Composition of matter for treating a closed cell foam substrate

There is disclosed a composition of matter which is used for treating a vinyl-coated foam substrate, such as a gym mat or the like to recondition such substrate, and which is comprised of a vinyl copolymer and a plasticizer in a solvent system including a ketone and a chlorinated hydrocarbon.

This invention relates to a composition of matter, and more particularly to 
a composition of matter for reconditioning a vinyl-coated substrate 
particularly a vinyl-coated closed cell foam substrate. 
BACKGROUND OF THE INVENTION 
In co-pending application Serial No. 643,699, filed Dec. 23, 1975, now U.S. 
Pat. No. 4,046,587 assigned to the same assignee as the present invention, 
there is disclosed a primer composition which is coated on a 
polyolefinic-containing closed cell foam prior to application of the vinyl 
film and which is preferably comprised of a chlorinated hydrocarbon 
solvent in which there are added a material selected from the group 
consisting of a chlorinated paraffin, an acrylic type ester, and a vinyl 
copolymer to form an acceptable impact absorbing article, e.g., gym mats 
and the like. 
After a certain period of use, such a gym mat may be replaced or must be 
reconditioned necessitating a return to the manufacturer with the 
concomitant handling costs of packing, shipping, etc. To date, the most 
practical workable system for reconditioning and recoating gym mats is the 
use of a highly flammable vinyl solution coating whose major danger is 
flammability, particularly in closed areas. Alternately, the mat may be 
reconditioned, in situ, requiring the handling of highly dangerous and 
flammable materials used by a manufacturer, usually necessitating the 
adherence to special ventilation procedures and to the use of protective 
masks and special equipment and procedures for handling flammable 
solvents. 
Further, the facile manufacture of free-exercise mats from such closed-cell 
polyolefinic foams, i.e., by adhering a woven or non-woven fabric to such 
a foam substrate, has suffered due to the lack of composition having 
required properties of tackiness, adhesiveness, flexibility and the like. 
OBJECTS OF THE INVENTION 
It is an object of the present invention to provide a novel composition of 
matter for reconditioning a vinyl-coated substrate. 
Another object of the present invention is to provide a novel composition 
of matter for applying in a facile way a vinyl film to a closed-cell foam 
substrate. 
Still another object of the present invention is to provide a novel 
composition of matter for reconditioning a vinyl-coated closed-cell foam. 
A further object of the present invention is to provide a novel composition 
of matter for reconditioning a vinyl-coated substrate while reducing the 
danger, equipment and procedures associated with highly flammable 
solvents. 
A still further object of the present invention is to provide a novel 
composition of matter for reconditioning a vinyl-coated substrate 
providing short drying and curing periods. 
Still another object of the present invention is to provide a novel 
composition of matter for applying in a facile manner a woven or non-woven 
fabric to an expanded closed-cell foam substrate. 
Another object of the present invention is to provide a novel composition 
of matter which is exempt from the present EPA standards. 
SUMMARY OF THE INVENTION 
These and other objects of the present invention are achieved by a 
composition of matter comprised of a vinyl copolymer and a plasticizer in 
a solvent system including a ketone and a chlorinated hydrocarbon.

