent unwanted backmixing. Furthermore, in some embodiments, the melt seal may be located just upstream of the HIPE zone.

[0070] As shown in Figure 1, the HIPE zone 43 may have a variable length. Depending on the supply composition (polymer, dispersant, neutralizer, etc.), it may be desirable to have a longer or shorter HIPE zone. Multiple dispersion medium injection points 46, 47, 48 may be provided to extend or shorten the HIPE zone as needed. Since the particle size of the dispersed polymer particles is formed in the HIPE zone, an appropriate mixture must be provided to develop the desired particle size. Having a variable length for the HIPE zone allows for the processing of a wider range of polymers in a single extruder, which can provide process flexibility among various benefits.

[0071] The methods described above are generally used to form a first polymer dispersion in which the polymer component is one or more polyolefins. These embodiments, in which the polymer component is polyester, polyurethane, epoxy, cellulosin, acrylate (including methacrylate), and polystyrene, can be prepared using any method for forming polymer dispersions (including emulsions and suspensions) known in the art.

[0072] Second polymer component The coating composition of the present invention comprises a second polymer component comprising one or more second polymer emulsions, wherein the polymer contained in the second polymer emulsion is 26 mJ / m 2 It has the following surface free energy and volume-average particle size of 0.005 to 1,000 microns: 26 mJ / m 2 All of the following individual values ​​and subranges are included and disclosed herein, for example, the surface free energy of the polymer in the second polymer emulsion is 26, 24, 22, or 20 mJ / m². 2It can be in the range from the upper limit. For example, the surface free energy of the polymer in the second polymer emulsion is 10-26 mJ / m². 2 , or alternatively, 15-26 mJ / m 2 Alternatively, in a different example, 10-22 mJ / m³ 2 Alternatively, in a different example, 12-24 mJ / m³ 2 The range may be as follows: All individual values ​​and subranges from 0.005 to 1,000 microns are included and disclosed herein, for example, the volume-average particle size of solids in the second polymer emulsion may range from a lower limit of 0.005, 0.05, 0.5, 5, 50, or 500 microns to an upper limit of 1, 0.1, 1, 10, 100, or 1,000 microns. For example, the volume-average particle size of solids in the second polymer emulsion may range from 0.005 to 1,000 microns, or in an alternative example, from 0.1 to 500, or in an alternative example, from 0.1 to 10 microns.

[0073] The second polymer emulsion comprises a silicone compound, an emulsifier, and water. Any emulsifiable silicone polymer can be used in the second polymer emulsion. Such organopolysiloxanes are disclosed, for example, in US2013 / 0143989, US2013 / 0121949, US2013 / 0122204, US2017 / 0000722, US2014 / 0371317, and US2013 / 0338239, which are incorporated herein by reference. Additional organopolysiloxanes useful for airbag applications are disclosed in WO2001 / 012894 and WO2011 / 060238, which are incorporated herein by reference.

[0074] In certain embodiments, the organopolysiloxane contains at least two groups selected from the group consisting of silicon-bonded hydroxyl groups, silicon-bonded alkoxy groups, and silicone polyethers. The molecular structure of the organopolysiloxane can be linear, cyclic, branched, dendritic, or networked. The silicon-bonded group selected from the groups consisting of hydroxyl groups, alkoxy groups, and alkoxyalkoxy groups may be located at terminal positions on the molecular chain, side chain positions on the molecular chain, or both. The alkoxy group is preferably an alkoxy group having 1 to 10 carbon atoms, such as a methoxy group, ethoxy group, n-propoxy group, isopropoxy group, n-butoxy group, t-butoxy group, hexyloxy group, cyclohexyloxy group, octyloxy group, decyloxy group, etc., while the alkoxyalkoxy group is preferably an alkoxyalkoxy group having 2 to 10 carbon atoms, such as a methoxymethoxy group, methoxyethoxy group, ethoxymethoxy group, methoxypropoxy group, etc.

[0075] Unsubstituted monovalent hydrocarbyl groups and substituted monovalent hydrocarbyl groups are examples of silicon-bonded organic groups other than those selected from the group consisting of hydroxyl groups, alkoxy groups, and polyether groups. Unsubstituted monovalent hydrocarbyl groups can be exemplified by alkyl groups having 1 to 10 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, butyl, t-butyl, hexyl, octyl, and decyl groups; cycloalkyl groups having 3 to 10 carbon atoms, such as cyclopentyl and cyclohexyl groups; alkenyl groups having 2 to 10 carbon atoms, such as vinyl, allyl, 5-hexenyl, and 9-decenyl groups; aryl groups having 6 to 10 carbon atoms, such as phenyl, tolyl, and xylyl groups; and aralkyl groups having 7 to 10 carbon atoms, such as benzyl, methylbenzyl, and phenethyl groups. Alkyl groups, alkenyl groups, and aryl groups are preferred, and methyl and phenyl groups are particularly preferred.

