Abstract:
A fused composition and a vinyl composition tile made from the fused composition have less PVC/PVAc copolymer than typical VCT. The fused composition consists essentially of binder, filler and optional pigment, wherein the binder consists essentially of PVC homopolymer, acrylic polymer, plasticizer and stabilizer. The binder includes a reduced amount of PVC/PVAc or may be free of PVC/PVAc. The composition is highly filled, having at least 77% by weight of filler and pigment. Polyvinyl butryal may replace some of the homopolymer and plasticizer. Post consumer or post industrial filler or binder may be used.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to a fused composition and a vinyl composition tile (“VCT”) consisting essentially of the fused composition, wherein the fused composition has less polyvinyl chloride/polyvinyl acetate copolymer than typical VCT. The fused composition consists essentially of binder, filler and optional pigment, wherein the binder consists essentially of polyvinyl chloride homopolymer (“PVC”), acrylic polymer, plasticizer and stabilizer,  
         [0002]     In some embodiments, the binder includes a reduced amount of polyvinyl chloride/polyvinyl acetate copolymer (“PVC/PVAc”). In other embodiments, the binder is has no or substantially no PVC/PVAc, in which case the binder is free or substantially free of PVC/PVAc. The filler and pigment comprises at least 77% by weight of the composition.  
         [0003]     In some embodiments, polyvinyl butryal (“PVB”) replaces some of the homopolymer and plasticizer. Therefore, in those embodiments the amount of PVC in the form of homopolymer and copolymer is further reduced.  
       SUMMARY OF THE INVENTION  
       [0004]     An object of the invention is to provide a fused composition having no or substantially no PVC/PVAc, or reduced amounts of PVC/PVAc.  
         [0005]     Another object of the invention is to provide a VCT comprising a fused composition having no or substantially no PVC/PVAc, or reduced amounts of PVC/PVAc.  
         [0006]     An additional object of the invention is to provide a fused composition and VCT comprising the composition having no or reduced amounts of PVC/PVAc in which polyvinyl butryal (“PVB”) replaces some of the PVC and plasticizer.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0007]     The present inventors have used acrylic esters (“acrylates”) to replace polyvinyl chloride/polyvinyl acetate copolymer in vinyl composition tile at the bench level and in scale-up tests. Modified VCT having no or substantially no PVC/PVAc was successfully made. The balance of the binder consisted of PVC homopolymer resin, phthalate or other plasticizers, and stabilizers. Other additives included tackifier resins, such as hydrocarbon resin and alpha-methyl styrene resin, acrylic impact modifiers, polymeric fillers, and post consumer or post industrial fillers or binders. Plant testing confirmed the viability of the formula to produce floor tile with properties equivalent to those using PVC/PVAc copolymer resin in the formula and is in commercial production.  
         [0008]     In some embodiments, the filler level was at least 84 weight percent of the total composition. The filler level can be up to 90 weight percent or higher. The formulations generally contained from 0.2% to 4.0% acrylic by weight and the binder level generally ranged from 12% to 20% by weight.  
         [0009]     Formulations having from about 0.4% to about 2.5% by weight of acrylic; from about 8% to about 14% by weight of homopolymer; about from 3.5% to about 6% by weight of plasticizer; about 2% of stabilizer based on the PVC used; and from about 84 to about 90% by weight of filler have produced sheets of modified VCT. In some embodiments the product was about 0.8% to about 1.2% by weight of acrylic; about 8% to about 11% by weight of homopolymer; about 4% to about 5% by weight of plasticizer; and about 84% to about 86% by weight of filler.  
         [0010]     In general, there was less acrylic used than in typical VCT which included acrylic in the form of PVC/PVAc copolymer. The homopolymer level was generally increased. Plasticizer level was slightly reduced. Stabilizer level was reduced because the overall vinyl level was reduced. The filler level was generally increased.  
         [0011]     Polyvinyl butryal (PVB) was also used to replace some of the homopolymer and plasticizer. The PVB used in some of the formulations was post industrial and included a stabilizer which also replaced the mixed metal stabilizer.  
         [0012]     The acrylic polymers may be methyl, ethyl, or butyl esters or copolymers thereof. The filler is typically calcium or magnesium carbonate, such as limestone. The stabilizer is typically a mixed metal stabilizer such as a calcium/zinc composition. The plasticizer blend is typically a mixture of phthalate esters and other plasticizers. The pigments can include titanium dioxide, iron oxides, phthalocyanine blue, phthalocyanine green, azo red, benzidene yellow, and carbon black.  
         [0013]     Standard VCT processing equipment and conditions can be used to fuse the non- or reduced PVC/PVAc resin. For example, the materials listed above were charged into a steam-jacketed, low shear mixer (Baker-Perkins) and mixed to a temperature of 285° F. to 300° F. The mixed material was placed on a two roll mill and calendered into a continuous web (blanket) about ⅛″ thick.  
         [0014]     The materials then may be cut or broken into small chips for further processing, or covered with decorative chips or polymeric wear layers to create a finished floor tile. The mixed materials may be blended with decorative chips before calendaring to create a more decorative effect (jaspe&#39; sheet) before being cut or broken. The chips are then reheated and reconsolidated into a continuous blanket and further calendered to a finished thickness of from 0.020″ to 0.200″. The blanket is heat treated to develop physical properties, cooled, polished, and cut to final dimension before packaging.  
         [0015]     The composition can also be used to form the base for a printed tile or used in a sheet floor.  
