KR20020064929A - Storage stable, foamable, single latex/epoxy emulsion - Google Patents

Abstract

The present invention relates to compositions useful for producing latex foams comprising bimodal latex and epoxy emulsions. In addition, the compositions may contain fillers, surfactants, bubble tackifiers, foam stabilizers, foam enhancers, catalysts that improve curing time during processing, viscosity reducers, compounds that improve elasticity, and antioxidants.

Description

Storage stable, foamable, single latex / epoxy emulsion

The present invention relates to a novel single latex / epoxy emulsion.

Latex foams are well known materials. Latex is in emulsion form when delivered to the end user. In certain applications, the emulsions are used in the manufacture of flooring, wallpaper, shoe linings and nonwoven materials. End users can add fillers to enhance the desired properties prior to coating the foam layer prepared from this emulsion on the provided support. Since the products can be stored for a long time, a stable emulsion will be highly desirable. Prior attempts to provide stable emulsions require the use of curable pastes, gelling agents, reaction promoters or stabilizers. Highly preferred are latex emulsions that are stable and do not require the curable pastes, gelling agents, reaction promoters or stabilizers described above. Particular preference is given to latex emulsions which crosslink in a backing process such that the desired final properties have sufficient strength.

The present invention provides a solution to one or more of the disadvantages and drawbacks described above.

In certain broad respects, the invention is an emulsion comprising latex and epoxy compounds. The latex is preferably a carboxylated styrene-butadiene polymer with a bimodal particle size. The composition may also contain a stabilizing surfactant as a crosslinking agent to improve the physical properties of the resulting foam. The composition may employ a binary catalyst system. The composition may also include performance enhancing additives such as paraffin wax and silicone anti-sticking agents. Advantageously, latex emulsions can be fed at the time of preparation which organic or inorganic fillers can be added to enhance the desired properties. More advantageously, additional curable pastes, gelling agents, reaction promoters or stabilizers are not necessary in the practice of the present invention. In certain non-limiting embodiments the emulsion is stable for 12 months at ambient temperature. During processing, the resulting foam will crosslink in a backing process that enhances the ultimate final properties so that the product has sufficient strength. Advantageously, the present invention provides a simplified production process and eliminates the need for the use of heavy metals, sulfur or nitrosamine release promoters commonly used to make such foams.

In another broad aspect, the present invention is a manufacturing method useful for forming an article, including coating a support formed from a composition comprising a bimodal latex and an epoxy emulsion in a support. In another broad sense, the present invention is a method useful for forming a composition useful for preparing latex foams, including blending bimodal latex and epoxy emulsions.

The bimodal latex used in the present invention may be characterized by having two separate and distinct particle size distributions, having a high solids content, good high shear flowability and good low shear viscosity. Large polymer particles of bimodal latex have heterogeneous properties.

The bimodal latex used in the present invention may comprise a proportion of large latex particles and a proportion of small latex particles. Preference is given to using large particles which are 2.5 to 10 times, most preferably 3 to 4 times the diameter of the small particles. It is also desirable for the weight percentage of large particles in the latex formulation to exceed the weight percentage of small particles. For example, a latex composition composed substantially of styrene / butadiene comprising 50 to 98% by weight of large particles, preferably 60 to 80% by weight and 2 to 50% by weight of small particles, preferably 20 to 40% by weight. Can be used. It goes without saying that the proportion of large particles and the proportion of small particles, the size distribution of particles, and the amount of solids in the formulation used may depend on the specific latex used and / or the specific application device used.

