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Publication numberCA2546075 A1
Publication typeApplication
Application numberCA 2546075
PCT numberPCT/US2004/037833
Publication date2 Jun 2005
Filing date12 Nov 2004
Priority date14 Nov 2003
Also published asCA2545203A1, CA2545203C, CA2546075C, CN1878799A, CN1878799B, CN1890276A, CN1890276B, EP1687345A1, EP1687345B1, EP1687346A1, EP1687346B1, US7390866, US7605217, US7928165, US8013093, US20050107529, US20050107530, US20050107534, US20050131142, WO2005049670A1, WO2005049671A1, WO2005049672A1
Publication numberCA 2546075, CA 2546075 A1, CA 2546075A1, CA-A1-2546075, CA2546075 A1, CA2546075A1, PCT/2004/37833, PCT/US/2004/037833, PCT/US/2004/37833, PCT/US/4/037833, PCT/US/4/37833, PCT/US2004/037833, PCT/US2004/37833, PCT/US2004037833, PCT/US200437833, PCT/US4/037833, PCT/US4/37833, PCT/US4037833, PCT/US437833
InventorsSudhin Datta, Rui Zhao, Srivatsan Srinivas Iyer, Majia Amin, Chia Y. Cheng, Abdelhadi Sahnoune, Periagaram S. Ravishankar
ApplicantExxonmobil Chemical Patents Inc., Sudhin Datta, Rui Zhao, Srivatsan Srinivas Iyer, Majia Amin, Chia Y. Cheng, Abdelhadi Sahnoune, Periagaram S. Ravishankar
Export CitationBiBTeX, EndNote, RefMan
External Links: CIPO, Espacenet
Propylene-based elastomers and uses thereof
CA 2546075 A1
Abstract
The present invention provides curable and cured propylene-based elastomers, optionally including a diene, and having isotactic polypropylene crystallinity, a melting point by DSC equal to or less than 110~C, and a heat of fusion of from 5 J/g to 50 J/g. The present invention also provides blend compositions comprising any of the propylene-based elastomers described herein. The present invention also provides compositions comprising any of the propylene-based elastomers described herein and 1 to 100 parts by weight of inorganic filler per 100 parts of polymer. The present invention also provides films, fibers, non-wovens, molded objects, and extruded forms which include any of the inventive compositions described herein.
Description  available in
Claims(43)
1. An elastomer comprising:
(a) propylene-derived units in an amount of at least 60 wt%, preferably within the range of from 80 to 90 wt%, based on the combined weight of components (a), (b), and (c);
(b) dime-derived units in an amount within the range of from 0.3 to 10 wt%, preferably from 0.3 to 3 wt%, based on the combined weight of components (a), (b), and (c); and (c) ethylene-derived units in an amount of at least 6 wt%, preferably within the range of from 8 to 20 wt%, more preferably within the range of from to 20 wt%, based on the combined weight of components (a), (b), and (c);
wherein the elastomer has isotactic polypropylene crystallinity, a melting point by DSC equal to or less than 110C, and a heat of fusion of from 5 J/g to 50 J/g.
2. The elastomer according to claim 1, wherein the dime is 5-ethylidene-2-norbornene and is preferably present in an amount within the range of from 1 to 3 wt%, based on the combined weight of components (a), (b), and (c).
3. The elastomer according to claim 1, wherein the dime is 5-vinyl-2-norbornene and is preferably present in an amount within the range of from 0.5 to 1.5 wt%, based on the combined weight of components (a), (b), and (c).
4. The elastomer according to any of the preceding claims, wherein the elastomer has a Mooney viscosity ML(1+4) at 125C of from 0.5 to 100, preferably from 5 to 40.
5. The elastomer according to any of the preceding claims, wherein the elastomer is partially insoluble and the fractions soluble at 23C and 31C, as measured by the extraction method described herein, have ethylene contents differing by 5 wt% or less.
6. The elastomer according to any of the preceding claims, wherein the elastomer has an isotactic propylene triad tacticity of from 65 to 95% and/or the elastomer has an m/r ratio of from 6 to 8 and/or the elastomer has an isotacticity index of from 40 to 55.