         [0016]     High intensity mixers may be used instead of the low shear mixers. This gives more flexibility in the formulation, allowing the process to run faster and hotter.  
         [0017]     The following tables list the formulas used to make the copolymer replacement compositions of the present invention and the results of the evaluation of the compositions.  
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               Formulas for Copolymer Replacement                                    Example No.            Component (by wt)   Comparative   1   2   3   4   5   6   7   8   9               PVC homopolymer   84.2   84.2   124.0   108.0   108.0   108.0   115.8   108.0   115.8   115.8       PVC/PVAc copolymer   52.6   44.6   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   12.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   12.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   0.0   8.0   14.0   21.0   12.0   12.0   21.0   21.0   21.0   21.0       Butylbenzyl phthalate/   44.2   41.5   44.2   44.2   44.2   44.2   44.2   44.2   44.2   44.2       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   11.0   10.4   11.0   11.0   11.0   11.0   11.0   11.0   11.0   11.0       Limestone   998.0   1001.5   997.1   1006.4   1003.4   1003.4   998.3   1006.4   998.5   998.5       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.8   2.6   2.5   2.2   2.2   2.2   2.5   2.2   2.3   2.3       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   16.2   15.9   16.3   15.5   15.8   15.8   16.2   15.5   16.2   16.2       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   10   11   12   13   14   15   16   17   18   19               PVC homopolymer   115.8   106.0   111.0   113.2   108.2   115.8   119.8   119.8   121.0   122.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       15.0   15.0       Hydrocarbon resin   0.0   0.0   0.0   0.0   5.0   5.0   5.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   5.0   5.0   5.0       Acrylic process aid   21.0   15.0   10.0   21.0   21.0   14.0   10.0   10.0   14.0   14.0       Butylbenzyl phthalate/   44.2   44.2   44.2   40.0   40.0   40.0   40.0   40.0   40.0   40.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   11.0   11.0   11.0   10.0   10.0   10.0   10.0   10.0   10.0   10.0       Limestone   998.5   999.5   999.5   1006.2   1006.2   1005.6   1005.6   1005.6   1000.4   999.4       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.3   2.1   2.1   2.4   2.4   2.4   2.4   2.4   2.4   2.4       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   16.2   16.1   16.1   15.6   15.6   15.6   15.6   15.6   16.0   16.1       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   20   21   22   23   24   25   26   27   28   29               PVC homopolymer   121.0   122.0   122.0   122.0   122.0   122.0   129.0   132.0   118.0   125.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   5.0   5.0   5.0   0.0   5.0   5.0   5.0   5.0   5.0       Alpha-methyl styrene resin   10.0   0.0   0.0   0.0   5.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   10.0   14.0   14.0   14.0   14.0   14.0   7.0   4.0   14.0   7.0       Butylbenzyl phthalate/   40.0   40.0   40.0   40.0   40.0   40.0   40.0   40.0   40.0   40.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   10.0   10.0   10.0   10.0   10.0   10.0   10.0   10.0   10.0   10.0       Limestone   999.4   999.4   999.4   999.4   999.4   999.4   999.4   999.4   1003.4   1003.4       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.4   2.4   2.4   2.4   2.4   2.4   2.4   2.4   2.4   2.4       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   16.1   16.1   16.1   16.1   16.1   16.1   16.1   16.1   15.8   15.8       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   30   31   32   33   34   35   36   37   38   39               PVC homopolymer   128.0   80.0   86.0   88.0   79.0   83.0   85.0   119.0   115.0   106.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   5.0   3.3   3.3   3.3   3.3   3.3   3.3   4.0   4.0   4.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   4.0   9.3   4.7   2.7   9.3   4.7   2.7   7.0   7.0   14.0       Butylbenzyl phthalate/   40.0   26.7   26.7   26.7   26.7   26.7   26.7   36.0   35.2   32.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   10.0   6.7   6.7   6.7   6.7   6.7   6.7   9.0   8.8   8.0       Limestone   1003.4   667.4   666.0   666.0   668.4   669.0   669.0   1015.4   1020.5   1026.8       Titanium dioxide pigment   7.2   4.8   4.8   4.8   4.8   4.8   4.8   7.2   7.2   7.2       VCT scrap   0.0   400.0   400.0   400.0   400.0   400.0   400.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.4   1.8   1.8   1.8   1.8   1.8   1.8   2.4   2.3   2.0       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   15.8   16.6   16.2   16.2   16.2   15.8   15.8   14.8   14.4   13.8       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   40   41   42   43   44   45   46   47   48   49               PVC homopolymer   100.0   42.0   79.3   76.7   70.7   66.7   28.0   121.0   121.0   128.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   4.0   4.0   2.7   2.7   2.7   2.7   2.7   2.5   1.2   5.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   14.0   42.0   4.7   4.7   9.3   9.3   28.0   14.0   14.0   7.0       Butylbenzyl phthalate/   28.8   16.0   24.0   23.5   21.3   19.2   13.3   40.0   40.0   41.6       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   7.2   4.0   6.0   5.9   5.3   4.8   3.3   10.0   10.0   10.4       Limestone   1036.8   1083.8   676.9   680.2   684.5   693.1   724.1   1002.9   1004.2   998.3       Titanium dioxide pigment   7.2   7.2   4.8   4.8   4.8   4.8   4.8   7.2   7.2   7.2       VCT scrap   0.0   0.0   400.0   400.0   400.0   400.0   400.