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    US20200317952A1

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    Fairmont Ind Quality Division

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    © All Rights Reserved
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    a9) oy oy fo) an @y on} ‘US 2020031795241 2) Patent Application Publication co) Pub. No.: US 2020/0317952 A1 United States FREEMAN et al. ANTE-TACK FORMULATION OF SOLIDS CONTENT, DIL FORMULATION AND METHOD OF Us DILUTED ANTI-TACK FORMULATION Applicant: Polymer Sol GA(US) ms Gi up, Acworth Inventors: Gary M. FREEMAN, Macoa, GA (US); Quang 1 Do, Kathleen, GA (US); Joshua D. Sparks, Macon, GA (ws) Appl. Nos 16/377,587 Filed: Apr 8, 2019 Publication Class Im. C1, coop 139/00 (200601) Coo 761 (2008.01) comp 7168 (2006.01) coop 740 (2005.01) (4s) Pub. Date: Oct. 8, 2020 usp 5708 (2006.01) bos 118 (2008.01; Coss 708 (2006.01 2) Us.€ cee C090 139/00 (2013.01); CO9D 76 (0181): Coop 763 20181): COO 7769 (201801); COSK 3/34 (2013.01); BOSD 118 (2013.01); Co8Y 704 (2013.01); BOSD 2201/02 (2013.01); BOSD S48 (2013.01) on ABSTRACT The present invention relates to an ant-tack formulation of high solids content that uses effective amounts of a fine particle size tale, a water soluble cationic polymer, one oF ‘more nonionic suefactants, and one oF more alkali metal fatty acid soaps. The high solids content ant-tack formulation is ‘capable of being easily shipped to a customer's location and js stable and easily pumped aller shipment to a customer The high solids content antisack formiaton ean be diluted to a low solide content Formulation for use in anti-tack applications, particularly rubber slab dipping applications. The ant-tack formulation provides improved ant-tack per- formance when coating uncured rubber products, Uncured Rubber Pieces after Dip Coating (from left to right used 4% dips from Formulas C, D, E, & F) US 2020/0317952 AI 2020 Sheet 1 of 3 3 Patent Application Publication puaa eL Fy —O— a einuog veinuoy - wpreg sa, suouiw Yayawelg apiued (%) Aouanbaiy Patent Application Publication Oct. 8, 2020 Sheet 2 of 3. US 2020/0317952 Al Fig. 2: Sedimentation Cylinders for 4% Dip Slurries from Formulas C, D, & E {from left to right) Patent Application Publication Oct. 8, 2020 Sheet 3 of 3. US 2020/0317952 Al Fig. 3: Uncured Rubber Pieces after Dip Coating {from left to right used 4% dips from Formulas C, D, E, & F) US 2020/0317952 Al ANTI-TACK FORMULATION OF HIGH SOLIDS CONTENT, DILUTED ANTL-TACK FORMULATION AND METHOD OF USE OF DILUTED ANTI-TACK FORMULATION, FIELD OF THE INVENTION [0001] The present invention relates to an antistack for- ‘ulation that uses primarily tale that has been cationic polymer treated forthe dip slur’ coating of uncured rubber ‘compounds in antitack applications BACKGROUND ART [0002] Inthe prior ant its known to use unt-tack form- Jations directed to coating uncured rubber compounds, Sueh formulations are applied 10 uncured rubber fo serve as process side. The applied coating keeps the uncured rubbee slabs or pellets from sticking to itsell (ie. prevents block= Jing) thereby enabling the rubber compounder to more easily handle, stack or convey the uncured rubber to other unit ‘operations such as the compression molds and to profile 10003] In general terms, ant-tack formulations commonly ‘employ a nnmber of ingredients such as mineral pigments, ling clays, metallic stearate pigments, alkali metal fatty id soaps, nonionic surfactans, defoamers, pigment sus- pension aides, waxes, etc. Some of the prior art also dis- ‘loses the use of varios water soluble polymer additives to ‘enhance the coating film properties of the applied ant-tack, Examples of water soluble polymer additives employed in the prior art ane: 0004] carbohydrate based polymers ike carboxyl ‘methyl cellulose (CMC) or polysaccharides (ike xan- than gums) [1005] "nonionic polymers ike polyvinyl aleohol (PVA) ‘or PVAIPVAC copolymers (PVAC=polyvinyl acetate): and 10006] anionic polymers or copolymers based on acry- lates (eg. aerylc binders or latexes) 10007] One application for anti-tack formulations is as @ slah dip shury of relatively low solids content. This is where fieshly compouaded uncured rubber coming off two roll mili ran through a dip sly tank containing the ant-ack Jormulation in diluted aqueous form w dip coat the rubber slabs. Aa example of a slab dip use for an anti-tack forme Jation is shovin ia US, Pat, No, 3,178,676, This patent discloses the use of a surfactant-treaed kaolin ely for use ‘san ant-ack, [0008] | U:S. Pat, No. 4354001 discloses the use of latex polymers containing carboxylate Functionality in combina- tion with filles as ant-tock composition but there is m0 teaching of the use of water soluble eaionie polymers. 