U.S. patent application number 16/144674 was filed with the patent office on 2019-01-24 for polyolefin elastomer compositions and methods of making the same.
This patent application is currently assigned to Cooper-Standard Automotive Inc.. The applicant listed for this patent is Cooper-Standard Automotive Inc.. Invention is credited to Krishnamachari Gopalan, Roland Herd-Smith, Gending Ji, Robert J. Lenhart.
Application Number | 20190021441 16/144674 |
Document ID | / |
Family ID | 60857179 |
Filed Date | 2019-01-24 |
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United States Patent
Application |
20190021441 |
Kind Code |
A1 |
Gopalan; Krishnamachari ; et
al. |
January 24, 2019 |
POLYOLEFIN ELASTOMER COMPOSITIONS AND METHODS OF MAKING THE
SAME
Abstract
An elastomeric article is provided that includes a composition
having a silane-crosslinked polyolefin elastomer with a density
less than 0.90 g/cm.sup.3. The elastomeric article can exhibit a
compression set of from about 5.0% to about 35.0%, as measured
according to ASTM D 395 (22 hrs @ 70.degree. C.). The
silane-crosslinked polyolefin elastomer can include a first
polyolefin having a density less than 0.86 g/cm.sup.3, a second
polyolefin having a crystallinity less than 40%, a silane
crosslinker, a grafting initiator, and a condensation catalyst.
Inventors: |
Gopalan; Krishnamachari;
(Troy, MI) ; Lenhart; Robert J.; (Fort Wayne,
IN) ; Ji; Gending; (Waterloo, Ontario, CA) ;
Herd-Smith; Roland; (Brignancourt, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cooper-Standard Automotive Inc. |
Novi |
MI |
US |
|
|
Assignee: |
Cooper-Standard Automotive
Inc.
Novi
MI
|
Family ID: |
60857179 |
Appl. No.: |
16/144674 |
Filed: |
September 27, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15836437 |
Dec 8, 2017 |
|
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16144674 |
|
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62497959 |
Dec 10, 2016 |
|
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62497954 |
Dec 10, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08F 210/06 20130101;
C08G 77/442 20130101; C08J 9/06 20130101; C08J 2203/06 20130101;
C08J 2423/16 20130101; C08K 5/0025 20130101; C08L 23/14 20130101;
A43B 13/04 20130101; C08J 5/18 20130101; C08J 9/122 20130101; C08L
53/00 20130101; B32B 27/32 20130101; C08J 2207/00 20130101; B32B
2266/0207 20130101; C08K 3/22 20130101; C08L 101/00 20130101; C08F
255/02 20130101; C08J 2423/14 20130101; C08L 23/06 20130101; C08L
23/08 20130101; B29D 35/122 20130101; C08J 3/246 20130101; B32B
2437/02 20130101; C08F 210/02 20130101; C08J 3/24 20130101; C08L
51/06 20130101; B32B 37/15 20130101; B32B 2307/3065 20130101; B32B
2307/56 20130101; C08F 8/00 20130101; C08L 2205/02 20130101; B32B
27/26 20130101; B32B 2307/51 20130101; B32B 2307/536 20130101; C08J
2383/10 20130101; C08J 2423/12 20130101; B32B 3/263 20130101; B32B
2307/4026 20130101; B32B 2307/704 20130101; C08J 2323/16 20130101;
C09K 3/1006 20130101; B32B 5/18 20130101; B32B 2266/08 20130101;
C08F 2800/20 20130101; C08L 2312/08 20130101; C08J 2203/04
20130101; C08K 5/00 20130101; C09K 2200/0617 20130101; C08J 2203/08
20130101; C08L 23/20 20130101; C08J 2201/03 20130101; E04D 5/10
20130101; B32B 2307/72 20130101; C08J 9/0061 20130101; C08F 230/08
20130101; C08F 2500/08 20130101; C08J 2300/26 20130101; C08L 23/12
20130101; B32B 2274/00 20130101; C08L 23/0815 20130101; C08L 43/04
20130101; B32B 2266/10 20161101; B32B 2305/72 20130101; C08J
2201/026 20130101; B32B 5/028 20130101; C08F 2500/21 20130101; C08F
2810/20 20130101; C08J 2423/06 20130101; C08K 5/5419 20130101; C08F
8/12 20130101; C08J 9/32 20130101; A43B 13/187 20130101; B32B 27/12
20130101; C08J 2205/052 20130101; B32B 2419/06 20130101; C08J
2423/08 20130101; E04D 5/06 20130101; B32B 2307/50 20130101; C08J
2323/08 20130101; C08J 2323/12 20130101; C08L 23/16 20130101; D06N
5/00 20130101; C08F 255/02 20130101; C08F 230/08 20130101; C08F
8/00 20130101; C08F 8/12 20130101; C08F 255/02 20130101; C08L
23/0815 20130101; C08L 23/0815 20130101; C08L 23/0815 20130101;
C08L 23/14 20130101 |
International
Class: |
A43B 13/04 20060101
A43B013/04; E04D 5/10 20060101 E04D005/10; A43B 13/18 20060101
A43B013/18; D06N 5/00 20060101 D06N005/00; E04D 5/06 20060101
E04D005/06; B29D 35/12 20100101 B29D035/12; B32B 5/02 20060101
B32B005/02; B32B 27/12 20060101 B32B027/12; B32B 27/26 20060101
B32B027/26; B32B 27/32 20060101 B32B027/32; B32B 37/15 20060101
B32B037/15; C08F 8/00 20060101 C08F008/00; C08F 8/12 20060101
C08F008/12; C08F 210/02 20060101 C08F210/02; C08F 210/06 20060101
C08F210/06; C08F 230/08 20060101 C08F230/08; C08F 255/02 20060101
C08F255/02; C08G 77/442 20060101 C08G077/442; C08J 3/24 20060101
C08J003/24; C08J 5/18 20060101 C08J005/18; C08J 9/00 20060101
C08J009/00; C08J 9/06 20060101 C08J009/06; C08J 9/32 20060101
C08J009/32; C08K 3/22 20060101 C08K003/22; C08K 5/00 20060101
C08K005/00; C08K 5/5419 20060101 C08K005/5419; C09K 3/10 20060101
C09K003/10; C08L 101/00 20060101 C08L101/00; C08L 53/00 20060101
C08L053/00; C08L 51/06 20060101 C08L051/06; C08L 43/04 20060101
C08L043/04; C08L 23/20 20060101 C08L023/20; C08L 23/16 20060101
C08L023/16; C08L 23/14 20060101 C08L023/14; C08L 23/12 20060101
C08L023/12; C08L 23/08 20060101 C08L023/08; C08L 23/06 20060101
C08L023/06 |
Claims
1. A silane-crosslinked polyolefin elastomer blend comprising: a
first polyolefin having a density less than 0.86 g/cm.sup.3; a
second polyolefin having a percent crystallinity less than 40%; a
silane crosslinker, wherein the silane-crosslinked polyolefin
elastomer blend exhibits a compression set of from about 5.0% to
about 35.0%, as measured according to ASTM D 395 (22 hrs @
70.degree. C.) and wherein the silane-crosslinked polyolefin
elastomer blend has a density less than 0.90 g/cm.sup.3.
2. The silane-crosslinked polyolefin elastomer blend of claim 1
further comprising a microencapsulated foaming agent.
3. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the density is less than 0.70 g/cm.sup.3.
4. The silane-crosslinked polyolefin elastomer blend of claim 1
further comprising a foaming agent.
5. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the density is less than 0.60 g/cm.sup.3.
6. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the compression set is from about 15.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.).
7. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the first polyolefin comprises an ethylene-octene copolymer
from about 60 wt % to about 97 wt %.
8. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the second polyolefin comprises a polypropylene homopolymer
from about 10 wt % to about 35 wt % and/or a
poly(ethylene-co-propylene).
9. The silane-crosslinked polyolefin elastomer blend of claim 1,
wherein the silane crosslinker comprises a vinyltrialkoxy silane
from about 1 wt % to about 4 wt %.
10. A silane-crosslinked polyolefin elastomer blend comprising: a
first polyolefin having a density less than 0.86 g/cm.sup.3; a
second polyolefin having a percent crystallinity less than 40%; a
silane crosslinker; a foaming agent; wherein the silane-crosslinked
polyolefin elastomer blend exhibits a compression set of from about
5.0% to about 35.0%, as measured according to ASTM D 395 (22 hrs @
70.degree. C.) and wherein the silane-crosslinked polyolefin
elastomer blend has a density less than 0.70 g/cm.sup.3.
11. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the first polyolefin comprises an ethylene-octene copolymer
from about 60 wt % to about 97 wt %.
12. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the second polyolefin comprises a polypropylene homopolymer
from about 10 wt % to about 35 wt % and/or a
poly(ethylene-co-propylene).
13. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the silane crosslinker comprises a vinyltrialkoxy silane
from about 1 wt % to about 4 wt %.
14. The silane-crosslinked polyolefin elastomer blend of claim 10,
further comprising a condensation catalyst that comprises an acid
catalyst, a sulfonic ester catalyst and/or a tin catalyst from
about 1 wt % to about 4 wt %.
15. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the density is less than 0.60 g/cm.sup.3.
16. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the foaming agent includes a microencapsulating foaming
agent.
17. The silane-crosslinked polyolefin elastomer blend of claim 10,
wherein the compression set is from about 15.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.).
18. A silane-crosslinked polyolefin elastomer blend comprising: a
first polyolefin having a density less than 0.86 g/cm.sup.3; a
second polyolefin having a percent crystallinity less than 40%; a
silane crosslinker; and a condensation catalyst including an acid
acatalyst, a sulfonic ester catalyst, and/or a tin catalyst,
wherein the silane-crosslinked polyolefin elastomer blend exhibits
a compression set of from about 5.0% to about 35.0%, as measured
according to ASTM D 395 (22 hrs @ 70.degree. C.) and wherein the
silane-crosslinked polyolefin elastomer blend has a density less
than 0.90 g/cm.sup.3.
19. The silane-crosslinked polyolefin elastomer blend of claim 18
further comprising a foaming agent.
20. The silane-crosslinked polyolefin elastomer blend of claim 18,
wherein the first polyolefin is an ethylene/.alpha.-olefin
copolymer and the second polyolefin is on or more of a
polypropylene homopolymer and a poly(ethylene-co-propylene).
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application that claims
priority to and the benefit under 35 U.S.C. .sctn..sctn. 119(e),
120 of the U.S. patent application Ser. No. 15/836,437, filed Dec.
8, 2017, entitled "POLYOLEFIN ELASTOMER COMPOSITIONS AND METHODS OF
MAKING THE SAME," which claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Patent Application No. 62/497,959, filed
Dec. 10, 2016, entitled "HOSE, COMPOSITION INCLUDING SILANE-GRAFTED
POLYOLEFIN, AND PROCESS OF MAKING A HOSE," and to U.S. Provisional
Patent Application No. 62/497,954 filed Dec. 10, 2016, entitled
"WEATHERSTRIP, COMPOSITION INCLUDING SILANE-GRAFTED POLYOLEFIN, AND
PROCESS OF MAKING A WEATHERSTRIP," all of which are herein
incorporated by reference in their entirety.
FIELD OF THE DISCLOSURE
[0002] The disclosure generally relates to silane-grafted
polyolefin elastomer compositions that may be used to form many
different end products, and more particularly, to compositions and
methods for manufacturing these compositions used to form
weatherstrip seals, membranes, hoses, and other elastic
materials.
BACKGROUND OF THE DISCLOSURE
[0003] Thermoplastic vulcanizates (TPV) are part of the
thermoplastic elastomer (TPE) family of polymers but are closest in
elastomeric properties to ethylene propylene diene monomer (EPDM)
thermoset rubber. TPVs are relatively easy to process, but their
properties can be limited in terms of elastomeric performance and
durability over time. Similarly, EPDM rubber formulations often
require many ingredients (e.g., carbon black, petroleum-based oil,
zinc oxide, miscellaneous fillers such as calcium carbonate or
talc, processing aids, curatives, blowing agents, and many other
materials to meet performance requirements), which tend to decrease
their elastic performance over time and increase their material
cost.
[0004] EPDM-based materials are also costly from a process
standpoint. The EPDM constituent ingredients are typically mixed
together in a one- or two-step process prior to shipping to an
extrusion facility. At the extrusion facility, the ingredients and
rubber compound(s) are extruded together to form a final material,
which is subsequently formed into a variety of elastomeric
materials. Hence, the extrusion process used to manufacture
weatherstrips can include many stages, depending on the type of
EPDM or other types of resins, and may additionally require long
lengths of curing ovens. For example, extrusion lines of up to 80
yards in length that are powered by natural gas and/or electricity
may be required. Much of the natural gas and/or electricity is used
to fuel hot air ovens, microwaves, infrared ovens, or other types
of equipment used to vulcanize the EPDM rubber compounds. The
vulcanization process also produces fumes that must be vented and
monitored to comply with environmental requirements. Overall, the
processes used to fabricate traditional EPDM-based products can be
very time consuming, costly, and environmentally unfriendly.
[0005] Mindful of the drawbacks associated with current TPV and
EPDM-based polymeric compositions, industry has a need for the
development of new compositions and methods for manufacturing
polyolefin elastomeric materials that are simpler, lighter in
weight, lower in cost, have superior long-term load loss (LLS), and
are more environmentally friendly.
SUMMARY OF THE DISCLOSURE
[0006] According to some aspects of the present disclosure, a
silane-crosslinked polyolefin elastomer blend is provided. The
silane-crosslinked polyolefin elastomer includes a first polyolefin
having a density less than 0.86 g/cm.sup.3; a second polyolefin
having a percent crystallinity less than 40%; and a silane
crosslinker. The silane-crosslinked polyolefin elastomer blend
exhibits a compression set of from about 5.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.) and
wherein the silane-crosslinked polyolefin elastomer blend has a
density less than 0.90 g/cm.sup.3.
[0007] According to other aspects of the present disclosure, a
silane-crosslinked polyolefin elastomer blend is disclosed. The
silane-crosslinked polyolefin elastomer blend includes a first
polyolefin having a density less than 0.86 g/cm.sup.3, a second
polyolefin having a crystallinity less than 40%, a silane
crosslinker, and a foaming agent. The silane-crosslinked polyolefin
elastomer blend exhibits a compression set of from about 5.0% to
about 35.0%, as measured according to ASTM D 395 (22 hrs @
70.degree. C.). The silane-crosslinked polyolefin elastomer blend
has a density less than 0.70 g/cm.sup.3.
[0008] According to still other aspects of the present disclosure,
a silane-crosslinked polyolefin elastomer blend is provided. The
silane-crosslinked polyolefin elastomer blend comprises a first
polyolefin having a density less than 0.86 g/cm.sup.3; a second
polyolefin having a percent crystallinity less than 40%; a silane
crosslinker; and a condensation catalyst including an acid
catalyst, a sulfonic ester catalyst and/or a tin catalyst. The
silane-crosslinked polyolefin elastomer blend exhibits a
compression set of from about 5.0% to about 35.0%, as measured
according to ASTM D 395 (22 hrs @ 70.degree. C.) and wherein the
silane-crosslinked polyolefin elastomer blend has a density less
than 0.90 g/cm.sup.3.
[0009] These and other aspects, objects, and features of the
present disclosure will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIG. 1 is a schematic reaction pathway used to produce a
silane-crosslinked polyolefin elastomer according to some aspects
of the present disclosure;
[0012] FIG. 2 is a flow diagram of a method for making a static
seal with a silane-crosslinked polyolefin elastomer using a
two-step Sioplas approach according to some aspects of the present
disclosure;
[0013] FIG. 3A is a schematic cross-sectional view of a reactive
twin-screw extruder according to some aspects of the present
disclosure;
[0014] FIG. 3B is a schematic cross-sectional view of a
single-screw extruder according to some aspects of the present
disclosure;
[0015] FIG. 4 is a flow diagram of a method for making a static
seal with a silane-crosslinked polyolefin elastomer using a
one-step Monosil approach according to some aspects of the present
disclosure;
[0016] FIG. 5 is a schematic cross-sectional view of a reactive
single-screw extruder according to some aspects of the present
disclosure;
[0017] FIG. 6 is a graph illustrating the stress/strain behavior of
a silane-crosslinked polyolefin elastomer compared to EPDM
compounds;
[0018] FIG. 7 is a graph illustrating the lip compression set of
inventive silane-crosslinked polyolefin elastomers and comparative
polyolefin elastomers;
[0019] FIG. 8 is a graph illustrating the lip set recovery of
inventive silane-crosslinked polyolefin elastomers and comparative
polyolefin elastomers;
[0020] FIG. 9 is a graph illustrating the relaxation rate of
several silane-crosslinked polyolefin elastomers and comparative
polyolefin elastomers;
[0021] FIG. 10 is a graph illustrating the stress/strain behavior
of an inventive silane-crosslinked polyolefin elastomer;
[0022] FIG. 11 is a graph illustrating the compression set of EPDM,
TPV, and a silane-crosslinked polyolefin elastomer as plotted with
respect to various test temperatures and time conditions;
[0023] FIG. 12 is a graph illustrating the compression set of EPDM,
TPV, and a silane-crosslinked polyolefin elastomer as plotted with
respect to temperatures ranging from 23.degree. C. to 175.degree.
C.;
[0024] FIG. 13 is a graph illustrating the compression set of TPV
and several silane-crosslinked polyolefin elastomers as plotted
with respect to 23.degree. C. and 125.degree. C. temperatures;
[0025] FIG. 14 is a graph illustrating the load versus position
behavior of a dynamic silane-crosslinked elastomer, as compared to
load versus position behavior of comparative EPDM compounds;
and
[0026] FIG. 15 is a set of micrographs of dynamic
silane-crosslinked elastomers, as processed with a supercritical
gas-injected fluid or a chemical foaming agent, according to
aspects of the disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] It is to be understood that the specific devices and
processes illustrated in the attached drawings, and described in
the following specification are simply exemplary embodiments of the
inventive concepts defined in the appended claims. Hence, specific
dimensions and other physical characteristics relating to the
embodiments disclosed herein are not to be considered as limiting,
unless the claims expressly state otherwise.
[0028] All ranges disclosed herein are inclusive of the recited
endpoint and independently combinable (for example, the range of
"from 2 to 10" is inclusive of the endpoints, 2 and 10, and all the
intermediate values). The endpoints of the ranges and any values
disclosed herein are not limited to the precise range or value;
they are sufficiently imprecise to include values approximating
these ranges and/or values.
[0029] A value modified by a term or terms, such as "about" and
"substantially," may not be limited to the precise value specified.
The approximating language may correspond to the precision of an
instrument for measuring the value. The modifier "about" should
also be considered as disclosing the range defined by the absolute
values of the two endpoints. For example, the expression "from
about 2 to about 4" also discloses the range "from 2 to 4."
[0030] As used herein, the term "and/or," when used in a list of
two or more items, means that any one of the listed items can be
employed by itself, or any combination of two or more of the listed
items can be employed. For example, if a composition is described
as containing components A, B, and/or C, the composition can
contain A alone; B alone; C alone; A and B in combination; A and C
in combination; B and C in combination; or A, B, and C in
combination.