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.0   1.0   1.6   1.5   1.4   1.6   0.6   2.4   2.4   2.5       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   13.0   9.1   14.8   14.4   13.8   12.8   8.9   15.8   15.7   16.2       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   50   51   52   53   54   55   56   57   58   59               PVC homopolymer   128.0   128.0   128.0   130.0   130.0   126.0   121.0   126.0   121.0   126.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   3.5   2.5   1.2   3.0   0.0   0.0   5.0   0.0   5.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   7.0   7.0   7.0   6.0   9.0   14.0   14.0   14.0   14.0   14.0       Butylbenzyl phthalate/   41.6   41.6   41.6   41.6   41.6   40.0   40.0   40.0   40.0   40.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   10.4   10.4   10.4   10.4   10.4   10.0   10.0   10.0   10.0   10.0       Limestone   999.8   1000.8   1002.1   999.2   999.2   1000.3   1000.4   1000.3   1000.4   1000.3       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.5   2.5   2.5   2.6   2.6   2.5   2.4   2.5   2.4   2.5       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   16.1   16.0   15.9   16.1   16.1   16.0   16.0   16.0   16.0   16.0       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   60   61   62   63   64   65   66   67   68   69               PVC homopolymer   122.0   122.0   119.0   109.0   109.0   122.0   122.0   122.0   122.0   122.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer                   3.0       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   14.0   14.0   9.0   14.0   11.0   14.0   14.0   14.0   7.0   7.0       Butylbenzyl phthalate/   40.0   40.0   36.0   32.8   32.8   40.0   40.0   40.0   40.0   40.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   10.0   10.0   9.0   8.2   8.2   10.0   10.0   10.0   10.0   10.0       Limestone   1004.4   1004.4   1017.5   1026.6   1026.6   1004.4   1004.4   1004.4   1011.4   1011.4       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.4   2.4   2.3   2.2   2.2   2.4   2.4   2.4   2.4   2.4       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   15.7   15.7   14.6   13.9   13.9   15.7   15.7   15.7   15.1   15.1       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   70   71   72   73   74   75   76   77   78   79               PVC homopolymer   122.0   87.6   122.0   119.0   109.0   82.6   122.0   119.0   109.0   82.6       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   7.0   21.0   14.0   9.0   9.0   21.0   14.0   9.0   9.0   21.0       Butylbenzyl phthalate/   40.0   31.8   40.0   36.0   44.0   36.0   40.0   40.0   44.0   36.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   10.0   8.0   10.0   9.0   11.0   9.0   10.0   10.0   11.0   9.0       Limestone   1011.4   1042.7   1004.4   1017.5   1017.7   1042.6   1004.4   1012.5   1017.7   1042.6       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2   7.2       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.4   1.7   2.4   2.3   2.1   1.6   2.4   2.3   2.1   1.6       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   15.1   12.5   15.7   14.6   14.6   12.5   15.7   15.0   14.6   12.5       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0                        Example No.            Component (by wt)   80   81   82   83   84   85   86   87   88   89               PVC homopolymer   110.0   100.8   84.0   122.0   110.0   100.8   84.0   104.8   104.8   104.8       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   10.4   14.0   21.0   14.0   10.2   14.0   21.0   8.0   8.0   5.5       Butylbenzyl phthalate/   44.0   40.0   36.0   40.0   44.0   40.0   36.0   33.4   33.4   33.4       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   11.0   10.0   9.0   10.0   11.0   10.0   9.0   8.3   8.3   8.3       Limestone   1015.3   1026.0   1041.1   1004.4   1015.5   1026.0   1041.1   837.5   837.5   834.5       Titanium dioxide pigment   7.2   7.2   7.2   7.2   7.2   7.2   7.2   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   5.5       impact modifier       Mixed metal stabilizer   2.1   2.0   1.7   2.4   2.1   2.0   1.7   2.0   2.0   2.0       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   14.8   13.9   12.6   15.7   14.8   13.9   12.6   15.7   15.7   16.0       Total (by weight)   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1200.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   90   91   92   93   94   95   96   97   98   99               PVC homopolymer   99.8   99.8   99.8   74.0   89.8   83.8   86.0   86.0   86.0   90.0       PVC/PVAc copolymer   0.0   0.0   0.0   5.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   4.0   4.0   4.0   4.0   4.0   6.0   8.0   8.0   8.0   9.5       Butylbenzyl phthalate/   36.6   36.6   36.6   34.0   35.2   34.4   34.4   34.4   34.4   35.2       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   9.1   9.1   9.1   8.0   8.8   8.6   8.6   8.6   8.6   8.8       Limestone   835.5   835.5   835.5   867.3   847.4   852.4   855.3   855.3   855.3   848.7       Titanium dioxide pigment   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   7.0   7.0   7.0   0.0   7.0   7.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.0   2.0   2.0   1.7   1.8   1.8   1.7   1.7   1.7   1.8       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   15.9   15.9   15.9   12.7   14.7   14.2   13.9   13.9   13.9   14.5       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   100   101   102   103   104   105   106   107   108   109               PVC homopolymer   90.0   90.0   90.0   90.0   85.0   85.0   83.0   80.0   90.0   90.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   6.0   6.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   8.