[0076] In other embodiments, substituted monovalent hydrocarbyl groups can be exemplified by groups provided by substituting all or some of the hydrogen atoms in the aforementioned unsubstituted monovalent hydrocarbyl groups, particularly alkyl or phenyl groups having 1 to 10 carbon atoms, with halogen atoms such as fluorine and chlorine; epoxy functional groups such as glycidyloxy and epoxycyclohexyl groups; methacrylic functional groups such as methacryloxy groups; acrylic functional groups such as acryloxy groups; amino functional groups such as amino groups, aminoethylamino groups, phenylamino groups, and dibutylamino groups; sulfur-containing functional groups such as mercapto groups and tetrasulfide groups; or substituents such as alkoxy groups, hydroxycarbonyl groups, and alkoxycarbonyl groups. Additional amino functional groups useful in embodiments of the present invention are disclosed in US2014 / 0308229, which is incorporated herein by reference. Non-restrictive examples include -CH2CH2NH2, --CH2CH2CH2NH2, --CH2CH(CH3)NH2, --CH2CH2CH2CH2NH2, --CH2CH2CH2CH2CH2NH2, --CH2CH2CH2CH2CH2CH2NH2, --CH2CH2NHCH3, --CH2CH2CH2NHCH3, --CH2CH(CH3)CH2NHCH3, --CH2CH2CH2CH2NHCH3, --Includes CH2CH2NHCH2CH2NH2,--CH2CH2CH2NHCH2CH2NH2,--CH2CH2CH2NHCH2CH2CH2NH2,--CH2CH2CH2CH2NHCH2CH2CH2NH2,--CH2CH2NHCH2CH2NHCH2CH2NH2,--CH2CH2NHCH2CH2NHCH3,--CH2CH2CH2NHCH2CH2NHCH2CH2NHCH3,--CH2CH2CH2NHCH2CH2NHCH2CH2NH3, and--CH2CH2NHCH2CH2NHCH2CH2CH2CH2CH3,--CH2CH(CH3)CH2NHCH2CH2NH2, or CH2CH2CH2NHCH2CH2NH2.

[0077] Non-limiting examples of substituted monovalent hydrocarbyl groups include 3,3,3-trifluoropropyl, perfluorobutylethyl, perfluorooctylethyl, 3-chloropropyl, 3-glycidyloxypropyl, 2-(3,4-epoxycyclohexyl)ethyl, 5,6-epoxyhexyl, 9,10-epoxydecyl, 3-methacryloxypropyl, 3-acryloxypropyl, 11-methacryloxyundecyl, 3-aminopropyl, N-(2-aminoethyl)aminopropyl, 3-(N-phenylamino)propyl, 3-dibutylaminopropyl, 3-mercaptopropyl, 3-hydroxycarbonylpropyl, methoxypropyl, and ethoxypropyl.

[0078] The second polymer emulsion further contains an emulsifier. The emulsifier may be ionic, nonionic, or a combination thereof.

[0079] Non-limiting examples of anionic emulsifiers include alkylbenzene sulfons, alkyl ether sulfates, polyoxyethylene alkyl ether sulfates, polyoxyethylene alkylphenyl ether sulfates, alkyl naphthyl sulfons, unsaturated aliphatic sulfons, and hydroxylated aliphatic sulfons. Alkyl groups referenced herein can be exemplified by intermediate and higher alkyl groups such as decyl, undecyl, dodecyl, tridecyl, tetradecyl, cetyl, and stearyl groups. Unsaturated aliphatic groups can be exemplified by oleyl, nonenyl, and octinyl groups. Counterions can be exemplified by sodium, potassium, lithium, and ammonium ions, of which sodium is typically used.

[0080] Non-limiting examples of cationic emulsifiers include alkyltrimethylammonium salts, such as octadecyltrimethylammonium chloride and hexadecyltrimethylammonium chloride, and quaternary ammonium salt type surfactants, such as dioctadecyldimethylammonium chloride, dihexadecyldimethylammonium chloride, and didecyldimethylammonium chloride.

[0081] Non-exclusive examples of amphoteric emulsifiers include alkylbetaines and alkylimidazolines.

[0082] Non-limiting examples of nonionic emulsifiers may include glycerol fatty acid esters, sorbitan fatty acid esters, polyoxyalkylene alkyl ethers, polyoxyalkylene alkylphenyl ethers, polyoxyalkylene sorbitan fatty acid esters, polyoxyalkylene glycerol fatty acid esters, and polyoxyethylene-polyoxypropylene copolymer type nonionic emulsifiers. Alkyl groups referenced herein can be exemplified by higher alkyl groups such as decyl, undecyl, dodecyl, tridecyl, tetradecyl, cetyl, and stearyl groups. Fatty acids can be exemplified by intermediate and higher fatty acids such as lauric acid, palmitic acid, stearic acid, and oleic acid.

[0083] The second polymer emulsion further contains water. Any additional optional components of the second polymer emulsion may include fillers, crosslinking agents, flame retardants, thickeners, biocides, pH adjusters, salts, and adhesion promoters.

