Selectively, partially hydrogenated polymer and rubber composition containing the same

Abstract: A selectively partially hydrogenated butadiene polymer produced by selectively, partially hydrogenating a butadiene polymer comprising: (1) a bound styrene content [S] of 0 to 40% by weight; (2) a vinyl linkage content [V] of 1 to 80% at the butadiene portion; (3) a weight average molecular weight (Mw)of 10,000 to 1,000,000; and (4) a molecular weight distribution (Mw/Mn) of 1.2 to 5.0; wherein the selectively partially hydrogenated butadiene polymer produced is characterized by (5) a hydrogenation ratio [A] of 3 to 85% of the total butadiene portion; and (6) a hydrogenation ratio [B] of 20% or more at the vinyl linkage moiety of the butadiene portion; and wherein the [A], [B], [S] and [V] satisfy the relationships of: (7) [A]/([S] + [V]) 1/2 which is 2 to 8; and (8) [B]·[V] 1/2 /[A] which is 10 to 16.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a selectively, partially hydrogenated polymer, and to a rubber composition containing the same. More specifically, it relates to a selectively, partially hydrogenated butadiene polymer having a specific structure and a composition thereof comprising a butadiene polymer, e.g., a butadiene homopolymer or a styrene-butadiene copolymer having a specific structure which is partially and selectively hydrogenated, and to a rubber composition containing the same. 2. Description of the Related Art Polymers obtained by partial hydrogenation of styrene-butadiene copolymer have been long known, and it has been proposed to obtain a composition having an improved green strength by blending this polymer with other diene type elastomers or ethylene-propylene copolymer rubbers (JP-B-46-35497). Proposals have been also made for a composition having an excellent strength at break, and a rubbery elasticity, comprising this polymer and a specific inorganic filler (JP-B-47-8928), and for a method for producing an oil-extended rubber having an excellent heat-resistant aging characteristic and resilience (JP-B-46-29020) and the like. Nevertheless, when the catalyst composed mainly of organic compounds of iron, nickel, cobalt of the prior art is used, it is difficult to partially hydrogenate the vinyl linkage by preferential selection, and to hydrogenate the vinyl linkage to a high extent, the 1,4-linkages including the cis-linkage and translinkage also must be hydrogenated to a high degree. This method also generated crystalline copolymers, and the intended improvement of resilience and heat-resistant aging characteristic resulted only in an undesirable marked increase in the hardness or a lowering of the exothermic property. A method has been also proposed in which only the side chain portion of a diene polymer (i.e., vinyl linkage portion in butadiene polymer) is selectively hydrogenated, and a method is also known of obtaining a selectively hydrogenated diene polymer having ozone resistance and oxidation stability (JP-A-52-41690). But the polymer obtained according to this method, although showing a slightly improved heat-resistant aging characteristic or resilience, does not have a sufficient improvement of such characteristics, and no improvement at all of the hardness and elasticity modulus was observed. FR-A-2 539 745 relates to a process for the hydrogenation of a diene polymer in an inert organic solvent, wherein all double bonds in the butadiene units are hydrogenated as completely as possible, while the aromatic nuclei of the butadiene-vinyl aromatic copolymer are not hydrogenated, whereby a remarkable improvement of weatherability, oxidation resistance and heat resistance of the thus prepared polymers or copolymers are achieved. DE-A-1 924 745 relates to a random copolymer produced by solution polymerization consisting of 5 to 30 parts by weight styrene units and 95 to 70 parts by weight butadiene units having a number average number molecular weight of more than 10 000, wherein less than 70 % of the butadiene units are hydrogenated and a process for producing said copolymer. SUMMARY OF THE INVENTION Accordingly, the objects of the present invention are to eliminate the above-mentioned problems of the prior art and to provide a novel polymer capable of solving the above-mentioned problems. Other objects and advantages of the present invention will be apparent from the following description. In accordance with the present invention, there is provided a selectively partially hydrogenated butadiene polymer produced by selectively, partially hydrogenating a butadiene polymer comprising: (1) a bound styrene content [S] of 0 to 40% by weight, said styrene being bound at random; (2) a vinyl linkage content [V] of 1 to 80% at the butadiene portion; (3) a weight average molecular weight (Mw) of 10,000 to 1,000,000; and (4) a molecular weight distribution (Mw/Mn) of 1.2 to 5.0; wherein