[0031] A silane-crosslinked polyolefin elastomer is provided. In
general, the silane-crosslinked polyolefin elastomer can exhibit a
compression set of from about 5.0% to about 35.0% measured
according to ASTM D 395 (22 hrs @ 70.degree. C.). The
silane-crosslinked polyolefin elastomer can be produced from a
blend including a first polyolefin having a density less than 0.86
g/cm.sup.3, a second polyolefin having a crystallinity less than
40.degree. C., a silane crosslinker, a grafting initiator, and a
condensation catalyst. In some aspects, the silane-crosslinked
polyolefin elastomer has a density less than 0.90 g/cm.sup.3. In
other aspects, the silane-crosslinked polyolefin elastomer has a
density less than 0.70 g/cm.sup.3. In still other aspects, the
silane-crosslinked polyolefin elastomer has a density less than
0.60 g/cm.sup.3.
[0032] Thus, the disclosure herein focuses on the composition,
method of making the composition, and the corresponding material
properties for the silane-crosslinked polyolefin elastomer used to
make elastomeric articles. The elastomeric article is formed from a
silane-grafted polyolefin where the silane-grafted polyolefin may
have a catalyst added to form a silane-crosslinkable polyolefin
elastomer. This silane-crosslinkable polyolefin may then be
crosslinked upon exposure to moisture and/or heat to form the final
silane-crosslinked polyolefin elastomer or blend. In many aspects,
the silane-crosslinked polyolefin elastomer or blend includes a
first polyolefin having a density less than 0.90 g/cm.sup.3, a
second polyolefin having a crystallinity of less than 40%, a silane
crosslinker, a graft initiator, and a condensation catalyst. In
other aspects, the silane-crosslinked polyolefin elastomer or blend
includes just one polyolefin having a density less than 0.90
g/cm.sup.3 and a crystallinity of less than 40%, a silane
crosslinker, a graft initiator, and a condensation catalyst.
First Polyolefin
[0033] The first polyolefin can be a polyolefin elastomer including
an olefin block copolymer, an ethylene/.alpha.-olefin copolymer, a
propylene/.alpha.-olefin copolymer, EPDM, EPM, or a mixture of two
or more of any of these materials. Exemplary block copolymers
include those sold under the trade names INFUSE.TM., an olefin
block co-polymer (the Dow Chemical Company) and SEPTON.TM.
V-SERIES, a styrene-ethylene-butylene-styrene block copolymer
(Kuraray Co., LTD.). Exemplary ethylene/.alpha.-olefin copolymers
include those sold under the trade names TAFMER.TM. (e.g., TAFMER
DF710) (Mitsui Chemicals, Inc.), and ENGAGE.TM. (e.g., ENGAGE 8150)
(the Dow Chemical Company). Exemplary propylene/.alpha.-olefin
copolymers include those sold under the trade name VISTAMAXX 6102
grades (Exxon Mobil Chemical Company), TAFMER.TM. XM (Mitsui
Chemical Company), and Versify (Dow Chemical Company). The EPDM may
have a diene content of from about 0.5 to about 10 wt %. The EPM
may have an ethylene content of 45 wt % to 75 wt %.
[0034] The term "comonomer" refers to olefin comonomers which are
suitable for being polymerized with olefin monomers, such as
ethylene or propylene monomers. Comonomers may comprise but are not
limited to aliphatic C.sub.2-C.sub.2.alpha.-olefins. Examples of
suitable aliphatic C.sub.2-C.sub.20.alpha.-olefins include
ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene,
1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene,
1-octadecene and 1-eicosene. In some aspects, the comonomer is
vinyl acetate. The term "copolymer" refers to a polymer, which is
made by linking more than one type of monomer in the same polymer
chain. The term "homopolymer" refers to a polymer which is made by
linking olefin monomers, in the absence of comonomers. The amount
of comonomer can, in some embodiments, be from greater than 0 to
about 12 wt % based on the weight of the polyolefin, including from
greater than 0 to about 9 wt % and from greater than 0 to about 7
wt %. In some embodiments, the comonomer content is greater than
about 2 mol % of the final polymer, including greater than about 3
mol % and greater than about 6 mol %. The comonomer content may be
less than or equal to about 30 mol %. A copolymer can be a random
or block (heterophasic) copolymer. In some embodiments, the
polyolefin is a random copolymer of propylene and ethylene.
[0035] In some aspects, the first polyolefin is selected from the
group consisting of: an olefin homopolymer, a blend of
homopolymers, a copolymer made using two or more olefins, a blend
of copolymers each made using two or more olefins, and a
combination of olefin homopolymers blended with copolymers made
using two or more olefins. The olefin may be selected from
ethylene, propylene, 1-butene, 1-propene, 1-hexene, 1-octene, and
other higher 1-olefin. The first polyolefin may be synthesized
using many different processes (e.g., using gas phase and solution
based using metallocene catalysis and Ziegler-Natta catalysis) and
optionally using a catalyst suitable for polymerizing ethylene
and/or .alpha.-olefins. In some aspects, a metallocene catalyst may
be used to produce low density ethylene/.alpha.-olefin
polymers.
[0036] In some aspects, the first polyolefin includes an
ethylene-octene copolymer, an ethylene-octene random copolymer, an
ethylene-octene block copolymer where the ethylene-octene copolymer
is made from about 30 wt % ethylene, about 35 wt % ethylene, about
40 wt % ethylene, about 45 wt % ethylene, about 50 wt % ethylene,
about 55 wt % ethylene, about 60 wt % ethylene, about 65 wt %
ethylene, about 70 wt % ethylene, about 75 wt % ethylene, about 80
wt % ethylene, or about 85 wt % ethylene. In other aspects, the
first polyolefin includes an ethylene-1-alkene copolymer, an
ethylene-1-alkene random copolymer, an ethylene-1-alkene block
copolymer where the ethylene-1-alkene copolymer is made from about
30 wt % ethylene, about 35 wt % ethylene, about 40 wt % ethylene,
about 45 wt % ethylene, about 50 wt % ethylene, about 55 wt %
ethylene, about 60 wt % ethylene, about 65 wt % ethylene, about 70
wt % ethylene, about 75 wt % ethylene, about 80 wt % ethylene, or
about 85 wt % ethylene.
[0037] In some aspects, the polyethylene used for the first
polyolefin can be classified into several types including, but not
limited to, LDPE (Low Density Polyethylene), LLDPE (Linear Low
Density Polyethylene), and HDPE (High Density Polyethylene). In
other aspects, the polyethylene can be classified as Ultra High
Molecular Weight (UHMW), High Molecular Weight (HMW), Medium
Molecular Weight (MMW) and Low Molecular Weight (LMW). In still
other aspects, the polyethylene may be an ultra-low density
ethylene elastomer.
[0038] In some aspects, the first polyolefin may include a
LDPE/silane copolymer or blend. In other aspects, the first
polyolefin may be polyethylene that can be produced using any
catalyst known in the art including, but not limited to, chromium
catalysts, Ziegler-Natta catalysts, metallocene catalysts or
post-metallocene catalysts.
[0039] In some aspects, the first polyolefin may have a molecular
weight distribution Mw/Mn of less than or equal to about 5, less
than or equal to about 4, from about 1 to about 3.5, or from about
1 to about 3.
[0040] The first polyolefin may be present in an amount of from
greater than 0 to about 100 wt % of the composition. In some
embodiments, the amount of polyolefin elastomer is from about 30 to
about 70 wt %. In some aspects, the first polyolefin fed to an
extruder can include from about 50 wt % to about 80 wt % of an
ethylene/.alpha.-olefin copolymer, including from about 60 wt % to
about 75 wt % and from about 62 wt % to about 72 wt %.
[0041] The first polyolefin may have a melt viscosity in the range
of from about 2,000 cP to about 50,000 cP as measured using a
Brookfield viscometer at a temperature of about 177.degree. C. In
some embodiments, the melt viscosity is from about 4,000 cP to
about 40,000 cP, including from about 5,000 cP to about 30,000 cP
and from about 6,000 cP to about 18,000 cP.
[0042] The first polyolefin may have a melt index (T2), measured at
190.degree. C. under a 2.16 kg load, of from about 20.0 g/10 min to
about 3,500 g/10 min, including from about 250 g/10 min to about
1,900 g/10 min and from about 300 g/10 min to about 1,500 g/10 min.
In some aspects, the first polyolefin has a fractional melt index
of from 0.5 g/10 min to about 3,500 g/10 min.
[0043] In some aspects, the density of the first polyolefin is less
than 0.90 g/cm.sup.3, less than about 0.89 g/cm.sup.3, less than
about 0.88 g/cm.sup.3, less than about 0.87 g/cm.sup.3, less than
about 0.86 g/cm.sup.3, less than about 0.85 g/cm.sup.3, less than
about 0.84 g/cm.sup.3, less than about 0.83 g/cm.sup.3, less than
about 0.82 g/cm.sup.3, less than about 0.81 g/cm.sup.3, or less
than about 0.80 g/cm.sup.3. In other aspects, the density of the
first polyolefin may be from about 0.85 g/cm.sup.3to about 0.89
g/cm.sup.3, from about 0.85 g/cm.sup.3to about 0.88 g/cm.sup.3,
from about 0.84 g/cm.sup.3to about 0.88 g/cm.sup.3, or from about
0.83 g/cm.sup.3to about 0.87 g/cm.sup.3. In still other aspects,
the density is at about 0.84 g/cm.sup.3, about 0.85 g/cm.sup.3,
about 0.86 g/cm.sup.3, about 0.87 g/cm.sup.3, about 0.88
g/cm.sup.3, or about 0.89 g/cm.sup.3.
[0044] The percent crystallinity of the first polyolefin may be
less than about 60%, less than about 50%, less than about 40%, less
than about 35%, less than about 30%, less than about 25%, or less
than about 20%. The percent crystallinity may be at least about
10%. In some aspects, the crystallinity is in the range of from
about 2% to about 60%.
Second Polyolefin
[0045] The second polyolefin can be a polyolefin elastomer
including an olefin block copolymer, an ethylene/.alpha.-olefin
copolymer, a propylene/.alpha.-olefin copolymer, EPDM, EPM, or a
mixture of two or more of any of these materials. Exemplary block
copolymers include those sold under the trade names INFUSE.TM. (the
Dow Chemical Company) and SEPTON.TM. V-SERIES (Kuraray Co., LTD.).
Exemplary ethylene/.alpha.-olefin copolymers include those sold
under the trade names TAFMER.TM. (e.g., TAFMER DF710) (Mitsui
Chemicals, Inc.) and ENGAGE.TM. (e.g., ENGAGE 8150) (the Dow
Chemical Company). Exemplary propylene/.alpha.-olefin copolymers
include those sold under the trade name TAFMER.TM. XM grades
(Mitsui Chemical Company) and VISTAMAXX.TM. (e.g., VISTAMAXX 6102)
(Exxon Mobil Chemical Company). The EPDM may have a diene content
of from about 0.5 to about 10 wt %. The EPM may have an ethylene
content of 45 wt % to 75 wt %.
[0046] In some aspects, the second polyolefin is selected from the
group consisting of: an olefin homopolymer, a blend of
homopolymers, a copolymer made using two or more olefins, a blend
of copolymers each made using two or more olefins, and a blend of
olefin homopolymers with copolymers made using two or more olefins.
The olefin may be selected from ethylene, propylene, 1-butene,
1-propene, 1-hexene, 1-octene, and other higher 1-olefin. The first
polyolefin may be synthesized using many different processes (e.g.,
using gas phase and solution based using metallocene catalysis and
Ziegler-Natta catalysis) and optionally using a catalyst suitable
for polymerizing ethylene and/or .alpha.-olefins. In some aspects,
a metallocene catalyst may be used to produce low density
ethylene/.alpha.-olefin polymers.
[0047] In some aspects, the second polyolefin includes an
ethylene-octene copolymer, an ethylene-octene random copolymer, an
ethylene-octene block copolymer where the ethylene-octene copolymer
is made from about 30 wt % ethylene, about 35 wt % ethylene, about
40 wt % ethylene, about 45 wt % ethylene, about 50 wt % ethylene,
about 55 wt % ethylene, about 60 wt % ethylene, about 65 wt %
ethylene, about 70 wt % ethylene, about 75 wt % ethylene, about 80
wt % ethylene, or about 85 wt % ethylene. In other aspects, the
first polyolefin includes an ethylene-1-alkene copolymer, an
ethylene-1-alkene random copolymer, an ethylene-1-alkene block
copolymer where the ethylene-1-alkene copolymer is made from about
30 wt % ethylene, about 35 wt % ethylene, about 40 wt % ethylene,
about 45 wt % ethylene, about 50 wt % ethylene, about 55 wt %
ethylene, about 60 wt % ethylene, about 65 wt % ethylene, about 70
wt % ethylene, about 75 wt % ethylene, about 80 wt % ethylene, or
about 85 wt % ethylene.
[0048] In some aspects, the second polyolefin may include a
polypropylene homopolymer, a polypropylene copolymer, a
polyethylene-co-propylene copolymer, or a mixture thereof. Suitable
polypropylenes include but are not limited to polypropylene
obtained by homopolymerization of propylene or copolymerization of
propylene and an alpha-olefin comonomer. In some aspects, the
second polyolefin may have a higher molecular weight and/or a
higher density than the first polyolefin.
[0049] In some embodiments, the second polyolefin may have a
molecular weight distribution M.sub.w/M.sub.n of less than or equal
to about 5, less than or equal to about 4, from about 1 to about
3.5, or from about 1 to about 3.
[0050] The second polyolefin may be present in an amount of from
greater than 0 wt % to about 100 wt % of the composition. In some
embodiments, the amount of polyolefin elastomer is from about 30 wt
% to about 70 wt %. In some embodiments, the second polyolefin fed
to the extruder can include from about 10 wt % to about 50 wt %
polypropylene, from about 20 wt % to about 40 wt % polypropylene,
or from about 25 wt % to about 35 wt % polypropylene. The
polypropylene may be a homopolymer or a copolymer.
[0051] The second polyolefin may have a melt viscosity in the range
of from about 2,000 cP to about 50,000 cP as measured using a
Brookfield viscometer at a temperature of about 177.degree. C. In
some embodiments, the melt viscosity is from about 4,000 cP to
about 40,000 cP, including from about 5,000 cP to about 30,000 cP
and from about 6,000 cP to about 18,000 cP.
[0052] The second polyolefin may have a melt index (T2), measured
at 190.degree. C. under a 2.16 kg load, of from about 20.0 g/10 min
to about 3,500 g/10 min, including from about 250 g/10 min to about
1,900 g/10 min and from about 300 g/10 min to about 1,500 g/10 min.
In some embodiments, the polyolefin has a fractional melt index of
from 0.5 g/10 min to about 3,500 g/10 min.
[0053] In some aspects, the density of the second polyolefin is
less than 0.90 g/cm.sup.3, less than about 0.89 g/cm.sup.3, less
than about 0.88 g/cm.sup.3, less than about 0.87 g/cm.sup.3, less
than about 0.86 g/cm.sup.3, less than about 0.85 g/cm.sup.3, less
than about 0.84 g/cm.sup.3, less than about 0.83 g/cm.sup.3, less
than about 0.82 g/cm.sup.3, less than about 0.81 g/cm.sup.3, or
less than about 0.80 g/cm.sup.3. In other aspects, the density of
the first polyolefin may be from about 0.85 g/cm.sup.3to about 0.89
g/cm.sup.3, from about 0.85 g/cm.sup.3to about 0.88 g/cm.sup.3,
from about 0.84 g/cm.sup.3to about 0.88 g/cm.sup.3, or from about
0.83 g/cm.sup.3to about 0.87 g/cm.sup.3. In still other aspects,
the density is at about 0.84 g/cm.sup.3, about 0.85 g/cm.sup.3,
about 0.86 g/cm.sup.3, about 0.87 g/cm.sup.3, about 0.88
g/cm.sup.3, or about 0.89 g/cm.sup.3.
[0054] The percent crystallinity of the second polyolefin may be
less than about 60%, less than about 50%, less than about 40%, less
than about 35%, less than about 30%, less than about 25%, or less
than about 20%. The percent crystallinity may be at least about
10%. In some aspects, the crystallinity is in the range of from
about 2% to about 60%.
[0055] As noted, the silane-crosslinked polyolefin elastomer or
blend includes both the first polyolefin and the second polyolefin.
The second polyolefin is generally used to modify the hardness
and/or processability of the first polyolefin having a density less
than 0.90 g/cm.sup.3. In some aspects, more than just the first and
second polyolefins may be used to form the silane-crosslinked
polyolefin elastomer or blend. For example, in some aspects, one,
two, three, four, or more different polyolefins having a density
less than 0.90 g/cm.sup.3, less than 0.89 g/cm.sup.3, less than
0.88 g/cm.sup.3, less than 0.87 g/cm.sup.3, less than 0.86
g/cm.sup.3, or less than 0.85 g/cm.sup.3 may be substituted and/or
used for the first polyolefin. In some aspects, one, two, three,
four, or more different polyolefins, polyethylene-co-propylene
copolymers may be substituted and/or used for the second
polyolefin.
[0056] The blend of the first polyolefin having a density less than
0.90 g/cm.sup.3 and the second polyolefin having a crystallinity
less than 40% is used because the subsequent silane grafting and
crosslinking of these first and second polyolefin materials
together are what form the core resin structure in the final
silane-crosslinked polyolefin elastomer. Although additional
polyolefins may be added to the blend of the silane-grafted,
silane-crosslinkable, and/or silane-crosslinked polyolefin
elastomer as fillers to improve and/or modify the Young's modulus
as desired for the final product, any polyolefins added to the
blend having a crystallinity equal to or greater than 40% are not
chemically or covalently incorporated into the crosslinked
structure of the final silane-crosslinked polyolefin elastomer.
[0057] In some aspects, the first and second polyolefins may
further include one or more TPVs and/or EPDM with or without silane
graft moieties where the TPV and/or EPDM polymers are present in an
amount of up to 20 wt % of the silane-crosslinker polyolefin
elastomer/blend.
Grafting Initiator
[0058] A grafting initiator (also referred to as "a radical
initiator" in the disclosure) can be utilized in the grafting
process of at least the first and second polyolefins by reacting
with the respective polyolefins to form a reactive species that can
react and/or couple with the silane crosslinker molecule. The
grafting initiator can include halogen molecules, azo compounds
(e.g., azobisisobutyl), carboxylic peroxyacids, peroxyesters,
peroxyketals, and peroxides (e.g., alkyl hydroperoxides, dialkyl
peroxides, and diacyl peroxides). In some embodiments, the grafting
initiator is an organic peroxide selected from di-t-butyl peroxide,
t-butyl cumyl peroxide, dicumyl peroxide,
2,5-dimethyl-2,5-di(t-butyl-peroxy)hexyne-3,
1,3-bis(t-butyl-peroxy-isopropyl)benzene,
n-butyl-4,4-bis(t-butyl-peroxy)valerate, benzoyl peroxide,
t-butylperoxybenzoate, t-butylperoxy isopropyl carbonate, and
t-butylperbenzoate, as well as bis(2-methylbenzoyl)peroxide,
bis(4-methylbenzoyl)peroxide, t-butyl peroctoate, cumene
hydroperoxide, methyl ethyl ketone peroxide, lauryl peroxide,
tert-butyl peracetate, di-t-amyl peroxide, t-amyl peroxybenzoate,
1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane,
a,a'-bis(t-butylperoxy)-1,3-diisopropylbenzene,
a,a'-bis(t-butylpexoxy)-1,4-diisopropylbenzene,
2,5-bis(t-butylperoxy)-2,5-dimethylhexane, and
2,5-bis(t-butylperoxy)-2,5-dimethyl-3-hexyne and
2,4-dichlorobenzoyl peroxide. Exemplary peroxides include those
sold under the tradename LUPEROX.TM. (available from Arkema,
Inc.).