[0084] In some embodiments, the second polymer emulsion contains 1 to 98% by weight of silicone. All individual values ​​and partial ranges of 1 to 98% by weight are included and disclosed herein, and for example, the amount of silicone may range from a lower limit of 1, 10, 20, 30, 40, or 50% by weight to an upper limit of 40, 50, 60, 70, 80, 90, or 98% by weight. For example, the amount of silicone may range from 1 to 98% by weight, or in an alternative example, 50 to 98% by weight, or in an alternative example, 1 to 50% by weight, or in an alternative example, 40 to 90% by weight.

[0085] In some embodiments, one or more organopolysiloxane polymers have a weight-average molecular weight (Mw) of 1,000 to 1,000,000. All individual values ​​and subranges of 1,000 to 1,000,000 are included and disclosed herein, and for example, molecular weights may range from a lower limit of 1,000, 50,000, 100,000, or 500,000 (Daltons) to an upper limit of 150,000, 550,000, 750,000, or 1,000,000 (Daltons). For example, the Mw of an organopolysiloxane may range from 1,000 to 1,000,000, or in alternative examples, 1,000 to 500,000, or in alternative examples, 500,000 to 1,000,000.

[0086] In some embodiments, the second polymer emulsion has an internal phase viscosity of 50 to 30,000,000 cP. All individual values ​​and subranges of 50 to 30,000 cP are included and disclosed herein, for example, the internal phase viscosity may range from a lower limit of 50, 500, or 5,000 cP to an upper limit of 10,000, 20,000, or 30,000 cP.

[0087] In some embodiments, the second polymer emulsion has a volume-average particle size of 0.005 to 1,000 micrometers. All individual values ​​and subranges of 0.005 to 1,000 micrometers are included and disclosed herein, for example, the volume-average particle size of the second polymer emulsion may range from a lower limit of 0.005, 0.05, 0.5, 5, 50, or 100 micrometers to an upper limit of 5, 50, 500, or 1,000 micrometers. For example, the volume-average particle size of the second polymer emulsion may range from 0.005 to 1000, or alternatively 0.005 to 500, or alternatively 0.01 to 100, or alternatively 0.05 to 500 micrometers.

[0088] Emulsions can be formed by any means known in the art for mixing emulsion components, with or without shear. Mixing can be achieved by any method known in the art for bringing about the mixing of high-viscosity materials. Mixing may occur as a batch, semi-continuous, or continuous process. Mixing may occur using batch mixing equipment with medium / low shear, including, for example, change can mixers, double planetary mixers, conical screw mixers, ribbon blenders, double-arm or sigma-blade mixers; batch equipment with high shear and high-speed dispersers, including those manufactured by Charles Ross & Sons (New York) and Hockmeyer Equipment Corp. (New Jersey); batch mixing equipment such as those sold under the trade name Speedmixer.RTM; and batch equipment with high shear action, including the Banbury type (CW Brabender Instruments Inc., New Jersey) and the Henschel type (Henschel mixers America, Texas). Examples of continuous mixers / compounders include extruders, single-screw, twin-screw, and multi-screw extruders, co-rotating extruders, for example, those manufactured by Krupp Werner & Pfleiderer Corp (Ramsey, New Jersey) and Leistritz (New Jersey); twin-screw counter-rotating extruders, two-stage extruders, twin-rotor continuous mixers, dynamic or static mixers, or combinations of these devices.

[0089] Components of additional coating compositions Generally, a coating composition contains 50 to 99.9% by weight of a first polymer component, based on the total solids content of the coating composition. All individual values ​​and partial ranges of 50 to 99.9% by weight are included and disclosed herein, and for example, the amount of the first polymer component may range from a lower limit of 50, 60, 70, 80, or 90% by weight to an upper limit of 55, 65, 75, 85, 95, or 99.9% by weight. For example, the amount of the first polymer component in a coating composition may be 50 to 99.9% by weight, or in an alternative example, 50 to 75% by weight, or in an alternative example, 75 to 99.9% by weight, or in an alternative example, 65 to 95% by weight, based on the total solids content of the coating composition. A coating composition also contains 0.1 to 50% by weight of a second polymer emulsion, based on the total solids content of the coating composition. All individual values ​​and partial ranges from 0.1 to 50% by weight are incorporated and disclosed herein, for example, the amount of the second polymer emulsion may range from a lower limit of 0.1, 1, 10, 20, or 30% by weight to an upper limit of 5, 15, 25, 35, 45, or 50% by weight, based on the total solids content of the coating composition. For example, the amount of the second polymer emulsion may be 0.1 to 50% by weight, or in an alternative example 0.1 to 25% by weight, or in an alternative example 25 to 50% by weight, or in an alternative example 5 to 35% by weight, based on the total solids content of the coating composition.

[0090] The second polymer emulsion generally contains 1 to 60% by weight of solid components and 99 to 40% by weight of water. All individual values ​​and partial ranges of 1 to 60% by weight are included and disclosed herein, for example, the solids content in the second polymer emulsion may range from a lower limit of 1, 10, 20, or 30% by weight to an upper limit of 25, 35, 45, 55, or 60% by weight. All individual values ​​and partial ranges of 99 to 40% by weight are included and disclosed herein, for example, the amount of water in the second polymer emulsion may range from a lower limit of 40, 50, 60, or 70% by weight to an upper limit of 60, 70, 80, 90, or 99% by weight.