10009] JP 2009 249533 discloses the use of a surfactant and a Water soluble polysaccharide polymer (xanthan gum), but theres no mention ofthe use of a water soluble, eationic polymer nor of tale [0010] JP 2010 247864 discloses the use of a water soluble PVA polymer for providing an antitack film on uavulea rized rubber but does not disclose the use of any water soluble eationie polymers [0011] | WO 2018207939 discloses a typical anti-ack pow ‘der product that i dispersed in Water a a rubber customer's facility. Ant-tack pomders of this kind are typically dise pers onsite in water at low solids conteats (2-696) for use Oct. 8, 2020 as dip slumies for rubber slabs. The inorganic silicates ‘amed inthis prior art, e.. component E, does not include tale, Instead, mica and kaolin are listed as the desired ‘material. Also employed ia this product is a Na or Kf ‘acid soap in combination with an organic surfactant. 0012] WO 2017164171 is an example of an anti-tack powder composition that employs a metallic stearate pige reat (ike Mg stearate or Zn stearate) as an ant-block aditve, [013] 12014095010 discloses an anti-tck aqueous dis- petsion of moderately high solids content, which when calculated has a solids content of about 33.5%. This disper- sion ules water soluble polymer in the formulation (eg carboxymethyl cellulose and xanthan gum are mentioned) but water soluble cationic polymers are not mentions! Carhoxymethyl cellulose and xanthan gum are carboby= ddrate-hased polymers that are frequently used as rheological thickening agents or as pigment suspension aides. [014] 122013124292 discloses an ant-tack powder com- positon. This prior art emphasizes the desirability of using Snonganic mineral pigmeats having a low crystalline silica content (for safety purposes with respect t© possible iha- Jation) and it also employs nonionic surfactants (Katty aleo- hol ethoxylates), [015] 12011144221 discloses an anti-tack powder com- Position that employs fo different classes of nonionic surfactants (fatty alcohol ethoxylates and aeetylene-based iol ethoxylates), [0016] _1P 2002363532 discloses an anti-tack composition that emphasizes an aqueous dispersion of CaCO, and/or tale in combination with 2 surfactant package, However, the dispersion i produced st a low solids content, ie. 7.5% solids hased on the amount of water specifi in this prior [0017] _1P 2001348495 discloses an anti-tack composition {hat employs a water soluble polymer, sueh a8 @ polyvinyl leo, but there is no mention of using a water soluble catia polymer ia combination with tale a an antieblock pigment [018] JP 56-47475 discloses an aat-tack composition that can be an agucous, high solids formulation, However, ‘his formulation isan emulsion derived from a combination of Na oleate soup aad an unsatursted fatty acid like oleic acid. There is no disclosure of an aqueous dispersion of a silicate mineral pigment like tale nor is there sty teachings concerning the use of a Water soluble cationic polymer [0019] IP 6.47476 discloses an ant-tack composition that ean be an aqueous, high solids formulation. However, ‘his formulation isan emulsion derived from a combination fof Na oleate soap, a hydroxy-teminated silicone and a IMuoro-surfactant. There is no disclosure of an aqueous ispersion ofa siicate mineral pigment lke tale nr is there teachings concerning the use of water soluble cation polymer 0020} 1 49-18780 discloses an ant-tack composition {hat is an aqueous dispersion of metal stearate ant-block pigment that is wetted with a nonionie or anionie surfactant. ‘The total solids content is about 30% and a silicate mineral pigment soch as tale isnot se [021] 2. 6902507 discloses an ant-tack composition that is an aqueous dispersion that consists principally of a combination of clay mineral, an alkals metal fatty aid soap, and an alkali metal alkyl solfate surfactant. However, the US 2020/0317952 Al solids content ofthe formulation is quite low (about 25%) tnd the use of tale or # water soluble cationic surfactant is not disclosed 10022] US. Pat. Nos. 6,156,177 and 6,402,827 disclose the formation of eationie polymer flocculated kaolin pige sents for use in paper coatings. Te prefered water soluble ‘cationic polymer in that application isan Epi-DMA polymer having & Mw=$0,000. Neither one of these patents are ‘concerned with anti-tack formulations for use On uncured rubber, 0023] _ In adliton, the use oftale as dry anti-tack powders Jor dusting elastomeric compounds i well known in the at. “The use of tale to produce pellet lube sluts for coating uncured rubber pellets is also well known inthe industry. Soch pellet lubes are typically spery-applied onto uncied rubber pellets ina rotary drum or altenatively the tae slurry Js Booded onto freshly formed, bot pellets as they emenge from a rubber exteuder such a Barwell extruder In these pellet lube applications, dhe tale-based slurries ae typically Utilized at a solids content of 10-18% solids. The pellet ube ormitlations themselves are relatively simple compositions as they are comprised mostly of fale and various alkali metal ‘of fly acids, One such commercial predict is sold by SASCO Chemical/PSG and is called Pellet Lube F3, 10024] Many of the ant-tack dispersions of the prior rt suffer from a number of problems that mandate improved dispersions for antsaek applications. These problems Include the requirement that the dry powder products need to be