"Large latex particles can vary in diameter from 1500 micrometers (0.15 micrometers) to 10,000 micrometers (1 micrometers), more preferably 1800 micrometers (0.18 micrometers) to 3000 micrometers (0.3 micrometers). The particles may vary in size from 500 microns (0.05 micrometers) to 1000 microns (0.1 micrometers), more preferably 600 microns (0.06 micrometers) to 8000 micrometers (0.08 micrometers). "

Heterogeneous polymer particles may be used in the practice of the present invention to provide large polymer particles of bimodal latex. Of particular interest are the types of polymer particles described in US Pat. No. 4,134,872. That is, the heterogeneous polymer particles are characterized by having a hard resinous polymer forming core or cored region of the copolymer, and preferably a hard copolymer shell or shell like region. Also useful herein are fusible heterogeneous polymer particles having a hard core or cored region and a soft shell or shelled region.

Roughly speaking, large heterogeneous polymer particles have relatively soft polymer regions and relatively hard polymer regions. It is believed that the hard polymer regions provide the desired gloss properties for the paint, while the soft, defoamable polymer regions provide the desired bonding properties for the paint.

Heterogeneous polymer particles typically comprise 10 to 90% by weight of the hard polymer region, preferably 40 to 75% by weight and 10 to 90% by weight of the soft polymer region, preferably 25 to 60% by weight. Generally, the hard polymer region may comprise 80 to 100% by weight of a monomer (eg, monovinylidene aromatic monomer) which, upon polymerization, forms the hard component of the hard polymer region; 0 to 20% by weight, preferably 10 to 20% by weight, of open chain aliphatic conjugated diene monomers or other such monomers which provide softening properties to the hard region upon polymerization; And hydrophilic, hydrolyzable or ionizable monomers, for example 0-10% by weight acrylic acid, preferably 0.5-5% by weight. The soft polymer region may be a monoethylenically unsaturated monomer (e.g., a monomer capable of forming a hard component of the polymer region, such as a monovinylidene aromatic monomer, or a monomer capable of forming a soft component of the soft polymer region, eg For example, acrylate monomer, or a combination thereof) 30 to 70% by weight, preferably 40 to 60% by weight; Soft monomers such as 70 to 30% by weight, preferably 60 to 40% by weight of conjugated open chain dienes; And from 0.1 to 10% by weight, preferably from 2 to 6% by weight, of hydrophilic, hydrolyzable or ionizable monomers. Typically, the minimum deposition temperature of the latex composition is less than about 30 ° C. Preferred heterogeneous polymer particles include carboxylated monovinylidene / conjugated diene containing polymer particles. For example, carboxylated styrene / butadiene containing polymer particles with heterogeneous properties are particularly useful.

The small polymer particles of the present invention have sufficient adhesion properties for the coating application to the backing material which provides the elastic foam backing layer in which the resulting particles adhere to the second structure, which is a support for the foam layer. It is prepared from a combination of monomers. In practice, any latex can be used that can be used as a foam paint and can be prepared for use in a bimodal composition. It is also desirable to carboxylate the latex to increase colloidal stability, thus increasing the degree of binding to paper and pigments. Examples of suitable monomers to provide the carboxylate properties include acrylic acid, methacrylic acid, itaconic acid and fumaric acid. Typically, the minimum deposition temperature of the latex composition is less than about 25 ° C. Representative monomers useful for making the latex of the present invention and methods for making individual discrete particles are described in US Pat. Nos. 3,404,116 and 3,399,080. Examples of suitable monomers for preparing the latex of the present invention include olefins such as ethylene and propylene, vinyl acetate, alkyl acrylates, hydroxyalkyl acrylates, alkyl methacrylates, hydroxyalkyl methacrylates, acrylamides, In addition to n-methylloylacrylamide, monomers such as vinyl chloride and vinylidene chloride may be included. Particularly preferred latexes are modified styrene / butadiene latexes such as styrene / butadiene / acrylic acid, styrene / butadiene / acrylic acid / itaconic acid, styrene / butadiene / vinylidene chloride, styrene / butadiene / beta-hydroxyethylacrylate, Styrene / butadiene / beta-hydroxyethylacrylate / acrylic acid, styrene / n-butylacrylate / acrylic acid, methyl methacrylate / n-butylacrylate / acrylic acid, vinyl acetate / acrylic acid, vinyl acetate / n-butylacrylate / Acrylic acid and / or styrene / n-butylacrylate / butadiene / acrylic acid. Mixtures of carboxylic acids can be used in the latex described above.