the selectively partially hydrogenated butadiene polymer produced is characterized by: (5) a hydrogenation ratio [A] of 3 to 85% of the total butadiene portion; (6) a hydrogenation ratio [B] of 20% or more at the vinyl linkage moiety of the butadiene portion; and wherein the [A], [B], [S] and [V] satisfy the relationships of: (7) [A]/([S] + [V]) 1/2 which is 2 to 8; and (8) [B]·[V] 1/2 /[A] which is 10 to 16. In accordance with the present invention, there is also provided a rubber composition suitable for use in tire manufacture, comprising 100 parts by weight of a starting material rubber containing at least 30% by weight of the above-mentioned selectively, partially hydrogenated butadiene polymer, 10 to 150 parts by weight of carbon black, and 0.1 to 10 parts of a vulcanizing agent. BRIEF DESCRIPTION OF THE DRAWING The present invention will be better understood from the description set forth below with reference to the drawings, in which: Fig. 1 is a diagram showing the FT-NMR absorption of the starting polymer in Example 1, and Fig. 2 is a diagram of the FT-NMR absorption of the polymer after a selective, partial hydrogenation in Example 1. DESCRIPTION OF THE PREFERRED EMBODIMENTS As the hydrogenation catalyst of butadiene polymers, styrene-butadiene copolymers, in addition to the organometallic compounds composed mainly of organic compounds of iron, nickel, cobalt, there are known catalysts comprising metals such as nickel, cobalt, platinum, palladium, and ruthenium supported on carriers such as carbon, silica, alumina, and diatomaceous earth. These catalysts, however, have a lower activity and hydrogenation under lower temperature, but low pressure conditions therefor is practically impossible. Also, a selective partial hydrogenation did not occur at the vinyl linkage of the butadiene portion. Recently, a highly active hydrogenation method using an organo-metallic compound of titanium was disclosed (JP-A-59-133203 and 60-220147), and it has become possible to easily hydrogenate only the butadiene portion under the mild conditions of a low temperature and low pressure on an industrial scale. The present invention has applied this method to a partial hydrogenation of a butadiene polymer or a styrene-butadiene polymer with a specific structure, to obtain a selectively partially hydrogenated polymer with a specific structure, to thereby solve the problems of the prior art. The butadiene polymer, e.g., a butadiene homopolymer or a styrene-butadiene copolymer which is the starting polymer of the selectively partially hydrogenated butadiene polymer must have a specific structure. Namely, said starting polymer must have a structure comprising: (1) a bound styrene content [S] of 0 to 40% by weight, said styrene being bound at random; (2) a vinyl linkage content [V] of 1 to 80% at the butadiene portion; and (3) a weight average molecular weight (Mw) of 10,000 to 1,000,000; and (4) a molecular weight distribution (Mw/Mn) of 1.2 to 5.0. If the bound styrene content exceeds 40% by weight, even if the other conditions of the present invention are satisfied, a sufficient improvement of the resilience and exothermic property cannot be obtained. The bound styrene content is preferably limited to 30% or less, and the styrene is bound at random. The vinyl linkage content at the butadiene portion is limited to 1 to 80%. Outside of this range, the vinyl linkage content is too high or too low, and therefore, the selective, partial hydrogenation of vinyl linkages of the present invention cannot be obtained and thus the required effect will not be exhibited. The vinyl linkage content is preferably to 5 to 60%, more preferably 10 to 50%. The weight average molecular weight (Mw) must be 10,000 to 1,000,000 and the molecular weight distribution as represented by Mw/Mn must be 1.2 to 5.0. If the molecular weight is less than 10,000 or the molecular weight distribution exceeds 5, the physical properties of the starting polymer to be improved, namely the hardness, modulus or resilience, and exothermic property will be remarkably inferior, and a satisfactory polymer cannot be obtained even by the present invention. On the other hand, if the molecular weight exceeds 1,000,000 or the molecular weight distribution is less than 1.2, processing of the polymer as a rubber or production thereof becomes difficult, and the present application cannot be applied. Preferably, the molecular weight is 50,000 to 800,000, more preferably 100,000 to 600,000, and the molecular weight distribution is preferably 1.5 to 3.0. The molecular weight and the molecular weight distribution are measured in a conventional manner by gel permeation chromatography. A part of the butadiene component of the butadiene polymer and styrene-butadiene copolymer having the specific structure as described above may be replaced with other conjugated diene components copolymerizable