[0059] In some aspects, the grafting initiator is present in an
amount of from greater than 0 wt % to about 2 wt % of the
composition, including from about 0.15 wt % to about 1.2 wt % of
the composition. The amount of initiator and silane employed may
affect the final structure of the silane grafted polymer (e.g., the
degree of grafting in the grafted polymer and the degree of
crosslinking in the cured polymer). In some aspects, the reactive
composition contains at least 100 ppm of initiator, or at least 300
ppm of initiator. The initiator may be present in an amount from
300 ppm to 1500 ppm, or from 300 ppm to 2000 ppm. The
silane:initiator weight ratio may be from about 20:1 to 400:1,
including from about 30:1 to about 400:1, from about 48:1 to about
350:1, and from about 55:1 to about 333:1.
[0060] The grafting reaction can be performed under conditions that
optimize grafts onto the interpolymer backbone while minimizing
side reactions (e.g., the homopolymerization of the grafting
agent). The grafting reaction may be performed in a melt, in
solution, in a solid-state, and/or in a swollen-state. The
silanation may be performed in a wide-variety of equipment (e.g.,
twin screw extruders, single screw extruders, Brabenders, internal
mixers such as Banbury mixers, and batch reactors). In some
embodiments, the polyolefin, silane, and initiator are mixed in the
first stage of an extruder. The melt temperature (i.e., the
temperature at which the polymer starts melting and starts to flow)
may be from about 120.degree. C. to about 260.degree. C., including
from about 130.degree. C. to about 250.degree. C.
Silane Crosslinker
[0061] A silane crosslinker can be used to covalently graft silane
moieties onto the first and second polyolefins and the silane
crosslinker may include alkoxysilanes, silazanes, siloxanes, or a
combination thereof. The grafting and/or coupling of the various
potential silane crosslinkers or silane crosslinker molecules is
facilitated by the reactive species formed by the grafting
initiator reacting with the respective silane crosslinker.
[0062] In some aspects, the silane crosslinker is a silazane where
the silazane may include, for example, hexamethyldisilazane (HMDS)
or Bis(trimethylsilyl)amine. In some aspects, the silane
crosslinker is a siloxane where the siloxane may include, for
example, polydimethylsiloxane (PDMS) and
octamethylcyclotetrasiloxane.
[0063] In some aspects, the silane crosslinker is an alkoxysilane.
As used herein, the term "alkoxysilane" refers to a compound that
comprises a silicon atom, at least one alkoxy group and at least
one other organic group, wherein the silicon atom is bonded with
the organic group by a covalent bond. Preferably, the alkoxysilane
is selected from alkylsilanes; acryl-based silanes; vinyl-based
silanes; aromatic silanes; epoxy-based silanes; amino-based silanes
and amines that possess --NH.sub.2, --NHCH.sub.3or
--N(CH.sub.3).sub.2; ureide-based silanes; mercapto-based silanes;
and alkoxysilanes which have a hydroxyl group (i.e., --OH). An
acryl-based silane may be selected from the group comprising
beta-acryloxyethyl trimethoxysilane; beta-acryloxy propyl
trimethoxysilane; gamma-acryloxyethyl trimethoxysilane;
gamma-acryloxypropyl trimethoxysilane; beta-acryloxyethyl
triethoxysilane; beta-acryloxypropyl triethoxysilane;
gamma-acryloxyethyl triethoxysilane; gamma-acryloxypropyl
triethoxysilane; beta-methacryloxyethyl trimethoxysilane;
beta-methacryloxypropyl trimethoxysilane; gamma-methacryloxyethyl
trimethoxysilane; gamma-methacryloxypropyl trimethoxysilane;
beta-methacryloxyethyl triethoxysilane; beta-methacryloxypropyl
triethoxysilane; gamma-methacryloxyethyl triethoxysilane;
gamma-methacryloxypropyl triethoxysilane;
3-methacryloxypropylmethyl diethoxysilane. A vinyl-based silane may
be selected from the group comprising vinyl trimethoxysilane; vinyl
triethoxysilane; p-styryl trimethoxysilane,
methylvinyldimethoxysilane, vinyldimethylmethoxysilane,
divinyldimethoxysilane, vinyltris(2-methoxyethoxy)silane, and
vinylbenzylethylenediaminopropyltrimethoxysilane. An aromatic
silane may be selected from phenyltrimethoxysilane and
phenyltriethoxysilane. An epoxy-based silane may be selected from
the group comprising 3-glycydoxypropyl trimethoxysilane;
3-glycydoxypropylmethyl diethoxysilane; 3-glycydoxypropyl
triethoxysilane; 2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane, and
glycidyloxypropylmethyldimethoxysilane. An amino-based silane may
be selected from the group comprising 3-aminopropyl
triethoxysilane; 3-aminopropyl trimethoxysilane;
3-aminopropyldimethyl ethoxysilane;
3-aminopropylmethyldiethoxysilane; 4-aminobutyltriethoxysilane;
3-aminopropyldiisopropyl ethoxysilane;
1-amino-2-(dimethylethoxysilyl)propane;
(aminoethylamino)-3-isobutyldimethyl methoxysilane;
N-(2-aminoethyl)-3-aminoisobutylmethyl dimethoxysilane;
(aminoethylaminomethyl)phenetyl trimethoxysilane;
N-(2-aminoethyl)-3-aminopropylmethyl dimethoxysilane;
N-(2-aminoethyl)-3-aminopropyl trimethoxysilane;
N-(2-aminoethyl)-3-aminopropyl triethoxysilane;
N-(6-aminohexyl)aminomethyl trimethoxysilane;
N-(6-aminohexyl)aminomethyl trimethoxysilane;
N-(6-aminohexyl)aminopropyl trimethoxysilane;
N-(2-aminoethyl)-1,1-aminoundecyl trimethoxysilane;
1,1-aminoundecyl triethoxysilane; 3-(m-aminophenoxy)propyl
trimethoxysilane; m-aminophenyl trimethoxysilane; p-aminophenyl
trimethoxysilane; (3-trimethoxysilylpropyl)diethylenetriamine;
N-methylaminopropylmethyl dimethoxysilane; N-methylaminopropyl
trimethoxysilane; dimethylaminomethyl ethoxysilane;
(N,N-dimethylaminopropyl)trimethoxysilane;
(N-acetylglycysil)-3-aminopropyl trimethoxysilane,
N-phenyl-3-aminopropyltrimethoxysilane,
N-phenyl-3-aminopropyltriethoxysilane,
phenylaminopropyltrimethoxysilane,
aminoethylaminopropyltrimethoxysilane, and
aminoethylaminopropylmethyldimethoxysilane. An ureide-based silane
may be 3-ureidepropyl triethoxysilane. A mercapto-based silane may
be selected from the group comprising 3-mercaptopropylmethyl
dimethoxysilane, 3-mercaptopropyl trimethoxysilane, and
3-mercaptopropyl triethoxysilane. An alkoxysilane having a hydroxyl
group may be selected from the group comprising hydroxymethyl
triethoxysilane; N-(hydroxyethyl)-N-methylaminopropyl
trimethoxysilane; bis(2-hydroxyethyl)-3-aminopropyl
triethoxysilane; N-(3-triethoxysilylpropyl)-4-hydroxy butylamide;
1,1-(triethoxysilyl)undecanol; triethoxysilyl undecanol, ethylene
glycol acetal; and N-(3-ethoxysilylpropyl)gluconamide.
[0064] In some aspects, the alkylsilane may be expressed with a
general formula: R.sub.nSi(OR').sub.4-n), wherein: n is 1, 2 or 3;
R is a C.sub.1-20alkyl or a C.sub.2-20alkenyl; and R' is an
C.sub.1-20alkyl. The term "alkyl" by itself or as part of another
substituent, refers to a straight, branched or cyclic saturated
hydrocarbon group joined by single carbon-carbon bonds having 1 to
20 carbon atoms, for example 1 to 10 carbon atoms, for example 1 to
8 carbon atoms, preferably 1 to 6 carbon atoms. When a subscript is
used herein following a carbon atom, the subscript refers to the
number of carbon atoms that the named group may contain. Thus, for
example, C.sub.1-6alkyl means an alkyl of one to six carbon atoms.
Examples of alkyl groups are methyl, ethyl, propyl, isopropyl,
butyl, isobutyl, sec-butyl, f-butyl, 2-methylbutyl, pentyl,
iso-amyl and its isomers, hexyl and its isomers, heptyl and its
isomers, octyl and its isomer, decyl and its isomer, dodecyl and
its isomers. The term "C.sub.2-20alkenyl" by itself or as part of
another substituent, refers to an unsaturated hydrocarbyl group,
which may be linear, or branched, comprising one or more
carbon-carbon double bonds having 2 to 20 carbon atoms. Examples of
C.sub.2-6alkenyl groups are ethenyl, 2-propenyl, 2-butenyl,
3-butenyl, 2-pentenyl and its isomers, 2-hexenyl and its isomers,
2,4-pentadienyl and the like.
[0065] In some aspects, the alkylsilane may be selected from the
group comprising methyltrimethoxysilane; methyltriethoxysilane;
ethyltrimethoxysilane; ethyltriethoxysilane;
propyltrimethoxysilane; propyltriethoxysilane;
hexyltrimethoxysilane; hexyltriethoxysilane; octyltrimethoxysilane;
octyltriethoxysilane; decyltrimethoxysilane; decyltriethoxysilane;
dodecyltrimethoxysilane: dodecyltriethoxysilane;
tridecyltrimethoxysilane; dodecyltriethoxysilane;
hexadecyltrimethoxysilane; hexadecyltriethoxysilane;
octadecyltrimethoxysilane; octadecyltriethoxysilane,
trimethylmethoxysilane, methylhydrodimethoxysilane,
dimethyldimethoxysilane, diisopropyldimethoxysilane,
diisobutyldimethoxysilane, isobutyltrimethoxysilane,
n-butyltrimethoxysilane, n-butylmethyldimethoxysilane,
phenyltrimethoxysilane, phenyltrimethoxysilane,
phenylmethyldimethoxysilane, triphenylsilanol,
n-hexyltrimethoxysilane, n-octyltrimethoxysilane,
isooctyltrimethoxysilane, decyltrimethoxysilane,
hexadecyltrimethoxysilane, cyclohexylmethyldimethoxysilane,
cyclohexylethyldimethoxysilane, dicyclopentyldimethoxysilane,
tert-butylethyldimethoxysilane, tert-butylpropyldimethoxysilane,
dicyclohexyldimethoxysilane, and a combination thereof.
[0066] In some aspects, the alkylsilane compound may be selected
from triethoxyoctylsilane, trimethoxyoctylsilane, and a combination
thereof.
[0067] Additional examples of silanes that can be used as silane
crosslinkers include, but are not limited to, those of the general
formula
CH.sub.2.dbd.CR--(COO).sub.x(C.sub.nH.sub.2n).sub.ySiR'.sub.3,
wherein R is a hydrogen atom or methyl group; x is 0 or 1; y is 0
or 1; n is an integer from 1 to 12; each R' can be an organic group
and may be independently selected from an alkoxy group having from
1 to 12 carbon atoms (e.g., methoxy, ethoxy, butoxy), aryloxy group
(e.g., phenoxy), araloxy group (e.g., benzyloxy), aliphatic acyloxy
group having from 1 to 12 carbon atoms (e.g., formyloxy, acetyloxy,
propanoyloxy), amino or substituted amino groups (e.g., alkylamino,
arylamino), or a lower alkyl group having 1 to 6 carbon atoms. x
and y may both equal 1. In some aspects, no more than one of the
three R' groups is an alkyl. In other aspects, not more than two of
the three R' groups is an alkyl.
[0068] Any silane or mixture of silanes known in the art that can
effectively graft to and crosslink an olefin polymer can be used in
the practice of the present disclosure. In some aspects, the silane
crosslinker can include, but is not limited to, unsaturated silanes
which include an ethylenically unsaturated hydrocarbyl group (e.g.,
a vinyl, allyl, isopropenyl, butenyl, cyclohexenyl or a
gamma-(meth)acryloxy allyl group) and a hydrolyzable group (e.g., a
hydrocarbyloxy, hydrocarbonyloxy, or hydrocarbylamino group).
Non-limiting examples of hydrolyzable groups include, but are not
limited to, methoxy, ethoxy, formyloxy, acetoxy, proprionyloxy, and
alkyl, or arylamino groups. In other aspects, the silane
crosslinkers are unsaturated alkoxy silanes which can be grafted
onto the polymer. In still other aspects, additional exemplary
silane crosslinkers include vinyltrimethoxysilane,
vinyltriethoxysilane, 3-(trimethoxysilyl)propyl methacrylate
gamma-(meth)acryloxypropyl trimethoxysilane), and mixtures
thereof.
[0069] The silane crosslinker may be present in the silane-grafted
polyolefin elastomer in an amount of from greater than 0 wt % to
about 10 wt %, including from about 0.5 wt % to about 5 wt %. The
amount of silane crosslinker may be varied based on the nature of
the olefin polymer, the silane itself, the processing conditions,
the grafting efficiency, the application, and other factors. The
amount of silane crosslinker may be at least 2 wt %, including at
least 4 wt % or at least 5 wt %, based on the weight of the
reactive composition. In other aspects, the amount of silane
crosslinker may be at least 10 wt %, based on the weight of the
reactive composition. In still other aspects, the silane
crosslinker content is at least 1% based on the weight of the
reactive composition. In some embodiments, the silane crosslinker
fed to the extruder may include from about 0.5 wt % to about 10 wt
% of silane monomer, from about 1 wt % to about 5 wt % silane
monomer, or from about 2 wt % to about 4 wt % silane monomer.
Condensation Catalyst
[0070] A condensation catalyst can facilitate both the hydrolysis
and subsequent condensation of the silane grafts on the
silane-grafted polyolefin elastomer to form crosslinks. In some
aspects, the crosslinking can be aided by the use of an electron
beam radiation. In some aspects, the condensation catalyst can
include, for example, organic bases, carboxylic acids, and
organometallic compounds (e.g., organic titanates and complexes or
carboxylates of lead, cobalt, iron, nickel, zinc, and tin). In
other aspects, the condensation catalyst can include fatty acids
and metal complex compounds such as metal carboxylates; aluminum
triacetyl acetonate, iron triacetyl acetonate, manganese
tetraacetyl acetonate, nickel tetraacetyl acetonate, chromium
hexaacetyl acetonate, titanium tetraacetyl acetonate and cobalt
tetraacetyl acetonate; metal alkoxides such as aluminum ethoxide,
aluminum propoxide, aluminum butoxide, titanium ethoxide, titanium
propoxide and titanium butoxide; metal salt compounds such as
sodium acetate, tin octylate, lead octylate, cobalt octylate, zinc
octylate, calcium octylate, lead naphthenate, cobalt naphthenate,
dibutyltin dioctoate, dibutyltin dilaurate, dibutyltin maleate and
dibutyltin di(2-ethylhexanoate); acidic compounds such as formic
acid, acetic acid, propionic acid, p-toluenesulfonic acid,
trichloroacetic acid, phosphoric acid, monoalkylphosphoric acid,
dialkylphosphoric acid, phosphate ester of p-hydroxyethyl
(meth)acrylate, monoalkylphosphorous acid and dialkylphosphorous
acid; acids such as p-toluenesulfonic acid, phthalic anhydride,
benzoic acid, benzenesulfonic acid, dodecylbenzenesulfonic acid,
formic acid, acetic acid, itaconic acid, oxalic acid and maleic
acid, ammonium salts, lower amine salts or polyvalent metal salts
of these acids, sodium hydroxide, lithium chloride; organometal
compounds such as diethyl zinc and tetra(n-butoxy)titanium; and
amines such as dicyclohexylamine, triethylamine,
N,N-dimethylbenzylamine, N,N,N',N'-tetramethyl-1,3-butanediamine,
diethanolamine, triethanolamine and cyclohexylethylamine. In still
other aspects, the condensation catalyst can include
ibutyltindilaurate, dioctyltinmaleate, dibutyltindiacetate,
dibutyltindioctoate, stannous acetate, stannous octoate, lead
naphthenate, zinc caprylate, and cobalt naphthenate. Depending on
the desired final material properties of the silane-crosslinked
polyolefin elastomer or blend, a single condensation catalyst or a
mixture of condensation catalysts may be utilized. The condensation
catalyst(s) may be present in an amount of from about 0.01 wt % to
about 1.0 wt %, including from about 0.25 wt % to about 8 wt %,
based on the total weight of the silane-grafted polyolefin
elastomer/blend composition.
[0071] In some aspects, a crosslinking system can include and use
one or all of a combination of radiation, heat, moisture, and
additional condensation catalyst. In some aspects, the condensation
catalyst may be present in an amount of from 0.25 wt % to 8 wt %.
In other aspects, the condensation catalyst may be included in an
amount of from about 1 wt % to about 10 wt %, or from about 2 wt %
to about 5 wt %.
Foaming Agent
[0072] The foaming agent can be a chemical foaming agent (e.g.,
organic or inorganic foaming agent) and/or a physical foaming
(e.g., gases and volatile low weight molecules) that is added to
the silane-grafted polyolefin elastomer and condensation catalyst
blend during the extrusion and/or molding process to produce the
foamed silane-crosslinked polyolefin elastomer.
[0073] In some aspects, the foaming agent may be a physical foaming
agent including a microencapsulated foaming agent, otherwise
referred to in the art as a microencapsulated blowing agent (MEBA).
MEBAs include a family of physical foaming agents that are defined
as a thermo expandable microsphere which is formed by the
encapsulation of a volatile hydrocarbon into an acrylic copolymer
shell. When the acrylic copolymer shell expands, the volatile
hydrocarbon (e.g., butane) positioned inside the shell additionally
expands within the shell to create a cell or pocket in the
silane-crosslinkable polyolefin elastomer to reduce its weight. The
shell of the MEBA is designed not to break so the blowing agent
does not lose its ability to expand and reduce the density of the
silane-crosslinkable polyolefin elastomer. In some aspects, the
MEBAs have an average particle size of from about 20 .mu.m to about
30 .mu.m. Exemplary MEBAs include those sold under the trade name
MATSUMOTO F-AC170D. In some aspects, MEBA's may be used in
combination with other foaming agents including organic and
inorganic foaming agents.