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0       Acrylic process aid   9.5   9.5   9.5   9.5   9.5   8.0   10.0   6.0   6.0   6.0       Butylbenzyl phthalate/   33.6   33.6   33.6   33.6   34.4   34.4   34.4   33.6   33.6   33.6       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   8.4   8.4   8.4   8.4   8.6   8.6   8.6   8.4   8.4   8.4       Limestone   850.7   850.7   850.7   850.7   854.8   856.3   856.4   856.4   848.2   848.2       Titanium dioxide pigment   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   1.8   1.8   1.8   1.8   1.7   1.7   1.6   1.6   1.8   1.8       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   14.3   14.3   14.3   14.3   13.9   13.8   13.8   13.8   14.6   14.6       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   110   111   112   113   114   115   116   117   118   119               PVC homopolymer   87.0   86.5   87.5   87.5   87.5   99.8   66.0   57.0   91.0   90.0       PVC/PVAc copolymer   6.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   10.0   10.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin           0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   8.0   8.0   8.0   8.0   8.0   4.0   5.0   5.0   4.0   2.0       Butylbenzyl phthalate/   36.0   35.2   35.2   35.2   35.2   36.0   26.7   24.0   36.0   33.6       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   9.0   8.8   8.8   8.8   8.8   9.0   0.0   0.0   9.0   8.4       Limestone   846.3   853.8   852.8   852.8   852.8   836.2   867.3   873.0   842.2   848.2       Titanium dioxide pigment   6.0   6.0   6.0   6.0   6.0   6.0   0.0   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   7.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   1.7   1.7   1.7   1.7   1.7   2.0   0.0   0.0   1.8   1.8       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   35.0   35.0   0.0   0.0       Percent Binder   14.8   14.0   14.1   14.1   14.1   15.8   13.3   12.1   15.2   14.6       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   120   121   122   123   124   125   126   127   128   129               PVC homopolymer   89.0   97.0   92.0   96.0   96.0   94.0   94.0   94.0   108.0   100.0       PVC/PVAc copolymer   0.0   5.0   10.0   10.0   10.0   8.0   8.0   8.0   0.0   6.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin       Acrylic process aid   11.6   5.0   2.0   2.0   2.0   4.0   4.0   4.0   6.0   2.0       Butylbenzyl phthalate/   34.1   36.0   32.0   36.0   36.0   36.0   36.0   36.0   36.0   36.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   8.5   9.0   8.0   9.0   9.0   9.0   9.0   9.0   9.0   9.0       Limestone   849.0   840.1   848.2   839.1   839.1   841.1   841.1   841.1   833.0   839.0       Titanium dioxide pigment   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   1.8   1.9   1.8   1.9   1.9   1.9   1.9   1.9   2.0   2.0       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   14.5   15.4   14.6   15.5   15.5   15.3   15.3   15.3   16.1   15.5       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   130   131   132   133   134   135   136   137   138   139               PVC homopolymer   100.0   100.0   100.0   100.0   91.0   94.0   104.8   108.6   90.0   100.6       PVC/PVAc copolymer   6.0   6.0   6.0   6.0   0.0   8.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin                           0.0   0.0   0.0   0.0       Acrylic process aid   2.0   2.0   2.0   2.0   11.6   4.0   11.6   5.8   11.6   5.8       Butylbenzyl phthalate/   36.0   36.0   36.0   36.0   36.0   36.0   41.7   43.5   35.8   40.2       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   9.0   9.0   9.0   9.0   9.0   9.0   0.0   0.0   0.0   0.0       Limestone   839.0   839.0   839.0   839.0   844.6   841.1   839.9   839.9   860.8   851.4       Titanium dioxide pigment   6.0   6.0   6.0   6.0   6.0   6.0   0.0   0.0   0.0   0.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   2.0   2.0   2.0   2.0   1.8   1.9   2.0   2.2   1.8   2.0       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   15.5   15.5   15.5   15.5   14.9   15.3   16.0   16.0   13.9   14.9       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.            Component (by wt)   140   141   142   143   144   145   146   147   148   149               PVC homopolymer   95.0   86.0   96.6   90.0   89.7   68.0   84.0   91.7   70.0   91.0       PVC/PVAc copolymer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Modified PVC/PVAc copolymer       Hydrocarbon resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Alpha-methyl styrene resin   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Acrylic process aid   5.8   11.6   5.8   5.8   8.7   17.5   11.6   8.7   17.5   11.6       Butylbenzyl phthalate/   38.0   39.8   44.2   43.0   47.8   38.1   41.8   45.8   36.1   36.0       epoxized soy oil plasticizer       Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Diisononyl phthalate plasticizer   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   9.0       Limestone   859.3   860.9   851.5   859.4   846.0   869.0   855.0   846.0   869.0   844.6       Titanium dioxide pigment   0.0   0.0   0.0   0.0   6.0   6.0   6.0   6.0   6.0   6.0       VCT scrap   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Methacrylate/butadiene   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       impact modifier       Mixed metal stabilizer   1.9   1.7   1.9   1.8   1.8   1.4   1.6   1.8   1.4   1.8       Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0   0.0       Percent Binder   14.1   13.9   14.9   14.1   14.8   12.5   13.9   14.8   12.5   14.9       Total (by weight)   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0   1000.0                        Example No.                    