In the preparation of small particle size polymer latex, it is preferred to use relatively small polymer particles (eg, "seed" latex) when initiating particle formation. Next, the latexes having separate and distinct particle sizes are blended together to obtain a bimodal latex composition. Alternatively, bimodal latex can be prepared by intermediate addition of seed latex during the heterogeneous particle emulsion polymerization process. For example, a large heterogeneous polymer particle having a hard core region and a soft shell region and a soft particle similar to the shell properties of the large particles can be prepared simultaneously with or after forming the core region of the large particles and forming the shell region of the large particles. Seed latex may be added to provide small polymer particles with properties. If necessary, any latex formulation can be concentrated.

In the practice of the present invention, it is preferred to use carboxylated latex consisting of a copolymer of a vinyl aromatic monomer and an unsaturated carboxylic acid monomer. In a preferred form, the copolymer may further comprise a diene monomer. Vinyl aromatic monomers are styrene, alpha-methylstyrene, a, r-methylstyrene, a, r-ethylstyrene, alpha-a, r-dimethylstyrene, a, r, a, r-dimethylstyrene, a, rt- Butylstyrene, vinylnaphthalene, methoxystyrene, cyanostyrene, acetylstyrene, monochlorostyrene, dichlorostyrene and other halostyrenes, and mixtures thereof. Vinyl aromatic monomers may be present in any effective amount. The vinyl aromatic monomer may be present in an amount of about 0 to 75% by weight based on the total weight of the polymer resin. Preferably, the vinyl aromatic monomer is present in an amount of about 35 to 70 weight percent.

The ethylenically unsaturated carboxylic acid may be a monocarboxylic acid, dicarboxylic acid or polycarboxylic acid, for example acrylic acid, methacrylic acid, fumaric acid, maleic acid, itaconic acid, derivatives thereof and mixtures thereof.

The ethylenically unsaturated carboxylic acid monomer may be present in an amount of about 0.5 to 25 weight percent based on the total weight of the polymeric resin. Preferably, the ethylenically unsaturated acid monomer is present in an amount of about 1 to 5% by weight, more preferably 3 to 5% by weight, based on the total weight of the copolymer.

The diene monomer, if present, may be selected from butadiene, isoprene, divinylbenzene, derivatives thereof and mixtures thereof. Preference is given to 1,3-butadiene monomers. The diene monomer may be present in an amount of about 0 to 85% by weight, preferably about 30 to 65% by weight, based on the total weight of the polymer resin.

The latex may comprise additional ethylenically unsaturated monomeric components or components. Specific examples of such ethylenically unsaturated compounds include methyl methacrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, lauryl methacrylate, phenyl acrylate, acrylonitrile, methacryl Nitrile, ethylchloroacrylate, diethyl maleate, polyglycol maleate, vinyl chloride, vinyl bromide, vinylidene chloride, vinylidene bromide, vinyl methyl ketone, methyl isopropenyl ketone and vinyl ethyl ester. Derivatives thereof and mixtures thereof.

The latex may comprise styrene / butadiene / acrylic acid copolymer or styrene / butadiene / hydroxyethylacrylate / itaconic acid copolymer. Latexes can also include mixtures of such copolymers. Mixtures of styrene / butadiene / acrylic acid with styrene / butadiene / hydroxyethylacrylate / itaconic acid polymers in terms of weight may be used.

Such monomers may be copolymerized in aqueous emulsions containing surfactants and modifiers under time, temperature, pressure and shaking conditions in accordance with the well known principles of emulsion polymerization.

In the practice of the present invention, an epoxy emulsion is used with bimodal latex.