therewith, within the range of not more than 30% by weight. Examples of such other conjugated diene components include isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene. The same also holds true for the styrene component, and a part of the styrene component may be replaced with vinyl-substituted aromatic hydrocarbons such as t-butylstyrene, α-methylstyrene, p-methylstyrene, and divinylbenzene. The butadiene polymer, styrene-butadiene copolymer having the specific structure which is the starting polymer for the selectively, partially hydrogenated butadiene polymer of the present invention may be produced by any preparation method, provided that the structure obtained corresponds to the limited structure specified above. Representative preparation methods for obtaining these polymers are described below. Namely, the starting polymer can be obtained by homopolymerization of monomeric butadiene or copolymerization with a predetermined ratio of styrene in an inert solvent such as hexane, cyclohexane, or benzene, by using an organic lithium such as n-butyllithium, sec-butyllithium, or other alkali metal compounds as the polymerization catalyst, optionally together with an organic compound, typically an alkoxide such as potassium butoxide, organic acid salts such as dodecylbenzenesulfonate or sodium stearate, and further optionally, a polar organic compound used as the compound for controlling the vinyl linkage content, such as ether, polyether, tertiary amine, polyamine, thioether, and hexamethylphosphortriamide. The vinyl linkage content can be controlled by the amount added of the above polar organic compound, and by the polymerization temperature. By coupling the polymeric chains having active terminal ends obtained according to the above-mentioned method with a polyfunctional compound such as silicon tetrachloride, tin tetrachloride, a polyepoxy compound, etc., or adding a branching agent such as divinylbenzene to the polymerization system, a branched or radial polymer or copolymer can be obtained. Further, in the above polymerization method, by controlling the method of addition of the monomer, or varying the polymerization conditions during the polymerization reaction, such as the amount of compound for controlling the vinyl linkage content, the addition method thereof, and the polymerization temperature, it is possible to form a polymer or a copolymer in which the styrene content or the vinyl linkage content can be increased or decreased, or formed into a block shape in the molecular chain as described above. During polymerization, various compounds such as acetylene, 1,2-butadiene, fluorene, primary amine, and secondary amine also can be used as the molecular weight controller. As the polymerization process for obtaining the above polymer, the batch or continuous process, or a combination thereof, may be used. The starting polymer of the present invention can be also prepared according to a polymerization method other than that employing a lithium catalyst; for example, a method employing a Ziegler type catalyst comprising an organic compound of nickel, cobalt, titanium, and an organometallic component of lithium, magnesium, aluminum, or an emulsion polymerization method. The polymer of the present invention comprises the specific butadiene polymer e.g., a butadiene homopolymer or a styrene-butadiene copolymer as described above, which is selectively partially hydrogenated, and is characterized by (5) a hydrogenation ratio [A] of 3 to 85% of the total butadiene portion; (6) a hydrogenation ratio [B] of 20% or more at the vinyl linkage moiety of the butadiene portion. The hydrogenation ratio [A] of the total butadiene portion is 3 to 85%, preferably 3 to 60%, and more preferably 5 to 50% or 8 to 40%, particularly preferably in the range of 10 to 30%. At a hydrogenation ratio lower than this range, a polymer having the high hardness, modulus and excellent resilience of the present invention cannot be obtained. On the contrary, at too high a hydrogenation ratio A , the polymer has a partial crystallinity, giving physical properties of a too high hardness and an inferior exothermic property. The hydrogenation ratio [B] at a vinyl linkage moiety of the butadiene portion is 20% or more, preferably 30% or more, more preferably 45 to 95%, most preferably 60 to 90%. At a hydrogenation ratio [B] lower than this range, the improvement of the heat-resistant aging characteristic and resilience is small. Especially when the present polymer is used in a rubber composition, the range of the hydrogenation ratio [A] of the whole butadiene portion is determined as a function of the bound styrene content [S] of the butadiene polymer, e.g., the butadiene homopolymer or the styrene-butadiene copolymer, and the bound vinyl linkage content [V] of the butadiene portion. (7) [A]/([S] +[V]) 1/2 is preferably 2 to 8, more