[0074] Organic foaming agents that may be used can include, for
example, azo compounds, such as azodicarbonamide (ADCA), barium
azodicarboxylate, azobisisobutyronitrile (AIBN),
azocyclohexylnitrile, and azodiaminobenzene, N-nitroso compounds,
such as N,N'-dinitrosopentamethylenetetramine (DPT),
N,N'-dimethyl-N,N'-dinitrosoterephthalamide, and
trinitrosotrimethyltriamine, hydrazide compounds, such as
4,4'-oxybis(benzenesulfonylhydrazide)(OBSH), paratoluene
sulfonylhydrazide, diphenylsulfone-3,3'-disulfonylhydrazide,
2,4-toluenedisulfonylhydrazide,
p,p-bis(benzenesulfonylhydrazide)ether,
benzene-1,3-disulfonylhydrazide, and allylbis(sulfonylhydrazide),
semicarbazide compounds, such as p-toluilenesulfonylsemicarbazide,
and 4,4'-oxybis(benzenesulfonylsemicarbazide), alkane fluorides,
such as trichloromonofluoromethane, and dichloromonofluoromethane,
and triazole compounds, such as 5-morpholyl-1,2,3,4-thiatriazole,
and other known organic foaming agents. Preferably, azo compounds
and N-nitroso compounds are used. Further preferably,
azodicarbonamide (ADCA) and N,N'-dinitrosopentamethylenetetramine
(DPT) are used. The organic foaming agents listed above may be used
alone or in any combination of two or more.
[0075] The decomposition temperature and amount of organic foaming
agent used can have important consequences on the density and
material properties of the foamed silane-crosslinker polyolefin
elastomer. In some aspects, the organic foaming agent has a
decomposition temperature of from about 150.degree. C. to about
210.degree. C. The organic foaming agent can be used in an amount
of from about 0.1 wt % to about 40 wt %, from about 5 wt % to about
30 wt %, from about 5 wt % to about 20 wt %, from about 10 wt % to
about 30 wt %, or from about 1 wt % to about 10 wt % based on the
total weight of the polymer blend. If the organic foaming agent has
a decomposition temperature lower than 150.degree. C., early
foaming may occur during compounding. Meanwhile, if the organic
foaming agent has a decomposition temperature higher than
210.degree. C., it may take longer, e.g., greater than 15 minutes,
to mold the foam, resulting in low productivity. Additional foaming
agents may include any compound whose decomposition temperature is
within the range defined above.
[0076] The inorganic foaming agents that may be used include, for
example, hydrogen carbonate, such as sodium hydrogen carbonate, and
ammonium hydrogen carbonate, carbonate, such as sodium carbonate,
and ammonium carbonate, nitrite, such as sodium nitrite, and
ammonium nitrite, borohydride, such as sodium borohydride, and
other known inorganic foaming agents, such as azides. In some
aspect, hydrogen carbonate may be used. In other aspects, sodium
hydrogen carbonate may be used. The inorganic foaming agents listed
above may be used alone or in any combination of two or more. The
inorganic foaming agent can be used in an amount of from about 0.1
wt % to about 40 wt %, from about 5 wt % to about 30 wt %, from
about 5 wt % to about 20 wt %, from about 10 wt % to about 30 wt %,
or from about 1 wt % to about 10 wt % based on the total weight of
the polymer blend.
[0077] Physical blowing agents that may be used include, for
example, supercritical carbon dioxide, supercritical nitrogen,
butane, pentane, isopentane, cyclopentane. The physical foaming
agent can be used in an amount of from about 0.1 wt % to about 40
wt %, from about 5 wt % to about 30 wt %, from about 5 wt % to
about 20 wt %, from about 10 wt % to about 30 wt %, or from about 1
wt % to about 10 wt % based the total weight of the polymer
blend.
[0078] In some aspects, an endothermic blowing (foaming) agent may
be used that can include, for example, sodium bicarbonate and/or
citric acid and its salts or derivatives. Exemplary citric acid
foaming agents include those sold under the trade name
HYDROCEROL.RTM. that includes a mixture of zinc stearate,
polyethylene glycol, and a citric acid or citric acid derivative.
The desired decomposition temperature for the endothermic blowing
(foaming) agent may be from about 160.degree. C. to about
200.degree. C., or about 175.degree. C., about 180.degree. C.,
about 185.degree. C., about 190.degree. C., or about 195.degree.
C.
Optional Additional Components
[0079] The silane-crosslinked polyolefin elastomer may optionally
include one or more fillers. The filler(s) may be extruded with the
silane-grafted polyolefin and in some aspects may include
additional polyolefins having a crystallinity greater than 20%,
greater than 30%, greater than 40%, or greater than 50%. In some
aspects, the filler(s) may include metal oxides, metal hydroxides,
metal carbonates, metal sulfates, metal silicates, clays, talcs,
carbon black, and silicas. Depending on the application and/or
desired properties, these materials may be fumed or calcined.
[0080] The metal of the metal oxide, metal hydroxide, metal
carbonate, metal sulfate, or metal silicate may be selected from
alkali metals (e.g., lithium, sodium, potassium, rubidium, caesium,
and francium); alkaline earth metals (e.g., beryllium, magnesium,
calcium, strontium, barium, and radium); transition metals (e.g.,
zinc, molybdenum, cadmium, scandium, titanium, vanadium, chromium,
manganese, iron, cobalt, nickel, copper, yttrium, zirconium,
niobium, technetium, ruthernium, rhodium, palladium, silver,
hafnium, taltalum, tungsten, rhenium, osmium, indium, platinum,
gold, mercury, rutherfordium, dubnium, seaborgium, bohrium,
hassium, and copernicium); post-transition metals (e.g., aluminum,
gallium, indium, tin, thallium, lead, bismuth, and polonium);
lanthanides (e.g., lanthanum, cerium, praseodymium, neodymium,
promethium, samarium, europium, gadolinium, terbium, dysprosium,
holmium, erbium, thulium, ytterbium, and lutetium); actinides
(e.g., actinium, thorium, protactinium, uranium, neptunium,
plutonium, americium, curium, berkelium, californium, einsteinium,
fermium, mendelevium, nobelium, and lawrencium); germanium;
arsenic; antimony; and astatine.
[0081] The filler(s) of the silane-crosslinked polyolefin elastomer
or blend may be present in an amount of from greater than 0 wt % to
about 50 wt %, including from about 1 wt % to about 20 wt % and
from about 3 wt % to about 10 wt %.
[0082] The silane-crosslinked polyolefin elastomer and/or the
respective articles formed (e.g., static sealing members 12) may
also include waxes (e.g., paraffin waxes, microcrystalline waxes,
HDPE waxes, LDPE waxes, thermally degraded waxes, byproduct
polyethylene waxes, optionally oxidized Fischer-Tropsch waxes, and
functionalized waxes). In some embodiments, the wax(es) are present
in an amount of from about 0 wt % to about 10 wt %.
[0083] Tackifying resins (e.g., aliphatic hydrocarbons, aromatic
hydrocarbons, modified hydrocarbons, terpens, modified terpenes,
hydrogenated terpenes, rosins, rosin derivatives, hydrogenated
rosins, and mixtures thereof) may also be included in the
silane-crosslinked polyolefin elastomer/blend. The tackifying
resins may have a ring and ball softening point in the range of
from 70.degree. C. to about 150.degree. C. and a viscosity of less
than about 3,000 cP at 177.degree. C. In some aspects, the
tackifying resin(s) are present in an amount of from about 0 wt %
to about 10 wt %.
[0084] In some aspects, the silane-crosslinked polyolefin elastomer
may include one or more oils. Non-limiting types of oils include
white mineral oils and naphthenic oils. In some embodiments, the
oil(s) are present in an amount of from about 0 wt % to about 10 wt
%.
[0085] In some aspects, the silane-crosslinked polyolefin elastomer
may include one or more filler polyolefins having a crystallinity
greater than 20%, greater than 30%, greater than 40%, or greater
than 50%. The filler polyolefin may include polypropylene,
poly(ethylene-co-propylene), and/or other ethylene/.alpha.-olefin
copolymers. In some aspects, the use of the filler polyolefin may
be present in an amount of from about 5 wt % to about 60 wt %, from
about 10 wt % to about 50 wt %, from about 20 wt % to about 40 wt
%, or from about 5 wt % to about 20 wt %. The addition of the
filler polyolefin may increase the Young's modulus by at least 10%,
by at least 25%, or by at least 50% for the final
silane-crosslinked polyolefin elastomer.
[0086] In some aspects, the silane-crosslinked polyolefin elastomer
of the present disclosure may include one or more stabilizers
(e.g., antioxidants). The silane-crosslinked polyolefin elastomer
may be treated before grafting, after grafting, before
crosslinking, and/or after crosslinking. Other additives may also
be included. Non-limiting examples of additives include antistatic
agents, dyes, pigments, UV light absorbers, nucleating agents,
fillers, slip agents, plasticizers, fire retardants, lubricants,
processing aides, smoke inhibitors, anti-blocking agents, and
viscosity control agents. The antioxidant(s) may be present in an
amount of less than 0.5 wt %, including less than 0.2 wt % of the
composition.
[0087] In some aspects, a coloring agent may be added to the
silane-crosslinked polyolefin elastomer during its production as
the silane-crosslinkable polyolefin elastomer or the silane-grafted
polyolefin elastomer. In some aspects, the coloring agent may be
added in combination with the condensation catalyst (e.g.,
LE4423/AMBICAT.TM.) and can include colors that include, for
example, black (PPM1200/2), blue (PPM1201/2), brown (PPM1202/2),
green (PPM1203/2), grey (PPM1204/2), orange (PPM1205/2), red
(PPM1206/2), violet (PPM1207/2), white (PPM1208/2), and/or yellow
(PPM1200/2) as provided by commercial suppliers.
Method for Making the Silane-Grafted Polyolefin Elastomer
[0088] The synthesis/production of the silane-crosslinked
polyolefin elastomer may be performed by combining the respective
components in one extruder using a single-step Monosil process or
in two extruders using a two-step Sioplas process which eliminates
the need for additional steps of mixing and shipping rubber
compounds prior to extrusion.
[0089] Referring now to FIG. 1, the general chemical process used
during both the single-step Monosil process and two-step Sioplas
process used to synthesize the silane-crosslinked polyolefin
elastomer is provided. The process starts with a grafting step that
includes initiation from a grafting initiator followed by
propagation and chain transfer with the first and second
polyolefins. The grafting initiator, in some aspects a peroxide or
azo compound, homolytically cleaves to form two radical initiator
fragments that transfer to one of the first and second polyolefins
chains through a propagation step. The free radical, now positioned
on the first or second polyolefin chain, can then transfer to a
silane molecule and/or another polyolefin chain. Once the initiator
and free radicals are consumed, the silane grafting reaction for
the first and second polyolefins is complete.
[0090] Still referring to FIG. 1, once the silane grafting reaction
is complete, a mixture of stable first and second silane-grafted
polyolefins is produced. A crosslinking catalyst may then be added
to the first and second silane-grafted polyolefins to form the
silane-grafted polyolefin elastomer. The crosslinking catalyst may
first facilitate the hydrolysis of the silyl group grafted onto the
polyolefin backbones to form reactive silanol groups. The silanol
groups may then react with other silanol groups on other polyolefin
molecules to form a crosslinked network of elastomeric polyolefin
polymer chains linked together through siloxane linkages. The
density of silane crosslinks throughout the silane-grafted
polyolefin elastomer can influence the material properties
exhibited by the elastomer.
[0091] Referring now to FIGS. 2 and 3A, a method 10 for making the
elastomeric article, using the two-step Sioplas process is shown.
The method 10 may begin with a step 14 that includes extruding
(e.g., with a twin screw extruder 66) the first polyolefin 54
having a density less than 0.86 g/cm.sup.3, the second polyolefin
58 having a crystallinity less than 40%, a silan cocktail 62,
including the silane crosslinker (e.g., vinyltrimethoxy silane,
VTMO) and the grafting initiator (e.g. dicumyl peroxide) together
to form a silane-grafted polyolefin blend 90. The first polyolefin
54 and second polyolefin 58 may be added to the reactive twin screw
extruder 66 using an addition hopper 70. The silan cocktail 62 may
be added to twin screws 74 further down the extrusion line to help
promote better mixing with the first and second polyolefin 54, 58
blend. A forced volatile organic compound (VOC) vacuum 78 may be
used on the reactive twin screw extruder 66 to help maintain a
desired reaction pressure. The twin screw extruder 66 is considered
reactive because the radical initiator and silane crosslinker are
reacting with and forming new covalent bonds with both the first
and second polyolefins 54, 58. The melted silane-grafted polyolefin
blend can exit the reactive twin screw extruder 66 using a gear
pump 82 that injects the molten silane-grafted polyolefin blend
into a water pelletizer 86 that can form a pelletized
silane-grafted polyolefin blend 90. In some aspects, the molten
silane-grafted polyolefin blend may be extruded into pellets,
pillows, or any other configuration prior to the incorporation of
the condensation catalyst 94 (see FIG. 3B) and formation of the
final elastomeric article.
[0092] The reactive twin screw extruder 66 can be configured to
have a plurality of different temperature zones (e.g., Z0-Z12 as
shown in FIG. 3A) that extend for various lengths of the twin screw
extruder 66. In some aspects, the respective temperature zones may
have temperatures ranging from about room temperature to about
180.degree. C., from about 120.degree. C. to about 170.degree. C.,
from about 120.degree. C. to about 160.degree. C., from about
120.degree. C. to about 150.degree. C., from about 120.degree. C.
to about 140.degree. C., from about 120.degree. C. to about
130.degree. C., from about 130.degree. C. to about 170.degree. C.,
from about 130.degree. C. to about 160.degree. C., from about
130.degree. C. to about 150.degree. C., from about 130.degree. C.
to about 140.degree. C., from about 140.degree. C. to about
170.degree. C., from about 140.degree. C. to about 160.degree. C.,
from about 140.degree. C. to about 150.degree. C., from about
150.degree. C. to about 170.degree. C., and from about 150.degree.
C. to about 160.degree. C. In some aspects, Z0 may have a
temperature from about 60.degree. C. to about 110.degree. C. or no
cooling; Z1 may have a temperature from about 120.degree. C. to
about 130.degree. C.; Z2 may have a temperature from about
140.degree. C. to about 150.degree. C.; Z3 may have a temperature
from about 150.degree. C. to about 160.degree. C.; Z4 may have a
temperature from about 150.degree. C. to about 160.degree. C.; Z5
may have a temperature from about 150.degree. C. to about
160.degree. C.; Z6 may have a temperature from about 150.degree. C.
to about 160.degree. C.; and Z7-Z12 may have a temperature from
about 150.degree. C. to about 160.degree. C.
[0093] In some aspects, the number average molecular weight of the
silane-grafted polyolefin elastomers may be in the range of from
about 4,000 g/mol to about 30,000 g/mol, including from about 5,000
g/mol to about 25,000 g/mol, from about 6,000 g/mol to about 14,000
g/mol, and greater than 25,000 g/mol. The weight average molecular
weight of the grafted polymers may be from about 8,000 g/mol to
about 60,000 g/mol, including from about 10,000 g/mol to about
30,000 g/mol.
[0094] Referring now to FIGS. 2 and 3B, the method 10 next includes
a step 18 of extruding the silane-grafted polyolefin blend 90 and
the condensation catalyst 94 together to form a
silane-crosslinkable polyolefin blend 114. In some aspects, one or
more optional additives 98 may be added with the silane-grafted
polyolefin blend 90 and the condensation catalyst 94 to adjust the
final material properties of the silane-crosslinked polyolefin
olefin blend. In step 18, the silane-grafted polyolefin blend 90 is
mixed with a silanol forming condensation catalyst 94 to form
reactive silanol groups on the silane grafts that can subsequently
crosslink when exposed to humidity and/or heat. In some aspects,
the condensation catalyst is AMBICAT.TM. LE4472 which can include a
mixture of sulfonic acid, antioxidant, process aide, and carbon
black for coloring where the ambient moisture is sufficient for the
condensation catalyst 94 to crosslink the silane-crosslinkable
polyolefin blend 114 over a longer time period (e.g., about 48
hours). The silane-grafted polyolefin blend 90 and the condensation
catalyst 94 may be added to a reactive single screw extruder 102
using an addition hopper and an addition gear pump 110. The
combination of the silane-grafted polyolefin blend 90 and the
condensation catalyst 94, and in some aspects one or more optional
additives 98, may be added to a single screw 106 of the reactive
single screw extruder 102. The single screw extruder 102 is
considered reactive because crosslinking can begin as soon as the
silane-grafted polyolefin blend 90 and the condensation catalyst 94
are melted and combined together to mix the condensation catalyst
94 thoroughly and evenly throughout the melted silane-grafted
polyolefin blend 90. The melted silane-crosslinkable polyolefin
blend 114 can exit the reactive single-screw extruder 102 through a
die that can inject the molten silane-crosslinkable polyolefin
blend into an uncured static sealing element.
[0095] During step 18, as the silane-grafted polyolefin blend 90 is
extruded together with the condensation catalyst 94 to form the
silane-crosslinkable polyolefin blend 114, a certain amount of
crosslinking may occur. In some aspects, the silane-crosslinkable
polyolefin blend 114 may be about 25% cured, about 30% cured, about
35% cured, about 40% cured, about 45% cured, about 50% cured, about
55% cured, about 60% cured, bout 65% cured, or about 70% cured
where gel test (ASTM D2765) can be used to determine the amount of
crosslinking in the final silane-crosslinked polyolefin
elastomer.
[0096] Still referring to FIGS. 2 and 3B, the method 10 further
includes a step 22 of molding the silane-crosslinkable polyolefin
blend 114 into the uncured elastomeric article. The single screw
extruder 102 melts and extrudes the silane-crosslinkable polyolefin
114 through a die that can extrude the molten silane-crosslinkable
polyolefin blend 114 into the uncured elastomeric element.
[0097] Referring again to FIG. 2, the method 10 can further include
a step 26 of crosslinking the silane-crosslinkable polyolefin blend
114 or the uncured elastomeric article at an ambient or elevated
temperature and/or an ambient or elevated humidity to form the
elastomeric article having a density from about 0.80 g/cm.sup.3 to
about 0.89 g/cm.sup.3, 0.60 g/cm.sup.3 to 0.69 g/cm.sup.3, or 0.50
g/cm.sup.3 to 0.59 g/cm.sup.3. More particularly, in this
crosslinking process, the water hydrolyzes the silane of the
silane-crosslinkable polyolefin elastomer to produce a silanol. The
silanol groups on various silane grafts can then be condensed to
form intermolecular, irreversible Si--O--Si crosslink sites. The
amount of crosslinked silane groups, and thus the final polymer
properties, can be regulated by controlling the production process,
including the amount of catalyst used.
[0098] The crosslinking/curing of step 26 of the method 10 may
occur over a time period of from greater than about 20 seconds to
about 200 seconds or 0 to about 20 hours. In some aspects, curing
takes place over a time period of from about 20 seconds to about
200 seconds, about 1 hour to about 20 hours, about 10 hours to
about 20 hours, from about 15 hours to about 20 hours, from about 5
hours to about 15 hours, from about 1 hour to about 8 hours, or
from about 3 hours to about 6 hours. The temperature during the
crosslinking/curing may be about room temperature, from about
20.degree. C. to about 25.degree. C., from about 20.degree. C. to
about 150.degree. C., from about 25.degree. C. to about 100.degree.
C., from about 20.degree. C. to about 75.degree. C., from about
50.degree. C. to about 200.degree. C., from about 100.degree. C. to
about 400.degree. C., from about 100.degree. C. to about
300.degree. C., or form about 100.degree. C. to about 200.degree.
C. The humidity during curing may be from about 30% to about 100%,
from about 40% to about 100%, or from about 50% to about 100%.
