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WO2021094249A1 - Silicone coating - Google Patents

Silicone coating Download PDF

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Publication number
WO2021094249A1
WO2021094249A1 PCT/EP2020/081483 EP2020081483W WO2021094249A1 WO 2021094249 A1 WO2021094249 A1 WO 2021094249A1 EP 2020081483 W EP2020081483 W EP 2020081483W WO 2021094249 A1 WO2021094249 A1 WO 2021094249A1
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WO
WIPO (PCT)
Prior art keywords
coating
free
silicone rubber
liquid
filler
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2020/081483
Other languages
French (fr)
Inventor
Miles CAIN
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Individual
Original Assignee
Individual
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Filing date
Publication date
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Publication of WO2021094249A1 publication Critical patent/WO2021094249A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/128—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with silicon polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/35—Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
    • C08L83/04—Polysiloxanes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/04—Polysiloxanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D06N3/005—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers obtained by blowing or swelling agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/28—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by elimination of a liquid phase from a macromolecular composition or article, e.g. drying of coagulum
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/02—Dispersion
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/02—Dispersion
    • D06N2205/023—Emulsion, aqueous dispersion, latex
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/04—Foam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/12—Treatments by energy or chemical effects by wave energy or particle radiation
    • D06N2207/123—Treatments by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation, e.g. IR, UV, actinic light, laser, X-ray, gamma-ray, microwave, radio frequency
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D06N2209/106—Roughness, anti-slip, abrasiveness
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/10—Clothing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/03—Fibrous web coated on one side with at least two layers of the same polymer type, e.g. two coatings of polyolefin
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0006—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using knitted fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
    • D06N3/0081—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments by wave energy or particle radiation

Definitions

  • the present invention relates to a silicone coating, and in particular to a foamed silicone composition for use on various pliable supports such as garments.
  • Silicone coatings are known to have good durability and anti-slip properties. Conventionally, silicone coatings have been applied to pliable supports, such as for example textiles including hosiery, stockings, brassieres or dresses, so as to reduce or prevent slipping or movement of garment while they are being worn by a user. It has however been found that the silicone coatings can cause discomfort and can irritate or inflame the skin of some users. The risk of discomfort is increased when garments are worn for prolonged periods of time.
  • the present invention provides a method of forming a filler-free foamed silicone coating, comprising: forming a filler-free water-in-oil emulsion by combining: a first liquid silicone rubber component comprising:
  • a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; applying the filler-free water-in-oil emulsion to a substrate to provide a filler-free silicone coating comprising an upper free surface and an opposed lower surface configured to be in contact with the substrate; and curing the filler-free silicone coating using a direct heat source configured to apply heat to the upper free surface of the coating to provide a foamed silicone coating comprising a plurality of aqueous liquid-containing closed cells located therein and to embed at least a portion of the lower surface of the coating into the substrate.
  • the filler-free water-in-oil emulsion may be applied to the substrate prior to curing the coating.
  • the water-in-oil emulsion may be applied to the substrate as a coating while being simultaneously cured by exposure to the direct heat source.
  • filler-free is used herein to mean that no additional filler composition has been introduced to the emulsion, such as for example, but not to be limited to, inorganic fillers such as sililca-based fillers, for example fused silica.
  • any suitable direct heat source may be used to cure the coating.
  • the direct heat source is an infra red heat source.
  • the filler-free silicone coating may be cured at any suitable temperature.
  • the filler-free silicone coating is cured at a temperature in the range of from 100 °C to 150 °C.
  • the filler-free water in oil emulsion comprises a ratio of first liquid silicone rubber component to second silicone rubber component in the range of between 1: 10 and 10:1, preferably in the range of between 1: 5 and 5: 1, more preferably in the range of between 1: 2 and 2: 1, for example about 1:1.
  • the first liquid silicone rubber component comprises a first liquid silicone rubber having a shore A hardness in the range of between 20 and 30, preferably in the range of between 25 and 28, for example about 26.
  • the second liquid silicone rubber comprises a shore A hardness in the range of between 30 and 50, preferably between 35 and 45, for example about 40.
  • the filler-free water in oil emulsion has a shore A hardness in the range of between 1 and 10, preferably between 5 and 10, for example about 7.
  • the viscosity of the first liquid silicone rubber component is in the region of between 90 and 120.
  • the viscosity of the second liquid silicone rubber component is in the region of between 140 and 150.
  • the catalyst may be any suitable catalyst.
  • the catalyst is a platinum catalyst.
  • the first and/or second liquid silicone rubber may for example comprise one or more water based silicone elastomers.
  • one or more, preferably each, of the first and/or second liquid silicone rubber comprises organopolysiloxanes.
  • one or more, preferably each, of the first and/or second liquid silicone rubber comprises a platinum catalyst polydimethylsiloxane.
  • the aqueous liquid is water.
  • the water may for example be present as one or more of: distilled, still, carbonated water, or a mixture thereof.