preferably 3 to 7, most preferably 4 to 6. If this value is less than 2, the effect of the present invention, particularly the elevation of the hardness and modulus, will not be exhibited, and conversely, if this value is higher than 8, the exothermic property will be lowered. The hydrogenation ratio [B] at the vinyl linkage portion of the butadiene portion is determined as a function of the vinyl linkage content [V] of the butadiene portion of the starting polymer and the hydrogenation ratio [A] of the whole butadiene portion. (8) [B]·[V] 1/2 /[A] is preferably limited to 10 to 16, more preferably 11 to 15, most preferably 12 to 14. Outside of this range, the excellent hardness and modulus, exothermic property, resilience and heat-resistant aging characteristic, which are the desired effects of the present invention, cannot be imparted to the polymer. If this numerical value exceeds 16, although there may be an improvement of other physical properties, the physical properties as a whole will become undesirably unbalanced with respect to an elevation of the hardness and modulus or heat-resistant aging characteristic. On the contrary, at a value lower than 10, the physical properties do not have a satisfactory resilience and exothermic property, resulting in unbalanced physical properties. As long as the selectively, partially hydrogenated butadiene polymer satisfies the above-mentioned requirements, any catalysts and any production methods may be utilized. The hydrogenation catalyst suitably used in the present invention may include an organometallic compound containing titanium as the metal component alone or a catalyst comprising a combination thereof with an organometallic compound of lithium, magnesium, aluminum, and specific examples thereof are disclosed in JP-A-59-133203 and 60-220147. The selective partial hydrogenation of the present invention must be practiced under extremely mild reaction conditions by using the above catalyst. More specifically, the partial hydrogen pressure in the reaction system must be 9.8 bar (10 kg/cm²) or less, preferably 5.9 bar (6 kg/cm²) or less, more preferably 2.9 bar (3 kg/cm²) or less. The reaction is preferably carried out at a temperature of 0 to 100°C, more preferably 20 to 80°C, most preferably 40 to 60°C. Under hydrogenation conditions outside of this range, a selectively, partially hydrogenated butadiene polymer having the specific structure of the present invention cannot be obtained. The hydrogenation reaction is practiced in the presence of a solvent which is inert to the catalyst and can dissolve the starting polymer. Suitable solvents may include aliphatic hydrocarbons such as n-pentane, n-hexane, and n-octane, alicyclic hydrocarbons such as cyclohexane, and cycloheptane, and ethers such as diethyl ether and tetrahydrofuran, alone or as mixtures composed mainly of such solvents. The hydrogenation reaction of the present invention may be practiced by maintaining the above-mentioned starting polymer at a predetermined temperature under a hydrogen or inert atmosphere, adding a hydrogenation catalyst while stirring or not-stirring, and subsequently, pressurizing the system to a predetermined pressure by an introduction of hydrogen gas. An inert atmosphere means an atmosphere which is not reactive with any reactant in the hydrogenation reaction, such as helium, neon, and argon, etc. Air or oxygen is not preferable, as this will cause a deactivation of the catalyst through an oxidation of the catalyst components. Also, nitrogen acts as a catalyst poison during the hydrogenation reaction, and lowers the hydrogenation activity. Particularly, most preferably the atmosphere within the hydrogenation reactor should consist of hydrogen gas alone. When a titanocene diaryl compound is used as the hydrogenation catalyst, it may be added as is to the reaction mixture, or alternatively, as a solution in an inert organic solvent. The inert organic solvent to be used when the catalyst is used as a solution may be any of the above various solvents which are not reactive with any reactant in the hydrogenation reaction. Preferably, it is the same solvent as the solvent used in the hydrogenation reaction. The amount of the catalyst added may be 0.02 to 20 mmols per 100 g of the starting polymer. The most preferable method for obtaining the polymer of the present invention comprises solution-polymerizing the starting polymer by using an organic lithium catalyst, and using the polymer solution obtained for the subsequent hydrogenation reaction. This method is extremely useful in commercial application. The selectively, partially hydrogenated polymer of the present invention is obtained by evaporating the solution obtained above to dryness. The polymer according to the present invention, by making use of the characteristics thereof, can be widely used for uses for which butadiene