[0091] The coating composition further comprises one or more rheological modifiers and optionally one or more second neutralizing agents. Those skilled in the art will understand that the amounts of rheological modifiers and neutralizing agents can be adjusted to achieve a suitable viscosity for coating while maintaining a basic pH, so as to be appropriate for keeping the dispersion stable. The use and / or amount of rheological modifiers may further depend on other components of the coating composition. For example, fillers may be included in the coating composition, and such fillers may affect the amount of rheological modifiers required because they may affect the viscosity.

[0092] In one embodiment, the second neutralizing agent is 0 to 15 volume percent of the total volume of the coating composition. All individual values ​​and ranges in the 0 to 15 volume percent range are included and disclosed herein, and for example, the amount of the second neutralizing agent may range from a lower limit of 0, 3, 6, 9, or 12 volume percent to an upper limit of 4, 7, 10, 13, or 15 volume percent. For example, the amount of the second neutralizing agent may be 0 to 15 volume percent, or in an alternative example 5 to 15 volume percent, or in an alternative example 0 to 5 volume percent, or in an alternative example 2 to 10 volume percent. As previously stated in relation to dispersions, any neutralizing agent known in the art, including organic and / or inorganic bases, can be used as the second neutralizing agent.

[0093] Any rheological modifier known in the art can be used. In certain embodiments, the rheological modifier may be selected from the group consisting of carboxylic acid polymers, cellulosic compounds, crosslinked polyacrylate polymers, polyacrylamide polymers, polysaccharides, and gums. In one embodiment, the rheological modifier is selected from the ACRYSOL line of rheological modifiers (available from The Dow Chemical Company).

[0094] The coating composition may further contain one or more additives selected from the group consisting of flame retardants, antiblocking agents, solvents, stabilizers, and pigments. Any additive known in the art may be used. Exemplary flame retardants include phosphonate esters, phosphate esters, halogenated phosphonate esters, or combinations thereof. Other flame retardants such as zeolites, hydrated phosphates, alkali silicates, borates, borosilicates, melamine, graphite, graphene, mica, vermiculite, alumina, aluminum hydroxide, perlite, antimony trioxide, polyphosphates, and melamine may also be used.

[0095] Halogen-free flame retardants such as diethylethanephosphonate (DEEP), triethyl phosphate (TEP), dimethylpropyl phosphate (DMPP), and diphenylklay phosphate (DCP) can also be used.

[0096] Formation of coating composition and application of coating The coating composition components can be blended using any known method. The viscosity and pH of the coating composition can be adjusted as needed. Alternatively, the viscosity can be adjusted after delivery to the end user so that it may be suitable for the selected coating method.

[0097] The coating composition can be applied to any woven or nonwoven fabric. Non-limiting examples of suitable fabrics include those made from synthetic or natural fibers such as polyester, polyimide, polyethylene, polypropylene, polyester-cotton blends, glass fibers, and polyamides. In certain embodiments, the fabric is polyester and / or nylon 66.

[0098] The coating composition can be applied to the fabric according to known techniques. Such techniques include knife coating, roll coating, dip coating, flow coating, squeeze coating, and spray coating. Knife coating methods include knife-over-air, knife-over-roll, knife-over-form, and knife-over-gaptable methods. Roll coating methods include single-roll, double-roll, multi-roll, reverse-roll, gravure-roll, and transfer-roll coating methods. In certain embodiments, the coating composition is applied by knife-over-air or knife-over-roll coating methods.

[0099] The coating composition can be applied to the fabric with a pre-curing coat weight of 20-150 g / m². 2 All individual values ​​and sub-ranges are included and disclosed herein. For example, pre-curing coat weights may be 20, 40, 60, 80, 100, 120, or 150 g / m². 2 From the lower limit, 50, 70, 90, 110, 130, or 150 g / m² 2 It can be within the upper limit range. For example, the wet coating weight may be 20-150, or alternatively 50-150, or alternatively 70-120 g / m². 2 It could be within the range.

[0100] The viscosity of the coating composition can be adjusted according to the desired coating technique. In one embodiment, the viscosity of the coating composition is adjusted to 1000-4000 cP. All individual values ​​and subranges of 1000-4000 cP are included herein, and for example, the viscosity can be adjusted to a range having a lower limit of 1000, 1500, 2000, 2500, or 3000 cP and an upper limit of 2250, 2750, 3250, or 4000 cP. For example, the viscosity of the coating composition can be adjusted to a range of 1000-4000 cP, or in an alternative example, 1000-3000 cP, or in an alternative example, 2000-4000 cP, or in an alternative example, 1750-3750 cP.