7. A curable composition comprising an elastomer according to any of the preceding claims 1 to 6 and a chemical crosslinking formulation as a curing package, not considered part of the polymer or filler content as used herein.
8. The curable composition according to claim 7 which further comprises a dispersed phase comprising a crystalline polymer component having a melting point by DSC of 115C or higher, preferably isotactic polypropylene having a heat of fusion of at least 50 J/g, preferably at least 75 J/g, dispersed in a matrix formed by the elastomer, and selected from the group consisting of propylene homopolymers, propylene graft copolymers, propylene block copolymers propylene random copolymers, and mixtures thereof.
9. The curable composition according to claim 7 or 8 which further comprises a polymer with no or ethylene type crystallinity, preferably comprising at least 50 mol% ethylene-derived units.
10. The curable composition according to any of claims 7 to 9 which further comprises an EP rubber, optionally containing a dime.
11. The curable composition according to any of claims 7 to 10 which further comprises from 1 to 100 parts by weight of inorganic filler per 100 parts of polymer, wherein the inorganic filler is selected from the group consisting of carbon black, clay, titanium and magnesium oxides, silica, glass fibers, mica, and mixtures thereof.
12. The curable composition according to any of claims 7 to 11 which further comprises less than 30 wt%, optionally less than 10 wt%, based on the total weight of the composition, of an extender oil.
13. The curable composition according to any of claims 7 to 11 which further comprises no extender oil or less than 1 wt% of an extender oil, based on the total weight of the composition.
14. A cured composition in which the composition according to any of claims 7 to 13 is cured to a degree such that the viscosity ratio of the elastomer is from 1 to 10, preferably from 1.2 to 10.
15. A cured composition in which the composition according to any of claims 7 to 14 is cured to a degree such that at least 2 wt%, preferably at least 10 wt%, and especially at least 20 wt%, of the elastomer is cured and optionally less than 95 wt% of the elastomer is cured as determined by the extraction method described herein.
16. The cured composition according to claim 14 or 15 wherein the composition has a tension set after 200% elongation of less than 50% and/or an ultimate tensile strength of at least 1000 psi (6.89 MPa).
17. The cured composition according to any of claims 14 to 16 having a tensile strength (TS), measured in MPa, which conforms to the relationship:
TS = 30*(Shore A hardness/MI@a 190C)-300+B1, where B1 is at least 2.
18. The cured composition according to any of claims 14 to 17 having a tensile strength (TS), measured in MPa, which conforms to the relationship:
TS = 30*(Shore A hardness/MI@190C)-300+B1, where B1 is at least 4, preferably at least 6, and especially at least 12.
19. The cured composition according to any of claims 14 to 18 having a Die C
tear strength (Die C), measured in Kn/m, which conforms to the relationship:
Die C = 40*(Shore A hardness/MI@190C)-400+B2, where B2 is at least 5, preferably at least 10, especially at least 15, and most preferably at least 20.
20. A process for making an extruded article, the process comprising:
(a) extruding a composition according to any of claims 7 to 13 to produce an extruded article, and (b) exposing the extruded article to a cure treatment so as to provide the extruded article having a composition according to any of claims 14 to 19.
21. A fiber or film produced according to the process of claim 20.
22. A non-woven web produced according to the process of claim 20.
23. A molded object produced from a composition according to any of claims 14 to 19.
24. A process for making an extruded article, the process comprising:
(a) extruding a composition comprising an elastomer to produce an extruded article, the elastomer having isotactic polypropylene crystallinity, a melting point by DSC of 110C or less, a heat of fusion of from 5 to 50 J/g, and comprising:

(i) propylene-derived units in an amount of at least 60 wt%, preferably within the range of from 80 to 97 wt%, more preferably within the range of from 80 to 90 wt%, based on the combined weight of components (i), (ii), and (iii), (ii) ethylene-derived units in an amount of at least 6 wt%, preferably within the range of from 10 to 20 wt%, based on the combined weight of components (i), (ii), and (iii), and (iii) optionally dime-derived units in an amount within the range of from 0.1 to 10 wt%, preferably from 0.3 to 10 wt%, more preferably from 0.3 to 3 wt%, based on the combined weight of components (i), (ii), and (iii); and (b) exposing the extruded article to irradiation to at least partially cure the extruded article.