polymers, e.g., the butadiene homopolymers and the styrene-butadiene copolymers are presently used. A particularly preferable use is for automobile tire manufacture, and the polymer of the present invention, either alone or as a blend with natural rubber or other synthetic rubbers, can be provided for final use via predetermined "formulation", "molding", and "vulcanization" processes. In this case, to enable the effect of the polymer of the present invention to be exhibited, the starting rubber must comprise at least 30% of the polymer of the present invention. Examples of synthetic rubbers available in the blend may include butadiene polymer, butadiene homopolymer, styrene-butadiene copolymer, isoprene-butadiene copolymer, acrylonitrile-butadiene copolymer, chloroprene polymer, ethylene-propylene copolymer, isoprene-isobutylene copolymer etc. As the formulating agents to be added to the above starting material rubber, and as the formulating agent to be added to the above rubber composition, there may be included reinforcing agents, softening agents, fillers, vulcanization agents, vulcanization accelerators, vulcanization aids, colorants, flame retardants, lubricants, blowing agents, and other formulating agents, which may be suitably selected and used depending on the intended use of the composition. Typical reinforcing agents are carbon blacks, and various kinds of carbon blacks with different particle sizes or structures obtained by various preparation methods can be used, preferably carbon blacks such as ISAF, HAF, FEF, etc. The amount of carbon black added may be used in view of the amount of the process oil added simultaneously, but may be 10 to 150 parts by weight, preferably 40 to 100 parts by weight based on 100 parts by weight of the starting rubber. The kind and amount of the above carbon black may be suitably controlled depending on the purpose of use of the rubber composition, and two or more kinds also may be used in combination. As other reinforcing agents added optionally, inorganic reinforcing agents such as silica, activated calcium carbonate, etc. or high-styrene resin, phenolformaldehyde resin, etc., may be employed, and these inorganic or organic reinforcing agents may be employed in amounts of 1 to 100 parts, preferably 5 to 50 parts by weight, based on 100 parts by weight of the starting rubber. Typical softening agents optionally added are process oils, and various kinds including paraffinic, naphthenic, and aromatic oils can be suitably used in the rubber composition, in amounts of 2 to 100 parts by weight, preferably 5 to 70 parts by weight, based on 100 parts by weight of the starting material rubber. Also, an oil-extended polymer in which a process oil is previously added to the starting material rubber can be used. As other softening agents, fluid paraffin, coal tar, fatty oil, rubber substitute (or factice), and the like can be used. Examples of the fillers may include calcium carbonate, clay, talc, aluminum hydroxide and the like. A typical vulcanizing agent is sulfur, which may be used in an amount of 0.1 to 10 parts by weight, preferably 0.2 to 5 parts by weight, based on 100 parts by weight of the starting material rubber. Other vulcanization agents may include sulfur compounds such as sulfur chloride, morpholine disulfide, alkylphenol disulfide, peroxides, etc., and these can be used either individually or in combination with sulfur. A variety of compounds are included as vulcanization accelerators, and are used in amounts of 0.01 to 5 parts by weight, per 100 parts by weight of the starting material rubber, and sometimes in combination of two or more kinds thereof. Representative vulcanization accelerators may include guanidine type, aldehyde-amine and aldehyde-ammonia type, thiazole type, imidazoline type, thiourea type, thiuram type, dithiocarbamate type, xanthate type accelerators, and mixed accelerators. The vulcanization aids may be exemplified by metal oxides such as zinc oxide, etc., fatty acid compounds such as stearic acid, etc., amines and others, and may be employed in amounts of 0.1 to 10 parts by weight based on 100 parts by weight of the starting rubber. Typical examples of the antioxidant agents are amine type, phenol type, phosphorous type, and sulfur type compounds, and may be added in amounts of 0.001 to 10 parts by weight, based on 100 parts by weight of the starting material rubber, sometimes in combination of two or more kinds. As the typical scorch preventive, there may be included phthalic anhydride, salicylic acid, N-nitrosodiphenylamine. As the tackifier, there may be included coumaroneindene resin, terpene-phenol resin, rosin ester, and the like. Further, if necessary, various formulating agents can be used. The rubber composition of the present invention can be obtained by mixing the starting material rubber with various formulating agents by various kinds of