Methods for preparing articles from processable and dimensionally stable elastomer compositions
AssigneeFreudenberg-NOK General Partnership
InventorsEdward Hosung Park, Francis Joseph Walker
Life of this patent
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Abstract
Methods for preparing a shaped rubber article, comprising admixing at least one thermoplastic material and at least one elastomer material to provide a processable and dimensionally stable rubber composition, shaping the composition, and irradiating the composition to form the shaped rubber article. The dimensional stability of the uncured composition may be provided by partial dynamic vulcanization, high performance reinforcing fillers, fractional curing, or combinations thereof. The elastomer material is present in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials present in the admixture.
Claims71
A method for preparing a shaped rubber article, comprising
- (a) admixing a thermoplastic material, an elastomer material, and at least two curatives, wherein the elastomer material is present in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials;
- (b) partially dynamically curing the elastomer material, the partial dynamic curing comprising not reacting at least one of the curatives, wherein a processable composition is formed comprising a thermoplastic phase comprising said thermoplastic material dispersed in a continuous elastomer phase comprising said elastomer material, the composition having a green strength sufficient to inhibit substantial creep of the composition;
- (c) shaping the processable composition;
- and
- (d) irradiating the shaped composition, wherein the composition is finally cured.
A method for preparing a shaped rubber article, comprising
- (a) admixing a thermoplastic material, an elastomer material, at least one curative, and a high performance reinforcing filler to form a processable composition;
- wherein the elastomer material is present in the composition in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials, the composition comprising a thermoplastic phase comprising said thermoplastic material dispersed in a continuous elastomer phase comprising said elastomer material, the composition having a green strength sufficient to inhibit substantial creep of the composition;
- (b) shaping the processable composition;
- and
- (c) irradiating the shaped composition, wherein the composition is finally cured.
A method for preparing a shaped rubber article, comprising
- (a) admixing a thermoplastic material, an elastomer material, and at least one curative to form a processable composition,
- wherein the at least one elastomer material comprises (i) a first curable elastomer and (ii) a second curable elastomer having a cure chemistry different than the first curable elastomer,
- wherein the total amount of elastomer materials (i) and (ii) is present in the composition in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials,
- (b) shaping the processable composition,
- (c) crosslinking the at least one of elastomer materials (i) and (ii) by chemically reacting the at least one curative with at least one of elastomer materials (i) and (ii), and
- (d) irradiating the shaped composition, wherein the composition is finally cured.
An isolated composition comprising a thermoplastic material as a dispersed phase in a continuous phase comprising an elastomer material,
- wherein the at least one elastomer material is partially dynamically cured with at least two curatives, wherein at least one of the curatives is not reacted, and the at least one elastomer material is present in the composition in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials,
- the composition having a Mooney viscosity (ML1+10@250° F.) from about 5% to about 100% greater than the uncured viscosity and a green strength that is sufficient to provide less than about 1% dimensional change after a 24-hour aging cycle at room temperature.
An isolated composition comprising a thermoplastic material as a dispersed phase in a continuous phase comprising an elastomer material,
- wherein the elastomer material is present in the composition in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials,
- the composition comprising high performance reinforcing filler in an amount from about 0.1 phr to about 80 phr, wherein the high performance reinforcing filler is a material selected from the group consisting of polyetherketone (PEEK), polysulfone (PS, PES, PPS), liquid crystalline polymer (LCP), polyphthalamide (PPA), polyphenylamide (Aramid), ultra-high molecular weight polyethylene (UHMWPE), and carbon nano-fiber, and
- the composition having a Mooney viscosity (ML1+10@250° F.) from about 5% to about 100% greater than the viscosity without the high performance reinforcing filler and a green strength that is sufficient to provide less than about 1% dimensional change after a 24-hour aging cycle at room temperature.
An isolated composition comprising a thermoplastic material as a dispersed phase in a continuous phase comprising an elastomer material,
- the elastomer material comprising (i) a first curable elastomer and (ii) a second curable elastomer having a cure chemistry different than the first curable elastomer,
- wherein the total amount of elastomer materials (i) and (ii) is present in the composition in an amount greater than about 65% by weight based on the total weight of the thermoplastic and elastomer materials,
- wherein at least one of elastomer materials (i) and (ii) is crosslinked by reaction with at least one curative, and
- the composition having a Mooney viscosity (ML1+10@250° F.) from about 5% to about 100% greater than the uncured viscosity and a green strength that is sufficient to provide less than about 1% dimensional change after a 24-hour aging cycle at room temperature.
Dependencies are inferred from the claim text.