mixed ata customer's site to foramilate the dispersion and this requires the customers to have extensive mixing ‘equipment, Other formulations use expensive anti-lock Pigments like metal stearates. Other formulations sufler from excessive Foaming, pigment settling and syneress hard and gummy dip shery sediments that make remixing of the dip slurry dispersion difficult, environmental concerns such atthe presence of fibrous asbestform materials or high levels of tora crystalline silica (TCS) in the associated mineral pigmentation, andor just inferior anti-ack perfor 10025] As such, « nocd exists to provide improved anti tack dispersions tha avoid or minimize the problem with ‘cureat aat-tack products and dispersions. The invention responds to this need by providing an improved ant-tack dispersion and method of tse in anti-tack appliations SUMMARY OF THE INVENTION 10026) In one embodiment, the invention relates to an sack formation that ean be conveniently delivered i & high solids liquid concentrate fom that can be readily pumped and is easily diluted with water to 4 lower solids ‘content level for ead application use as «dip eoating slurry. “The desired anti-tack formulation is also relatively low cost sit principally employs cost effective tale pigmentation rather than requiting the use of expensive antilock pig- ments such as metal stenrtes. [0027] Another aspect of the invention is the use of the ‘ntitack formblation in an antisack coating. application such as in the spraying of uncured robber pellets or slab ‘ipping of uncured rubber slabs. 0028] Yet another aspect ofthe invention is dikted anti tack formulation tha is useful in ant-tck coating appli tions for uncured rubber compounds wherchy the died ormulation is effective at low solids contents and does not Oct. 8, 2020 dard poek sete in dip tanks and slurry lines when let son-agitatd for extended periods of time {0029} Other objects and advantages will be become Snparcat as & ful desertion othe invention is made. {0030} Ono aspoct ofthe invention roates to an aquous fnttack formulation of high loll solids contest ringing from 45 t0 75% by weigh of the formulation, preferably 50.75%, The formblation inches tale particles having a Cites median particle size range of es than 7 microns, the tale particles being present in an amount ranging rom 40% {0 72% of the tot lormulation weiaht [0031] The antiack formulation also includes polyqua- temary cationic polymer having a molecular weight between bout $0,000 to 2,000,000 Dalions in an effective amount wo at fost prevent hard pack seting ofthe tale when the fnttak formulation i used in cited form. for coring ured ruber compound produets andor improving cat coverage of the une rubber compotid product [0032] "The formulation can also have one or eombina- tion of tho follwing: {0033} 2) one or more nonionic surfactants of intermediate FHLB vale of 6 to 12 in total amosnt ranging fom aboot 0.01-4.0% ofthe total formulation weight, preterably up to about 3.0%, and more prefembly about 0.5 40 20% by ‘weiaht ofthe fommaton; and b) one of mow alkali metal Sourte oF uasatrated, Cy-C Katy eid soaps ina toll mount ranging from about 001-8.0% ofthe tt form Jaton weight, prefraly Tess than 2.0% by weight ofthe formulation {0034} An optional ative to the formulation inches oe oF more sispension aids in 3 total amount of ask more than about 2.0% by weight of the Formulation, {0035} "The balance of the aqueous formulation is water [0036] In a more prefered embodiment, the povguatr- ary cationic polymer ean be in amount ranging fom 0.01 {0 025% by weiat ofthe formulation, and more preferably Jess than 0.10% by weight {0037}. In terms of wscosiy: the viseosty ofthe agusous Snack conecatete Formulation ean be controled to ave fe oF more ofthe fllowing viseosties {0038} an inital 2rpm state BrookildViseosty of 3,000 {0 25.000 ep 10039] a two-week aed 2 pm Satie Brookfield Vi Jess than 150,000 eps {0040} "a two-week aged 20 pm Jysumie Brookfield Vi cosity les an 25, 000 {0041} wherein the intial and aged static and dynamic ‘Viscosiis are measured using a Brookfield RVDVE helo~ pth viscometer anit equiped with Tespindles and are a t For 20 pm and 28 degrees C [0042] The polyquterary cationic polymer i preferably srichlorohydrinimethylamine (Epi-DMA), one or more Polyqusteraiums, oe combination thereat and more pee sity ‘erably polyillydimethy ammonium chloride (PolyDAD- MAC), [0043] The one or more nonionic surfactants can be selected from the group of ethoxylates of alkylphenols, cetboxylates of 24,7.9-etramethyl 5 decyn-4,7-diol, ethoxy Jates of linear or branched fay alcohols having & carbon chain length ranging from C.-C, , FO/PO alkoxylates of Jinear or branched fatty alcohols having a carbon chain length ranging from C.