mixing devices generally employed for mixing rubber compositions, such as open rolls, a Banbury mixer, a kneader, and an extruder, and subsequently molded into a desired shape followed by vulcanization. The polymer and the rubber composition of the present invention may be suitably used by utilizing the specific features thereof for various uses, such as tires for automobiles, industrial articles such as belts, hoses and anti-vibration rubbers; footwear; articles for daily use; construction materials; and other uses. As described above and explained below, with the selectively, partially hydrogenated polymer having the specific structure of the present invention, a starting material rubber having well-balanced physical properties, with a high hardness and modulus, excellent resilience and exothermic property, and an excellent heat-resistant aging characteristics, is provided. The carbon-formulated composition of the starting material rubber of this polymer alone, or obtained by blending with another rubber, is also suitable for tires, particularly tire treads. Examples The present invention will now be further illustrated by, but is by no means limited to, the following Examples and Comparative Examples. Example 1 and Comparative Example 3 Using an autoclave of 10 liter inner volume equipped with a stirrer and a jacket as the reactor, a butadiene/n-hexane mixture (butadiene concentration 20% by weight) is introduced at a rate of 20 liter/hr. and a n-butyllithium/n-hexane solution (concentration 5% by weight) at a rate of 60 ml/hr., and a continuous polymerization of the butadiene is carried out at a polymerization temperature of 110°C. The active polymer obtained is deactivated with methanol, and 8 liters of the polymer solution is transferred to another reactor having a 10 liters inner volume equipped with a stirrer and a jacket. At a temperature of 60°C, a mixture of 250 ml of di-p-toluylbis(1-cyclopentadienyl)titanium/cyclohexane solution (concentration 1 mmol/liter) and 50 ml of n-butyllithium solution (concentration 5 mmol/liter) mixed at 0°C under a hydrogen pressure of 1.96 bar (2.0 kg/cm²) is added, and the reaction is carried out under a partial hydrogen pressure of 2.45 bar (2.5 kg/cm²) for 30 minutes. The selectively, partially hydrogenated polymer solution obtained is added with 0.5 parts by weight of 2.6-di-tert-butylhydroxy-toluene as an antioxidant, followed by removal of the solvent. The analytical values of the starting polymer obtained by sampling after methanol deactivation (the butadiene polymer of Comparative Example 3) and the analytical values of the selectively, partially hydrogenated polymer are shown in Table 1. Also, the vulcanized physical properties of carbon-formulated composition of the 75/25 blend of this product with natural rubber are shown in Table 2. Examples 2 - 8 and Comparative Examples 1, 2, 4 - 11 Butadiene polymers and styrene-butadiene polymers obtained by batch polymerization or continuous polymerization by using organic lithium catalysts (alone or together with tetrahydrofuran as the modifier) are hydrogenated by varying the reaction conditions (hydrogenation pressure, hydrogenation temperature, time and catalyst amount) to obtain the selectively hydrogenated polymers of Examples 2 to 8 and Comparative Examples 1, 2, 4 - 9. In comparative Example 10 and 11, the hydrogenation is effected using a nickel catalyst disclosed in JP-B-46-35497. Furthermore, in Comparative Example 6, the starting polymer used in Example 6 is used without hydrogenation. The structural analytical values of the respective polymers are shown in Table 1. Also, the vulcanized physical properties of the carbon-formulated compositions of these polymers alone or after blending with natural rubber are shown in Table 2 and Table 3. Using an autoclave having a 10 liters inner volume and equipped with a stirrer and a jacket as the reactor, a butadiene/n-hexane mixture (butadiene concentration 20% by weight containing 100 ppm tetramethyl ethylene diamine) is introduced at a rate of 20 liters/hr and an n-butyllithium/n-hexane solution (concentration 5% by weight) at a rate of 70 ml/h, and a continuous polymerization of the butadiene is carried out at a polymerization temperature of 110°C. The active polymer obtained is deactivated with methanol, and 8 liters of the polymer solution is transferred into another reactor having a 10 liters inner volume and equipped with a stirrer and a jacket. At a temperature of 60°C, a mixture of 250 ml of di-p-toluylbis(1-cyclopentadienyl) titanium/cyclohexane solution (concentration 1 mmol/liter) and 50 ml of n-butyllithium solution (concentration 5 mmol/liter) mixed at 0°C under a hydrogen pressure of 1.96 bar (2.0 kg/cm²) is added, and the reaction is carried out under a partial hydrogen pressure of 2.94 bar (3.0 kg/cm²) for 30 minutes. The partially hydrogenated polymer