[0099] In some aspects, an extruder setting is used that is capable
of extruding thermoplastic, with long LID, 30 to 1, at an extruder
heat setting close to TPV processing conditions wherein the
extrudate crosslinks at ambient conditions becoming a thermoset in
properties. In other aspects, this process may be accelerated by
steam exposure. Immediately after the extrusion step, the gel
content (also called the crosslink density) may be about 40%, about
50%, or about 60%, but after 96 hrs at ambient conditions, the gel
content may reach greater than about 80%, about 85%, about 90%, or
about 95%.
[0100] In some aspects, one or more reactive single screw extruders
102 may be used to form the uncured sealing element and
corresponding static sealing member that have one or more types of
silane-crosslinked polyolefin elastomers. For example, in some
aspects, one reactive single screw extruder 102 may be used to
produce and extrude the silane-crosslinked polyolefin elastomer
while a second reactive single screw extruder 102 may be used to
produce and extrude a second silane-crosslinked polyolefin
elastomer. The complexity and architecture of the final article or
product will determine the number and types of reactive single
screw extruder 102.
[0101] It is understood that the description outlining and teaching
the various elastomeric articles and their respective
components/composition previously discussed, which can be used in
any combination, applies equally well to the method 10 for making
the elastomeric article using the two-step Sioplas process as
shown.
[0102] Referring now to FIGS. 4 and 5, a method 200 for making the
elastomeric article, using the one-step Monosil process is shown.
The method 200 may begin with a step 204 that includes extruding
(e.g., with a single screw extruder 216) the first polyolefin 54
having a density less than 0.86 g/cm.sup.3, the second polyolefin
58 having a crystallinity less than 40%, the silan cocktail 62
including the silane crosslinker (e.g., vinyltrimethoxy silane,
VTMO) and grafting initiator (e.g. dicumyl peroxide), and the
condensation catalyst 94 together to form the crosslinkable
silane-grafted polyolefin blend 114. The first polyolefin 54,
second polyolefin 58, and silan cocktail 62 may be added to the
reactive single screw extruder 216 using an addition hopper 70. In
some aspects, the silan cocktail 62 may be added to a single screw
220 further down the extrusion line to help promote better mixing
with the first and second polyolefin 54, 58 blend. In some aspects,
one or more optional additives 98 may be added with the first
polyolefin 54, second polyolefin 58, and silan cocktail 62 to
modify the final material properties of the silane-crosslinkable
polyolefin blend 114. The single screw extruder 216 is considered
reactive because the radical initiator and silane crosslinker of
the silan cocktail 62 are reacting with and forming new covalent
bonds with both the first and second polyolefin blends 54, 58. In
addition, the reactive single screw extruder 216 mixes the
condensation catalyst 94 in together with the melted silane-grafted
polyolefin blend 90. The melted silane-crosslinkable polyolefin
blend 114 can exit the reactive single screw extruder 216 using a
gear pump (not shown) and/or die that can inject, eject, and/or
extrude the molten silane-crosslinkable polyolefin blend into the
uncured static sealing element.
[0103] During step 204, as the first polyolefin 54, second
polyolefin 58, silan cocktail 62, and condensation catalyst 94 are
extruded together, a certain amount of crosslinking may occur in
the reactive single screw extruder 216 (see FIGS. 4 and 5). In some
aspects, the silane-crosslinkable polyolefin blend 114 may be about
25% cured, about 30% cured, about 35% cured, about 40% cured, about
45% cured, about 50% cured, about 55% cured, about 60% cured, bout
65% cured, or about 70% as it leaves the reactive single screw
extruder 216. The gel test (ASTM D2765) can be used to determine
the amount of crosslinking in the final silane-crosslinked
polyolefin elastomer.
[0104] The reactive single screw extruder 216 can be configured to
have a plurality of different temperature zones (e.g., Z0-Z7 as
shown in FIG. 5) that extend for various lengths along the
extruder. In some aspects, the respective temperature zones may
have temperatures ranging from about room temperature to about
180.degree. C., from about 120.degree. C. to about 170.degree. C.,
from about 120.degree. C. to about 160.degree. C., from about
120.degree. C. to about 150.degree. C., from about 120.degree. C.
to about 140.degree. C., from about 120.degree. C. to about
130.degree. C., from about 130.degree. C. to about 170.degree. C.,
from about 130.degree. C. to about 160.degree. C., from about
130.degree. C. to about 150.degree. C., from about 130.degree. C.
to about 140.degree. C., from about 140.degree. C. to about
170.degree. C., from about 140.degree. C. to about 160.degree. C.,
from about 140.degree. C. to about 150.degree. C., from about
150.degree. C. to about 170.degree. C., and from about 150.degree.
C. to about 160.degree. C. In some aspects, Z0 may have a
temperature from about 60.degree. C. to about 110.degree. C. or no
cooling; Z1 may have a temperature from about 120.degree. C. to
about 130.degree. C.; Z2 may have a temperature from about
140.degree. C. to about 150.degree. C.; Z3 may have a temperature
from about 150.degree. C. to about 160.degree. C.; Z4 may have a
temperature from about 150.degree. C. to about 160.degree. C.; Z5
may have a temperature from about 150.degree. C. to about
160.degree. C.; Z6 may have a temperature from about 150.degree. C.
to about 160.degree. C.; and Z7 may have a temperature from about
150.degree. C. to about 160.degree. C.
[0105] In some aspects, the number average molecular weight of the
silane-grafted polyolefin elastomers may be in the range of from
about 4,000 g/mol to about 30,000 g/mol, including from about 5,000
g/mol to about 25,000 g/mol, from about 6,000 g/mol to about 14,000
g/mol, and greater than 25,000 g/mol. The weight average molecular
weight of the grafted polymers may be from about 8,000 g/mol to
about 60,000 g/mol, including from about 10,000 g/mol to about
30,000 g/mol.
[0106] Still referring to FIGS. 4 and 5, the method 200 further
includes a step 208 of molding the silane-crosslinkable polyolefin
blend into the elastomeric element. The reactive single screw
extruder 216 can melt and extrude the silane-crosslinkable
polyolefin blend 114 through the die that can extrude the molten
silane-crosslinkable polyolefin blend 114 into the uncured
elastomeric article.
[0107] Still referring to FIG. 4, the method 200 can further
include a step 212 of crosslinking the silane-crosslinkable
polyolefin blend 114 of the uncured elastomeric article at an
ambient or elevated temperature and an ambient or elevated humidity
to form the elastomeric article having a density from about 0.80
g/cm.sup.3 to about 0.89 g/cm.sup.3, 0.60 g/cm.sup.3 to 0.69
g/cm.sup.3, or 0.50 g/cm.sup.3 to 0.59 g/cm.sup.3. The amount of
crosslinked silane groups, and thus the final polymer properties,
can be regulated by controlling the production process, including
the amount of catalyst used.
[0108] The step 212 of crosslinking the silane-crosslinkable
polyolefin blend 114 may occur over a time period of from greater
than about 40 seconds to about 200 seconds, 0 hours to about 10
hours, or 0 to about 20 hours. In some aspects, curing takes place
over a time period of from about 10 seconds to about 200 seconds,
about 40 seconds to about 400 seconds, about 1 hour to about 20
hours, 10 hours to about 20 hours, from about 15 hours to about 20
hours, from about 5 hours to about 15 hours, from about 1 hour to
about 8 hours, or from about 3 hours to about 6 hours. The
temperature during the crosslinking and curing may be about room
temperature, from about 20.degree. C. to about 425.degree. C., from
about 20.degree. C. to about 250.degree. C., from about 25.degree.
C. to about 200.degree. C., or from about 20.degree. C. to about
75.degree. C. The humidity during curing may be from about 30% to
about 100%, from about 40% to about 100%, or from about 50% to
about 100%.
[0109] In some aspects, an extruder setting is used that is capable
of extruding thermoplastic, with long L/D, 30 to 1, at an extruder
heat setting close to TPV processing conditions wherein the
extrudate can crosslink at ambient temperature or greater
conditions becoming a thermoset in properties. In other aspects,
this process may be accelerated by steam exposure. Immediately
after extrusion, the gel content (also called the crosslink
density) may be about 40%, about 50%, or about 60%, but after 96
hrs at ambient conditions, the gel content may reach greater than
about 80%, about 85%, about 90%, or about 95%.
[0110] In some aspects, one or more reactive single screw extruders
216 (see FIG. 5) may be used to form the uncured sealing element
and corresponding static sealing member that have one or more types
of silane-crosslinked polyolefin elastomers. For example, in some
aspects, one reactive single screw extruder 216 may be used to
produce and extrude the silane-crosslinked polyolefin elastomer
while a second reactive single screw extruder 216 may be used to
produce and extrude the second silane-crosslinked polyolefin
elastomer. The complexity and architecture of the final article or
product will determine the number and types of reactive single
screw extruder 216.
[0111] It is understood that the description outlining and teaching
the various silane-crosslinked polyolefin elastomer and their
respective components/composition previously discussed, which can
be used in any combination, applies equally well to the method 200
for making the elastomeric article using the one-step Monosil
process as shown.
[0112] Non-limiting examples of the elastomeric articles that the
silane-crosslinked polyolefin elastomer of the disclosure may be
used to manufacture include static seals such as weather seals
(e.g., glass run channels including molded details/corners),
sunroof seals, convertible top seals, mirror seals, body-panel
interface seals, stationary window moldings, glass encapsulations,
cut-line seals, greenhouse moldings, occupation detector system
sensor switches, rocker seals, outer and inner belts, auxiliary and
margin seals, edge protector/gimp seals, and below-belt brackets
and channels; automotive hoses such as coolant hoses, air
conditioning hoses, and vacuum hoses; anti-vibration system (AVS)
components such as mounts (e.g., engine, body, accessory,
component), dampers, bushings, strut mounts, and isolators;
coatings such as coatings for brake lines, fuel lines, transmission
oil cooler lines, brackets, cross members, frame components, body
panels and components, suspension components, wheels, hubs,
springs, and fasteners; air deflectors, spoilers, fascia, and trim;
building, window, and door seals; boots, bellows, and grommets;
gaskets (e.g., pneumatic and/or hydraulic gaskets); wire and cable
sheathing; tires; windshield wipers and squeegees; floor mats;
pedal covers; automotive belts; conveyor belts; shoe components;
marine bumpers; O-rings; valves and seals; and springs (e.g., as
substitutes for mechanical metal springs).
Molding Techniques
[0113] Injecting or adding the silane-crosslinkable polyolefin
elastomer blend 114 into a mold may be performed using one of
several different approaches. Depending on the molding approach
selected, different material properties may be achieved for the
elastomeric article. The molding can be performed by using one of
the four following processes: Compression Molding, Injection
Molding, Injection Compression Molding, and Supercritical Injection
Molding.
[0114] According to the compression mold process, the
silane-crosslinkable polyolefin elastomer 114 is pressurized in a
compression mold or press under predetermined temperature,
pressure, and time conditions to obtain a foamed silane-crosslinked
polyolefin elastomer in the form of a plate-like sponge. As the
silane-crosslinkable polyolefin elastomer 114 is heated and pressed
in the compression mold, the chemical and/or physical foaming
agents are activated to form the foamed silane-crosslinked
polyolefin elastomer. Portions and/or edges of the plate-like
sponge may then be skived, cut, and/or ground into a desired shape
for the elastomeric article. Subsequently, the elastomeric article
is again molded in a final mold with elastomeric article and other
respective components under heat and pressure and the assembly is
then pressurized during cooling in a closed state of the mold.
[0115] According to the injection molding process, the reactive
single screw extruder 102, 216 used in either the Sioplas or
Monosil process prepares and injects the silane-crosslinkable
polyolefin elastomer 114 into a mold having an upper mold and a
lower mold. Upon initial injection of the silane-crosslinkable
polyolefin elastomer 114 into the mold, an uncured elastomeric
article is formed. As the uncured elastomeric article is heated and
cured, the chemical and/or physical foaming agents are activated to
form the foamed silane-crosslinked polyolefin elastomer. The mold
used in these aspects is designed to have a smaller size than the
size of the final cured elastomeric article (foamed
silane-crosslinked polyolefin elastomer). After foaming and
expansion of the silane-crosslinkable polyolefin elastomer, the
uncured elastomeric article is expanded to the desired size of the
elastomeric article and the mold releases the final article.
[0116] The injection compression mold provides a hybrid approach to
forming the elastomeric article by using aspects of both the
compression mold and the injection mold. According to the injection
compression process, the reactive single screw extruder 102, 216
used in either the Sioplas or Monosil process prepares and injects
a mass of the silane-crosslinkable polyolefin elastomer 90 into a
mold having an upper mold and a lower mold. The mass of
silane-crosslinkable polyolefin elastomer 114 is then heated and
pressed in the mold to form the uncured elastomeric article while
the chemical and/or physical foaming agents are activated to form
the foamed silane-crosslinked polyolefin elastomer making up the
final cured elastomeric article. The mold used in these injection
compression processes is designed to have a smaller size than the
size of the final cured elastomeric article (foamed
silane-crosslinked polyolefin elastomer). After foaming and
expansion of the silane-crosslinked polyolefin elastomer, the mold
is released to eject the final cured elastomeric article.
[0117] According to the supercritical fluid foaming approach, a
supercritical fluid injector is coupled to an extruder. The process
begins by extruding (e.g., with the reactive single screw extruder
216 as provided in FIG. 5) the first polyolefin having a density
less than 0.86 g/cm.sup.3 54, the second polyolefin 58, the silan
cocktail 62 including the silane crosslinker (e.g., vinyltrimethoxy
silane, VTMO), grafting initiator (e.g. dicumyl peroxide), and the
condensation catalyst 94 together to form the crosslinkable
silane-grafted polyolefin blend 114. The first polyolefin 54,
second polyolefin 58, and silan cocktail 62 may be added to the
reactive single screw extruder 216 using the addition hopper 70 and
gear pump. In some aspects, the silan cocktail 62 may be added to
the single screw 220 further down the extrusion line to help
promote better mixing with the first and second polyolefin 54, 58
blend. In some aspects, one or more optional additives 98 may be
added with the first polyolefin 54, second polyolefin 58, and silan
cocktail 62 to tweak the final material properties of the
silane-crosslinkable polyolefin blend 114.
[0118] A supercritical fluid injector may be coupled to the single
screw extruder 216 to add a supercritical fluid such as carbon
dioxide or nitrogen to the silane-crosslinkable polyolefin blend
114 before it is injected through the die into a mold. The reactive
single screw extruder 216 then injects the silane-crosslinkable
polyolefin elastomer 114 into the mold. Upon initial injection of
the silane-crosslinkable polyolefin elastomer 11 into the mold, an
uncured elastomeric article is formed. As the uncured elastomeric
article is heated and cured, the supercritical fluid foaming agent
expands to form the foamed silane-crosslinked polyolefin elastomer.
The mold used in these aspects is designed to have a smaller size
than the size of the final cured elastomeric article (foamed
silane-crosslinked polyolefin elastomer). After foaming, the foamed
silane-crosslinked polyolefin elastomer is expanded to the desired
size of the elastomeric article using core pull back to accommodate
the expansion, and the mold releases.
Silane-Crosslinked Polyolefin Elastomer Physical Properties
[0119] A "thermoplastic", as used herein, is defined to mean a
polymer that softens when exposed to heat and returns to its
original condition when cooled to room temperature. A "thermoset",
as used herein, is defined to mean a polymer that solidifies and
irreversibly "sets" or "crosslinks" when cured. In either of the
Monosil or Sioplas processes described above, it is important to
understand the careful balance of thermoplastic and thermoset
properties of the various different materials used to produce the
final thermoset silane-crosslinked polyolefin elastomeric article.
Each of the intermediate polymer materials mixed and reacted using
a reactive twin screw extruder, a reactive single screw extruder,
and/or a reactive single screw extruder are thermosets.
Accordingly, the silane-grafted polyolefin blend and the
silane-crosslinkable polyolefin blend are thermoplastics and can be
softened by heating so the respective materials can flow. Once the
silane-crosslinkable polyolefin blend is extruded, molded, pressed,
and/or shaped into the uncured elastomeric article, the
silane-crosslinkable polyolefin blend can begin to crosslink or
cure at an ambient or elevated temperature and an ambient or
elevated humidity to form the elastomeric article and
silane-crosslinked polyolefin blend or silane-crosslinked
polyolefin elastomer blend.
[0120] The thermoplastic/thermoset behavior of the
silane-crosslinkable polyolefin blend and corresponding
silane-crosslinked polyolefin blend are important for the various
compositions and articles disclosed herein because of the potential
energy savings provided using these materials. For example, a
manufacturer can save considerable amounts of energy by being able
to cure the silane-crosslinkable polyolefin blend at an ambient or
reduced temperature and an ambient or reduced humidity. This curing
process is typically performed in the industry by applying
significant amounts of energy to heat or steam treat crosslinkable
polyolefins. The ability to cure the inventive silane-crosslinkable
polyolefin blend with ambient temperature and/or ambient humidity
are not properties necessarily intrinsic to crosslinkable
polyolefins, but rather is a property dependent on the relatively
low density (i.e., as compared to EPDM and/or TPV) of the
silane-crosslinkable polyolefin blend. In some aspects, no
additional curing overs, heating ovens, steam ovens, or other forms
of heat producing machinery other than what was provided in the
extruders are used to form the silane-crosslinked polyolefin
elastomers.
[0121] The specific gravity of the silane-crosslinked polyolefin
elastomer of the present disclosure may be lower than the specific
gravities of existing TPV and EPDM formulations used in the art.
The reduced specific gravity of these materials can lead to lower
weight parts, thereby helping automakers meet increasing demands
for improved fuel economy. For example, the specific gravity of the
silane-crosslinked polyolefin elastomer of the present disclosure
may be from about 0.80 g/cm.sup.3 to about 0.89 g/cm.sup.3, from
about 0.85 g/cm.sup.3 to about 0.89 g/cm.sup.3, from about 0.60
g/cm.sup.3 to about 0.69 g/cm.sup.3, from about 0.50 g/cm.sup.3 to
about 0.59 g/cm.sup.3, less than 0.90 g/cm.sup.3, less than 0.89
g/cm.sup.3, less than 0.88 g/cm.sup.3, less than 0.87 g/cm.sup.3,
less than 0.86 g/cm.sup.3, or less than 0.85 g/cm.sup.3 as compared
to existing TPV materials which may have a specific gravity of from
0.95 to 1.2 g/cm.sup.3 and EPDM materials which may have a specific
gravity of from 1.0 to 1.35 g/cm.sup.3. The low specific gravity or
density of the silane-crosslinked polyolefin elastomer is
attributable to the low crystallinity of the found in Examples 1-7
described below. In some aspects, the percent crystallinity of the
silane-crosslinked polyolefin elastomer is less than 10%, less than
20%, or less than 30%.
