Porous polymer coatings

Abstract

The present invention provides porous polymer coatings having adhesive and air flow resistive properties. The porous polymer coating comprises a polymeric foam having a void fraction of greater than about 15% and an air permeability greater than 3 cubic feet per minute per square foot as measured based on ASTM D737-04.

1 . A porous polymer coating comprising:
 a polymeric foam having thermally activated adhesive properties, a void fraction of greater than about 15%, and an air permeability greater than 1 cubic feet per minute per square foot as measured based on ASTM D737-04,   wherein said polymeric foam comprises a plurality of open cells;   wherein said polymeric foam comprises an acrylic binder; and   wherein said porous polymer coating has an airflow resistance in a range of about 200 Rayls to about 10,000 Rayls as measured based on ASTM C522-03.   
     
     
         2 . The porous polymer coating of  claim 1 , wherein said polymeric foam further comprises at least one thermoplastic polymer and the at least one additional thermoplastic polymer is selected from the group consisting of: polyacrylates, polyvinylacetates, styrene butadiene rubbers, diallylorthophthalates, ionomers, formulated epoxys, polysulfones, polyether-etherketones, acrylonitrilebutadienstyrenes, polycarbonates, vinylesters, styrene copolymers, polyamides, polyamines, ethylenevinylacetates, polyvinylalcohols, polyvinylchlorides, polyvinylidiene chloride, chlorinated polyethylenes, polyesters, nitriles, and polyethylenes. 
     
     
         3 . The porous polymer coating of  claim 1 , wherein said polymeric foam comprises one or more non-thermoplastic polymers. 
     
     
         4 - 6 . (canceled) 
     
     
         7 . The porous polymer coating of  claim 1 , wherein said airflow resistance greater than about 250 Rayls as measured based on ASTM C522-03. 
     
     
         8 . The porous polymer coating of  claim 1 , wherein said airflow resistance is in a range of about 500 Rayls to about 2,500 Rayls as measured based on ASTM C522-03. 
     
     
         9 . The porous polymer coating of  claim 1 , wherein said airflow resistance is greater than about 1000 Rayls as measured based on ASTM C522-03. 
     
     
         10 . The porous polymer coating of  claim 1 , wherein said airflow resistance is in a range of about 500 Rayls to about 2,500 Rayls as measured based on ASTM C522-03. 
     
     
         11 . The porous polymer coating of  claim 1 , wherein said air permeability is greater than about 10 cubic feet per minute per square foot as measured based on ASTM D737-04. 
     
     
         12 . The porous polymer coating of  claim 1 , wherein said air permeability is greater than about 40 cubic feet per minute per square foot as measured based on ASTM D737-04. 
     
     
         13 . The porous polymer coating of  claim 1 , wherein said air permeability is greater than about 73 cubic feet per minute per square foot as measured based on ASTM D737-04. 
     
     
         14 . The porous polymer coating of  claim 1 , wherein said porous polymer coating has a basis weight of about 10 grams per square meter to about 75 grams per square meter. 
     
     
         15 . The porous polymer coating of  claim 1 , wherein said porous polymer coating has a basis weight of about 10 grams per square meter to about 45 grams per square meter. 
     
     
         16 . The porous polymer coating of  claim 1 , wherein the polymeric foam is a reticulated polymeric foam. 
     
     
         17 . The porous polymer coating of  claim 1 , further comprising thermally activatable adhesive particles. 
     
     
         18 . The porous polymer coating of  claim 1 , further comprising a filled latex polymer coating. 
     
     
         19 . The porous polymer coating of  claim 1 , further comprising an additive containing latex polymer coating. 
     
     
         20 . A composite material, comprising:
 a first substrate;   a second substrate; and   the porous polymer coating of  claim 1  interposed between said first substrate and second substrate.   
     
     
         21 - 31 . (canceled) 
     
     
         32 . A method of forming a composite material, comprising:
 applying the porous polymer coating of  claim 1  to a substrate.   
     
     
         33 - 42 . (canceled) 
     
     
         43 . The porous polymer coating of  claim 1 , wherein said air permeability is in a range of about 5 cfm/sq. ft. to about 100 cfm/sq. ft. as measured based on ASTM D737-04. 
     
     
         44 . The porous polymer coating of  claim 1 , wherein the void fraction is in a range of about 20% to about 50%.