  • the weight of the foamed filler-free silicone coating is in the range of between 1 g/m and 50 g/m, preferably between 3 g/m and 50 g/m, for example between 3 g/m and 15 g/m.
  • foamed filler-free silicone coating may have any suitable thickness and/or width depending on the requirements for the coating.
  • a foamed filler-free silicone coating comprising an upper free surface and an opposed lower surface, in which the foamed filler- free silicone coating comprises a plurality of aqueous liquid-containing closed cells located between the upper free surface and lower surface thereof.
  • the foamed filler-free silicone coating may be formed from a water-in-oil emulsion prepared by combining: a first liquid silicone rubber component comprising: 99.4% to 99.9 % of a first liquid silicone rubber, and 0.1% to 0.6% of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising 100% of a second liquid silicone rubber.
  • the lower surface is preferably configured to be contacted with or embedded into a contact surface, such as for example a surface of a garment, such as for example a surface of one or more of: hosiery, stockings, brassieres or dresses,
  • the centre-point of the coating may extend midway between the upper free surface and the opposed lower surface thereof.
  • the upper region of the coating is herein defined as being the region extending between the centre-point and the upper free surface of the coating.
  • the lower region of the coating is herein defined as being the region extending between the centre-point and the lower surface of the coating.
  • the coating comprises two layers located between the upper free surface and the opposed lower surface of the coating.
  • the coating may comprise a first layer providing a lower region of a coating and a second layer providing an upper region of a coating.
  • a first layer is located adjacent, and preferably providing, the lower surface of the coating; and a second layer is located adjacent, and preferably providing, the upper free surface of the coating.
  • one of the first and second layers may for example be a barrier layer.
  • a plurality of aqueous liquid-containing closed cells may be located within or at surface the upper region of the coating.
  • the majority of the aqueous liquid- containing closed cells may be located within the upper region of the coating, for example more than 50%, preferably more than 60%, more preferably more than 80%, more preferably more than 90%, for example about 95% of the aqueous liquid-containing closed cells may be located within the upper region of the coating.
  • the upper surface and/or the upper region of the coating preferably comprises substantially all of the aqueous liquid-containing closed cells.
  • the minority of the aqueous liquid-containing closed cells may be located within the lower region of the coating, for example less than 50%, preferably less than 40%, more preferably less than 20%, more preferably less than 10%, for example about 5% of the aqueous liquid- containing closed cells may be located within the lower region of the coating.
  • between 5% and 50%, preferably between 10% and 40% of the aqueous-liquid containing closed cells may be located within the lower region of the coating.
  • the lower surface and/or the lower region of the coating is preferably substantially free from aqueous liquid-containing closed cells.
  • the aqueous liquid-containing closed cells may be uniformly dispersed within the coating.
  • each aqueous liquid-containing closed cell within the coating may be uniform.
  • the coating may comprise a plurality of aqueous liquid-containing closed cells with varying volumes.
  • the total volume is the sum of the volume of all of the aqueous liquid containing closed cells within the coating or a particular region of a coating.
  • the total volume of the aqueous liquid-containing closed cells located within the upper region of the coating may be greater than the total volume of the aqueous liquid-containing closed cells located within the lower region of the coating.
  • the total volume of the aqueous liquid-containing closed cells located within the lower region of the coating may be greater than the total volume of the aqueous liquid-containing closed cells located within the upper region of the coating.
  • one or more regions of the coating may be substantially free of aqueous liquid-containing closed cells.
  • the presence of the aqueous-liquid containing closed cells help provide a malleable upper region of the silicone coating which enables the coating to have an improved ability to conform to the shape of the user's skin or contact surface.
  • the upper free surface provides a plurality of open cells. These open cells may act as micro-suckers and therefore provide increased friction and improved grip between the upper free surface of the coating and the skin of a user or an external contact surface. The presence of the micro-suckers reduces the relative movement between the coating and/or garment and the user's skin and thereby reduces any irritation which could potentially be caused by such undesirable movement.
  • the present invention therefore provides an improved silicone coating with an improved ability to conform to a user's skin or contact surface whilst also providing increased friction and improved grip through the presence of the aqueous liquid-containing closed cells and optionally the open cells provided on the upper surface of the coating.
  • the present invention provides a garment comprising a foamed filler-free silicone coating as herein described located on at least one surface of the garment to generate in use friction between a wearer's skin and the garment, and/or an external contact surface and the garment.
  • the surface(s) of the garment may be composed of any suitable material.
  • suitable materials include, but are not limited to, one or more of: knitted, woven or non-woven material.
  • the present invention provides an apparatus for forming a foamed filler- free silicone coating on a substrate, the apparatus comprising: a filler-free water-in-oil emulsion dispensing unit having a dispensing head for dispensing a water-in-oil emulsion formed by combining: a first liquid silicone rubber component comprising:
  • aqueous-liquid containing phase 0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; and to provide a filler-free silicone coating comprising an upper free surface and a lower surface configured to be in contact with a substrate; and a direct heat source configured to emit heat to the upper free surface of the filler-free silicone coating.