[0122] Referring now to FIG. 6, the stress/strain behavior of an
exemplary silane-crosslinked polyolefin elastomer of the present
disclosure (i.e., the "Silane-Crosslinked Polyolefin Elastomer" in
the legend) relative to two existing EPDM materials is provided. In
particular, FIG. 6 displays a smaller area between the
stress/strain curves for the silane-crosslinked polyolefin of the
disclosure, versus the areas between the stress/strain curves for
EPDM compound A and EPDM compound B. This smaller area between the
stress/strain curves for the silane-crosslinked polyolefin
elastomer can be desirable for the application of elastomeric
articles. Elastomeric materials typically have non-linear
stress-strain curves with a significant loss of energy when
repeatedly stressed. The silane-crosslinked polyolefin elastomers
of the present disclosure may exhibit greater elasticity and less
viscoelasticity (e.g., have linear curves and exhibit very low
energy loss). Embodiments of the silane-crosslinked polyolefin
elastomers described herein do not have any filler or plasticizer
incorporated into these materials so their corresponding
stress/strain curves do not have or display any Mullins effect
and/or Payne effect. The lack of Mullins effect for these
silane-crosslinked polyolefin elastomers is due to the lack of any
conventional reinforcing fillers (e.g., carbon black) or
plasticizer added to the silane-crosslinked polyolefin blend so the
stress-strain curve does not depend on the maximum loading
previously encountered where there is no instantaneous and
irreversible softening. The lack of Payne effect for these
silane-crosslinked polyolefin elastomers is due to the lack of any
filler or plasticizer added to the silane-crosslinked polyolefin
blend so the stress-strain curve does not depend on the small
strain amplitudes previously encountered where there is no change
in the viscoelastic storage modulus based on the amplitude of the
strain.
[0123] The silane-crosslinked polyolefin elastomer or elastomeric
article can exhibit a compression set of from about 5.0% to about
30.0%, from about 5.0% to about 25.0%, from about 5.0% to about
20.0%, from about 5.0% to about 15.0%, from about 5.0% to about
10.0%, from about 10.0% to about 25.0%, from about 10.0% to about
20.0%, from about 10.0% to about 15.0%, from about 15.0% to about
30.0%, from about 15.0% to about 25.0%, from about 15.0% to about
20.0%, from about 20.0% to about 30.0%, or from about 20.0% to
about 25.0%, as measured according to ASTM D 395 (22 hrs @
23.degree. C., 70.degree. C., 80.degree. C. 90.degree. C.,
125.degree. C., and/or 175.degree. C.).
[0124] In other implementations, the silane-crosslinked polyolefin
elastomer or elastomeric article can exhibit a compression set of
from about 5.0% to about 20.0%, from about 5.0% to about 15.0%,
from about 5.0% to about 10.0%, from about 7.0% to about 20.0%,
from about 7.0% to about 15.0%, from about 7.0% to about 10.0%,
from about 9.0% to about 20.0%, from about 9.0% to about 15.0%,
from about 9.0% to about 10.0%, from about 10.0% to about 20.0%,
from about 10.0% to about 15.0%, from about 12.0% to about 20.0%,
or from about 12.0% to about 15.0%, as measured according to ASTM D
395 (22 hrs @ 23.degree. C., 70.degree. C., 80.degree. C.,
90.degree. C., 125.degree. C., and/or 175.degree. C.).
[0125] The silane-crosslinked polyolefin elastomers and elastomeric
articles of the disclosure may exhibit a crystallinity of from
about 5% to about 40%, from about 5% to about 25%, from about 5% to
about 15%, from about 10% to about 20%, from about 10% to about
15%, or from about 11% to about 14% as determined using density
measurements, differential scanning calorimetry (DSC), X-Ray
Diffraction, infrared spectroscopy, and/or solid state nuclear
magnetic spectroscopy. As disclosed herein, DSC was used to measure
the enthalpy of melting in order to calculate the crystallinity of
the respective samples.
[0126] The silane-crosslinked polyolefin elastomers and elastomer
articles may exhibit a glass transition temperature of from about
-75.degree. C. to about -25.degree. C., from about -65.degree. C.
to about -40.degree. C., from about -60.degree. C. to about
-50.degree. C., from about -50.degree. C. to about -25.degree. C.,
from about -50.degree. C. to about -30.degree. C., or from about
-45.degree. C. to about -25.degree. C. as measured according to
differential scanning calorimetry (DSC) using a second heating run
at a rate of 5.degree. C./min or 10.degree. C./min.
[0127] The silane-crosslinked polyolefin elastomers and elastomeric
articles may exhibit a weathering color difference of from about
0.25 .DELTA.E to about 2.0 .DELTA.E, from about 0.25 .DELTA.E to
about 1.5 .DELTA.E, from about 0.25 .DELTA.E to about 1.0 .DELTA.E,
or from about 0.25 .DELTA.E to about 0.5 .DELTA.E, as measured
according to ASTM D2244 after 3000 hrs exposure to exterior
weathering conditions.
[0128] The silane-crosslinked polyolefin elastomers and elastomeric
articles may exhibit exceptional stain resistance properties as
compared to EPDM samples. Ex. 3, as disclosed below, showed no
cracking, wrinkling, crazing, iridescence, bloom, milkiness,
separation, loss of adhesion, or loss of embossment as measured
according to ASTM D1566. In addition, Ex. 3 which is representative
of all the silane-crosslinked polyolefin elastomers produced,
showed no spotting or discoloration in pH 11, pH 12.5, and pH 13
NaOH solutions as measured according to SunSimulation and Spotting
Test (PR231-2.2.15).
EXAMPLES
[0129] The following examples represent certain non-limiting
examples of elastomeric articles, compositions and methods of
making them, according to the disclosure.
Materials
[0130] All chemicals, precursors and other constituents were
obtained from commercial suppliers and used as provided without
further purification.
Example 1
[0131] Example 1 or ED4 was produced by extruding 77.36 wt %
ENGAGE.TM. 8150 and 19.34 wt % VISTAMAX.TM. 6102 together with 3.3
wt % SILFIN 13 to form the silane-grafted polyolefin elastomer. The
Example 1 silane-grafted polyolefin elastomer was then extruded
with 3 wt % AMBICAT.TM. LE4472 condensation catalyst to form a
silane-crosslinkable polyolefin elastomer, which was then extruded
into an uncured elastomeric article. The Example 1
silane-crosslinkable polyolefin elastomer of the uncured
elastomeric article was cured at ambient temperature and humidity
to form a silane-crosslinked polyolefins elastomer, consistent with
the elastomers of the disclosure. The composition of Example 1 is
provided in Table 1 below.
Example 2
[0132] Example 2 or ED76-4A was produced by extruding 82.55 wt %
ENGAGE.TM. 8842 and 14.45 wt % MOSTEN.TM. TB 003 together with 3.0
wt % SILAN RHS 14/032 or SILFIN 29 to form the silane-grafted
polyolefin elastomer. The Example 2 silane-grafted polyolefin
elastomer was then extruded with 3 wt % AMBICAT.TM. LE4472
condensation catalyst to form a silane-crosslinkable polyolefin
elastomer, which was then extruded into an uncured elastomeric
article. The Example 2 silane-crosslinkable polyolefin elastomer of
the uncured elastomeric article was cured at ambient temperature
and humidity to form a silane-crosslinked polyolefins elastomer,
consistent with the elastomers of the disclosure. The composition
of Example 2 is provided in Table 1 below and some of its material
properties are provided in FIGS. 7-10.
Example 3
[0133] Example 3 or ED76-4E was produced by extruding 19.00 wt %
ENGAGE.TM. 8150, 58.00 wt % ENGAGE.TM. 8842, and 20.00 wt %
MOSTEN.TM. TB 003 together with 3.0 wt % SILAN RHS 14/032 or SILFIN
29 to form the silane-grafted polyolefin elastomer. The Example 3
silane-grafted polyolefin elastomer was then extruded with 3 wt %
AMBICAT.TM. LE4472 condensation catalyst to form the
silane-crosslinkable polyolefin elastomer, which was then extruded
into an uncured elastomeric article. The Example 3
silane-crosslinkable polyolefin elastomer of the uncured
elastomeric article was cured at ambient temperature and humidity
to form a silane-crosslinked polyolefins elastomer, consistent with
the elastomers of the disclosure. The composition of Example 3 is
provided in Table 1 below.
Example 4
[0134] Example 4 or ED76-5 was produced by extruding 19.00 wt %
ENGAGE.TM. 8150, 53.00 wt % ENGAGE.TM. 8842, and 25.00 wt % MOSTEN
TB 003 together with 3.0 wt % SILAN RHS 14/032 or SILFIN 29 to form
the silane-grafted polyolefin elastomer. The Example 4
silane-grafted polyolefin elastomer was then extruded with 3 wt %
AMBICAT.TM. LE4472 condensation catalyst to form the
silane-crosslinkable polyolefin elastomer, which was then extruded
into an uncured elastomeric article. The Example 4
silane-crosslinkable polyolefin elastomer of the uncured
elastomeric article was cured at ambient temperature and humidity
to form a silane-crosslinked polyolefins elastomer, consistent with
the elastomers of the disclosure. The composition of Example 4 is
provided in Table 1 below.
Example 5
[0135] Example 5 or ED76-6 was produced by extruding 16.36 wt %
ENGAGE.TM. 8150, 45.64 wt % ENGAGE.TM. 8842, and 35.00 wt %
MOSTEN.TM. TB 003 together with 3.0 wt % SILAN RHS 14/032 or SILFIN
29 to form the silane-grafted polyolefin elastomer. The Example 5
silane-grafted polyolefin elastomer was then extruded with 3 wt %
AMBICAT.TM. LE4472 condensation catalyst to form the
silane-crosslinkable polyolefin elastomer, which was then extruded
into an uncured elastomeric article. The Example 5
silane-crosslinkable polyolefin elastomer of the uncured
elastomeric article was cured at ambient temperature and humidity
to form a silane-crosslinked polyolefins elastomer, consistent with
the elastomers of the disclosure. The composition of Example 5 is
provided in Table 1 below.
[0136] Table 1 below sets forth the compositions of the
silane-grafted polyolefin elastomers of Examples 1-5.
TABLE-US-00001 TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 ENGAGE 8150
77.36 -- 19.00 19.00 16.36 ENGAGE 8842 -- 82.55 58.00 53.00 45.64
MOSTEN TB 003 -- 14.45 20.00 25.00 35.00 VISTAMAXX 6102 19.34 -- --
-- -- SILAN RHS 14/032 -- 3.00 3.00 3.00 3.00 or SILFIN 29 SILFIN
13 3.30 -- -- -- -- TOTAL 100 100 100 100 100
Example 6
[0137] Example 6 or ED108-2A was produced by extruding 48.7 wt %
ENGAGE.TM. XLT8677 or XUS 38677.15 and 48.7 wt % ENGAGE.TM. 8842
together with 2.6 wt % SILAN RHS 14/032 or SILFIN 29 to form the
silane-grafted polyolefin elastomer. The Example 6 silane-grafted
polyolefin elastomer was then extruded with about 360 ppm
dioctyltin dilaurate (DOTL) condensation catalyst to form a
silane-crosslinkable polyolefin elastomer as an uncured elastomeric
article. The Example 6 silane-crosslinkable polyolefin elastomer of
the uncured elastomeric article was cured at ambient temperature
and humidity to form a silane-crosslinked polyolefins elastomer,
consistent with the elastomers of the disclosure. The composition
of Example 6 is provided in Table 2 below and some of its material
properties are provided in FIGS. 7-10.
Example 7
[0138] Example 7 or ED92 was produced by extruding 41.4 wt %
ENGAGE.TM. XLT8677 or XUS 38677.15 and 41.4 wt % ENGAGE.TM. 8842,
and 14.4 wt % MOSTEN.TM. TB 003 together with 2.8 wt % SILAN RHS
14/032 or SILFIN 29 to form the silane-grafted polyolefin
elastomer. The Example 7 silane-grafted polyolefin elastomer was
then extruded with about 360 ppm dioctyltin dilaurate (DOTL)
condensation catalyst to form a silane-crosslinkable polyolefin
elastomer as an uncured elastomeric article. The Example 7
silane-crosslinkable polyolefin elastomer of the uncured
elastomeric article was cured at ambient temperature and humidity
to form a silane-crosslinked polyolefins elastomer, consistent with
the elastomers of the disclosure. The composition of Example 7 is
provided in Table 2 below and some of its material properties are
provided in FIGS. 7-10.
[0139] Table 2 below sets forth the compositions of the
silane-grafted polyolefin elastomers of Examples 6-7.
TABLE-US-00002 TABLE 2 Ingredients Ex. 6 Ex. 7 ENGAGE XLT8677/XUS
38677.15 48.7 41.4 ENGAGE 8842 48.7 41.4 SILAN RHS 14/032 or SILFIN
29 2.6 2.8 MOSTEN TB 003 -- 14.4 TOTAL 100 100
[0140] Table 3 below sets forth several of the material properties
of Example 1. In particular, plied compression set percentages are
provided using ASTM D 395, method B for 22 hrs at 23.degree. C.,
70.degree. C., 80.degree. C., 90.degree. C., 125.degree. C., and
175.degree. C. Example 1 is representative of the
silane-crosslinked polyolefin elastomers disclosed herein in that
the compression set percentage does not vary as much as standard
EPDM or TPV materials do across a range of different temperatures.
In some aspects, the percent difference in plied compression set
percentage values for the silane-crosslinked polyolefin elastomer
is less than 400%, less than 300%, less than 275%, less than 250%,
less than 225%, or less than 210%.
TABLE-US-00003 TABLE 3 Test Ex. 1 Durometer (Type A per ASTM D
2240) 75 Tensile MPa (ASTM D 412, die C) 9.8 Elongation % (ASTM D
412, die C) 291 Tear Resistance (ASTM D624, die C) 19 22
hrs/23.degree. C. Plied Compression Set % 20.0 22 hrs/70.degree. C.
Plied Compression Set % 12.6 22 hrs/80.degree. C. Plied Compression
Set 16.5 22 hrs/90.degree. C. Plied Compression Set % 10.9 22
hrs/125.degree. C. Plied Compression Set % 7.6 22 hrs/175.degree.
C. Plied Compression Set % 9.6 Gel % 90
[0141] Table 4 below sets forth density, hardness, low and high
temperature performance, compression set, and weathering material
properties for Examples 2-4.
TABLE-US-00004 TABLE 4 Property Test Method Units/Output Ex. 2 Ex.
3 Ex. 4 Originals Density ASTM D297 g/cc 0.88 0.89 0.89 Hardness
ASTM D412 Die C Shore A 76 84 88 Tensile ASTM D412 Die C MPa 10.4
13.2 14.5 Elongation ASTM D412 Die C % 300 306 314 Tear C ASTM D624
Die C N/mm 24 37 48 Hardness JIS K 6253 IRHD 72 82 87 Tensile JIS K
6251 MPa 8.3 13.3 16.1 Elongation JIS K 6251 % 260 255 334 Tear C
JIS K 6252 N/cm 249 401 564 Low & High Hardness Heat Age (70
h/100.degree. C.) ASTM D573 Change -2 -2 1 Temperature (Shore A)
Performance Tensile Heat Age (70 h/100.degree. C.) ASTM D573 %
Change -3.1 -6 9.1 Elongation Heat Age (70 h/100.degree. C.) ASTM
D573 % Change -10.4 -8.7 -2.6 Hardness Heat Age (168 h/100.degree.
C.) JIS K 6251/7 Change 0 2 -5 (IRHD) Tensile Heat Age (168
h/100.degree. C.) JIS K 6251/7 % Change 0 -15.1 -9.9 Elongation
Heat Age (168 h/100.degree. C.) JIS K 6251/7 % Change -18 -22.7 -21
Tear Heat Age (168 h/100.degree. C.) JIS K 6251/7 % Change -11.2
-8.7 -10 Tensile Heat Age (1000 h/125.degree. C.) ASTM D573 Change
-2 -1 0 (Shore A) Elongation Heat Age ASTM D573 % Change -4.4 18.7
1.4 (1000 h/125.degree. C.) Tear Heat Age (1000 h/125.degree. C.)
ASTM D573 % Change -6.1 -11 -8.8 -40.degree. C. Tensile ASTM D412
Die C % Change 38.5 -- -- -40.degree. C. Elongation ASTM D412 Die C
% Change 17.6 -- -- Low Temperature (-40.degree. C.) ASTM D2137 --
Nonbrittle Nonbrittle Nonbrittle Method A 80.degree. C. Tensile
ASTM D412 Die C % Change -10.8 -- -- 80.degree. C. Elongation ASTM
D412 Die C % Change -1.5 -- -- Compression Plied C/S (22
h/70.degree. C.) ASTM D395 % 20.7 25 30 Set Method B Plied C/S (22
h/80.degree. C.) ASTM D395 % 20.2 30.5 -- Method B Plied C/S (72
h/80.degree. C.) ASTM D395 % 22.5 32.6 -- Method B Plied C/S (100
h/80.degree. C.) ASTM D395 % 39.2 44.3 54.7 Method B Plied C/S (168
h/80.degree. C.) ASTM D395 % 29 39 -- Method B Plied C/S (500
h/80.degree. C.) ASTM D395 % 41.2 53.8 -- Method B Plied C/S (1000
h/80.degree. C.) ASTM D395 % 43.8 55.4 -- Method B Plied C/S (22
h/90.degree. C.) ASTM D395 % 22.5 32.8 -- Method B Plied C/S (22
h/100.degree. C.) ASTM D395 % 25.4 35 42.5 Method B Plied C/S (70
h/125.degree. C.) ASTM D395 % 29 37.9 46.6 Method B Plied C/S (22
h/135.degree. C.) ASTM D395 % 38.5 46.6 -- Method B Plied C/S (22
h/150.degree. C.) ASTM D395 % 44.3 61 -- Method B Plied C/S (22
h/175.degree. C.) ASTM D395 % 23.3 38.1 -- Method B Permanent
Compressive Distortion JIS K 6257 % 30 41 43 (22 h/100.degree. C.)
Miscellaneous Volume Resistivity IEC 60093 .OMEGA. cm 2.1 .times.
10.sup.16 2.2 .times. 10.sup.16 2.2 .times. 10.sup.16 Weathering
(3000 hrs.) SAE J2527 AATCC 4-5 4-5 4-5 Arizona Natural Weathering
(2 yrs.) SAE J1976, .DELTA.E 1.6 1.2 1.7 Procedure A Florida
Natural Weathering (2 yrs.) SAE J1976, .DELTA.E 1.6 1.0 1.2
Procedure A Fogging SAE J1756 % 97 96 97 Ozone Resistance ASTM
D1171 Retention 100 100 100 Method B Rating (%) Flammability ISO
3795 Burn Rate 19 22 17 (mm/min) Odor SAE J1351 No Pass Pass Pass
Disagreeable Odor Wet or Dry Paint Staining (24 h/70.degree. C.)
ASTM D925 -- No No No Method A Staining Staining Staining
[0142] Table 5 below sets forth the chemical resistance material
properties for Example 2, which is representative of all of the
disclosed silane-crosslinked polyolefin elastomers. Method B
includes reporting any evidence of softening, staining, blistering,
flaking, chipping, checking, chalking, cracks, spills, sinks,
bulges, tackiness, peeling, or delamination. The fairness grade is
5 for a CELAB difference of 0 and a Tolerance of 0.2 and the
fairness grade is 4 for a CELAB difference of 1.7 and a Tolerance
of .+-.0.3.