-C; ethylene oxidelpmopylene oxide block copolymers, ethoxylates of sorbitan esters, ethoxy Tated fatty avid, ethoxylated castor oils, ethoxylated fatty US 2020/0317952 Al nines, and PEG esters or dieters of saturated or unsatus rated Cy to Cay fay acids. The one or more alkali metal Saturated oF unsaturated, Cx-Cay fatty acid soaps can be feclected fom sodium or potsium soaps of saturated oF unsaturated Cy-Cay fatty acids, 10044] - While only one size tale particle can be used, the tale can be a blend of to differently sized tale particles wherein a size difference between the two dilerently-sized tale particles is at Teast two microns, the blend is peeferably based on a weight ratio of larger to smaller particles of 1.521 10 9:1, The tale can also be substituted with one oF more of nother ant-block pigment in an amount up t0 25% of the total weight of tale in the formulation. The ant-block Pigment can be selected from the group consisting of oolinite eleined Kaolin clas, smeetite clay minerals sue as bentonite and hectorte, atapulgite,sepiolite, barytes repheline syenite,caeium earbonate (ground or precipitated forms), dolomite, fine particle micas consisting of muscovite ‘or phlogopite, feldspar, synthetic amorphous silica pig ments such as precipitated silica and fumed silica, alumina teihydrate, hydrotaleite and various metal stearate pigments such as calcium stearate, magnesium stearate and zine stearate [0045] Other adaltives that ean be employed in the ani tack formulation inchide one oF more defoamers ia & total amount of not more than ahout [0% ofthe total formulation weight and one or more biocides in a total amount of not tore than about 0.15% by weight of the formulation, 10045] |The invention also entails a method of coating aa ‘uncured rubber compound to provide ant-tack properties to ‘a surface of the rubber compound by using the inventive high solids ant-ack formulation, dating it to 1-10% total solids content, preferably 2-6%% and more preferably 3.4% and applying the diluted anti-tack formulation othe rubber ‘compound, The applications can include any’ type tht would ‘coat a incured rubber compound for anti-iack purposes, ‘and examples include a dip tank slur application oF & spraying application 10047] A more prefered ant-sek formulation is one that ‘ses at least polyiallyldimethy! ammonium chloride as the polyquatemary caionie polymer, anda combination of both the nonionie surfactant and the one or more alkali metal, saturated of unsaturated, CyoCa fatty acid soaps, with the nonionic surfactant preferably being one or more of ethoxy lates of trideey] alcohol and ethoxslates of 2.47.9-e ethyl S decyn-t,7-diol nonionic surfactants apd the ene oF ‘more alkali meta, saturated or unsaturated, y-Ca fatty acid soaps being one’ or more sodium or potassium soaps of strated oF unsaturated Ca-Ca fatty acids, and one or more pigment suspension ides of fimed silica xanthan pum and sepiolite 10048] _ Yet another aspect of the invention is providing an fagueous ant-tack formulation comprising the high solids ‘content ant-tack formulation described aboxe in diluted form such thatthe total sold content ranges from about 1 10 (0%, This formulation aa also have the same aspects ofthe high solids fommulation in tems of different talc particle sizes, the substiuton of tale with one oF moze aali-block Pigments, presence of optional additives, and the like, For the diluted ant-tack formation, i is prefered that it has 2 relative sediment volume (RSV) of at least 35 em", the relative sediment volume measured using 1000 ml of a 4% solids diluted form ofthe ant-tac slurry formulation ina 1 Titer araduated eylinder after 24 hours of state settling. Oct. 8, 2020 [0049] A further aspect of the invention is a method of making the aqueous ant-tack formulation having total solids content ranging from 45-75%, This method ineludes ‘adding « number of components together tw make the ani-tack formulation. More paniculary, the adding step ‘adds an amount of at least one size of fie particle size tale, ‘an amount of one or more polyquatemary catione polymers, fan amount of cither or both of: (i) one or more nonionic ‘trfactans of intermediate HLB value of 6 0 12; and ( fone of more alkali metal, ssturted or unsaturated, Cy-Coy faty acid soaps, an optional amount of one or more sus. pension aids, defoamers, ad biocides, and water to fon the mn. When adding these various ‘components together, the amount of the one oF more poly- quatemary eationie polymers is made into an aqueous sol tion and this aqueous solution is used when making the ant-tack formulation by adding. the other components together BRIEF DESCRIPTION OF THE DRAWINGS [0050] FIG. 1 isa Horibo laser Hight scattering partie size istribution curve showing the patel size distribution for two different antciack formulations compared to the particle size distribution of the starting tale pigmentation. [0081] FIG. 2 isa photograph of thee ltr sedimentation cylinders for diffeent talesbased ant-tack formolations showing ther lative sedimentation volumes, [0052] FIG, 3 are photographs of uncured rubber com- pound slabs after being dip coated with different tle-based fnt-tack formulations. DETAILED DESCRIPTION OF THE INVENTION [0053] Most rubber antistack products are produced and Gelivered in dry powder form. Dry powder products maxi- nize solids content from a freight delivery standpoint but they require extensive