The epoxy resin component is suitably any compound having at least one 1,2-epoxy group. Generally, the epoxy resin component is saturated or unsaturated aliphatic or cycloaliphatic, aromatic or heterocyclic, and can be substituted or unsubstituted. The epoxy resin may be selected from polyglycidyl ethers of bisphenol compounds, polyglycidyl ethers of novolak resins and polyglycidyl ethers of polyglycols. Mixtures of two or more epoxy resins may also be used.

Preferred epoxy resins are polyglycidyl ethers of bisphenol compounds. Epoxy resins of bisphenol A or bisphenol F have been found to be suitable. Epoxy resins can be formed as reaction products of epichlorohydrin and bisphenol A or bisphenol F or derivatives thereof.

The epoxy resin component of the curable latex composition may further comprise an emulsifier or surfactant. Anionic or nonionic surfactants can be used. Nonionic surfactants are preferred. Ethoxylated nonionic surfactants are more preferred. Most preferred are ethoxylated nonionic surfactants having an HLB of about 16-20. Nonionic surfactants sold under the trade name “Capcure 65” from Diamond Shamrock Corporation have been found to be suitable. Emulsifiers or surfactants may be present in amounts of about 5 to 10 weight percent based on the weight of the epoxy resin. Preferably the emulsifier or surfactant is present in an amount of at least about 8% by weight. Where nonionic surfactants or emulsifiers are included, the epoxy resin emulsions thus formed have been found to provide a relatively reduced particle size. Reduced particle size provides improved stability in epoxy resins, and then in curable latex compositions.

Preferably, in the preparation of the epoxy resin emulsion, the epoxy resin and the surfactant or emulsifier are homogenized by a suitable high shear blender. The particle size of the epoxy resin emulsion thus prepared may be about 2-5 times the particle size of tile latex (eg, about 3 times the particle size of the latex (eg, less than 1000 nm)). High shear homogenization may continue during phase inversion to assist in obtaining small particle size.

The level of epoxy resin used will vary widely depending on the type of epoxy resin and carboxylic acid used, as well as the properties of the final product required.

Low viscosity resins are preferred because they are easy to produce stable emulsions from them. Representative commercial epoxy resins include those sold under the trade names DER ^R 351-A and DER ^R 330 (The Dow Chemical Company).

The epoxy resin emulsion component as described above comprises an organo-soluble or organo-miscible catalyst. Suitable organo-soluble or organo-miscible catalysts are phosphonium salts such as ethyltriphenyl phosphonium acetate and ethyltriphenyl phosphonium phosphate and quaternary ammonium salts such as alkylbenzyl dimethyl ammonium chloride, Benzyltrimethyl ammonium chloride, methyltrioctyl ammonium chloride, tetraethyl ammonium bromide, N-dodecyl pyridinium chloride and tetraethyl ammonium iodide. Preferred organo-soluble or organo-miscible catalysts are ethyltriphenyl ammonium acid acetate, ethyltriphenyl phosphonium phosphate and methyltrioctyl ammonium chloride. Ethyltriphenyl phosphonium phosphate is not readily available, but it can be prepared by reaction with phosphoric acid from ethyltriphenyl phosphonium acetate.

The organo-soluble or organo-miscible catalyst may be present in an amount of about 0.1 to about 10.0 weight percent, preferably 0.3 to 2.0 weight percent based on the weight of the epoxy resin.

The water soluble catalyst curing agent may be present in an amount of about 0.1 to about 15 weight percent based on the weight of the copolymer. Suitable catalyst curing agents include tridimethyl aminomethyl phenol, dimethyl aminomethyl phenol, dicyandiamide, polyamides such as ethylenediamine, diethylenetriamine, triethylene tetramine, tetraethylene pentamine and isophorone diamine. .

Curable latex compositions according to the invention may further comprise standard blending components such as fillers, thickeners, antioxidants, dispersants, pH adjusters and flame retardants.