[0101] After application of the coating composition, the coating is cured by removing water from the coating composition and melting the polymer components of the coating composition to form a polymer film. In certain embodiments, the coated cloth is cured by ambient exposure to 190°C for 5 minutes, or in alternative examples, for a time sufficient to remove water. In other embodiments, the coating is cured by ambient exposure to a rising temperature lamp in the range of approximately 24°C to 200°C. All individual values ​​and partial ranges of 24°C to 200°C are included and disclosed herein. For example, the temperature lamp may be in the range of 24 to 200°C, or in alternative examples, 30 to 155°C, or in alternative examples, 27 to 160°C. The 24°C to 200°C limit is merely illustrative and not restrictive, as the upper limit depends on the melting point of the solid components of the dispersion. The temperature lamp may be continuous or discontinuous; that is, the temperature change may be stepwise, or the temperature may change discontinuously in different zones. Furthermore, those skilled in the art will readily understand that the temperature required to displace water or dissolve polymer dispersion components is affected by pressure. For example, under sufficiently low pressure, water can be removed without raising the temperature above ambient temperature.

[0102] After water removal and coating film formation, the coating weight is 20-50 g / m². 2It can be in the range of 20-50 g / m². 2 All individual values ​​and sub-ranges are included and disclosed herein. For example, the cured coat weight may be 20, 22, 24, 26, 28, 30, or 32 g / m². 2 From the lower limit: 27, 29, 31, 33, 40, or 50 g / m² 2 It may be within the upper limit. For example, the cured coating weight may be 20-50, or alternatively 21-28, or alternatively 20-33, or alternatively 28-34 g / m². 2 It could be within the range.

[0103] During the curing process, the first polymer dispersion and the second polymer emulsion exhibit self-stratification, with the second polymer emulsion selectively migrating to the surface of the applied coating. As a result, the portion of the cured coating closest to the fabric contains primarily hydrocarbons, while the portion of the cured coating closest to the surface contains a higher silicone content than the portion of the cured coating closer to the fabric.

[0104] In one embodiment, the outer surface (the surface furthest from the fabric) contains 10–25 atomic percent of silicon. All individual values ​​and subranges of 10–25 atomic percent are included and disclosed herein. For example, the atomic percent of silicon on the surface may range from the lower limit of 10, 12, 14, or 16 to the upper limit of 14, 18, 22, or 25. For example, the amount of silicon on the coating surface may range from 10–25 atomic percent, or in an alternative example, 12–20 atomic percent, or in an alternative example, 14–19 atomic percent, or in an alternative example, 15–25 atomic percent.

[0105] In some embodiments, the amount of silicon at a depth of 40 nm from the cured coating surface may be in the range of 0 to 5 atomic percent. All individual values ​​and subranges of 0 to 5 atomic percent are included and disclosed herein. For example, the amount of silicon at a depth of 40 nm from the cured coating surface may range from a lower limit of 0, 0.3, 0.5, or 1 atomic percent to an upper limit of 0.5, 0.8, 2, or 5 atomic percent. For example, the amount of silicon in the cured coating at a depth of 40 nm from the coating surface may be in the range of 0 to 5 atomic percent, or alternatively 0.2 to 3 atomic percent, or alternatively 0 to 2 atomic percent, or alternatively 0.5 to 1.5 atomic percent, or alternatively 1 to 5 atomic percent. As shown in the data in Table VIIIA, the atomic percentage of silicon gradually decreases as the distance (depth) from the coating surface increases.

[0106] After curing, one or more additional coatings may optionally be applied to the coated cloth. Such additional coatings may include those known in the art for improving or imparting properties such as reducing the coefficient of friction, increasing blocking resistance, or increasing scrubbing resistance. In one embodiment, an additional coating comprising a polyorganosiloxane and / or polymer silicone material is added to the coated cloth of the present invention.

[0107] End-use and characteristics The coating compositions of the present invention can be used, for example, in applications requiring the retention of air and / or other gas pressures. Non-limiting examples of such applications include vehicle airbags and aircraft emergency chutes.

[0108] The cured coated fabric of the present invention exhibits pressure retention of 95% or more of an applied pressure of 200 kPa for a period of 15 seconds or more. All individual values ​​of 95% or more and 15 seconds or more are incorporated herein. For example, the coated fabric can retain 95%, 96%, 97%, 98%, or 99% or more of an applied pressure of 200 kPa for a period of at least 15, 20, 25, 30, or 45 seconds. Based on the pressure retention values, it is clear that the coated fabric exhibits a pressure drop of 5% or less at an applied pressure of 200 kPa for a period of at least 15 seconds. All individual values ​​of 5% or less and 15 seconds or more are incorporated herein. For example, the coated fabric may have a pressure drop of 5%, 4%, 3%, 2%, or 1% or less of an applied pressure of 200 kPa for a period of at least 15, 20, 25, 30, or 45 seconds.

[0109] In one embodiment, the cured coated fabric exhibits a static friction coefficient (COF) of 1 or less. All individual values ​​and subranges of 1 or less are included and disclosed herein, for example, the static friction coefficient may range from the upper limits of 1, 0.9, 0.7, 0.5, or 0.3. For example, the static friction coefficient may range from 2.0 to 0.92, or in an alternative example from 2.0 to 0.5, or in an alternative example from 2.0 to 0.4, or in an alternative example from 2.0 to 1.