  • Figure 1 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to one embodiment of the present invention
  • Figure 2 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to a further embodiment of the present invention
  • Figure 3 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to a further embodiment of the present invention.
  • Figure 4 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention.
  • Figure 5 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention.
  • Figure 6 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention.
  • Figure 7 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to the embodiment of Figure 1 in which the upper surface has open cells;
  • Figure 8 is a flow diagram of the method of forming a foamed filler-free silicone coating according to an embodiment of the present invention.
  • FIG. 1 to 7 illustrates a foamed filler-free silicone coating 2a-c, 2a-c' comprising an upper free surface 4a-c, 4a-c' and an opposed lower surface 6a-c, 6a-c'.
  • the lower surface 6a-c, 6a-c' is configured to be contacted with, preferably embedded within, a contact surface, such as for example a surface of a garment (not shown).
  • the garment may be composed of any suitable material. Examples of suitable materials include, but are not limited to, one or more of: knitted, woven or non- woven material.
  • the foamed filler-free silicone coating 2a-c, 2a-c' of the present invention is produced according to the method illustrated in the flow diagram of Figure 8.
  • the first stage is to form a filler-free water-in-oil emulsion by combining a first liquid silicone rubber component comprising: 99.5% of a first liquid silicone rubber, and 0.5% of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising 100% of a second liquid silicone rubber.
  • the first liquid silicone rubber component comprises a platinum catalyst.
  • the ratio of the first liquid silicone rubber component to the second liquid silicone rubber component is approximately 1:1.
  • the filler-free water-in-oil emulsion is then applied to a substrate of a garment to provide a silicone coating illustrated in Figures 1 to 6 comprising an upper free surface 4a-c, 4a-c' and an opposed lower surface 6a-c, 6a-c' in contact with the substrate.
  • the filler-free silicone coating is then cured using a direct heat source provided by an IR heat source configured to apply heat at a temperature in the range of 100 °C to 150 °C to the upper free surface 4a-c, 4a-c' of the coating 2a-c, 2a-c' to provide a foamed silicone coating comprising a plurality of aqueous liquid-containing closed cells 8a-c,8a-c' located therein and to also embed at the lower surface of the coating 2a-c, 2a-c' into the substrate.
  • a direct heat source provided by an IR heat source configured to apply heat at a temperature in the range of 100 °C to 150 °C to the upper free surface 4a-c, 4a-c' of the coating 2a-c, 2a-c' to provide a foamed silicone coating comprising a plurality of aqueous liquid-containing closed cells 8a-c,8a-c' located therein and to also embed at the lower surface of the coating 2a-c, 2
  • the number and volume of aqueous liquid-containing closed cells 8a-c,8a-c' present within the foamed filler-free silicone coating of the present invention will depend on a number of factors including: the thickness of the coating; the temperature and duration of the applied heat from the heat source; and the ratio of the first liquid silicone rubber component to the second liquid silicone rubber component within the filler-free water-in-oil emulsion.
  • the coating of the present invention may be provided as a single layer foamed silicone coating.
  • the coating of the present invention may be provided as a two layer foamed filler-free silicone coating comprising a first layer 10a-c' located adjacent the upper region of the coating; and a second layer 12a-c' located adjacent the lower region of the coating.
  • the two layers may be secured together by adhesive or by heat curing.
  • Figures 1 and 4 illustrate a foamed filler-free silicone coating comprising a uniform distribution of aqueous liquid-containing closed cells 8a, 8a' between the upper free surface 4a, 4a' and the lower surface 6a, 6a' of the coating 2a, 2a'.
  • the aqueous liquid-containing closed cells 8a, 8a' are of uniform volume throughout the coating.
  • Figures 2 and 5 illustrate a foamed filler-free silicone coating comprising a greater volume of aqueous liquid-containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b' than adjacent the upper free surface 4b, 4b' of the coating 2b, 2b'.
  • the number density of aqueous liquid containing closed cells 8b, 8b' located adjacent the upper free surface 4b, 4b' is approximately equal to the number density of aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'.
  • the aqueous liquid containing closed cells 8b, 8b' located adjacent the upper free surface 4b, 4b' are smaller in volume than the aqueous liquid containing closed cells 8b, 8b' located adjacent lower surface 6b, 6b'.
  • the foamed filler- free coating 2b, 2b' may comprise a smaller number of aqueous liquid containing closed cells 8b, 8b' located adjacent the upper surface 4b, 4b' than the number of aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'.
  • the aqueous liquid containing closed cells 8b, 8b' located adjacent the upper surface 4b, 4b' may be smaller in number but of equal dimension to the aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'.
  • Figures 3 and 6 illustrate a foamed filler-free silicone coating comprising a greater volume of aqueous liquid-containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c' than adjacent the lower free surface 6c, 6c' of the coating 2c, 2c'.
