US 5,977,271 A · Process for preparing thermoset interpolymers and foams

Abstract

The subject invention provides a thermoset elastomer comprising a crosslinked pseudorandom or substantially random interpolymer of: (a) from 15 to 70 weight percent of at least one .alpha.-olefin, (b) from 30 to 70 weight percent of at least one vinylidene aromatic compound, and (c) from 0 to 15 weight percent of at least one diene. The subject invention further provides a thermoplastic vulcanizate comprising the thermoset elastomers of the invention as provided in a thermoplastic polyolefin matrix. The subject invention further provides processes for preparing the inventive thermoset elastomers and thermoplastic vulcanizates, as well as parts fabricated therefrom. The inventive materials have a superior balance of properties, as compared to EPM and EPDM based materials. The subject invention also pertains to foams and methods for their preparation.

Claims23

Dependent claims

A process for preparing a thermoset elastomer comprising:

(a) reacting at least one .alpha.-olefin with at least one vinylidene aromatic compound and optionally at least one diene, in the presence of a constrained geometry catalyst, to form a pseudorandom interpolymer;
and
(b) curing the pseudorandom interpolymer to form a thermoset elastomer.

A process for making a thermoplastic vulcanizate comprising:

(a) polymerizing at least one .alpha.-olefin with at least one vinylidene aromatic compound and optionally at least one diene in the presence of a constrained geometry catalyst to form a pseudorandom interpolymer;
(b) intimately mixing the pseudorandom interpolymer with at least one thermoplastic polyolefin at a temperature above the melting or softening point of the thermoplastic polyolefin;
(c) providing to the intimate mixture an agent for curing the pseudorandom interpolymer;
(d) simultaneously curing the pseudorandom interpolymer and compounding the intimate mixture to form a thermoplastic vulcanizate.

1 more element

A process for making a thermoplastic vulcanizate comprising:

(a) polymerizing at least one .alpha.-olefin with at least one vinylidene aromatic compound and optionally at least one diene in the presence of a constrained geometry catalyst to form a substantially random interpolymer;
(b) intimately mixing the substantially random interpolymer with at least one thermoplastic polyolefin at a temperature above the melting or softening point of the thermoplastic polyolefin;
(c) providing to the intimate mixture an agent for curing the substantially random interpolymer;
(d) simultaneously curing the substantially random interpolymer and compounding the intimate mixture to form a thermoplastic vulcanizate.

1 more element

A method for cross-linking a polymer composition comprising

(A) from about 2 to 100 percent by weight based on the combined weight of components (A) and (B) of at least one substantially random interpolymer comprising
(1) from about 1 to about 65 mole percent of polymer units derived from (a) at least one vinylidene aromatic monomer, or (b) at least one hindered aliphatic vinylidene monomer, or (c) a combination of at least one vinylidene aromatic monomer and at least one hindered aliphatic vinylidene monomer, and
(2) from about 35 to about 99 mole percent of polymer units derived from at least one aliphatic .alpha.-olefin having from 2 to about 20 carbon atoms;
(B) from 0 to about 98 percent by weight based on the combined weight of components (A) and (B) of at least one of the following polymers:
(1) a polymer containing polymer units derived from an .alpha.-olefin or aromatic substituted .alpha.-olefin having from 2 to about 20 carbon atoms;
(2) a copolymer containing (a) from about 2 to about 98 mole percent of polymer units derived from ethylene and (b) from about 98 to about 2 mole percent of polymer units derived from at least one of .alpha.-olefins having from 3 to about 20 carbon atoms, acrylic acid, methacrylic acid, vinyl alcohol, vinyl acetate, or diene having from 4 to about 20 carbon atoms;
(3) a styrenic block copolymer;
(4) a substantially random interpolymer defined as in (A) wherein the interpolymers (A) and (B4) are distinct in that:
(a) the amount of vinylidene aromatic monomer and/or hindered aliphatic or cycloaliphatic vinylidene monomer in any interpolymer of component (1) differs from that amount in any interpolymer of component (4) by at least 0.5 mole percent;
and/or
(b) there is a difference of at least 20 percent between the number average molecular weight (Mn) in any interpolymer of component (1) and any interpolymer of component (4);
which method for cross-linking comprises:
subjecting the polymer composition to a sufficient amount of electron beam radiation to at least partially cross-link the polymer composition;
or
contacting the polymer composition with a sufficient amount of at least one peroxide compound to at least partially cross-link the polymer composition;
or
contacting the polymer composition with a sufficient amount of at least one azide compound to at least partially cross-link the polymer composition;
or
contacting the polymer composition with a sufficient amount of at least one silane compound, initiator, and optional catalyst, to at least partially cross-link the polymer composition;
or
a combination of any two or more of the above cross-linking methods.

18 more elements

Dependencies are inferred from the claim text.

Process for preparing thermoset interpolymers and foams

Life of this patent

Process for preparing thermoset interpolymers and foams

Life of this patent

Abstract

Claims23