The pH of the mixture of reactive latex and co-reactive material can, if necessary, be adjusted by the addition of conventional acidifying or alkalizing agents, for example, dilute aqueous solutions of acetic acid, citric acid, dilute mineral acid, ammonium hydroxide and alkali metal hydroxides. have.

The shelf life of the blend of latex and epoxy resin emulsions can be improved by selecting the pH of the blend such that a significant portion of the carboxyl groups on the latex copolymer are protonated. It has been found that extended shelf life can be obtained when the pH is maintained in the range of about 6 to 6.5. The pH can be adjusted in any suitable manner. It has been found that adding the estimated amount of ammonia is suitable for pH adjustment.

In addition to bimodal, epoxy emulsions may include additional components and additives. Such additional components may include, but are not limited to, 0.1-10 parts per 100 dry parts of the bimodal latex, preferably paraffin wax emulsions for improving bubble adhesion and water resistance. The composition may comprise 0.1 to 5 parts, preferably about 1 part, of bubble tackifiers, such as silicone foam tackifiers, used to prevent the bubble walls of the foam from sticking together. The composition may comprise 0.1 to 5 parts, preferably about 3 parts, suspension of foam stabilizer, for example disodium N-cetostearyl sulfosuccinimate. The composition may comprise 0.1 to 5 parts, preferably about 1 part, of the foam enhancer. The composition, when present, may comprise 0.1 to about 2 parts, preferably about 0.4 parts, of any filler dispersant, such as polyphosphate dispersant, added to enhance dispersion of the inorganic (mineral) filler. . The composition comprises 0.1 to 5 parts of an aqueous mixture consisting of a catalyst or binary catalyst, such as 2,4,6-tri (dimethylaminomethyl) phenol and ethyltriphenyl phosphonium acid ester, which improves curing time during processing, Preferably about 1.5 parts. The composition may comprise 0.1 to 2 parts, preferably 0.5 parts, of ammonium sulfate to reduce the viscosity. The composition may comprise 0.1 to 10 parts, preferably about 4 parts, of an epoxy emulsion which acts as a crosslinking agent. The composition may include 0.1 to 5 parts, preferably 1.5 parts, of a compound for improving elasticity, for example, ammonium oleate. The composition may comprise 0.1 to 5 parts of one or more antioxidants, for example about 1.2 parts of a blend of polymeric containment phenol and ditridecyl dithio dipropionate.

The composition of the present invention may further comprise one or more mineral fillers. Examples of mineral fillers are those known in the art, such as clays, titanium dioxide, carbon, silicates, zinc oxide, calcium carbonate, zinc sulfide, calcium titanate and titanate whiskers, glass flakes, clays, kaolins and glass fibers It includes. The amount of filler used may vary depending on the density of the filler and the desired application properties. Each of the above ingredients is mixed in an aqueous medium to obtain a formulation that is about 10 to about 90 weight percent solids.

Of course, the various components of the curable latex composition of the present invention can be separated until just before use because of their ambient temperature curing properties. In certain cases, two or more components that do not react with each other may be premixed. For example, latex and a water soluble catalyst curing agent may be provided as one component, and an epoxy emulsion containing an organo-soluble or organo-miscible catalyst may be provided as another component. Latexes can also be combined with epoxy emulsions containing organo-soluble or organo-miscible catalysts, and then added separately just before using the water soluble catalyst curing agent. Upon compounding, the composition may be used immediately or further diluted with water depending on the solids level desired for the particular application method used. Advantageously, however, the compositions of the present invention containing bimodal latex and epoxy emulsions can be mixed and stored for a long time, for example about one year.

The curing temperature can be any suitable temperature above the ambient temperature. Indeed, some curing occurs at ambient temperature, but because the reaction time is extremely delayed, this temperature is impractical.

Preferred temperature ranges are about 120-180 ° C. The residence time is variable. Factors affecting residence time include components of temperature, film thickness, moisture content and curable paint. For temperatures in this range, a total residence time of about 5 to 10 minutes has been found to be suitable.