TABLE-US-00005 TABLE 5 Test Chemical Method Units/Output Ex. 2
Solvent Resistance 7:3 (Kerosene:Mineral Spirits) TSM1720G % Change
in 170 (72 h/RT) Volume Fluid Resistance Gasoline 87 Octane, Lead
Free, 20% FLTM BI 168-01, Rating (see Pass, 4 Ethanol Method B
above) Diesel, Grade 2, 20% Biodiesel FLTM BI 168-01, Rating (see
Pass, 4 Method B above) Coolant, Ethylene glycol/Water 50/50 FLTM
BI 168-01, Rating (see Pass, 5 Method B above) Engine Oil, Meets
API-ILSAC Requirements FLTM BI 168-01, Rating (see Pass, 5 Method B
above) Deionized Water FLTM BI 168-01, Rating (see Pass, 5 Method B
above) Multipurpose Cleaner (Formula 409, FLTM BI 168-01, Rating
(see Pass, 5 Fantastic, or Armor All) Method B above) Windshield
Wash Fluid, Methanol Based, 1 FLTM BI 168-01, Rating (see Pass, 5
Part Motorcraft Fluid to 1.5 Parts Water Method B above) Motorcraft
Bug and Tar Remover FLTM BI 168-01, Rating (see Pass, 5 Method B
above) Glass Cleaner FLTM BI 168-01, Rating (see Pass, 5 Method B
above) Isopropyl Alcohol 1:1 with Water FLTM BI 168-01, Rating (see
Pass, 5 Method B above)
[0143] Referring now to FIG. 7, the compression set percentage is
given by
C.sub.B=[(H.sub.0-H.sub.0')/(H.sub.0-H.sub.comp).times.100% where
H.sub.0 is the original specimen thickness before compression,
H.sub.0' is the specimen thickness after testing, and H.sub.comp is
the specimen thickness during the test. As provided in FIG. 7, each
of Examples 2, 6, and 7 ("Exs. 2, 6 and 7" in FIG. 7) made from the
silane-crosslinked polyolefin elastomers exhibited a lower
compression set after one hour and a higher speed of set recovery
as compared to TOSE 539 70 ("TPS" in FIG. 7), a styrenic TPV or
TPS, and SANTOPRENE 12167W175 ("EPDM/PP" in FIG. 7), a EPDM/PP
copolymer. The compression set percentages provided by each of the
silane-crosslinked polyolefin elastomers (Exs. 2, 6 and 7) relative
to the comparative TPV and EPDM materials demonstrate the improved
high elastic properties exhibited by these materials.
[0144] Referring now to FIG. 8, the lip set recovery percentage is
given by LSR=[(L.sub.0')/(L.sub.0).times.100% where L.sub.0 is the
original lip thickness before compression and L.sub.0' is the lip
thickness after testing. As provided in FIG. 8, each of Examples 2,
6, and 7 made from the silane-crosslinked polyolefin elastomers
exhibited a higher lip set recovery after one hour (97%, 97.5%, and
99.2%, respectively) and a higher speed of lip set recovery as
compared to TPS (93%) or EPDM/PP copolymer (94%). Again, the lip
set recovery percentages provided by each of the silane-crosslinked
polyolefin elastomers relative to TPV and EPDM materials
demonstrate the improved elastic properties exhibited by these
materials.
[0145] Referring now to FIG. 9, the lip relaxation rate percentage
for 1 hr at 23.degree. C. is given by
R(%)=(F.sub.0-F.sub.t)/(F.sub.0) where F.sub.0 is the initial force
required for the first compression and F.sub.t is the final force
required for compression for the testing period. As provided in
FIG. 9, each of Examples 2, 6, and 7 made from the
silane-crosslinked polyolefin elastomers exhibited an improved
relaxation rate as compared to TPS or EPDM/PP copolymer.
[0146] Referring now to FIG. 10, the stress/strain behavior of an
exemplary silane-crosslinked polyolefin elastomer of the present
disclosure is provided. The traces in FIG. 10 demonstrate the
particularly small areas that can be achieved between the
stress/strain curves for the silane-crosslinked polyolefin of the
disclosure. Elastomeric materials typically have non-linear
stress-strain curves with a significant loss of energy when
repeatedly stressed. The silane-crosslinked polyolefin elastomers
of the present disclosure exhibit greater elasticity and less
viscoelasticity (e.g., have linear curves and exhibit very low
energy loss). The lack of any filler or plasticizer in these
materials lead to no demonstration of any Mullins and/or Payne
effect.
[0147] Referring now to FIGS. 11-12, compression set performance is
provided across a range of elevated temperatures and increasing
periods of time for Example 1, a comparative TPV, and a comparative
EPDM. As shown in the graph of FIG. 12, the compression set % of
the silane-crosslinked polyolefin elastomer (Ex. 1) increases
slightly over the provided increasing temperatures (23.degree.
C.-175.degree. C.) for a test time of 22 h relative to the
comparative TPV and EPDM materials. The compression set % of the
Ex. 1 silane-crosslinked polyolefin elastomer stays surprisingly
even across the provided temperature range as compared to the
dramatic increase in compression set % demonstrated for the TPV and
EPDM materials.
[0148] As shown in the graph of FIG. 11, the compression set % of
the silane-crosslinked polyolefin elastomer (Ex. 1) increases
slightly over the provided increasing temperatures (70.degree. C.
-175.degree. C.) and test times (22 h-1000 h) relative to the
comparative TPV and EPDM materials.
[0149] FIG. 13 and Table 6 below provide additional data regarding
the compression set performance of Examples 2-4 relative to EPDM
9724 and TPV 121-67. Table 6 provides compression set data
performed in triplicate for Examples 2-4 relative to EPDM 9724
("EPDM") and TPV 121-67 ("TPV"). FIG. 13 plots the average
compression set values for these samples performed at 72 hrs at
23.degree. C. and 70 hrs at 125.degree. C.
TABLE-US-00006 TABLE 6 Compound 72 h/23.degree. C. 70 h/125.degree.
C. Ex. 2 13.8 22.1 Ex. 2 15.7 22.3 Ex. 2 20.4 22.9 Avg. 16.6 22.4
Ex. 3 19.9 31.0 Ex. 3 21.4 33.6 Ex. 3 23.6 33.6 Avg. 21.6 32.7 Ex.
4 24.8 41.9 Ex. 4 24.6 40.2 Ex. 4 28.4 40.0 Avg. 25.9 40.7 EPDM 5.6
75.4 EPDM 8.3 76.3 EPDM 11.5 82.3 Avg. 8.5 78.0 TPV 21.2 51.2 TPV
21.4 52.4 TPV 21.5 47.8 Avg. 21.4 50.5
Example 8
[0150] Example 8 (Ex. 8) or ED108-2A was produced by extruding
48.70 wt % ENGAGE.TM. 8842 and 48.70 wt % XUS38677.15 together with
2.6 wt % SILAN RHS 14/032 or SILFIN 13 to form a silane-grafted
polyolefin elastomer. The Example 8 silane-grafted polyolefin
elastomer was then extruded with 1.7 wt % Hydrocerol 1170 foaming
agent, 2 wt % AMBICAT.TM. LE4472 condensation catalyst, and 360 ppm
dioctyltin dilaurate (DOTL) condensation catalyst to form a
silane-crosslinkable polyolefin elastomer, which was then extruded
into an uncured elastomeric article. The Example 8
silane-crosslinkable polyolefin elastomer of the uncured dynamic
sealing member was then cured at ambient temperature and humidity
to form a silane-crosslinked polyolefin elastomer, consistent with
the elastomers of the disclosure. The composition of Example 8 is
provided in Table 7 below and its material properties are provided
in Table 8 below.
Example 9
[0151] Example 9 (Ex. 9) or ED108-2B was produced by extruding
48.70 wt % ENGAGE 8842 and 48.70 wt % XUS38677.15 and 2.6 wt %
SILAN RHS 14/032 or SILFIN 13 together with Exact 9061/SpectraSyn
10 (70/30) to form the silane-grafted polyolefin elastomer. The
Example 9 silane-grafted polyolefin elastomer was then extruded
with 1.7 wt % Hydrocerol 1170 foaming agent, 2 wt % AMBICAT.TM.
LE4472 condensation catalyst, and 360 ppm dioctyltin dilaurate
(DOTL) condensation catalyst to form a silane-crosslinkable
polyolefin elastomer, which was then extruded into an uncured
elastomeric article. The Example 9 silane-crosslinkable polyolefin
elastomer of the uncured elastomeric article was then cured at
ambient temperature and humidity to form a silane-crosslinked
polyolefin elastomer, consistent with the elastomers of the
disclosure. The composition of Example 9 is provided in Table 7
below and its material properties are provided in Table 8 below.
Also provided below in Table 8 are properties associated with a
comparative EPDM material ("EPDM").
TABLE-US-00007 TABLE 7 Ingredients Ex. 8 Ex. 9 ENGAGE XLT8677/XUS
38677.15 48.7 46.25 ENGAGE 8842 48.7 46.25 SILAN RHS 14/032 or
SILFIN 29 2.6 2.5 Exact 9061/SpectraSyn 10 (70/30) -- 5 TOTAL 100
100
TABLE-US-00008 TABLE 8 Property Test Method Units/Output Ex. 8 Ex.
9 EPDM Structural Density ASTM D297 g/cc 0.52 0.55 0.66 Tensile
ASTM D412 MPa 2.6 2.0 2.9 Die C Elongation ASTM D412 % 230 209 354
Die C 100% Modulus ASTM D412 MPa 1.5 1.4 0.80 Die C Tear C ASTM
D624 N/mm 8.0 9.6 8.8 Die C Compression Plied C/S (22 h/80.degree.
C.) ASTM D395 % 29.4 35.4 47.4 Set Method B (50% Plied C/S (96
h/80.degree. C.) ASTM D395 % 37.6 58.9 56.4 compression) Method B
Plied C/S (168 h/80.degree. C.) ASTM D395 % 67.0 69.6 67.8 Method B
Plied C/S (500 h/80.degree. C.) ASTM D395 % 76.4 -- 73.5 Method B
Plied C/S (1000 h/80.degree. C.) ASTM D395 % 78.6 -- 97.3 Method B
Miscellaneous Water Absorption GM9888P % 0.16 -- 0.21
[0152] Referring now to FIG. 14, a load vs. position plot is
provided for the Ex. 8 ED108-2A resin (i.e., as prepared above in
Example 8), as crosslinked with 2% catalyst ("Ex. 8 with 2% cat"),
3% catalyst (Ex. 8 with 3% cat"), and 2% catalyst with a slip coat
("Ex. 8 with 2% cat and slip coat"). A comparative example load v.
position plot is provided for a traditional EPDM sponge material
("EPDM"). The Ex. 8 materials (i.e., dynamic silane-crosslinked
polyolefin elastomers according to the disclosure) display a
smaller area between the load/position curves as compared to the
areas between the load/position curves for the comparative EPDM
compound. This smaller area between the load/position curves for
the dynamic silane-crosslinked polyolefin elastomers can be
desirable for elastomeric articles, e.g., weatherstrips, that can
be used for various sealing applications. Further, the Ex. 8
polyolefin blends do not contain any filler or plasticizer
incorporated so each of corresponding load/position curves for
these blends do not have or display any Mullins effect and/or Payne
effect.
[0153] The selection of the condensation catalyst may have an
influence on the final material properties for a sample. For
example, the Example 9 ED108-2B silane-grafted polyolefin elastomer
was produced by extruding 48.70 wt % ENGAGE 8842 and 48.70 wt %
XUS38677.15 and 2.6 wt % SILAN RHS 14/032 or SILFIN 13 together
with Exact 9061/SpectraSyn 10 (70/30) to form the silane-grafted
polyolefin elastomer. These Example 9 silane-grafted polyolefin
elastomers were then extruded with two different condensation
catalysts: (a) with 1.7 wt % Hydrocerol 1170 foaming agent, 2 wt %
AMBICAT.TM. LE4472 condensation catalyst, and 360 ppm dioctyltin
dilaurate (DOTL) condensation catalyst; and (b) with 1.7 wt %
Hydrocerol 1170 foaming agent, 2 wt % AMBICAT.TM. LE4472
condensation catalyst, and 360 ppm dibutyltin dilaurate (DBTDL)
condensation catalyst. Accordingly, two silane-crosslinkable
polyolefin elastomers were formed (identified as "DOTL" and
"DBTDL"), which were then extruded into an uncured elastomeric
article. The difference in material properties of these
crosslinkable elastomers are given below in Tables 9 and 10.
TABLE-US-00009 TABLE 9 Elastomer 22 h/80 C. 168 h/80 C. Tube Group
Tube C/S (%) 96 h/80 C. Tube C/S (%) C/S DOTL 38.9 42.1 52.3 DBTDL
25.9 27.9 34.0
TABLE-US-00010 TABLE 10 100% Auburn Elongation Modulus Density TC
Group Duro Tensile MPa (%) (Mpa) (g/cc) (N/mm) DOTL 43 2.8 294 1.3
0.52 9.3 DBTDL 39 2.9 170 1.9 0.51 7.6
[0154] Referring now to FIG. 15, cross-sectional views are provided
for a silane-crosslinked polyolefin elastomer foamed used
supercritical gas injection and chemical foaming agents. As
provided by the images, the pore size resulting from the chemical
foaming agent is from 20 .mu.m to 147 .mu.m while the pore size
resulting from the supercritical gas injection is from 46 .mu.m to
274 .mu.m. Depending on the type of foaming agent selected to foam
each of the respective silane-crosslinkable polyolefin elastomer
disclosed herein, a variety of different pore sizes can be obtained
which will affect the final density of the foamed
silane-crosslinked polyolefin elastomer. In some aspects, the pore
size may be from 20 .mu.m to 200 .mu.m, from 25 .mu.m to 400 .mu.m,
or from 25 .mu.m to 300 .mu.m.
Example 10
[0155] Example 10 (Ex. 10) or ED76-4A was produced by extruding
82.55 wt % ENGAGE.TM. 8842 and 14.45 wt % MOSTEN.TM. TB 003
together with 3.0 wt % SILAN RHS 14/032 or SILFIN 29 to form a
silane-grafted polyolefin elastomer. The Example 10 silane-grafted
polyolefin elastomer was then extruded with 2.0 wt % MBF-AC170EVA
microencapsulated blowing agent, 3 wt % AMBICAT.TM. LE4472
condensation catalyst, and 0.7 wt % AD-2 process aide to form a
foamed silane-crosslinkable polyolefin elastomer, which was then
extruded into the form of an uncured elastomeric article. The
Example 10 foamed silane-crosslinkable polyolefin elastomer of the
uncured elastomeric article was then cured at ambient temperature
and humidity to form a foamed silane-crosslinked polyolefin
elastomer, consistent with the elastomers of the disclosure. The
composition of Example 10 is provided in Table 11 below and the
material properties associated with its foamed silane-crosslinked
polyolefin blend are provided in Table 12 below.
Example 11
[0156] Example 11 (Ex. 11) or ED76-4E was produced by extruding
19.00 wt % ENGAGE.TM. 8150, 58.00 wt % ENGAGE.TM. 8842, and 20.00
wt % MOSTEN.TM. TB 003 together with 3.0 wt % SILAN RHS 14/032 or
SILFIN 29 to form a silane-grafted polyolefin elastomer. The
Example 11 silane-grafted polyolefin elastomer was then extruded
with 2.0 wt % MBF-AC170EVA microencapsulated blowing agent, 3 wt %
AMBICAT.TM. LE4472 condensation catalyst, and 0.7 wt % AD-2 process
aide to form a foamed silane-crosslinkable polyolefin elastomer,
which was then extruded into an uncured elastomeric article. The
Example 11 foamed silane-crosslinkable polyolefin elastomer of the
uncured elastomeric article was then cured at ambient temperature
and humidity to form a foamed silane-crosslinked polyolefin
elastomer, consistent with the elastomers of the disclosure. The
composition of Example 11 is provided in Table 11 below and the
material properties associated with its foamed silane-crosslinked
polyolefin blend are provided in Table 12 below.
Example 12
[0157] Example 12 (Ex. 12) or ED76-5 was produced by extruding
19.00 wt % ENGAGE.TM. 8150, 53.00 wt % ENGAGE.TM. 8842, and 25.00
wt % MOSTEN.TM. TB 003 together with 3.0 wt % SILAN RHS 14/032 or
SILFIN 29 to form the silane-grafted polyolefin elastomer. The
Example 12 silane-grafted polyolefin elastomer was then extruded
with 2.0 wt % MBF-AC170EVA microencapsulated blowing agent, 3 wt %
AMBICAT.TM. LE4472 condensation catalyst, and 0.7 wt % AD-2 process
aide to form a foamed silane-crosslinkable polyolefin elastomer,
which was then extruded into an uncured elastomeric article. The
Example 12 foamed silane-crosslinkable polyolefin elastomer of the
uncured elastomeric article was then cured at ambient temperature
and humidity to form a foamed silane-crosslinked polyolefin
elastomer, consistent with the elastomers of the disclosure. The
composition of Example 12 is provided in Table 11 below and the
material properties associated with its foamed silane-crosslinked
polyolefin blend are provided in Table 12 below.
Example 13
[0158] Example 13 (Ex. 13) or ED76-6 was produced by extruding
16.36 wt % ENGAGE.TM. 8150, 45.64 wt % ENGAGE.TM. 8842, and 35.00
wt % MOSTEN.TM. TB 003 together with 3.0 wt % SILAN RHS 14/032 or
SILFIN 29 to form the silane-grafted polyolefin elastomer. The
Example 13 silane-grafted polyolefin elastomer was then extruded
with 2.0 wt % MBF-AC170EVA microencapsulated blowing agent, 3 wt %
AMBICAT.TM. LE4472 condensation catalyst, and 0.7 wt % AD-2 process
aide to form a foamed silane-crosslinkable polyolefin elastomer,
which was then extruded into an uncured elastomeric article. The
Example 13 foamed silane-crosslinkable polyolefin elastomer of the
uncured elastomeric article was then cured at ambient temperature
and humidity to form a foamed silane-crosslinked polyolefin
elastomer, consistent with the elastomers of the disclosure. The
composition of Example 13 is provided in Table 11 below and the
material properties associated with its foamed silane-crosslinked
polyolefin blend are provided in Table 12 below.
TABLE-US-00011 TABLE 11 Ingredients Ex. 10 Ex. 11 Ex. 12 Ex. 13
ENGAGE 8150 -- 19.00 19.00 16.36 ENGAGE 8842 82.55 58.00 53.00
45.64 MOSTEN TB 003 14.45 20.00 25.00 35.00 SILAN RHS 14/032 or
SILFIN 29 3.00 3.00 3.00 3.00 TOTAL 100 100 100 100
TABLE-US-00012 TABLE 12 Property Test Method Units/Output Ex. 10
Ex. 11 Ex. 12 Ex. 13 Physical Density ASTM g/cc 0.67 0.66 0.67 0.69
Properties D297 Hardness ASTM Shore A 60 67 69 87 D412 Die C
Tensile ASTM MPa 5.0 7.2 8.7 7.6 D412 Die C Elongation ASTM % 160
174 203 293 D412 Die C Tear C ASTM N/mm 12.6 22.8 22.5 46.8 D624
Die C Aged Hardness Heat Age ASTM Change 2 0 1 1 Properties (70
h/70.degree. C.) D573 (Shore A) Tensile Heat Age ASTM % Change 12.6
5.5 -0.8 7 (70 h/70.degree. C.) D573 Elongation Heat Age ASTM %
Change -0.6 -7.2 -13.5 -12.8 (70 h/70.degree. C.) D573 Compression
Plied C/S (22 h/70.degree. C.) ASTM % 40 41 61 78 Set D395 Method B
Miscellaneous Water Absorption MS-AK-92 % 0.5 0.2 0.7 0.5 Ozone
Resistance ASTM -- No No No No (168 h/40% D1149 Cracks Cracks
Cracks Cracks Elongation) Odor SAE J1351 No odor wet Pass Pass Pass
Pass or dry Paint Staining ASTM -- No No No No (24 h/70.degree. C.)