  • the number density of aqueous liquid containing closed cells 8c, 8c' located adjacent the lower free surface 6c, 6c' is approximately equal to the number density of aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'.
  • the aqueous liquid containing closed cells 8c, 8c' located adjacent the lower free surface 6c, 6c' are smaller in volume than the aqueous liquid containing closed cells 8c, 8c' located adjacent upper surface 4c, 4c'. It is however to be understood that the foamed coating 2c, 2c' may comprise a smaller number of aqueous liquid containing closed cells 8c, 8c' located adjacent the lower surface 6c, 6c' than the number of aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'.
  • the aqueous liquid containing closed cells 8c, 8c' located adjacent the lower surface 6c, 6c' may be smaller in number but of equal dimension to the aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'.
  • the number and volume of aqueous liquid containing closed cells located within the coating may depend on a number of factors including the intensity and duration of the heat applied by the direct heat source.
  • the thickness (as measured in a direction extending between the upper surface 4a-c' and the lower surface 6a-c' of the coating 2a-c') of each of the first and second layers 10a-c', 12a-c' is substantially uniform. It is however to be understood that the relative thickness of the first and second layers 10a-c', 12a-c' may vary depending on the particular requirements for the coating.
  • the two layer foamed coating may be prepared by applying a first layer 10a-c' of foamed coating comprising a first number density and a first volume of aqueous liquid containing closed cells to the substrate to provide the lower region of the coating 2a-c'.
  • a second layer 12a-c' of foamed filler-free coating comprising a second number density and a second volume of aqueous liquid containing closed cells may then be applied to the free surface of the first layer lOa-c to provide the upper region of the coating 2a-c'. It is to be understood that the number density and volume of aqueous liquid containing closed cells within each of the first and second layers 10a-c', 12a-c' of the coating 2a-c' may be selected depending on the particular requirements for the coating 2a-c'.
  • the upper surface 4a may provide a plurality of open cells 14a. It is to be understood that the upper surface 4 of any of the coatings of the present invention, whether a single layer or a two layer coating, may comprise open cells. These open cells 14a have been found to act as micro-suckers and therefore provide increased friction and improved grip between the upper free surface of the coating and the skin of a user or an external contact surface. The presence of the micro suckers reduces the relative movement between the coating and/or garment and the user's skin and thereby reduces any irritation which could potentially be caused by such undesirable movement.
  • the illustrated embodiments of the coating show aqueous liquid- containing closed cells in both the upper and lower regions of the coating, that one or more regions may be substantially free of aqueous liquid-containing closed cells.
  • the lower region of the coating may be substantially free of aqueous liquid-containing closed cells.

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Abstract

A method of forming a foamed filler-free silicone coating, comprising: forming a filler-free water-in-oil emulsion by combining: a first liquid silicone rubber component comprising: 95% to 99.9 % of a first liquid silicone rubber, and 0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising 100% of a second liquid silicone rubber, in which at least one of the first and second liquid silicone rubber components comprises a catalyst; further comprising applying the emulsion to a substrate to provide a filler-free silicone coating comprising an upper free surface and an opposed lower surface configured to be in contact with the substrate. The filler-free silicone coating is cured using a direct heat source to apply heat to the upper free surface of the coating to provide a foamed filler-free silicone coating comprising a plurality of aqueous liquid-containing closed cells located therein.

Description

SILICONE COATING
The present invention relates to a silicone coating, and in particular to a foamed silicone composition for use on various pliable supports such as garments.
BACKGROUND
Silicone coatings are known to have good durability and anti-slip properties. Conventionally, silicone coatings have been applied to pliable supports, such as for example textiles including hosiery, stockings, brassieres or dresses, so as to reduce or prevent slipping or movement of garment while they are being worn by a user. It has however been found that the silicone coatings can cause discomfort and can irritate or inflame the skin of some users. The risk of discomfort is increased when garments are worn for prolonged periods of time.
There is therefore a need for a coating composition for use with pliable supports which has good durability and anti-slip properties whilst also have a reduced risk of irritating the skin of a user.
STATEMENT OF INVENTION
According to a first aspect, the present invention provides a method of forming a filler-free foamed silicone coating, comprising: forming a filler-free water-in-oil emulsion by combining: a first liquid silicone rubber component comprising:
95% to 99.9 % of a first liquid silicone rubber, and 0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; applying the filler-free water-in-oil emulsion to a substrate to provide a filler-free silicone coating comprising an upper free surface and an opposed lower surface configured to be in contact with the substrate; and curing the filler-free silicone coating using a direct heat source configured to apply heat to the upper free surface of the coating to provide a foamed silicone coating comprising a plurality of aqueous liquid-containing closed cells located therein and to embed at least a portion of the lower surface of the coating into the substrate. The filler-free water-in-oil emulsion may be applied to the substrate prior to curing the coating. In one embodiment, the water-in-oil emulsion may be applied to the substrate as a coating while being simultaneously cured by exposure to the direct heat source.