The universality of the present invention should not be limited in any way by the theory based on the results of our experiments, but the water soluble catalyst curing agent is somewhat transferred to the epoxy resin upon drying, and not only polymerization of the epoxy resin, but also carboxyl- It can be assumed to promote the epoxy reaction. It also makes the latex more miscible with the epoxy resin. Organic soluble catalysts exhibit suitable activity for acid-epoxy reactions, so that resin emulsions precatalyzed with organo-soluble catalysts achieve a long shelf life. Organic soluble catalysts also make the carboxylated latex polymer more miscible with epoxy resins. Therefore, it is reasonable to assume that the latex particles crosslink with the built-in network of homopolymerized epoxy resins.

The foaming step can be carried out in any suitable conventional manner. Foams or foams are known in the art for the decomposition of gas-releasing agents which chemically react with components in the mixture by releasing non-condensable gases such as nitrogen or by releasing non-condensable gases as reaction products. By inducing it. Mixtures of reactive latex with co-reactive materials are also formed by means of granules or by the use of devices having commercially available foam heads. Known foaming aids, for example sodium lauryl sulfate, or foam stabilizers, for example potassium oleate, can be added if necessary. Preferably such added material should be non-reactive with the reactive groups in the latex polymer or co-reactive material, and therefore the preference will depend on the composition of the mixture. However, other soaps, emulsifiers, wetting agents and surfactants may be used, although they may be reactive to a limited extent.

The foamed mixture can be injected into a mold, sprayed onto a flat tray or belt, or applied to a support. For the purposes of this specification, the term "support" refers to any form, such as cloth, fabric, leather, wood, glass or metal, or any form that adheres to the foamed mixture when applied and after curing. It is defined as a backing material.

In a preferred embodiment in which the foam is used as the fabric backing material, the foam can be applied to the fabric prior to drying and curing. Typical foams formed from continuous foam will have a density in their wet state in the range of about 200 to 400 g / l, preferably about 350 g / l. The foam can be applied to the support using a doctor blade.

Once formed, the foam can be cured by drying at a temperature of about 110-150 ° C. Drying and curing can be carried out in a forced air circulation oven. The internal temperature of the oven should preferably be kept at or above about 120 ° C.

The following examples illustrate the invention and are not intended to limit the scope of the invention or the claims that follow. Unless otherwise indicated, all percentages are parts by weight.

In a stainless steel reactor equipped with a nitrogen inlet, mechanical stirrer and condenser, 20.75 parts of bisphenol A and D.E.R. 68.48 parts of 330 epoxy resin are heated to 130 ° C. while stirring. 0.05 part of a 70% solution of the Al catalyst in methanol is added and then the temperature is raised to 150 ° C. to initiate exotherm. Under adiabatic conditions, peak exotherm that occurs at about 180 ° C is observed. 30 minutes after the peak exotherm, 0.026 parts of methyl-para-toluene sulfonic acid ester is added while cooling the resin to 120 ° C. Add 4.3 parts of Aerosol 108 (surfactant, ICI), 1.4 parts of Disponil TA 430 (Henkel) and Aerosol TO 75, then mix for 30 minutes while lowering the temperature further to 90 ° C. A final epoxy equivalent weight (EEW) value of 500 ± 20 is obtained. The resin product is dispersed in a centrifugal pump to yield an epoxy emulsion having a volume average particle size of less than 0.6 microns, an EEW value of 780-910 and a solids content of 56-61%.