[0110] In one embodiment, the cured coated fabric exhibits a dynamic coefficient of friction (COF) of 1 or less. All individual values ​​and subranges of 1 or less are included and disclosed herein, for example, the static coefficient of friction may be from the upper limit of 1, 0.9, 0.7, 0.5, or 0.3. For example, the static coefficient of friction may be in the range of 0.1 to 0.8, or in an alternative example 0.1 to 0.5, or in an alternative example 0.1 to 0.4, or in an alternative example 0.1 to 0.6.

[0111] In one embodiment, the cured coated fabric exhibits a scrub resistance to 40 or more scrubs. All individual values ​​and subranges of 40 or more scrubs are included and disclosed herein, for example, the scrub resistance may be in the lower limit range of 40, 50, 60, or 80 scrubs. For example, the scrub resistance may be in the range of 40 to 500, or in an alternative example, 40 to 400, or in an alternative example, 50 to 350 scrubs.

[0112] In one embodiment, the present invention provides a coated fabric comprising a woven or nonwoven fabric substrate and a coating derived from the coating composition of the present invention. In another embodiment, the present invention provides an article comprising a coated fabric. Non-limiting examples of such articles include airbags and emergency chutes for use in automobiles.

[0113] Airbags are generally formed from woven or knitted fabrics made of synthetic fibers such as polyamide (e.g., nylon-6,6) or polyester, with at least one of their sides coated. Airbags can be made from flat pieces of fabric that are coated and then sewn together to provide sufficient mechanical strength, or they can be woven together in a single piece with a single woven seam. Sewn airbags are usually assembled with the coated fabric surface facing inward. In a single woven fabric airbag, the outside of the airbag is coated. The present invention provides any airbag comprising the coated fabric of the present invention. In one embodiment, the present invention provides a side impact airbag. In another embodiment, the present invention provides a driver's or passenger's side front airbag.

[0114] As used herein, the term “remains deployed” means retaining at least 50% of the initial deployment pressure of the airbag. [Examples]

[0115] The following examples illustrate the present invention, but are not intended to limit its scope.

[0116] Examples of dispersions Dispersions 1 and 2 were prepared according to the following process. The dispersions were prepared using a 25 mm BERSTORFF with 12 zones. The polyolefin resin was delivered to the system as pellets via a large Schenk feeder dropping into the feedthroat. The compatibilizer was delivered using a KQX K-tron feeder dropping into the feedthroat. The dispersant was delivered to the system as a liquid via a 1000D ISCO syringe pump through an injector located in zone 5A, or as a solid delivered using a KQX K-tron feeder dropping into the feedthroat. Initial water was delivered via a 500D ISCO pump through an injector located in zone 4B. Base was added to provide 100–140% neutralization and delivered along with the initial water via a 500D ISCO pump piped through it. Base was also added through zone 4B. Finally, dilution water was delivered via a large Hydracell pump through an injector located in zone 8A. Table I lists the specific components of each dispersion 1 and 2, as well as the weight % solids and volume-average particle size of each dispersion. Table II provides information regarding the components of the dispersion and coating compositions. [Table 1] [Table 2]

[0117] Ammonium hydroxide (NH4OH), dimethylethanolamine (DMEA), oleic acid, and KOH (30% in H2O) were provided by Fisher Scientific.

[0118] Coating compositions 1-8 and comparative coating compositions A-D of the present invention The coating composition was prepared by adding 20 g of dispersion to a speed mixer cup. Emulsion was added in 0, 2, or 5% by weight. 28% of 0.08 g of NH4OH (ammonium hydroxide) in water was added and mixed at 2000 rpm for 30 seconds. 0.15 g of ACRYSOL ASE-60 (acrylic emulsion copolymer) was added and mixed at 2000 rpm for 30 seconds. The formulation was allowed to stand for 30 minutes before coating. Table III provides compositional information for the coating composition of the present invention, and Table IV provides compositional information for a comparative coating composition. [Table 3] [Table 4]

[0119] Preparation of coated fabric Laboratory-scale sample: A small sample of airbag fabric, composed of Hyosung 470 Dtex polyester yarn woven into cloth by Global Safety Textiles, was cut into a 5-inch x 5-inch square. The sample was pressed onto a flat glass clipboard. 3 mL of the coating composition was pipettered evenly over the entire top surface of the fabric. The coating was spread using a Gardco size 28 wire circular pull rod, targeting a wet film thickness of 66.7 microns. The sample was then placed in a 150°C oven for 3 minutes. Upon drying, the coat weight was measured by comparing the weight of an uncoated fabric sample with the weight of a coated fabric of the same size. [Table 5] [Table 6] [Table 7]

[0120] The coating of a specific example of a coated cloth of the present invention was analyzed by X-ray photoelectron spectroscopy using the conditions described below. As seen in Tables VIII and IX, the coating composition of the present invention self-stratifies to form a coating, with the silicone component mainly located near the surface of the cured coating. To determine the thickness of the coating, the sample was also measured by XPS after sputtering. Furthermore, sputtering time versus thickness was determined by calibrating the sputtering rate. After 3 hours of sputtering, a 7 μm crater was measured using a line scan with a stylus profilometer. This corresponds to a sputtering rate of approximately 40 nm / min. This indicated a potential thickness of 40 nm, as the silicon signal was observed to be higher than the bulk at up to 60 seconds. [Table 8] [Table 9] [Table 10]

[0121] Test method The test method includes the following: The average particle size was measured using a Beckman Coulter LS230 particle size analyzer equipped with a small-volume module used as a sample delivery system. The software version used was version 3.29. Hardware and software are available from Beckman Coulter Inc. in Miami, Florida.