The term "filler-free" is used herein to mean that no additional filler composition has been introduced to the emulsion, such as for example, but not to be limited to, inorganic fillers such as sililca-based fillers, for example fused silica.
Any suitable direct heat source may be used to cure the coating. Preferably, the direct heat source is an infra red heat source.
The filler-free silicone coating may be cured at any suitable temperature. Preferably, the filler-free silicone coating is cured at a temperature in the range of from 100 °C to 150 °C.
In one embodiment, the filler-free water in oil emulsion comprises a ratio of first liquid silicone rubber component to second silicone rubber component in the range of between 1: 10 and 10:1, preferably in the range of between 1: 5 and 5: 1, more preferably in the range of between 1: 2 and 2: 1, for example about 1:1.
In one embodiment, the first liquid silicone rubber component comprises a first liquid silicone rubber having a shore A hardness in the range of between 20 and 30, preferably in the range of between 25 and 28, for example about 26.
In one embodiment, the second liquid silicone rubber comprises a shore A hardness in the range of between 30 and 50, preferably between 35 and 45, for example about 40.
In one embodiment, the filler-free water in oil emulsion has a shore A hardness in the range of between 1 and 10, preferably between 5 and 10, for example about 7.
In one embodiment, the viscosity of the first liquid silicone rubber component is in the region of between 90 and 120.
In one embodiment, the viscosity of the second liquid silicone rubber component is in the region of between 140 and 150.
The catalyst may be any suitable catalyst. In one embodiment, the catalyst is a platinum catalyst.
The first and/or second liquid silicone rubber may for example comprise one or more water based silicone elastomers. Preferably, one or more, preferably each, of the first and/or second liquid silicone rubber comprises organopolysiloxanes. In one embodiment, one or more, preferably each, of the first and/or second liquid silicone rubber comprises a platinum catalyst polydimethylsiloxane. In one embodiment, the aqueous liquid is water. The water may for example be present as one or more of: distilled, still, carbonated water, or a mixture thereof.
In one embodiment, the weight of the foamed filler-free silicone coating is in the range of between 1 g/m and 50 g/m, preferably between 3 g/m and 50 g/m, for example between 3 g/m and 15 g/m.
It is to be understood that the foamed filler-free silicone coating may have any suitable thickness and/or width depending on the requirements for the coating.
According to a second aspect of the present invention, there is provided a foamed filler-free silicone coating comprising an upper free surface and an opposed lower surface, in which the foamed filler- free silicone coating comprises a plurality of aqueous liquid-containing closed cells located between the upper free surface and lower surface thereof.
The foamed filler-free silicone coating may be formed from a water-in-oil emulsion prepared by combining: a first liquid silicone rubber component comprising: 99.4% to 99.9 % of a first liquid silicone rubber, and 0.1% to 0.6% of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising 100% of a second liquid silicone rubber.
The lower surface is preferably configured to be contacted with or embedded into a contact surface, such as for example a surface of a garment, such as for example a surface of one or more of: hosiery, stockings, brassieres or dresses,
The centre-point of the coating may extend midway between the upper free surface and the opposed lower surface thereof. The upper region of the coating is herein defined as being the region extending between the centre-point and the upper free surface of the coating. The lower region of the coating is herein defined as being the region extending between the centre-point and the lower surface of the coating.
In one embodiment, the coating comprises two layers located between the upper free surface and the opposed lower surface of the coating. For example, the coating may comprise a first layer providing a lower region of a coating and a second layer providing an upper region of a coating. In one embodiment, a first layer is located adjacent, and preferably providing, the lower surface of the coating; and a second layer is located adjacent, and preferably providing, the upper free surface of the coating.
In one embodiment, one of the first and second layers, preferably the first layer, may for example be a barrier layer. In one embodiment, a plurality of aqueous liquid-containing closed cells may be located within or at surface the upper region of the coating. In a further embodiment, the majority of the aqueous liquid- containing closed cells may be located within the upper region of the coating, for example more than 50%, preferably more than 60%, more preferably more than 80%, more preferably more than 90%, for example about 95% of the aqueous liquid-containing closed cells may be located within the upper region of the coating. For example, between 50% and 95%, preferably between 60% and 90% of the aqueous-liquid containing closed cells may be located within the upper region of the coating. In one embodiment, the upper surface and/or the upper region of the coating preferably comprises substantially all of the aqueous liquid-containing closed cells.
In a further embodiment, the minority of the aqueous liquid-containing closed cells may be located within the lower region of the coating, for example less than 50%, preferably less than 40%, more preferably less than 20%, more preferably less than 10%, for example about 5% of the aqueous liquid- containing closed cells may be located within the lower region of the coating. For example, between 5% and 50%, preferably between 10% and 40% of the aqueous-liquid containing closed cells may be located within the lower region of the coating. In one embodiment, the lower surface and/or the lower region of the coating is preferably substantially free from aqueous liquid-containing closed cells.
In a further embodiment, the aqueous liquid-containing closed cells may be uniformly dispersed within the coating.