D925 Staining Staining Staining Staining Method A
Example 14
[0159] A foamed elastomeric article was prepared using a reactive
twin-screw extruder 66 (see FIG. 3A) to extrude 48.7 wt %
ENGAGE.TM. XLT8677 or XUS 38677.15 and 48.7 wt % ENGAGE.TM. 8842
together with 2.6 wt % SILAN RHS 14/032 or SILFIN 29 to form the
ED108-2A silane-grafted polyolefin elastomer. Next, a reactive
single screw extruder 102 (see FIG. 3B) equipped with a
supercritical fluid injector (not shown) was employed to further
process the blend, where the supercritical fluid medium was
nitrogen (N.sub.2) with a gas flow rate of 0.29 kg/h. The injector
open time was 10 sec and the pressure was maintained at 140 bar. A
gas load of 0.5 wt % was used with an injection speed of 75 mm/s.
The weight of the ED108-2A material used was 153.4 g. The resulting
sample has a density of 0.382 g/cm.sup.3, as measured using a
density scale. No condensation catalyst was added and the precision
opening was 1.5 mm. The material properties for Example 14 are
listed below in Table 13, where the compression set values were
measured according to ASTM D 395 and the density values were
measured by measuring the weight, length, width and thickness of a
sample (approximately 9 cm.times.10 cm, and 0.2-0.5 cm in
thickness).
TABLE-US-00013 TABLE 13 Compression Set 6 h/50.degree. C.
Compression 30 min 24 hr 48 hr 25% 37.4% 30.6% 26.5% 50% 44.9%
38.2% 35.0% Density % Rebound ASKER C ShA 0.46 48.6 43.8 25.6
Example 15
[0160] A foamed elastomeric article was prepared using a reactive
twin-screw extruder 66 (see FIG. 3A) to extrude 82.55 wt %
ENGAGE.TM. 8842 and 14.45 wt % MOSTEN.TM. TB 003 together with 3.0
wt % SILAN RHS 14/032 or SILFIN 29 to form the ED76-4A
silane-grafted polyolefin elastomer. Next, a reactive single screw
extruder 102 was then used to load and extrude silane-grafted
polyolefin elastomer, with 1.0 wt % dioctyltin dilaurate (DOTL)
condensation catalyst, and 10 wt % MEBA chemical foaming agent. The
density of the corresponding foamed silane-crosslinked polyolefin
elastomer was 0.304 g/cm.sup.3, as measure using a density scale.
The compression set data for Example 15 is listed below in Table
14.
TABLE-US-00014 TABLE 14 Compression Set 6 h/50.degree. C.
Compression 30 min 24 hr 48 hr 25% 22.1% 17.2% 18.4% 50% 14.6%
12.9% 10.4%
Example 16
[0161] Example 16 or ED76-4A was produced by extruding 82.55 wt %
ENGAGE.TM. 8842, 14.45 wt % MOSTEN.TM. TB 003 together with 3.0 wt
% SILAN RHS14/032 or SILFIN 29 to form the silane-grafted
polyolefin elastomer. The Example 16 silane-grafted polyolefin
elastomer was then extruded with 300 ppm to 400 ppm dioctyltin
dilaurate (DOTL) condensation catalyst to form a
silane-crosslinkable polyolefin elastomer that can be molded or
extruded into an uncured hose element. The Example 16
silane-crosslinkable polyolefin elastomer was then cured at ambient
temperature and humidity to form the corresponding
silane-crosslinked polyolefin elastomer. The composition of Example
16 and acceptable composition ranges for the various components of
this example are provided in Table 15 below.
TABLE-US-00015 TABLE 15 Relative Second Component amount (wt %)
First range (wt %) range (wt %) ENGAGE 8842 82.55 60-90 75-85 RHS
14/032 3.00 1-5 2-4 MOSTEN TB 003 14.45 5-25 10-20 Total 100 100
100
Example 17
[0162] Example 17 (Ex. 17) or ED 92-GF was produced by extruding
34.20 wt % ENGAGE.TM. 8842, 41.20 wt % ENGAGE.TM. XLT8677 or XUS
38677.15, 14.50 wt % and 19.34 wt % MOSTEN.TM. TB 003, and 7.50 wt
% RHS14/033 (35% GF) with 2.6 wt % SILAN RHS14/032 or SILFIN 29 to
form the silane-grafted polyolefin elastomer. The Example 17
silane-grafted polyolefin elastomer was then extruded with
dioctyltin dilaurate (DOTL) condensation catalyst to form a
silane-crosslinkable polyolefin elastomer that can be molded or
extruded into an uncured hose element. The Example 17
silane-crosslinkable polyolefin elastomer was cured at ambient
temperature and humidity to form the corresponding
silane-crosslinked polyolefin elastomer. The composition of Example
17 and acceptable composition ranges for the various elements of
this example are provided in Table 16 below. The material
properties of Example 17 are provided in Table 17 below, the
provided material properties are representative of those shared by
each of the silane-crosslinked polyolefin elastomers disclosed
herein.
[0163] The composition of Example 17 may be cured using 200 ppm to
about 500 ppm dioctyltin dilaurate (DOTL) catalyst system.
ENGAGE.TM. 8842 polyolefin elastomer is an ultra-low density
ethylene-octene copolymer. ENGAGE.TM. XLT8677 polyolefin elastomer
is an ethylene-octene copolymer that is added to function as an
impact modifier. MOSTEN.TM. TB 003 is a polypropylene homopolymer.
RHS 14/033 is an ethylene-octene copolymer having 35 wt % glass
fibers. SILAN RHS 14/032 and SILFIN 29 are both blends of a
vinyltrimethoxysilane monomer and a peroxide molecule for grafting
and crosslinking the various polyolefins added to the blend.
TABLE-US-00016 TABLE 16 Relative Second Component Amount (wt %)
First range (wt %) range (wt %) ENGAGE 8842 34.20 20-50 30-40
ENGAGE XLT8677 41.20 20-60 35-45 (XUS 38677.15) MOSTEN TB 003 14.50
5-25 10-20 RHS14/033 (35% GF) 7.50 2-20 5-10 SILAN RHS14/032 or
2.60 1-10 2-3 SILFIN 29 Total 100 100 100
TABLE-US-00017 TABLE 17 Property Test Method Units/Output Ex. 1
Originals Hardness ASTM D412 Die C Shore A 74 Tensile ASTM D412 Die
C Mpa 9.3 Elongation ASTM D412 Die C % 301 Tear C ASTM D624 Die C
N/mm 33.4 Delft Tear Ambient Delft Tear ISO 34-2 N 44.3 100.degree.
C. Delft Tear ISO 34-2 N 14.8 125.degree. C. Delft Tear ISO 34-2 N
9.4 135.degree. C. Delft Tear ISO 34-2 N 8.5 Heat Age Hardness Heat
Age (1000 h/120.degree. C.) ASTM D573 Change -1 (Shore A) Tensile
Heat Age (1000 h/120.degree. C.) ASTM D573 % Change 9.1 Elongation
Heat Age (1000 h/120.degree. C.) ASTM D573 % Change -28.2 Hardness
Heat Age (168 h/135.degree. C.) ASTM D573 Change -1 (Shore A)
Tensile Heat Age (168 h/135.degree. C.) ASTM D573 % Change 6.5
Elongation Heat Age (168 h/135.degree. C.) ASTM D573 % Change -17
Hardness Heat Age (1000 h/135.degree. C.) ASTM D573 Change -3
(Shore A) Tensile Heat Age (1000 h/135.degree. C.) ASTM D573 %
Change 20.8 Elongation Heat Age (1000 h/135.degree. C.) ASTM D573 %
Change -25.5 Hardness Heat Age (168 h/150.degree. C.) ASTM D573
Change 0 (Shore A) Tensile Heat Age (168 h/150.degree. C.) ASTM
D573 % Change -1.3 Elongation Heat Age (168 h/150.degree. C.) ASTM
D573 % Change -33 Compression Plied C/S (22 h/80.degree. C.) ASTM
D395 % 28 Set Method B Misc. Weathering (3000 hrs.) SAE J2527 AATCC
4-5 (pass)
[0164] Abrasion testing results were performed for Examples 16 and
17 using a William's Abrasion Testing method (JIS K6242). The test
conditions included a rotation speed of 37.+-.3 rpm, a load of
35.5N, and a testing time of 6 minutes. The results are provided
below in Table 18.
TABLE-US-00018 TABLE 18 Abrasion volume SG mass decrease (g) V
V1000 Material (g/cm.sup.3) 1 2 3 Ave. (mm.sup.3) (mm.sup.3) Ex. 16
0.880 1 0.0036 0.0062 0.0045 0.0044 5.0 21.8 2 0.0029 0.0033 0.0057
Ex. 17 0.911 1 0.0450 0.0424 0.0271 0.0296 32.5 142.3
Silane Effect
[0165] Blends of polyolefin elastomers (Engage 8842), polypropylene
(PP 4.0), and silane (silfin 13) were mixed in a twin-screw
extruder at high temperature to graft the silane onto the
polyolefin. The amount of silane was varied. The results are shown
in Table 19 below. For this blend, tensile, elongation, and Tear C
(TC) were good at 2.6 wt % silane cocktail but C/S results were
lower for 2.8 wt %.
TABLE-US-00019 TABLE 19 Test ED76 ED76-2.4 ED76-2.6 ED76-2.8
Component Engage 8842 0.8245 0.8296 0.8279 0.8262 PP 4.0 0.1455
0.1464 0.1461 0.1458 silfin 13 0.03 0.024 0.026 0.028 Property
Orig. Tensile Durometer 67 67 72 68 (D412 die) Lrg (ShA) die Peak
Stress 7.7 7.7 8.7 8.4 (MPa) Elongation (%) 223 246 271 263 100%
3.3 3.2 3.2 3.1 Modulus (MPa) TC Tear C 20.8 20.3 21.4 19.3 (N/mm)
VW C/S 22 h/90 C. (%) 76.5 78.2 -- 75 (compression set) VW C/S 22
h/70 C. (%) 76 74.7 78.4 75 Daimler Plied C/S 22 h/80 C. (%) 22.6
19.5 21.6 17.6
Polypropylene Effect
[0166] The effect of polypropylene was also tested. Varying amounts
of TAMFER.TM. PN 3560 and PP 4.0 were used. The results are shown
in Table 20 below. Comparing ED76 to ED87, a slight improvement in
elongation was observed but overall, no significant improvement was
seen from the addition of PN-3560 (propylene-based polymer, a
specialty olefinic resin designed to improve transparency,
flexibility, softness, and impact resistance). Without wishing to
be bound by theory, it is believed that PN3560 improves plied C/S
due to higher melting point of the crystalline region.
TABLE-US-00020 TABLE 20 Test ED76 ED86 ED87 Component Engage 8842
0.8245 0.8279 0.8279 PN 3560 0.1461 0.0487 PP 4.0 0.1455 -- 0.0974
silfin 13 0.03 0.026 0.026 -- -- Property Orig. Tensile Durometer
(ShA) 67 60 66 (D412 die) Lrg Peak Stress (MPa) 7.7 6.1 8 die
Elongation (%) 223 299 284 100% Modulus 3.3 2.1 2.9 (MPa) TC Tear C
(N/mm) 20.8 14.6 19.2 VW C/S 22 h/90 C. (%) 76.5 78.8 76.7 VW C/S
22 h/70 C. (%) 76 76.6 74.7 Daimler Plied C/S 22 h/80 C. (%) 22.6
16.1 20.7
XUS Polymer Effect
[0167] The effect of XUS polymer was also studied. The results are
shown in Table 21 below. ENGAGE.TM. 8842 and XUS 38677.15 are both
ethylene-octene copolymers. ENGAGE.TM. 8842 has about 55% ethylene
and XUS 38677.15 has about 52% ethylene. However, XUS 38677.15 is a
block olefin copolymer where the soft segment is amorphous (to have
low compression set). The hard segment has a melting point well
above 70.degree. C. Excellent tensile and TC results were observed
for ED89 but C/S was high. Lower C/S resulted from ED92.
TABLE-US-00021 TABLE 21 Test ED88 ED89 ED92 Component XUS 38677
0.828 0.414 0.414 (XUS) Engage 8003 -- 0.414 Engage 8842 -- --
0.414 PP 4.0 0.146 0.146 0.146 silfin 13 0.026 0.026 0.026 Property
Orig. Durometer 75 84 74 Tensile (ShA) (D412 Peak Stress 9.7 12.2
8.6 die) (MPa) Lrg die Elongation (%) 254 310 257 100% Modulus 4.7
5.3 3.7 (MPa) TC Tear C (N/mm) 26 33.3 25.7 VW 22 h/90 C. (%) 66
85.6 60.2 C/S VW 22 h/70 C. (%) 58.4 83.5 53.1 C/S Daimler Plied 22
h/80 C. (%) 21.8 29.5 16.5 C/S
[0168] For purposes of this disclosure, the term "coupled" (in all
of its forms, couple, coupling, coupled, etc.) generally means the
joining of two components directly or indirectly to one another.
Such joining may be stationary in nature or movable in nature. Such
joining may be achieved with the two components and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two components. Such joining may
be permanent in nature or may be removable or releasable in nature
unless otherwise stated.
[0169] It is also important to note that the construction and
arrangement of the elements of the device as shown in the exemplary
embodiments is illustrative only. Although only a few embodiments
of the present innovations have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited. For example, elements shown as integrally
formed may be constructed of multiple parts or elements shown as
multiple parts may be integrally formed, the operation of the
interfaces may be reversed or otherwise varied, the length or width
of the structures and/or members or connector or other elements of
the system may be varied, the nature or number of adjustment
positions provided between the elements may be varied. It should be
noted that the elements and/or assemblies of the system may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Accordingly, all such
modifications are intended to be included within the scope of the
present innovations. Other substitutions, modifications, changes,
and omissions may be made in the design, operating conditions, and
arrangement of the desired and other exemplary embodiments without
departing from the spirit of the present innovations.
[0170] It will be understood that any described processes or steps
within described processes may be combined with other disclosed
processes or steps to form structures within the scope of the
present device. The exemplary structures and processes disclosed
herein are for illustrative purposes and are not to be construed as
limiting.
[0171] The above description is considered that of the illustrated
embodiments only. Modifications of the device will occur to those
skilled in the art and to those who make or use the device.
Therefore, it is understood that the embodiments shown in the
drawings and described above is merely for illustrative purposes
and not intended to limit the scope of the articles, processes and
compositions, which are defined by the following claims as
interpreted according to the principles of patent law, including
the Doctrine of Equivalents.
LISTING OF NON-LIMITING EMBODIMENTS
[0172] Embodiment A is a silane-crosslinked polyolefin elastomer
blend comprising: a first polyolefin having a density less than
0.86 g/cm.sup.3; a second polyolefin having a percent crystallinity
less than 40%; a silane crosslinker, wherein the silane-crosslinked
polyolefin elastomer blend exhibits a compression set of from about
5.0% to about 35.0%, as measured according to ASTM D 395 (22 hrs @
70.degree. C.) and wherein the silane-crosslinked polyolefin
elastomer blend has a density less than 0.90 g/cm.sup.3.
[0173] The silane-crosslinked polyolefin elastomer blend of
Embodiment A further comprising a microencapsulating foaming
agent.
[0174] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the density is less than 0.70 g/cm.sup.3.
[0175] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
further comprising a foaming agent.
[0176] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the density is less than 0.60 g/cm.sup.3.
[0177] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the compression set is from about 15.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.).
[0178] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the first polyolefin comprises an ethylene-octene copolymer
from about 60 wt % to about 97 wt %.
[0179] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the second polyolefin comprises a polypropylene homopolymer
from about 10 wt % to about 35 wt % and/or a
poly(ethylene-co-propylene).
[0180] The silane-crosslinked polyolefin elastomer blend of
Embodiment A or Embodiment A with any of the intervening features
wherein the silane crosslinker comprises a vinyltrimethoxy silane
from about 1 wt % to about 4 wt %.
[0181] Embodiment B is a silane-crosslinked polyolefin elastomer
blend comprising: a first polyolefin having a density less than
0.86 g/cm.sup.3; a second polyolefin having a percent crystallinity
less than 40%; a silane crosslinker; a foaming agent; wherein the
silane-crosslinked polyolefin elastomer blend exhibits a
compression set of from about 5.0% to about 35.0%, as measured
according to ASTM D 395 (22 hrs @ 70.degree. C.) and wherein the
silane-crosslinked polyolefin elastomer blend has a density less
than 0.70 g/cm.sup.3.
[0182] The silane-crosslinked polyolefin elastomer blend of
Embodiment B wherein the first polyolefin comprises an
ethylene-octene copolymer from about 60 wt % to about 97 wt %.
[0183] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
wherein the second polyolefin comprises a polypropylene homopolymer
from about 10 wt % to about 35 wt % and/or a
poly(ethylene-co-propylene).
[0184] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
wherein the silane crosslinker comprises a vinyltrimethoxy silane
from about 1 wt % to about 4 wt %.
[0185] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
further comprising a condensation catalyst that comprises a
sulfonic ester from about 1 wt % to about 4 wt %.
[0186] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
wherein the density is less than 0.60 g/cm.sup.3.
[0187] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
wherein the foaming agent includes a microencapsulating foaming
agent.
[0188] The silane-crosslinked polyolefin elastomer blend of
Embodiment B or Embodiment B with any of the intervening features
wherein the compression set is from about 15.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.).
[0189] Embodiment C is a method for making an elastomeric article,
the method comprising: extruding a first polyolefin having a
density less than 0.86 g/cm.sup.3, a second polyolefin having a
crystallinity less than 40%, a silane crosslinker and a grafting
initiator together to form a silane-grafted polyolefin blend;
extruding the silane-grafted polyolefin blend and a condensation
catalyst together to form a silane-crosslinkable polyolefin blend;
molding the silane-crosslinkable polyolefin blend into an uncured
elastomeric article; and crosslinking the crosslinkable-polyolefin
blend of the uncured elastomeric article at an ambient temperature
and an ambient humidity to form the elastomeric article having a
density less than 0.70 g/cm.sup.3, wherein the elastomeric article
exhibits a compression set of from about 5.0% to about 35.0%, as
measured according to ASTM D 395 (22 hrs @ 70.degree. C.).
[0190] The method of Embodiment C wherein the silane-grafted
polyolefin blend and the crosslinkable-polyolefin blend are
thermoplastics and the crosslinked polyolefin blend is a
thermoset.
[0191] The method of Embodiment C or Embodiment C with any of the
intervening features wherein the first polyolefin is an
ethylene/.alpha.-olefin copolymer and the second polyolefin is a
polypropylene homopolymer and/or a poly(ethylene-co-propylene).
* * * * *