DETAILED DESCRIPTION OF THE INVENTION 
Further objects and advantages of the present invention will be had from 
the following detailed description thereof. 
The system of the present invention meets the following requirements: 
1. Classified as a combustible Class 3 liquid. 
2. Safely used with proper ventilation and simple protective masks normally 
used by operators. 
3. Simple application techniques, e.g., spraying, roller coating, painting, 
etc. 
4. Dries at room temperature within a short period of time to permit 
successive applications thereof and yet possess the required physical 
properties of high elongation, tensile strength, etc., to provide "as-new" 
protective and wear qualities. 
5. Compatability to existing substrates, foam or vinyl coated foams. 
Accordingly, the systems include a flexible vinyl co-polymer and a 
plasticizer therefor in a solution of solvents comprised of fast drying 
chlorinated hydrocarbons and strong solvating ketones. 
The solution of solvents should contain a maximum amount of chlorinated 
hydrocarbons as possible in order to obtain a system which will depress a 
lighted flame as well as keep the flash point of the system at the highest 
point possible preferably above 150.degree. F. In order to obtain a high 
vinyl solids content, the solvent system should contain enough ketone or 
other vinyl solvating solvents. Since ketone or high vinyl solvating 
solvents are usually quite flammable, a balance of the chlorinated 
hydrocarbons and ketone is necessary to obtain the proper properties. 
Obviously, a maximum chlorinated hydrocarbon to high solvating ketone 
solvent should be used. During application of the composition, the solvent 
balance must be such that upon drying the coating will level and flow to a 
smooth continuous film. A solvent unbalance results in air bubbles and 
many air pockets causing weakness in the finish film product. 
The chlorinated hydrocarbon solvent includes those listed in the Raw 
Materials Index Solvent Section of the "National Paint and Coating 
Association" on Pages 47 and 48 designated Sct. No. 1 April 1973 from a 
publication dated October 1972 constituting a superceding publication 
dated June 1968 and include, for example, methylene chloride, ethylene 
dichloride, trichloroethylene, trichloroethylene propylene dichloride, 
monochlorobenzene, 1,2,4-trichlorobenzene and the like. 
1,1,1-trichloroethane being less toxic has been found to be particularly 
useful since it may be readily handled with standard ventilation 
requirements. Some of the other chlorinated solvents are quite toxic 
requiring special handling procedures. 
Strong vinyl solvating ketones include methyl isobutyl, cyclohexanone and 
solutions thereof. 
The solids content for practical and economical purposes should be between 
about 25 to 30% by volume. In order to obtain such a solids level, in 
addition to fluid quick drying, there is employed a low molecular high 
acetate content vinyl chloride copolymer. Although such a resin allows 
maximum solids build, it in itself is also quite soft, so that the 
flexibilizer or plasticizer must be the right balance and at the proper 
level to resin. A vinyl copolymer includes those sold by Tenneco under the 
trademark "Blacar" together with a number designation, e.g. 315, 314, 380, 
382, 384. 
A plasticizer for such a low molecular weight, high acetate content vinyl 
chloride copolymer resin when such composition is to be used for 
re-conditioning a vinyl coated gym mat is comprised of both monomeric and 
polymeric plasticizers whereas for use in the manufacture or repair of a 
free exercise mat only the monomeric plasticizer is used. 
In actual use, pigment is added to the foregoing composition of matter and 
may be effected during formulation or by admixing shortly prior to actual 
use. 
The following Table I lists specific ingredients and ranges thereof in a 
particularly preferred form of the invention: 
______________________________________ 
Ingredient Range 
Ingredients Max: Min: 
______________________________________ 
Methylene Chloride 35 25 
1,1,1-Trichloroethane 
35 25 
MIBK 10 0 
Cyclohexanone 10 0 
Vinyl Copolymer Resin 
25 15 
Polymeric Plasticizer 
4 1 
Monomeric Plasticizer 
8 2 
Pigment 3 1 
______________________________________ 
The resulting system or composition of matter is a product which does not 
flash under test conditions, but does flash outside the test apparatus at 
above 150.degree. F., which is a liquid highly stable solution which 
easily applies by brush, roller or spray and which upon drying is highly 
compatible with the substrate to which it is applied; which dries quickly; 
and which when applied in 2 to 3 coats provides adequate color coverage 
and millage buildup to produce a finished product with acceptable physical 
properties. 
Generally, to obtain exceedingly excellent results, the composition is 
applied by spraying (hot or cold) or by painting (roller or brush) at a 
temperature generally from 50.degree. F. to about 140.degree. F. 
Pre-cleaning and washing with a solvent, such as the solvent system of the 
present invention, is generally recommended to remove from the surface, 
dirt, grease and the like. 
The system or composition of matter of the present invention has been 
discussed with reference to the reconditioning of vinyl coated closed-cell 
foams, such as those used as gym mats. I have also found in a particularly 
preferred form of the invention, that newly prepared closed-cell foam 
substrates may be vinyl coated. It will be understood that for other 
applications, for instance, vinyl coated automobile roof, that certain of 
the aforementioned materials may be omitted. 
For example, the ketone solvent portion may be solely MIBK or 
cyclohexanone. Since the pigment is not an essential ingredient, the 
pigment may be subsequently added. As hereinabove mentioned, when using 
the composition as a vehicle for adhering a woven or non-woven fabric to a 
closed-cell foam, the polymeric plasticizer may be omitted. 
EXAMPLE OF THE INVENTION 
The following example is illustrative of the present invention: 
EXAMPLE 
A vinyl coated polyvinyl chloride closed cell foam is coated by roller 
painter with a conditioner comprised of the following components: 
______________________________________ 
Ingredient % by weight 
______________________________________ 
Methylene Chloride 34.5 
1,1,1-trichloroethane 34.5 
MIBK 1.5 
Cyclohexanone 6.5 
Vinyl Copolymer Resin 15.0 
Polymeric Plasticizer 2.0 
Monomeric Plasticizer 4.0 
Pigment 2.0 
Total 100 
______________________________________ 
After one hour, the coating is dry enough to permit application of another 
coating of the conditioner. After 24 hours, the coating is cured and may 
be handled in the usual manner. 
While the present invention has been described with reference to 
reconditioning gym mats, it will be appreciated that other items may be 
made of such a vinyl coated film, e.g., wall panels and the like, may be 
reconditioned using the composition of matter of the present invention.