25. The process according to claim 24 in which the elastomer has a Mooney viscosity ML(1+4) at 125C of from 0.5 to 100, preferably from 5 to 40.
26. The process according to claim 24 or 25 in which the elastomer is partially insoluble and the fractions soluble at 23C and 31C, as measured by the extraction methods described herein, have ethylene contents differing by less than wt%, preferably less than 2 wt%.
27. The process according to any of the preceding claims 24 to 26 in which the elastomer has an isotactic propylene triad tacticity of from 65 to 95%, and/or the elastomer has an m/r ratio of from 6 to 8, and/or the elastomer has an isotacticity index of from 40 to 55.
28. The process according to any of the preceding claims 24 to 27 in which the composition further comprises a dispersed phase comprising a crystalline polymer component having a melting point by DSC of 115C or higher, preferably isotactic polypropylene having a heat of fusion of at least 50 J/g, preferably at least 75 J/g, dispersed in a matrix formed by the elastomer, and selected from the group consisting of propylene homopolymers, propylene graft copolymers, propylene block copolymers, propylene random copolymers, and mixtures thereof.
29. The process according to any of the preceding claims 24 to 28 in which the composition further comprises a polymer with no or ethylene type crystallinity, preferably comprising at least 50 mol% ethylene-derived units.
30. The process according to any of the preceding claims 24 to 29 in which the composition further comprises an EP rubber, optionally containing a diene.
31. The process according to any of the preceding claims 24 to 30 in which the composition further comprises from 1 to 104 parts by weight of inorganic filler per 100 parts of polymer, wherein the inorganic filler may be carbon black, clay, titanium and magnesium oxides, silica, glass fibers, mica, or mixtures thereof.
32. The process according to any of claims 24 to 31 in which the composition further comprises less than 30 wt%, optionally less than 10 wt%, based on the total weight of the composition, of an extender oil.
33. The process according to any of claims 24 to 31 in which the composition comprises no extender oil or less than 1 wt% of an extender oil, based on the total weight of the composition.
34. The process according to any of claim 24 to 33 in which the composition further comprises a chemical crosslinking formulation as a curing package, not considered part of the polymer of filler content as used herein.
35. The process according to any of claims 24 to 34 in which the composition is cured to a degree such that the viscosity ratio of the elastomer is from 1 to 10, preferably from 1.2 to 10.
36. The process according to any of claims 24 to 35 in which the composition is cured to a degree such that at least 2 wt% preferably at least 10 wt%, and especially at least 20 wt%, of the elastomer is cured and optionally less than wt% of the elastomer is cured as determined by the extraction method described herein.
37. The process according to any of claims 24 to 36 in which the extruded article has a tension set after 200% elongation of less than 50% and/or an ultimate tensile strength of at least 1000 psi (6.89 MPa).
38. The process according to any of claims 24 to 37 in which the extruded article has a tensile strength (TS), measured in MPa, which conforms to the relationship:
TS = 30*(Shore A hardness/MI@190C)-300+B1, where B 1 is at least 2.
39. The process according to any of claims 24 to 37 in which the extruded article has a tensile strength (TS), measured in MPa, which conforms to the relationship:
TS = 30*(Shore A hardness/MI@190C)-300+B1, where B1 is at least 4, preferably at least 6, and especially at least 12.
40. The process according to any of claims 24 to 39 in which the extruded article has a Die C tear strength (Die C), measured in Kn/m, which conforms to the relationship:
Die C = 40*(Shore A hardness/MI@190C)-400+B2, where Ba is at least 5, preferably at least 10, especially at least 15, and most preferably at least 20.
41. A fiber produced according to the process of any of the preceding claims 24 to 40.
42. A non-woven web produced according to the process of any of the preceding claims 24 to 40.
43. A film produced according to the process of any of the preceding claims 24 to 40.
Classifications
International ClassificationC08F8/00, C08F4/659, C08L23/16, C08F210/18, C08F210/06
Cooperative ClassificationY10T442/678, A43B13/04, C08F210/06, C08F210/18, C08F4/65908
European ClassificationC08F210/18, C08F210/06
Legal Events
DateCodeEventDescription
15 May 2006EEERExamination request