The volume of each aqueous liquid-containing closed cell within the coating may be uniform. In other embodiments, the coating may comprise a plurality of aqueous liquid-containing closed cells with varying volumes.
The total volume is the sum of the volume of all of the aqueous liquid containing closed cells within the coating or a particular region of a coating.
In one embodiment, the total volume of the aqueous liquid-containing closed cells located within the upper region of the coating may be greater than the total volume of the aqueous liquid-containing closed cells located within the lower region of the coating.
In one embodiment, the total volume of the aqueous liquid-containing closed cells located within the lower region of the coating may be greater than the total volume of the aqueous liquid-containing closed cells located within the upper region of the coating.
In one embodiment, one or more regions of the coating, for example the upper or lower regions of the coating, may be substantially free of aqueous liquid-containing closed cells. The presence of the aqueous-liquid containing closed cells help provide a malleable upper region of the silicone coating which enables the coating to have an improved ability to conform to the shape of the user's skin or contact surface.
In a further embodiment, the upper free surface provides a plurality of open cells. These open cells may act as micro-suckers and therefore provide increased friction and improved grip between the upper free surface of the coating and the skin of a user or an external contact surface. The presence of the micro-suckers reduces the relative movement between the coating and/or garment and the user's skin and thereby reduces any irritation which could potentially be caused by such undesirable movement.
The present invention therefore provides an improved silicone coating with an improved ability to conform to a user's skin or contact surface whilst also providing increased friction and improved grip through the presence of the aqueous liquid-containing closed cells and optionally the open cells provided on the upper surface of the coating.
According to a third aspect, the present invention provides a garment comprising a foamed filler-free silicone coating as herein described located on at least one surface of the garment to generate in use friction between a wearer's skin and the garment, and/or an external contact surface and the garment.
The surface(s) of the garment may be composed of any suitable material. Examples of suitable materials include, but are not limited to, one or more of: knitted, woven or non-woven material.
According to a further aspect, the present invention provides an apparatus for forming a foamed filler- free silicone coating on a substrate, the apparatus comprising: a filler-free water-in-oil emulsion dispensing unit having a dispensing head for dispensing a water-in-oil emulsion formed by combining: a first liquid silicone rubber component comprising:
95% to 99.9 % of a first liquid silicone rubber, and
0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; and to provide a filler-free silicone coating comprising an upper free surface and a lower surface configured to be in contact with a substrate; and a direct heat source configured to emit heat to the upper free surface of the filler-free silicone coating.
Embodiments of the present invention will now be described with reference to the accompanying Figures:
BRIEF DESCRIPTION OF FIGURES
Figure 1 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to one embodiment of the present invention;
Figure 2 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to a further embodiment of the present invention;
Figure 3 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to a further embodiment of the present invention;
Figure 4 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention;
Figure 5 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention;
Figure 6 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone two-layer coating according to a further embodiment of the present invention; and
Figure 7 is a schematic illustration of a cross-sectional view of a foamed filler-free silicone coating according to the embodiment of Figure 1 in which the upper surface has open cells;
Figure 8 is a flow diagram of the method of forming a foamed filler-free silicone coating according to an embodiment of the present invention.
DETAILED DESCRIPTION
Each of Figures 1 to 7 illustrates a foamed filler-free silicone coating 2a-c, 2a-c' comprising an upper free surface 4a-c, 4a-c' and an opposed lower surface 6a-c, 6a-c'. The lower surface 6a-c, 6a-c' is configured to be contacted with, preferably embedded within, a contact surface, such as for example a surface of a garment (not shown). The garment may be composed of any suitable material. Examples of suitable materials include, but are not limited to, one or more of: knitted, woven or non- woven material. The foamed filler-free silicone coating 2a-c, 2a-c' of the present invention is produced according to the method illustrated in the flow diagram of Figure 8.
The first stage is to form a filler-free water-in-oil emulsion by combining a first liquid silicone rubber component comprising: 99.5% of a first liquid silicone rubber, and 0.5% of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising 100% of a second liquid silicone rubber. The first liquid silicone rubber component comprises a platinum catalyst.
The ratio of the first liquid silicone rubber component to the second liquid silicone rubber component is approximately 1:1.
The filler-free water-in-oil emulsion is then applied to a substrate of a garment to provide a silicone coating illustrated in Figures 1 to 6 comprising an upper free surface 4a-c, 4a-c' and an opposed lower surface 6a-c, 6a-c' in contact with the substrate.
The filler-free silicone coating is then cured using a direct heat source provided by an IR heat source configured to apply heat at a temperature in the range of 100 °C to 150 °C to the upper free surface 4a-c, 4a-c' of the coating 2a-c, 2a-c' to provide a foamed silicone coating comprising a plurality of aqueous liquid-containing closed cells 8a-c,8a-c' located therein and to also embed at the lower surface of the coating 2a-c, 2a-c' into the substrate.