Component (by wt)   150   151   152   153                       PVC homopolymer   81.0   66.1   89.0   75.0           PVC/PVAc copolymer   0.0   0.0   0.0   0.0           Modified PVC/PVAc copolymer           Hydrocarbon resin   0.0   0.0   0.0   0.0           Alpha-methyl styrene resin   0.0   0.0   0.0   0.0           Acrylic process aid   15.6   22.5   11.6   20.0           Butylbenzyl phthalate/   32.6   28.1   34.1   30.9           epoxized soy oil plasticizer           Dibutyl phthalate plasticizer   0.0   0.0   0.0   0.0           Diisononyl phthalate plasticizer   8.2   7.0   8.5   7.7           Limestone   855.0   869.0   849.0   859.0           Titanium dioxide pigment   6.0   6.0   6.0   6.0           VCT scrap   0.0   0.0   0.0   0.0           Methacrylate/butadiene   0.0   0.0   0.0   0.0           impact modifier           Mixed metal stabilizer   1.6   1.3   1.8   1.4           Polyvinyl butryal post industrial   0.0   0.0   0.0   0.0           Percent Binder   13.9   12.5   14.5   13.5           Total (by weight)   1000.0   1000.0   1000.0   1000.0                      
 
         [0018]     Batch Notes for Copolymer Replacement Evaluation  
                                   Example No.   Comments                   Comparative   All vinyl control; 10 min mix time; good, lumpy mix @ 285° F.; good           blanket, good roll tack, good hot strength, self feeding, FR 215° F.       1   10 min mix time; good, lumpy mix @ 283° F.; good blanket, good roll tack,           good hot strength, self feeding, FR 215° F.       2   20 min mix time; slightly lumpy mix @ 300° F.; good blanket; good roll tack;           good hot strength; not self feeding; FR 250° F.       3   18 min mix time; good, lumpy mix @ 287° F.; very good roll tack; good           blanket; good hot strength; self feeding; FR 242° F.       4   10 min mix time; good, lumpy mix @ 283° F.; good roll tack; good blanket;           good hot strength; not self feeding; FR 233° F.       5   10 min mix time; slightly dry mix @ 281° F.; good roll tack; good blanket;           good hot strength; self feeding; FR 235° F.       6   15 min mix time; slightly lumpy mix @ 304° F.; fair roll tack; poor blanket;           no hot strength; not self feeding; FR 230° F.       7   15 min mix time; sandy mix with some lumps; good mill feed; good roll           tack; excellent hot strength; FR 235° F.       8   5.5 min mix; lumpy mix; good roll tack; good blanket; fair hot strength;           FR 235° F.       9   9.5 min mix; lumpy mix; poor initial feed, but improved; mix went to back           roll initially, but came to front roll with repeated milling; good blanket;           good hot strength; FR 235° F.       10   12.5 min mix; lumpy mix; good feed, but poor initial roll tack; tack           improved on second pass on mill; good blanket; good hot strength; FR           235° F.       11   7.5 min mix; lumpy mix; fair mill feed; good roll tack; good blanket; good           hot strength; FR 235° F.       12   7.5 min mix; lumpy mix; fair mill feed; fair to good roll tack; poor blanket;           poor hot strength; fell apart after calendaring; FR 235° F.       13   17 min mix; good, lumpy batch; good mill feed; poor roll tack that got           better with repeated passes through the mill; good blanket; good hot           strength; FR 225° F.       14   10 min mix; good, lumpy batch; good mill feed; excellent roll tack; good           blanket; good hot strength; FR 240° F.       15   10 min mix; good, lumpy batch; good mill feed; excellent roll tack; good           blanket; good hot strength; FR 240° F.       16   10 min mix; good, lumpy batch; fair mill feed; fair roll tack; good blanket;           fair hot strength; FR 240° F.       17   10 min mix; good, lumpy batch; good mill feed; good roll tack; good           blanket; good hot strength; FR 240° F.       18   19 min mix; lumpy mix; MT 293° F.; good mill feed; fair roll tack; fair           blanket; good hot strength; FR 240° F.       19   20 min mix; dry, powdery mix; MT 293° F.; fed well with closed mill nip;           opened nip; excellent roll tack; excellent blanket; excellent hot strength;           FR 240° F.       20   20 min mix; dry, powdery mix; closed mill nip; batch fused on mill; opened           nip; excellent roll tack, blanket, hot strength; FR 240° F.       21   9.5 min mix; nice, lumpy batch; MT 287° F.; excellent mill feed and roll           tack; excellent blanket and hot strength; FR 240° F.       22   9 min mix; nice, lumpy batch; MT 286° F.; excellent mill feed and roll tack;           excellent blanket and hot strength; FR 240° F.       23   15.5 min mix; dry, powdery mix; MT 289° F.; closed mill nip; batch fused on           mill; excellent tack; excellent blanket and hot strength; FR240° F.       24   9.5 min mix; nice, lumpy batch; MT 291° F.; excellent mill feed and roll           tack; excellent blanket and hot strength; FR 240° F.       25   15 min mix; very dry, powdery mix; MT 290° F.; closed mill nip; batch fused           on mill; opened nip; good roll tack; excellent blanket and hot strength; FR           240° F.       26   9.5 min mix; good, lumpy mix; MT 284° F.; good mill feed; excellent roll           tack; very good blanket; good hot strength; FR 240° F.       27   9.5 min mix; good, lumpy mix; slightly drier than Example 18; MT 289° F.;           good mill feed and roll tack; good blanket; poor hot strength; FR 240° F.       28   9.5 min mix; good, lumpy mix; MT 290° F.; good mill feed; excellent roll           tack; good blanket; fair hot strength; FR 240° F.       29   9.5 min mix; good, lumpy mix; MT 291° F.; good mill feed; very good roll           tack; fair blanket; poor hot strength; FR 240° F.       30   10 min mix; good, lumpy mix; MT 289° F.; good mill feed; very good roll           tack; poor blanket and hot strength; FR 240° F.       31   8 min mix; good, lumpy mix; MT 282° F.; excellent mill feed and roll tack;           excellent blanket and hot strength; FR 240° F.       32   7 min mix; good, lumpy