Weatherable and flame-resistant thermoplastic vulcanizates and methods for making them
AssigneeExxonMobil Chemical Patents Inc.
InventorsRandal H. Kerstetter, III, Karla D. Caton, Edward J. Blok, Eugene R. Uhl
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Abstract
A weatherable, flame-resistant thermoplastic vulcanizate composition comprising a thermoplastic matrix; and dispersed within said matrix, an at least partially cured rubber, a flame retardant, and carbon black.
Claims22
A weatherable, flame-resistant thermoplastic vulcanizate composition comprising:
- i. a thermoplastic matrix;
- and
- ii. dispersed within said matrix, an at least partially cured rubber, a flame retardant, and carbon black,
- wherein the thermoplastic vulcanizate composition comprises from about 10 to about 30 wt. % thermoplastic resin, based on the weight of the thermoplastic vulcanizate, and from about 10 to 25 wt. % of the rubber, based on the weight of the thermoplastic vulcanizate;
- wherein the thermoplastic vulcanizate composition comprises from about 10 to about 50 wt. % of the flame retardant, based on the weight of the thermoplastic vulcanizate, where the flame retardant comprises a halogenated hydrocarbon and a metal oxide;
- and
- wherein the composition is substantially devoid of UV stabilizer and antioxidants other than carbon black.
A method for producing a weatherable, flame-resistant thermoplastic vulcanizate, the method comprising:
- i. dynamically vulcanizing a rubber within a molten blend that includes the rubber, a thermoplastic resin, optionally an extender, optionally carbon black, and optionally an inert filler other than carbon black, where the molten blend is substantially devoid of flame retardants, to thereby produce a thermoplastic vulcanizate;
- ii. after said step of dynamically vulcanizing, blending said thermoplastic vulcanizate while in its molten state with a flame retardant and optionally with carbon black, where the flame retardant includes decabromodiphenylethane, antimony trioxide, and zinc borate hydrate, with the proviso that said step of dynamically vulcanizing takes place with carbon black in the molten blend or said step of blending includes blending the thermoplastic vulcanizate with carbon black, to thereby produce a thermoplastic vulcanizate having weatherability and flame resistance;
- and
- iii. extruding the thermoplastic vulcanizate, wherein the thermoplastic vulcanizate comprises from about 10 to about 30 wt. % of thermoplastic resin, from about 10 to 25 wt. % of rubber, and from about 10 to about 50 wt. % of flame retardant, based on the weight of the thermoplastic vulcanizate, and wherein the composition is substantially devoid of UV stabilizer and antioxidants other than carbon black.
A weatherable, flame-resistant thermoplastic vulcanizate composition comprising an at least partially cured rubber dispersed in a thermoplastic matrix, wherein the thermoplastic vulcanizate composition comprises:
- (i) from about 10 to about 40 wt. % thermoplastic resin, based on the weight of the thermoplastic vulcanizate composition;
- (ii) from about 10 to about 25 wt. % rubber, based on the weight of the thermoplastic vulcanizate composition;
- (iii) from about 1.5 to about 6.0 wt. % carbon black, based on the weight of the thermoplastic vulcanizate composition;
- (iv) from about 10 wt. % to about 50 wt. % flame retardant, based on the weight of the thermoplastic vulcanizate composition;
- (v) clay;
- (vi) oil;
- and
- (vii) less than 2 wt. % of UV stabilizers and antioxidants other than carbon black, and wherein the thermoplastic vulcanizate has a Shore A hardness of at least 50.
Dependencies are inferred from the claim text.