The number and volume of aqueous liquid-containing closed cells 8a-c,8a-c' present within the foamed filler-free silicone coating of the present invention will depend on a number of factors including: the thickness of the coating; the temperature and duration of the applied heat from the heat source; and the ratio of the first liquid silicone rubber component to the second liquid silicone rubber component within the filler-free water-in-oil emulsion.
As illustrated in Figures 1 to 3, the coating of the present invention may be provided as a single layer foamed silicone coating. In other embodiments of the present invention, as illustrated in Figures 4 to 6, the coating of the present invention may be provided as a two layer foamed filler-free silicone coating comprising a first layer 10a-c' located adjacent the upper region of the coating; and a second layer 12a-c' located adjacent the lower region of the coating. The two layers may be secured together by adhesive or by heat curing.
Figures 1 and 4 illustrate a foamed filler-free silicone coating comprising a uniform distribution of aqueous liquid-containing closed cells 8a, 8a' between the upper free surface 4a, 4a' and the lower surface 6a, 6a' of the coating 2a, 2a'. The aqueous liquid-containing closed cells 8a, 8a' are of uniform volume throughout the coating. Figures 2 and 5 illustrate a foamed filler-free silicone coating comprising a greater volume of aqueous liquid-containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b' than adjacent the upper free surface 4b, 4b' of the coating 2b, 2b'. In the illustrated embodiment, the number density of aqueous liquid containing closed cells 8b, 8b' located adjacent the upper free surface 4b, 4b' is approximately equal to the number density of aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'. The aqueous liquid containing closed cells 8b, 8b' located adjacent the upper free surface 4b, 4b' are smaller in volume than the aqueous liquid containing closed cells 8b, 8b' located adjacent lower surface 6b, 6b'. It is however to be understood that the foamed filler- free coating 2b, 2b' may comprise a smaller number of aqueous liquid containing closed cells 8b, 8b' located adjacent the upper surface 4b, 4b' than the number of aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'. Furthermore, the aqueous liquid containing closed cells 8b, 8b' located adjacent the upper surface 4b, 4b' may be smaller in number but of equal dimension to the aqueous liquid containing closed cells 8b, 8b' located adjacent the lower surface 6b, 6b'.
Figures 3 and 6 illustrate a foamed filler-free silicone coating comprising a greater volume of aqueous liquid-containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c' than adjacent the lower free surface 6c, 6c' of the coating 2c, 2c'. In the illustrated embodiment, the number density of aqueous liquid containing closed cells 8c, 8c' located adjacent the lower free surface 6c, 6c' is approximately equal to the number density of aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'. The aqueous liquid containing closed cells 8c, 8c' located adjacent the lower free surface 6c, 6c' are smaller in volume than the aqueous liquid containing closed cells 8c, 8c' located adjacent upper surface 4c, 4c'. It is however to be understood that the foamed coating 2c, 2c' may comprise a smaller number of aqueous liquid containing closed cells 8c, 8c' located adjacent the lower surface 6c, 6c' than the number of aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'. Furthermore, the aqueous liquid containing closed cells 8c, 8c' located adjacent the lower surface 6c, 6c' may be smaller in number but of equal dimension to the aqueous liquid containing closed cells 8c, 8c' located adjacent the upper surface 4c, 4c'. The number and volume of aqueous liquid containing closed cells located within the coating may depend on a number of factors including the intensity and duration of the heat applied by the direct heat source.
With regards to the two-layer foamed filler-free coatings illustrated in Figures 4 to 6, the thickness (as measured in a direction extending between the upper surface 4a-c' and the lower surface 6a-c' of the coating 2a-c') of each of the first and second layers 10a-c', 12a-c' is substantially uniform. It is however to be understood that the relative thickness of the first and second layers 10a-c', 12a-c' may vary depending on the particular requirements for the coating. The two layer foamed coating may be prepared by applying a first layer 10a-c' of foamed coating comprising a first number density and a first volume of aqueous liquid containing closed cells to the substrate to provide the lower region of the coating 2a-c'. A second layer 12a-c' of foamed filler-free coating comprising a second number density and a second volume of aqueous liquid containing closed cells may then be applied to the free surface of the first layer lOa-c to provide the upper region of the coating 2a-c'. It is to be understood that the number density and volume of aqueous liquid containing closed cells within each of the first and second layers 10a-c', 12a-c' of the coating 2a-c' may be selected depending on the particular requirements for the coating 2a-c'.
As illustrated in Figure 7, the upper surface 4a may provide a plurality of open cells 14a. It is to be understood that the upper surface 4 of any of the coatings of the present invention, whether a single layer or a two layer coating, may comprise open cells. These open cells 14a have been found to act as micro-suckers and therefore provide increased friction and improved grip between the upper free surface of the coating and the skin of a user or an external contact surface. The presence of the micro suckers reduces the relative movement between the coating and/or garment and the user's skin and thereby reduces any irritation which could potentially be caused by such undesirable movement.