mix; MT 281° F.; excellent mill feed and roll tack;           very good blanket; good hot strength; FR 240° F.       33   9 min mix; good, lumpy mix; MT 287° F.; excellent mill feed and roll tack;           very good blanket; good hot strength; FR 240° F.       34   9.5 min mix; good, lumpy mix; MT 286° F.; excellent mill feed and roll tack;           excellent blanket and hot strength; FR 240° F.       35   9.5 min mix; good, lumpy mix; MT 289° F.; excellent mill feed and roll tack;           excellent blanket; very good hot strength; FR 240° F.       36   dry, powdery mix; MT 292° F.; closed mill nip; mix fused on mill; poor roll           tack; very brittle blanket with fair hot strength; FR 240° F.       37   9 min mix; good, lumpy batch; MT 286° F.; excellent mill feed; very good           roll tack; very good blanket and hot strength; FR 240° F.       38   8.5 min mix; good, lumpy batch; excellent mill feed; very good roll tack;           good blanket and hot strength; FR 240° F.       39   11 min mix; good, lumpy batch; MT 287° F.; very good mill feed and roll           tack; very good blanket and hot strength; FR 240° F.       40   15 min mix; lumpy batch but slightly dry; very good mill feed and roll           tack; very good blanket; fair hot strength; FR 240° F.       41   20 min mix; dry, powdery mix; MT 291° F.; closed mill nip; mix fused on           mill; fair roll tack; brittle blanket with poor hot strength; FR 240° F.       42   12 min mix; good, lumpy mix; MT 292° F.; excellent mill feed and roll tack;           very good blanket; fair hot strength; FR 240° F.       43   18 min mix; good, lumpy batch; MT 295° F.; excellent mill feed and roll           tack; excellent blanket and hot strength; FR 240° F.       44   8 min mix; good, lumpy mix; MT 287° F.; excellent mill feed and roll tack;           excellent blanket and hot strength; FR 240° F.       45   8 min mix; good, lumpy mix; MT 286° F.; excellent mill feed and roll tack;           very good blanket and hot strength; FR 240° F.       46   9 min mix; good, lumpy mix; MT 287° F.; excellent mill feed and roll tack;           fair blanket and hot strength; FR 240° F.       47   13 min mix; good, lumpy mix; MT 290° F.; excellent mill feed and roll tack;           fair blanket and hot strength; FR 240° F.       48   25 min mix; very dry, powdery mix; closed mill nip; mix fused on mill; very           brittle blanket; no hot strength       49   25 min mix; very dry, powdery mix; closed mill nip; mix fused on mill; very           brittle blanket; no hot strength       50   20 min mix; dry, powdery mix; MT 291 F; closed mill nip; mix fused on           mill; excellent mill feed and roll tack; excellent blanket and hot strength;           FR 240° F.       51   7.5 min mix; good, lumpy mix; MT 289° F.; excellent mill feed and roll tack;           excellent blanket and hot strength; FR 240° F.       52   15 min mix; dry, powdery mix; MT 286° F.; closed mill nip; mix fused on           mill; excellent mill feed and roll tack; excellent blanket; very good hot           strength; FR 240° F.       53   20 min mix; dry, powdery mix; MT 286° F.; closed mill nip; mix fused on           mill; excellent mill feed and roll tack; excellent blanket and hot strength;           FR 240° F.       54   20 min mix; dry, powdery mix; MT 284° F.; closed mill nip; mix fused on           mill; excellent mill feed and roll tack; excellent blanket and hot strength;           FR 240° F.       55   15 min mix; dry, powdery mix; MT 287° F.; closed mill nip; mix fused on           mill; excellent mill feed and roll tack; excellent blanket and hot strength;           FR 240° F.       56   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed;           excellent roll tack; excellent blanket and hot strength; FR 40 psi       57   20 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack, blanket; very good hot strength; FR 260° F.       58   20 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed, roll           tack; fair blanket, very brittle; poor hot strength; FR 260° F.       59   20 min mix; very dry mix; MT 302° F.; fused on mill; excellent mill feed;           very good roll tack; good blanket and hot strength; FR 258° F.       60   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; strong odor; FR 36 psi       61   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 36 psi       62   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 36 psi       63   12 min mix; very dry mix; MT 285° F.; fused on mill; excellent mill feed;           good roll tack, blanket, hot strength; FR 36 psi       64   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack; good blanket, hot strength; FR 36 psi       65   14 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack; good blanket; fair hot strength; FR 36 psi       66   15 min mix; very dry mix; MT 288° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 245° F.       67   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 242° F.       68   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed;           very good roll tack; good hot strength; very brittle blanket;       69   15 min mix; very dry mix; MT 288° F.; fused on mill; excellent mill feed;           very good roll tack; good hot strength; very brittle blanket; FR 242 F       70   15 min mix; very dry mix; MT 287° F.; fused on mill; very good mill feed           and roll tack; good hot strength; very brittle blanket; FR 246° F.       71   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack, hot strength; slightly brittle blanket; FR 246° F.       72   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 246° F.       73   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack; good hot strength; very good blanket; FR 246° F.       74   15 min mix; very dry mix; MT 288° F.; fused