An emulsion according to the invention is prepared by mixing the following ingredients: 100 parts of bimodal carboxylated styrene-butadiene latex, 4 parts of paraffin wax emulsion (IMPERMAX T940, manufactured by Govi), which improves foam adhesion and water resistance, bubbles of foam 1 part silicone foam anti-sticking agent (PROSIL E70, manufactured by Stephenson Brothers), used to prevent walls from sticking together, foam stabilizer (EMPINIM MKB, disodium N-cetostearyl sulfosuccinimate, manufactured by Albright and Wilson Surfactants Group) 3 parts, foam enhancer (SLS) 1 part, filler dispersant (CALGON PT, 0.4 parts polyphosphate dispersant added to improve dispersion of inorganic filler), binary catalyst (ETPPAAc to improve curing time during processing) / Ancamine K54, Aqueous mixture of 2,4,6-tri (dimethylaminomethyl) phenol and ethtriphenylphosphonium acid ester, manufactured by Morton Performance Che micals Europe) 1.5 parts, 0.5 parts of ammonium sulfate to reduce viscosity, 4 parts of epoxy emulsion to act as a crosslinking agent, 1.5 parts of ammonium oleate to improve elasticity and antioxidants (polymeric blocking phenol (WINGSTAY L) and second antioxidant , EMULSION L, consisting of ditridecyl dithio dipropionate (DTDTDP) from Great Lakes, Austria) 1.2 parts.

By mixing 100 parts by weight of the dry weight of the emulsion of the preceding paragraph and 160 parts by weight of the dry calcium carbonate, the emulsion was used in a foam backing process, with a solids content of 78% and a viscosity of 3,500 cps (Brookfield Spindle 4 at 20 rpm). To provide the product. Fillers are used to improve the elasticity and strength of the final foam. Calcium carbonate is used as extender in the foam production process. Calcium carbonate is preferably selected to be easily dispersible at high addition amounts, such as 200 parts per 100 parts of dry latex, exhibit low foam viscosity and stability, and provide good final foam properties. Representative calcium carbonate fillers are generally available from Omya as BL 200. The product is mechanically foamed using air to reduce density, applied onto a support, and dried in an oven at about 140 ° C. to remove moisture from the system.

Further modifications and further aspects of the invention will be apparent to those skilled in the art in view of the above description. Accordingly, the above description should be construed as illustrative only, and to teach those skilled in the art how to practice the invention. It is a matter of course that the forms of the invention presented and described herein should be taken as illustrative embodiments. Equivalent elements or materials may be substituted for those exemplified and described herein, and certain features of the invention may be used independently of the use of other features, all of which are skilled in the art because of the advantages of the techniques of the invention. Will be self explanatory.

Claims (45)