mixing equipment on site at the customer's location to properly disperse the produets into agucaus dip stutes. Also, the aforementioned dispersion process roquites plant personnel to oversee its production 0 insure the powder makedowa protocol yields well dispersed ip slurries of appropriate % solids content. In many cases, the mixing procest requires heating of the batch water to ‘heilitate wetting, swelling, and dispersion of the various ant-block mineral pigments and extended mixing times to ‘achieve good dispersion, These mixing challenges are par- ‘iculaly-the case when the anti-lack powder fomauation utilizes any significant amount of swelling clays such as bentonite, [0054] Providing the ant-tack formulation in pre-i persod shirt form provides level of quality and ease of use forthe customer. Liguid concentrates can be readily vith water 10 the desired target solids on site using auto- ‘mated dilution/mixing systems requiring minimal oversight. Such Tiguid concentrates do-not require heating since the anicblock pigments therein are already wetted and well ‘dispersed, However, is desirable to provide the lighid concentrate of an anf-tacke formolation in a high solids fcontent form to minimize their fcight costs during ship- ‘ment. The lid concentrate should also be stable yet fakd ‘and should be easily pumped from totes or other containers ‘using conventional psitive displacement pumps. The ligt tack formulation of this iavention meets these wtlity US 2020/0317952 Al requirements by providing a ale dispersion having a solids ‘content equal oo rear Un 48%, which x esi banded ‘and puped, more preterably 50% or more. While dere is no upper end ta the sold contents of the tale dispersion pretcal upp limits about 75%, and solids contents above this amoust are jst to vstous oe high shear mixed nd ‘ensily pumped once transported to a customer's cites 10088] Masy pre ax anti-uck formulations employ ‘expensive anti-lock pigments such as metal stearate pig ments of calcium, magnesium oF zine in appreciable amounts oF thay’ can employ expensive antilock additives Such as wanes or film Torming polymers (like polyiny! leoho)). Minimizing the use of such expensive chemical aditives is essential to contlling the final cost of the ‘omulation tis therefore particularly desirable o develop ‘tlw cost ant-tak coating formulation based pciplly on tinea pigments that is effctive in reducing the tokiness ‘of uncured elastomeric compounds in slab or pellet form Swhcn applic os coating ln via a dip tank lary appli ‘ation OF via a spay application. The attack formula should be elctive when applied tothe uncured rubber slab ata died slid content of 2-6% by weight. The diluted solide conlent can range fom 1-10?% to a more preferred range of 2-6% and even more prefered range of 34% 10086) The ani-tck formulations of dhe inveaion are Principally comprised of ene or more fine pace size tle Pigments hat ar ow cost mineral pigments being produced fiom various dry grinding processes such a pin ml, @ roller mill an air swept impact milo jet mill based dry prinding/lasifcation process, Tale pigments prexived by Water Washed-hased mineral processing technologies are Known and also commercially svalole. The wate-washed tale pigments cam also be used but they are typically mee expensive than the dry ground grades and they are not absolutely nccessary for producing effective antick for mulation in accordance withthe invention 0087] However, ii important vo employ tale pigments produced from high grade ores that conain minimal Amount of other mineral impurities in them. The ofemste- Fals should contin preferably no o st most race ppm type levels of any fibous asbestiform materials and they should alka contain a negligible amovnt of total cystine silica ICS) content because of the respiratory health hazads tributed to these materials. The TCS content is analytically ‘etemied by Xray Dilation (whichis detection init ‘f 0.10%) and is defined as the collective sum ofall the ‘entlline silica species that ae present in the mineral pret as minor impurities. Wilh respect to the TCS value ‘termined by XRD, ihe three erste silica species of Primary respiratory concern are quiets, efstobalte and trite. In the inventive anti-ack formations itis there~ {ore pecfrred that the fine particle tale pgients have a TCS ‘content less than 0.5% by weight and moe preferably have ES content less than 0.3% by weight. On total Liquid Formulation basis this puts the amount of TCS content be Jess than 0.2596 by weight of the tol formula oF mere preferably 10 be less than 0.15% by weight of th total Formula 10038) "Given the recent rollout of reduced! OSHA oceu- ational exposure sidelines for respirable exystalline silica in general industry applications (see 29 CER. 19101053) rubber compounders are becoming increasingly concerned host sxing nt ack formations tht contin high levels of ‘erste sca content. Many rubber compounders ate Oct. 8, 2020 requiring that suppliers provide ant-tack products that have TCS contents les than 1% of frequenly even lower inorder {0 meet these environmental