on mill; excellent mill feed, roll           tack; very good hot strength, blanket; FR 246° F.       75   15 min mix; very dry mix; MT 293° F.; fused on mill; poor mill feed, added           alpha-methyl styrene resin; blanket went to back roll(300° F.); excellent           blanket, hot strength; FR 246° F.       76   12 min mix; nice lumpy batch; MT 285° F.; poor mill feed; blanket went to           back roll(300° F.); fair roll tack to back roll; very good blanket, but very soft           and flexible; FR 275° F.       77   15 min mix; very dry mix; MT 280° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 240° F.       78   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 240° F.       79   15 min mix; very dry batch; MT 284° F.; fused on mill; excellent mill feed,           roll tack, blanket, hot strength; FR 240° F.       80   15 min mix; very dry mix; MT 281° F.; fused on mill; excellent mill feed, roll           tack; very good blanket, hot strength; FR 250° F.       81   15 min mix; very dry mix; MT 281° F.; fused on mill; excellent mill feed, roll           tack; fair blanket; good hot strength; FR 250° F.       82   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack, hot strength; very good blanket; FR 28 psi       83   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack; hot strength; very good blanket; FR 28 psi       84   15 min mix; very dry mix; MT 290° F.; fused on mill; excellent mill feed;           very good roll tack; good blanket; fair hot strength; brittle blanket; FR 28 psi       85   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, hot           strength; fair roll tack; very good blanket; FR 245° F.       86   15 min mix; very dry mix; MT 285° F.; fused on mill; excellent mill feed, roll           tack, blanket; good hot strength; FR 240° F.       87   15 min mix; very dry mix; MT 285° F.; fused on mill; excellent mill feed, roll           tack, blanket; very good hot strength; FR 260° F.       88   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed; fair           roll tack; very brittle blanket; poor hot strength; FR 250° F.       89   15 min mix; very dry mix; MT 290° F.; fused on mill; excellent mill feed; fair           roll tack that got worse with continued milling; poor brittle blanket; good           hot strength; FR 250° F.       90   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed, roll           tack; fair blanket; very good hot strength; FR 230° F.       91   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, roll           tack; good blanket; very good hot strength; FR 230° F.       92   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack; good blanket; very good hot strength; FR 235° F.       93   15 min mix; very dry mix; MT 281° F.; fused on mill; excellent mill feed, roll           tack; very good blanket, hot strength; FR 235° F.       94   15 min mix; very dry batch; MT 281° F.; fused on mill; excellent mill feed,           roll tack, blanket, hot strength; FR 230° F.       95   15 min mix; very dry mix; MT 279° F.; fused on mill; excellent mill feed, roll           tack, blanket; very good hot strength; FR 235° F.       96   15 min mix; very dry mix; MT 279° F.; fused on mill; fair mill feed; good           roll tack; fair blanket; excellent hot strength; FR 235° F.       97   15 min mix; very dry mix; MT 273° F.; fused on mill; excellent mill feed, roll           tack, blanket; hot strength; FR 235° F.       98   12 min mix; nice lumpy mix; MT 285° F.; poor mill feed, roll tack at first,           but improved with repeated milling; excellent blanket, hot strength; FR           235° F.       99   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed;           very good roll tack, blanket; good hot strength; FR 245° F.       100   15 min mix; very dry mix; MT 272° F.; fused on mill; excellent mill feed;           very good roll tack; good blanket; very good hot strength; FR 240° F.       101   15 min mix; very dry mix; MT 272° F.; fused on mill; excellent mill feed;           good roll tack; poor, very brittle blanket; very good hot strength; FR 235° F.       102   16 min mix; fused in mixer with small lumps, slightly dry; MT 290° F.;           excellent mill feed, roll tack; very good blanket; fair hot strength; FR 234° F.       103   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed;           very good roll tack; fair blanket; poor hot strength; FR 244° F.; BR 307° F.       104   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed;           very good roll tack; poor blanket, hot strength; FR 244° F.; BR 307° F.       105   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, roll           tack; poor blanket, hot strength; FR 244° F.; BR 307° F.       106   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 244° F.; BR 307° F.       107   15 min mix; very dry mix; MT 284° F.; fused on mill; very good mill feed;           excellent roll tack, blanket, hot strength; FR 245° F.; BR 310° F.       108   15 min mix; very dry mix; MT 280+° F.; fused on mill; excellent mill feed,           roll tack, blanket; hot strength; FR 244° F.; BR 309° F.       109   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, roll           tack; very good blanket; good hot strength; FR 244° F.;       110   15 min mix; very dry mix; MT 280+° F.; fused on mill; excellent mill feed;           good roll tack, blanket; very good hot strength; FR 254° F.       111   Mottle line all fresh; mix time 17 min; MT 265° F. (read out); very nice           lumpy mix; excellent mill feed; very good roll tack, blanket; good hot           strength; FR 230° F.       112   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed;           very good roll tack; fair blanket; poor hot strength; FR 250° F.; BR 305° F.       113   15 min mix; very dry mix; MT 280° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 240° F.; BR 305° F.       114   15 min mix; very dry mix; MT 282° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 250° F.; BR 305° F.       115   15 min mix; very dry mix; MT 283° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 260° F.; BR 305° F.       116   15 min mix; very dry mix; fused on mill; excellent mill feed; good roll tack;           very good blanket; fair hot strength; FR 251° F.; BR 305° F.       117   15 min mix; MT 277° F.; very dry mix; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 251° F.; BR 305° F.       118   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack; very poor blanket, hot strength; FR 250° F.; BR 305° F.       119   18 min mix; lumpy slightly dry mix; MT 287° F.; excellent mill feed, roll           tack; good blanket; fair hot strength; FR 250° F.; BR 305° F.       120   15 min mix; very dry mix; MT 286° F.; fused on mill; excellent mill feed, roll           tack; very good blanket, hot strength; FR 250° F.; BR 305° F.       121   25 min mix; very dry mix; MT 285° F.; fused on mill; good mill feed, roll           tack; very poor blanket; no hot strength; FR 243° F.; BR 308° F.       122   25 min mix; lumpy slightly dry mix; MT 293° F.; good mill feed; fair roll           tack; poor blanket; very poor hot strength; FR 241° F.; BR 309° F.       123   24 min mix; lumpy slightly dry mix; MT 291° F.; good mill feed; very good           roll tack, blanket, hot strength; FR 241° F.; BR 309° F.       124   24 min mix; lumpy slightly dry mix; MT 292° F.; very good mill feed, roll           tack; poor blanket, hot strength; FR 242° F.; BR 309° F.       125   24 min mix; lumpy mix; MT 291° F.; very good mill feed; excellent roll tack;           very good blanket, hot strength; FR 242° F.; BR 309° F.       126   24 min mix; lumpy slightly dry mix; MT 292° F.; good mill feed; very good           roll tack; good blanket, hot strength; FR 242° F.; BR 309° F.       127   27 min mix; very dry mix; MT 296° F.; fused on mill; excellent mill feed;           very good roll tack; poor blanket, hot strength; FR 242° F.; BR 309° F.       128   25 min mix; very dry mix; MT 292° F.; fused on mill; excellent mill feed;           very good roll tack, blanket, hot strength; FR 242° F.; BR 309° F.       129   24 min mix; very dry mix; MT 287° F.; fused on mill; very good mill feed;           fair roll tack; poor blanket; no hot strength; FR 238° F.; BR 311° F.       130   24 min mix; very dry mix; MT 293° F.; fused on mill; very good mill feed;           good roll tack; poor blanket; very poor hot strength; FR 243° F.; BR 311° F.       131   24 min mix; very dry mix; MT 291° F.; fused on mill; excellent mill feed;           good roll tack; poor blanket, hot strength; FR 235° F.; BR 311° F.       132   27 min mix; lumpy slightly dry mix; MT 295° F.; good mill feed, roll tack;           poor blanket, hot strength; FR 238° F.; BR 311° F.       133   27 min mix; very dry mix; MT 294° F.; fused on mill; good mill feed, roll           tack; poor blanket, hot strength; FR 238° F.; BR 311° F.       134   27 min mix; very dry mix; MT 291° F.; fused on mill; very good mill feed,           roll tack; fair blanket; poor hot strength; FR 238° F.; BR 311° F.       135   24 min mix; lumpy slightly dry mix; MT 291 F; fair mill feed; very good roll           tack; fair blanket, hot strength; FR 238° F.; BR 311° F.       136   processed normally on mottle line; 292° F. Mix temp       137   processed well on mottle line; 293° F. Mix temp; front roll temp 240° F.       138   processed well on mottle line; 290° F. Mix temp; front roll temp 240° F.       139   processed well on mottle line; 293° F. mix temp; front roll temp 240° F.       140   processed well on mottle line; 291° F. mix temp; front roll temp 240° F.       141   15 min mix; very dry mix; MT 291° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 36 psi       142   15 min mix; very dry mix; MT 284° F.; fused on mill; excellent mill feed;           very good roll tack, hot strength; good blanket; FR 36 psi       143   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed;           very good roll tack; fair blanket; good hot strength; FR 36 psi       144   15 min mix; very dry mix; MT 287° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 245° F.       145   15 min mix; very dry mix; MT 288° F.; fused on mill; excellent mill feed, roll           tack, blanket, hot strength; FR 245° F.       146   15 min mix; very dry batch; MT 272° F.; fused on mill; excellent mill feed,           roll tack, blanket, hot strength; FR 240° F.       147   15 min mix; very dry batch; MT 268° F.; fused on mill; excellent mill feed,           roll tack, blanket; very good hot strength; FR 260° F.       148   15 min mix; very dry batch; excellent mill feed, roll tack, blanket; very           good hot strength; FR 220° F.; had to mill repeatedly due to low front roll           temperature       149   MT 290° F.; very nice looking mix; good roll tack and edge bands; processed           well through the dicer       150   very nice looking mix; MT 290° F.; good mill feed, roll tack, edge bands,           blanket; fed well through the dicer       151   nice looking mix; MT 290° F.; very intermittent mill feed; fair roll tack; poor           edge bands; required hydrocarbon resin to feed and keep edge bands;           processing fair through the dicer       152   very nice looking mix; MT 290° F.; good mill feed; excellent roll tack; fair           edge bands; excellent blanket; very good processing through the dicer       153   very nice looking mix; MT 290° F.; excellent mill feed, roll tack, blanket;           good edge bands; processed well through the dicer                 BR = Back Roll Temperature,            FR = Front Roll Temperature,            MT = Mix Temperature