[0122] All measurement analysis conditions utilize a fluid refractive index of 1.332, a sample real refractive index of 1.5, and a sample imaginary refractive index of 0.0. Extended optical models are not used. Polarization intensity differential scattering (PIDS) option is activated and used to generate particle size information. Average particle size is measured and reported in μm.

[0123] Polymer density is measured according to ASTM D792.

[0124] The melt index (I2) of ethylene polymers is measured according to ASTM D-1238-04, 190°C / 2.16 kg. The melt index (I5) of ethylene polymers is measured according to ASTM D-1238-04, 190°C / 5.0 kg. 10 The melt index (I) of the ethylene polymer is measured according to ASTM D-1238-04, 190°C / 10.0kg. 21 The following conditions are met: ) are measured according to ASTM D-1238-04, 190°C / 21.0kg. For propylene polymers, the melt flow rate (MFR) is measured according to ASTM D-1238-04, 230°C / 2.16kg.

[0125] The polymer molecular weight was determined by gel permeation chromatography (GPC) as follows. The chromatography system used was Polymer Laboratories Model PL-210. The column and carousel compartment were operated at 145°C. Four Polymer Laboratories 20-um Mixed-A LS columns were used with 1,2,4-trichlorobenzene (TCB) solvent. Samples were prepared at a concentration of 0.1 g of polymer in 50 mL of solvent. The solvent contained 200 ppm of the antioxidant, butylated hydroxytoluene (BHT). Samples were prepared by gently stirring at 160°C for 1-2 hours. The injection volume was 200 microliters, and the flow rate was 1.0 mL / min. Calibration of the GPC column set was performed using polystyrene standards with a narrow molecular weight distribution purchased from Varian Inc. (previously Polymer Laboratories). The standard peak molecular weight of polystyrene is given by Williams, T. and IMWard, "The Construction of Polyethylene Calibration Curve for Gel Permeation Chromatography Using Polystyrene Fractions," J.Polym.Sci.Polym.Lett.6, 631 (1968):M ポリエチレン =0.431(M ポリスチレン The molecular weight was converted to polyethylene using ).

[0126] Polyethylene equivalent molecular weight calculations will be performed using Viscotek TriSEC software version 3.0.

[0127] The pH of the dispersion / emulsion is measured using a Denver Instruments / Sartorius handheld pH meter.

[0128] Viscosity was measured at 20 rpm using a Brookfield viscometer.

[0129] Unless otherwise specified, the acid value is calculated as the mass of milligrams of potassium hydroxide (KOH) required to neutralize one gram of the component.

[0130] Flammability was measured according to ISO 3795 and scored based on EASC standard 9904 0180.

[0131] Pressure holding was tested using variations of ASTM d737 and ISO 9237, where only the pressure drop is measured. This system involves the use of a 10L pressure tank capable of being filled to a target pressure of 200kPa. A 4-inch x 4-inch sample is cut from a coated cloth sample and positioned on the opposite side of the pressurized tank. The sample is placed on a 3.75-inch diameter gasket used to create a seal that prevents air leakage between the cloth and the metal plate. A second metal plate is placed on top of the lower platen and the system is tightened. The jig is pressurized with 200kPa ± 10kPa of air directed towards the uncoated side of the coated cloth. The pressure drop was monitored during a 30-second test period, with the coated cloth sample as the sole leak point. The value at the end of the test period was recorded and compared to the starting pressure. A Swagelok CF-3M valve was opened to allow pressure to be applied to the coated cloth, and the pressure was recorded using a ROSEMOUNT® 3051 pressure transmitter with the HART® protocol. Pressure information is captured via the LabVIEW software.

[0132] The cured coat weight was measured by comparing it to the weight of a coated cloth of the same size as an uncoated cloth sample. The wet coat weight can be measured using the same method, or by spectroscopic or optical interference techniques, such as Specmetrix's robust optical interference (ROI) instrument.

[0133] The static and dynamic coefficients of friction (COF) were measured according to ISO 8295.

[0134] The adhesion of rubber to fabric was tested for coated materials using a scrub test based on ISO 5981. According to this test, coated fabric samples were repeatedly bent under a specified force using a scrub tester conforming to ISO 5981. The surface of the coated fabric was inspected after the specified number of scrubs for signs of delamination, such as peeling or pinholes. Failures were determined by evidence of pinholes seen through the coating when observed under a lightbox. The number of scrubs before failure was reported for each sample. A higher number indicated better adhesion of the silicone to the substrate.