exposure standards. As such, utlizing fine particle tle pigments that can meet these requirements is an important aspect of the inventive foemn- lations [0059] Beyond its low cost, fine particle tale is of interest to use in anti-tack formulations because its platelet mor- shology provides good ant-block properties while its mod- tmtely hydrophobic surface lends to good affinity of the particles to elastomeric surfaces. Tae is aso recognized as providing very good slip and hubrication properties. Por ‘example the use of tae as dry antitack powders for dusting tlastomeric compounds is well known in the industry. Far thermore, the use of tale pigmentation in pellet lube form lations for coating uncured rubber pellets is know in the at as discussed above in connection with the Pellet Lube F3 product, While such tale formulations ane effective for coating uber pellets a solids contents of 10-18%, they are less effective as anti-tocks when wsed as rubber slab dip srtes at lower solids contents of 34% solids. While a fine particle tale pls fatty acid soap combination provided in Slury form provides some desirable properties it til sulfers from several disadvantages that Timit its ease of use and utlty for rubber slab dip applications and these are detailed below. 10060] a, Tale slurries in high solids slurry concentrate form are frequen dillicult to stabilize so as to inhibit syneresis and pigment sting, Aevordingly, significant mounts of various suspension aides, such as CMC, anthan gum, of bentonite, are commonly employed ia the formulations to improve thei pigment suspension propenies 0061] b. Despite the use of suspension aides in a tale slurry concentrate, it subsoquent dilution into water- home slurries of about 3-49 solids content for subse _quent potential use as a rubber slab dip normaly results in-dip slurries with poor tale suspension properties. Even when fine particle grades are employed, the tale pigmentation inthe dip shureysetles rapidly and tends to form hard packed or gummy sediments whieh are very difficult to re-stir ito suspension. 10062]. When utilized as rubber slab dip slurces at 34% solids content, the tle-based pellet lubes fre- ‘quently yield poor coating coverage of uncured rubber grades such that poor antiack performance is ‘blained. The slab dip sluries derived from pellet lubes ddo not wel the elastomeric surface very well and ‘consequently they tend to run off the rubber in steaks rather than provide a uniform continvows coating film, [0063]. The heavy reliance on wsing alkali metal fry ‘acid soaps in tale-based pellet lube formulations ean frequently lend to the formation of notable amounts of foam in the dip slurry tank systems that must be proactively managed to keep under control. The gen ‘ration of excessive foam in the dip slurry tanks ean ‘often create problems with respect to uniform coating coverage on the rubber slab andlor the pickup of ‘lumps of foam froth that can dry down to form erasty fareas.on the rubber slab which can ttap_ moisture ‘undemeath, The trapping of moisture undemeath these died clumps of foam can subsequently result in the formation of blisters during the subsequent molding or profile exirsion staes of final nlbber product manu US 2020/0317952 Al facture, Hence using antiack formulations that have ow potential for producing foam in the dip tank systems are very desirable. 10063] In contrast tothe aforementioned pellet tubes and fther prior art discussed above, the tale-based ant-iack formulations of this invention address the previous perfor mance shortcomings associated with tale-dominated fonmi- Jations because the tale pigmentation therein has now been Aooculated with one or more water-soluble cationic poly- mers. The details of the water soluble eationie polymer are discussed below, The tale-based antistack formulations of this invention possess a number of advantageous ateibutes that provide a number of improvements over prior art ant-tack formulations. The attributes are discussed below. 10065] The inventive formulation can be produced in & high solids concentrate form (sluery solids content being ‘equal to or greater than 45%, more preferably 50% or more) that is stable and is easily pumped and readily diluted as roeded. It is a low cost ant-tack formulation wherchy ‘expensive antsblock pigments or additives like metal stear~ tes oF waxes are not needed t yield a proict that provides good ant-ack coating coverage on untcured rubber com pounds. The high solids content is desirable from the stnd- point of minimizing freight costs whea shipping tbe product to distant customer locations 10066] All ofthe pigmentation is pretispersed and fully ‘wetted in the formulation soit dacs not rogue any heating nor extended mixing times when diluted on-site for subse- ‘quent use, The producti ready To ase as soon asi is dled with water tothe proper solids content. This ean be aor plished with minimal supervision through the uilization of ‘an automated dilution and metering system whereby slurry ‘concentrate is pumped from a delivery tote ino the dition system, water is added, the