It is to be understood that although the illustrated embodiments of the coating show aqueous liquid- containing closed cells in both the upper and lower regions of the coating, that one or more regions may be substantially free of aqueous liquid-containing closed cells. In particular, the lower region of the coating may be substantially free of aqueous liquid-containing closed cells.

Claims

1. A method of forming a foamed filler-free silicone coating, comprising: forming a filler-free water-in-oil emulsion by combining: a first liquid silicone rubber component comprising:
95% to 99.9 % of a first liquid silicone rubber, and
0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; and applying the filler-free water-in-oil emulsion to a substrate to provide a filler-free silicone coating comprising an upper free surface and an opposed lower surface configured to be in contact with the substrate; and curing the filler-free silicone coating using a direct heat source configured to apply heat to the upper free surface of the coating to provide a foamed filler-free silicone coating comprising a plurality of aqueous liquid-containing closed cells located therein and to embed at least a portion of the lower surface of the coating into the substrate.
2. A method as claimed in claim 1, in which the direct heat source is an infra red heat source.
3. A method as claimed in either of claims 1 and 2, in which the filler-free silicone coating is cured at a temperature in the range of from 100 °C to 150 °C.
4. A method as claimed in any one of claims 1 to 3, in which the first liquid silicone rubber component comprises a first liquid silicone rubber having a shore A hardness in the range of between 20 and 30.
5. A method as claimed in any preceding claim, in which the second liquid silicone rubber comprises a shore A hardness in the range of between 30 and 50.
6. A method as claimed in any preceding claim, in which the filler-free water in oil emulsion has a shore A hardness in the range of between 1 and 10.
7. A method as claimed in any preceding claim, the viscosity of the first liquid silicone rubber component is in the region of between 90 and 120.
8. A method as claimed in any preceding claim, in which the viscosity of the second liquid silicone rubber component is in the region of between 140 and 150.
9. A method as claimed in any preceding claim, in which one or more of the first and/or second liquid silicone rubber comprises one or more water based silicone elastomers.
10. A method as claimed in claim 9, in which one or more of the first and/or second liquid silicone rubber comprises organopolysiloxanes.
11. A method as claimed in 10, in which one or more of the first and/or second liquid silicone rubber comprises a platinum catalyst polydimethylsiloxane.
12. A method as claimed in any preceding claim, in which the aqueous liquid is water.
13. A method as claimed in claim 12, in which water is one or more of: distilled, still, carbonated water, or a mixture thereof.
14. A foamed filler-free silicone coating comprising an upper free surface and an opposed lower surface, in which the foamed filler-free silicone coating comprises a plurality of aqueous liquid-containing closed cells located between the upper free surface and lower surface thereof.
15. A foamed filler-free silicone coating as claimed in claim 14, in which a plurality of aqueous liquid-containing closed cells are located within the upper region of the coating.
16. A foamed filler-free silicone coating as claimed in either of claims 14 and 15, in which the lower surface and/or the lower region of the coating is substantially free from aqueous liquid- containing closed cells.
17. A foamed filler-free silicone coating as claimed in any one of claims 14 to 16, in which the upper free surface provides a plurality of open cells.
18. A foamed filler-free silicone coating as claimed in any one of claims 14 to 17, in which the coating is formed from liquid silicone rubber.
19. A foamed filler-free silicone coating as claimed in claim 18 in which the coating is formed from a filler-free water-in-oil emulsion formed from a first liquid silicone rubber component comprising: 95% to 99.9 % of a first liquid silicone rubber, and 0.1% to 5 % of aqueous- liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst.
20. A foamed filler-free silicone coating as claimed in any one of claims 14 to 19 in which the aqueous liquid is water.
21. A coating as claimed in claim 20, in which water is one or more of: distilled, still, carbonated water, or a mixture thereof.
22. A garment comprising a foamed filler-free silicone coating as claimed in any one of claim 14 to 21 located on at least one surface of the garment to generate in use friction between a wearer's skin and the garment, and/or an external contact surface and the garment.
23. A garment as claimed in claim 22, in which the surface(s) of the garment comprises one or more of: knitted, woven or non-woven material.
24. An apparatus for apparatus for forming a foamed filler-free silicone coating on a substrate, the apparatus comprising: a filler-free water-in-oil emulsion dispensing unit having a dispensing head for dispensing a water-in-oil emulsion formed by combining: a first liquid silicone rubber component comprising:
95% to 99.9 % of a first liquid silicone rubber, and 0.1% to 5 % of aqueous-liquid containing phase; and a second liquid silicone rubber component comprising substantially 100% of a second liquid silicone rubber, in which at least one of the first liquid silicone rubber component and second liquid silicone rubber component comprises a catalyst; to provide a filler-free silicone coating comprising an upper free surface and a lower surface configured to be in contact with a substrate; and a direct heat source configured to emit heat to the upper free surface of the silicone coating to form a foamed filler-free silicone coating on the substrate.
PCT/EP2020/081483 2019-11-12 2020-11-09 Silicone coating Ceased WO2021094249A1 (en)

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