Compositions useful for making latex foams, including bimodal latex and epoxy emulsions. The composition of claim 1 further comprising a filler. The bimodal latex according to claim 1, wherein the bimodal latex is styrene / butadiene / acrylic acid, styrene / butadiene / acrylic acid / itaconic acid, styrene / butadiene / vinylidene chloride, styrene / butadiene / beta-hydroxyethylacrylate, styrene / butadiene / beta Hydroxyethyl acrylate / acrylic acid, styrene / n-butylacrylate / acrylic acid, methyl methacrylate / n-butylacrylate / acrylic acid, vinyl acetate / acrylic acid, vinyl acetate / n-butylacrylate / acrylic acid, styrene / n-butylacrylate / butadiene / acrylic acid or a combination thereof. The composition of claim 1 wherein the bimodal latex is carboxylated styrene-butadiene latex. The composition of claim 1 comprising about 0.1 to 10 parts of an epoxy emulsion per 100 parts of bimodal latex. The composition of claim 1 wherein the epoxy is a polyglycidyl ether of a bisphenol compound. The composition of claim 1 wherein the epoxy is a polyglycidyl ether of a bisphenol compound, a polyglycidyl ether of a novolak resin or a polyglycidyl ether of polyglycol. The composition of claim 1 further comprising a paraffin wax emulsion. The composition of claim 1 further comprising a cell detackifier. The composition of claim 1 further comprising a foam stabilizer. The composition of claim 1 further comprising a foam booster. The composition of claim 1 further comprising a dispersant for the filler. The composition of claim 1, further comprising a catalyst that reduces curing time. The composition of claim 1 further comprising an elasticity enhancer. The composition of claim 1 further comprising an antioxidant. A method useful in forming an article comprising applying a foam formed from a composition comprising a bimodal latex and an epoxy emulsion to a support. The method of claim 16, wherein the composition further comprises a filler. The method of claim 16, wherein the bimodal latex is styrene / butadiene / acrylic acid, styrene / butadiene / acrylic acid / itaconic acid, styrene / butadiene / vinylidene chloride, styrene / butadiene / beta-hydroxyethylacrylate, styrene / butadiene / beta Hydroxyethyl acrylate / acrylic acid, styrene / n-butylacrylate / acrylic acid, methyl methacrylate / n-butylacrylate / acrylic acid, vinyl acetate / acrylic acid, vinyl acetate / n-butylacrylate / acrylic acid, styrene / n-butylacrylate / butadiene / acrylic acid or combinations thereof. The method of claim 16, wherein the bimodal latex is carboxylated styrene-butadiene latex. The method of claim 16, wherein the composition comprises about 0.1 to 10 parts of an epoxy emulsion per 100 parts of bimodal latex. The method of claim 16 wherein the epoxy is a polyglycidyl ether of a bisphenol compound. The method of claim 16 wherein the epoxy is a polyglycidyl ether of a bisphenol compound, a polyglycidyl ether of a novolak resin or a polyglycidyl ether of polyglycol. The method of claim 16, wherein the composition further comprises a paraffin wax emulsion. 17. The method of claim 16, wherein the composition further comprises a bubble antitack agent. The method of claim 16, wherein the composition further comprises a foam stabilizer. The method of claim 16, wherein the composition further comprises a foam enhancer. The method of claim 16, wherein the composition further comprises a dispersant for the filler. The method of claim 16, wherein the composition further comprises a catalyst that reduces curing time. The method of claim 16, wherein the composition further comprises an elasticity enhancer. The method of claim 16, wherein the composition further comprises an antioxidant. A method useful for forming a composition useful for making latex foams, including blending bimodal latex and epoxy emulsions. The method of claim 31, wherein the composition further comprises a filler. The method of claim 31 wherein the bimodal latex is styrene / butadiene / acrylic acid, styrene / butadiene / acrylic acid / itaconic acid, styrene / butadiene / vinylidene chloride, styrene / butadiene / beta-hydroxyethylacrylate, styrene / butadiene / beta Hydroxyethyl acrylate / acrylic acid, styrene / n-butylacrylate / acrylic acid, methyl methacrylate / n-butylacrylate / acrylic acid, vinyl acetate / acrylic acid, vinyl acetate / n-butylacrylate / acrylic acid, styrene / n-butylacrylate / butadiene / acrylic acid or combinations thereof. 32. The method of claim 31, wherein the bimodal latex is carboxylated styrene-butadiene latex. 32. The method of claim 31 wherein the composition comprises about 0.1 to 10 parts of an epoxy emulsion per 100 parts of bimodal latex. 32. The method of claim 31 wherein the epoxy is a polyglycidyl ether of a bisphenol compound. 32. The method of claim 31 wherein the epoxy is a polyglycidyl ether of a bisphenol compound, a polyglycidyl ether of a novolak resin or a polyglycidyl ether of polyglycol. 32. The method of claim 31, wherein the composition further comprises a paraffin wax emulsion. 32. The method of claim 31, wherein the composition further comprises a bubble antitack agent. The method of claim 31, wherein the composition further comprises a foam stabilizer. 32. The method of claim 31, wherein the composition further comprises a foam enhancer. 32. The method of claim 31, wherein the composition further comprises a filler dispersant. 32. The method of claim 31, wherein the composition further comprises a catalyst that reduces curing time. The method of claim 31, wherein the composition further comprises an elasticity enhancer. 32. The method of claim 31, wherein the composition further comprises an antioxidant.