combination is mixed for several ‘minutes until homogeneous, and the solids content is con- tinuously monitred via an inline probe and adjusted accord- ingly hased on the target set point. The difsed anti-tack slury product is then sent to the rubber line's dip tank system for aplication use. Automated dilution and metering system for draving down a high solids shury to a lower solids content are well known and an example of such @ system is commercially provided or sold by SASCOVPSG, {0067} The inventive tale based formulation when diluted to 34% solids content performs as an effective rubber slab dip formulation. It provides good ant-tack covernge on 8 wide array of uncured rubber compounds. Because the tale Pizmentation has been lightly to moderately flocculsted ‘through the zldtion ofa water-soluble cationic polymer, the ‘agglomersted particles of tale wil sell o yield sof, Sully ‘er sediments that do not become hard packed i mixing in the dip sum tanks is ever discontinue for extended periods ‘of time, This fife sedimentation arising from a dip surry ‘of the inventive formillaton is clearly reflected by the fact thatthe resultant wet sediments of ale exhibit higher RSV value (RSV-relative sediment volume). Being. soft and ful, the wer sediments of tale avsing from the iaventive ormulations are found to be easily sired back into sus- pension when mixing. is resumed, [0068] The concept of RSV for wet pigment sediments has been previously explained and discussed in US. Pat. No. 6,156,117. As disclosed there, the RSV value or wet void volume for a given mineral pigment is a measure of how Oct. 8, 2020 densely the individual particles from an aqueous suspension have been packed together once they have completely settled into a wet sediment, The more compactor denser the ‘mineral sediment isthe less wet void volume there will be in the sediment. RSV (or wet void volume) results from ‘imperfect particle packing arising from the shapo(s) of the various particles that ate present. Flocculation ofthe platy tale pantcles with water soluble eationie polymer results in the formation of agglomerates that are regularly shaped and of different size and this consequently results in imper- feet particle packing. Dense phase packing of the tale platelets is also likely prevented by steric hindrance as a Single long-chain water soluble cationic polymer is most likely attached to several tale particle via malliple points of ionic interaction. Henee, sogments of the polymer chain thereby act as spacers to keep these placlets within the ‘agglomerate physically separated from one another by 3 certain small distance. AS such, it is believed that the agglomerates are likely loosely bound collections of tale platelets having interparticle spaces rather chan being tightly ‘ound, compacted collections of tule platelets. The overall magnitude of RSV increase can be impacted by the particle size of the starting tale, the amount of surfactant that is present in the formula and the overall dosage ofthe water Soluble cationic polymer that is employed. However, increases in RSV on the order of 1.56 times greater have been observed when RSV comparisons are made to sed ‘meats arising from similae tale formulations not employing ay water soluble eationi polymer like PolyDADMAC. For purposes of experimental comparison, the RSV of different {ale antistack Formulations have been assessed as 4% solids dip slurries alter 6 hours and then again after 24 hours of static settling. No further change in RSV is typically noted beyond the 24 hour time period. 1 is believed that RSV values of 35 em? or more when measured for 24 hours for a diluted anti-tack formulation, preferably more than 50 fm, provide the desired anticiack properties when testing fan uncured rubher compound using the inventive anti-ack qormulation in an anti-tack application like spraying or dip slury use. A more detailed explanation of the manner of sieaiurement of the RSV value is given below [0069] A. particularly effective water-soluble cationic polymer forthe inventive ani-ack formblations are Poly- DADMAC polymers (PolyDADMAC-polydillyldimethy] ammonium chloride) of moderately high to high molecular ‘eight. PolyDADMAC polymers having Mw values, as determined by GPC-T, ranging from about 200,000 Daltons ‘ 2,000,000 Dalions are useful in the inventive process however a particularly effective Miv for the PolyDADMAC ‘ooculating agent used in the inventive formulation is about 500,000 Daltons, A feature of the inventive formulation is the formation of fully tale sediments that could be easily stimed back into suspension with low shear agitation. la other tale-based anisack formulations, the tale wet sedi sents are frequently hard-packed or even in eases where they are not hard packed the tale wet sediments ae instead ‘gummy in nature and sill highly problematic to resuspend ‘with moderate agitation [0070] While PolyDADMAC is one water soluble cationic polymer that is prefered for use in the inveative ant-tck ormolations, other water soluble eationie polymers having a Mw range, as determined by GPC-T, ranging