[0135] X-ray photoelectron spectroscopy (XPS) was performed under the following conditions:

[0136] Surface XPS: Data was collected using the PHI VersaProbe II microprobe XPS instrument. Pass energy: 23.5 eV Step energy: 0.1 eV / step A sufficient number of scans were collected to provide a adequate signal-to-noise ratio.

[0137] GCIB depth profile: Pass energy 23.5 eV Sputter cycle time: 30 seconds x 10 cycles, 60 seconds x 25 cycles Sputtering conditions: Ar at 20kV 2500 + The target current is set to 20 nanoamperes (nA) for a 2x2 mm raster. The results will be reported as atomic percentages.

[0138] To calibrate the thickness of the silicone coating, the sample was subjected to a 10kV Ar beam current of 20 nanoamperes. 2500 + The material was sputtered with an ion beam and rasterized over a 2x2 mm area. After sputtering, the craters were measured using a line scan with a stylus profilometer.

[0139] The surface free energy of polymers is measured according to the method described in "Estimation of the Surface Free Energy of Polymers," Journal of applied polymer science, vol. 13, p. 1741 (1969), which calculates the surface energy from the contact angles with water and methyl iodide.

[0140] The present invention can be implemented in other forms without departing from its spirit and essential attributes, and therefore, the appended claims, rather than the foregoing specification, should be used to illustrate the scope of the invention.

Claims

1. A coating composition, (1) A first polymer component comprising a first polymer dispersion, wherein the first polymer contained in the first polymer dispersion has a concentration of 28 mJ / m ２ A first polymer component having the above surface free energy and a volume-average particle size of 0.1 to 10 microns, (2) A second polymer component comprising one or more second polymer emulsions, wherein the second polymer contained in the second polymer emulsion is 26 mJ / m ２ A second polymer component having the following surface free energy and volume-average particle size of 0.005 to 1,000 microns, (3) The coating composition comprises one or more rheological modifiers in an amount sufficient to have a viscosity of 100 to 2000 cP, (4) Optionally, a sufficient amount of base to maintain the basic pH of the coating composition, Includes, The first polymer component is present in such an amount that the solid matter in the first polymer component accounts for 96.9 to 99.9% by weight of the total solids of the coating composition. A coating composition in which the second polymer component is present in an amount such that the solid matter in the second polymer component is 0.1 to 3.1% by weight of the total solids of the coating composition.

2. The coating composition according to claim 1, wherein the first polymer component comprises a dispersion of 90 to 99% by weight of one or more polyurethanes and 0.2 to 2% by weight of an acrylic rheology modifier, based on the total solid weight of the first polymer dispersion.

3. The coating composition according to claim 1, wherein the second polymer component comprises an organopolysiloxane emulsion comprising one or more organopolysiloxane polymers as the second polymer having a weight-average molecular weight of 1,000 to 1,000,000, one or more surfactants, and water, wherein the organopolysiloxane emulsion comprises 1 to 98% by weight of organopolysiloxane polymers (or more) having an internal phase viscosity of 50 to 30,000,000 cP and a volume-average particle size of 0.005 to 1,000 microns.

4. The coating composition according to claim 1, wherein the second polymer has a volume-average particle size of 0.01 to 100 micrometers.

5. The coating composition according to claim 1, wherein the second polymer comprises a functionalized organopolysiloxane having one or more functional groups selected from the group consisting of amino, hydroxyl, acrylate, alkoxy, alkyl, aryl, carboxy, polyether, and epoxy functional groups.

6. The coating composition according to claim 3, wherein the organopolysiloxane emulsion has a pH of 4 to 9.

7. The coating composition according to claim 3, wherein the organopolysiloxane emulsion comprises 40 to 90% by weight of the organopolysiloxane polymer.

8. A coated fabric for use in airbags, (1) Woven fabric or nonwoven fabric base material, (2) A coating derived from the coating composition described in any one of claims 1 to 7, wherein the amount is 20 to 50 g / m². ２ A coating, which is applied to at least one surface of a substrate with a total coating weight, includes, The coating self-stratifies during drying such that the surface of the cured coating contains 10 to 25 atomic percent of silicon, and the surface of the cured coating contains 0 to 5 atomic percent of silicon at a depth of 40 nm from the surface of the cured coating. The coated cloth, as tested using ASTM d737 and ISO 9237, maintains a pressure of 95% or more of an applied pressure of 200 kPa for a period of 15 seconds or more.

9. An airbag comprising a coated cloth as described in claim 8.

10. A method for preparing a coated cloth, To provide a woven or nonwoven fabric base material, A wet-coated substrate is produced by applying the coating composition according to any one of claims 1 to 7 to at least one surface of the substrate by one or more coating methods selected from the group consisting of knife coating, roll coating, dip coating, flow coating, squeeze coating, and spray coating. The wet-coated substrate is dried to a density of 20-50 g / m². ２ A method comprising producing a coated cloth having a coating weight and being tested using ASTM d737 and ISO 9237 to maintain a pressure of 95% or more of an applied pressure of 200 kPa for a period of 15 seconds or more.

11. Use of the coating composition according to any one of claims 1 to 7 as a coating for airbags.

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