from about US 2020/0317952 Al 50,000 Daltons to 2,000,000 Daltoas and ability to form ily tale sediments that can be easily sired back into suspension with low shear agitation canbe used asthe Water toluble eationic polymer of the invention One or more ‘water soluble cationic polymers ean be used as part of the antitack formulation of the invention. Examples of other ceionie polymers include epichlorobydrn-cinsthylamine (Epi-DMA}, and polyquateeniums, including. cationic paly- scrylamides (CPAM) apd quaternized modifications of vari Oct. 8, 2020 the art can be used as the polyquaternary cationic polymer of the invention. It should be noted that inthe list below, polyquaterniuim-6 comesponas to the PolyDADMAC mien: tioned above, List of Polyguaternium ” [oo7) Fgura Petiusterten> Polpquatenins| Pelyuaeniens Patsquterien Palpuatercns| Polyqustemien 9 Pelpquterient0 Palate Polya Polyquatenint3 Pelyusterien Palpuaterten Pelyaerien Pelee Polpquterien 19 Pelyaerien Pelee Pelyqustemien 21 Potyquaterien-¥0 Pelpuateren 38 ‘thu, 22:7, poles wih Ios and NNN Nc ren ine Ponfbihloot etcrae hat -lineylanon pers um suse sponse Copa fata sn atin dnethynnonionty tase Fobudaibinedtanmones cee Copano i aatyionan ne 7 cpu fm an tea ety lnm tr of etn i quand wi ‘ier Homopls of NGinetvanio ol eter of mete wi ttenizet with emote utenae! honey elon Scpivn of vinyls alee nt ‘pl metry shenl char etamintn sale lot meen mete icyamictt metic copter quad wih dnt wilte {Thmtaninthimetsste hmaeimer Acolanedinehanaetiy nary mtn ide oper pot of vying yuna ‘Aloisi inetaninonentanize a seetiyherepoer ‘adic ed dneismnprpamie tn bros cop eoiyn fp asl a3 hoppers cpp of pv exalt ste nd 3epyoeplanise ‘oon of ts sd inydietnmonnan Cone {Gienaryanioat st oft cee exe wit uy cneiy anon sabe sponte ‘lek sonaer of Foti? and Povasenin.17 oy iene tl enn tnetysenoken Basan, Xeboumchal Nelo 2(G-nehye 06-2 ep 3b RiTintylanioopey Ney nd nih tye hou Hock of poses Tebcecntane Rueda ageytncsty sania clot) Coos of tinetynncetis heres si acta {Goan Ica Nh NN eh rps etucyksoneinc cya Coun of ttn banca, cin! wit inet Teponmeraf yest acyaide ad Galen immo Cioie Rbloveloiwtimptiaimspcn Gmanstyen See SMe wyatt mel mite Nsimipyaldone cops Copeync of Deine Ncebonpbenenehaedtoe and Netanya, cen siihdietyt mip “eehmer af ane, vinpymes, an geri iyi Temple of mie mi eta namconpy ecient hari sed met ene nests] metre cite cpa queried wih diet inser st payer with oh Fan apn pf Pick Gans nay in Hac Prana (amet ha NY ae ne Xan Mss NS ‘ous polyamine polymers. Some representative examples of symthetic polyamines that are suitable for quaterization linchide polyethyleneimine [0072] In terms of useful cationic polymers, it should also ‘be note that polyquateenary polymers are recommended for ED, use as the pKa value associated with polyamines is usually poly(amidoamine)s (PAA), poly(amino-co-esters (PAE) and poly(2-N.N-din- ‘ethylaminoethylmethaerylate) (PDMAEMA), In addition, the range of polyquaternary polymers commonly referred 10 ‘2 polyquatemiuns inthe cosmetic and personal care indus tty are stitable cationie polymers. Some common poly- ‘quaterniums known inthe art are found inthe Fist below. Tt should be understood tht this listing of polyguaterivms is ‘only exemplary and that other known polygtateriuins i too low int relation to the typical operable pl range of 85-105 for the tle bated aati-tack formulations of this invention sch thatthe polyamines will Iargely be present in ‘ non-protonated form. Consequently, this means that polyamines will not be cationic in the operable pH range, 0073] In an effort to judge the sizeof the tale agglomer- ates being produced by the interaction ofthe water soluble US 2020/0317952 Al ‘cationic polymer, when PolyDADMAC is preferably used, ‘with the individual tale platelets, testing was conducted to ‘examine the change in the particle size distribution of the tale pigmentation used therein, Using a Horiba LA-300 laser Tight scaring analyzer, the median panicle size and par- tile size distribution properties ofthe starting tale feedstock ‘was characterized and then the resultant changes in those particle size properties upon treatment of the tale with the ‘water soluble eationie polymer, ie, the PolyDADMAC polymer, that is employed in the formulation were exam- Ined. A shift in the overall particle size distribution is seen in FIG. 1 asa consequence of the eationi polymer behaving 15 &flocevlant and creating loosely bound agglomerates of the tale platelets. The net result is about a 25% increase ia the median particle size valne associated with the agglom- ‘erated tale species being eeated as compared to is starting tale coateo! without any water soluble cationic polymer, e.g. PolyDADMAC. 10074] While the exact mode(s) of interaction between ‘water soluble eationie polymer, eg., PolyDADMAC, and le particles in the inventive formulations are not totally iy crystalline, virgin form, tale i a layered silicate structure consisting of octa- hedral-coordinated Mg’ that is sandwiched between two layers of tetrahedra-

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