solution obtained is added with 0.5 parts by weight of 2,6-di-tert-butylhydroxytoluene as the antioxidant, followed by removal of the solvent. The analytical values of the starting polymer A obtained by sampling after methanol deactivation and the analytical values of the partially hydrogenated polymer D are shown in Table 5. The butadiene polymers obtained in the same way as the Polymer A are hydrogenated by varying the hydrogenation reaction conditions (hydrogenation pressure, hydrogenation temperature, time and catalyst amount) to obtain partially hydrogenated polymers B, C, and E to K. The structural analytical values of these polymers are also shown in Table 5. As for polymers A and D, but using an organic lithium catalyst modified with tetrahydrofuran as the catalyst, a polymer L is obtained. This polymer is hydrogenated under various hydrogenation reaction conditions to obtain partially hydrogenated polymers M - T. The analytical values of the polymers obtained are shown in Table 6. Instead of the continuous polymerization process, polybutadiene rubber is obtained by the batch polymerization process. Namely, an autoclave having a 10 liters inner volume and equipped with a stirrer and a jacket is washed and dried, and after replacement with nitrogen, 100 parts by weight of previously purified and dried 1,3-butadiene and 700 parts by weight of n-hexane, then 3.2 parts by weight of 5% by weight of n-hexane solution of n-butyllithium and 0.2 part by weight of tetrahydrofuran, as the vinyl controlling agent are added, followed by initiation of the polymerization at 70°C. The polymerization temperature is raised to 100°C. After 30 minutes, 0.06 part by weight of silicon tetrachloride is added to the polymer solution and the reaction is carried out for 30 minutes to obtain a polybutadiene rubber solution. As described above, but adding 0.6 part by weight of an epoxidized polybutadiene (epoxy addition ratio: 8 mol/mon) in place of silicon tetrachloride, the reaction is carried out for 30 minutes to obtain a polybutadiene rubber solution. A part of the rubber solution is hydrogenated in the same manner as in the preparation of polymers B, C, and E to K, and according to the same method as used in the preparation of polymer A, an unhydrogenated polybutadiene rubber (U) and partially hydrogenated polybutadiene rubbers (V - BB) are obtained. The characteristics of the rubbers obtained are shown, in Table 7. A part of the rubber solution is hydrogenated in the same manner as in the preparation of polymers B, C, and E to K , and according to the same method as used in the preparation of polymer A, an unhydrogenated polybutadiene rubber (CC) and partially hydrogenated polybutadiene rubbers (DD - II) are obtained. The characteristics of the rubbers obtained are shown, in Table 8.

Claims: Claims for the following Contracting States : BE, DE, FR, GB, IT, NL A selectively partially hydrogenated butadiene polymer produced by selectively, partially hydrogenating a butadiene polymer comprising: (1) a bound styrene content [S] of 0 to 40% by weight, said styrene being bound at random; (2) a vinyl linkage content [V] of 1 to 80% at the butadiene portion; (3) a weight average molecular weight (Mw) of 10,000 to 1,000,000; and (4) a molecular weight distribution (Mw/Mn) of 1.2 to 5.0; wherein the selectively, partially hydrogenated butadiene polymer produced is characterized by: (5) a hydrogenation ratio [A] of 3 to 85% of the total butadiene portion; and (6) a hydrogenation ratio [B] of 20% or more at the vinyl linkage moiety of the butadiene portion; said [A], [B], [S] and [V] satisfying the relationships of: (7) [A]/([S] + [V]) 1/2 which is 2 to 8; and (8) [B]·[V] 1/2 /[A] which is 10 to 16. The selectively partially hydrogenated butdiene polymer as claimed in claim 1, wherein the hydrogenation ratio [A] is 3 to 60% and the hydrogenation ratio [B] is of 30% or more. The selectively, partially hydrogenated butadiene polymer as claimed in claim 1, wherein the butadiene polymer being partially hydrogenated comprises: (1) a bound styrene content [S] of 0 to 30% by weight; (2) a vinyl linkage content [V] of 5 to 60% by weight at the butadiene portion; (3) a weight average molecular weight (Mw) of 50,000 to 800,000; and (4) a molecular weight distribution (Mw/Mn) of 1.5 to 3.0. The selectively, partially hydrogenated butadiene polymer as claimed in claim 1, wherein the butadiene polymer being hydrogenated is a butadiene homopolymer, or a styrene-butadiene copolymer having a styrene content of 30% by weight or less, said styrene being bound at random. A rubber composition suitable for use in tire manufacture comprising 100 parts by weight of a starting material rubber containing at least 30% by weight of the selectively partially hydrogenated butadiene polymer of claim 1, 10 to 150 parts by weight of carbon black, and 0.1 to 10 parts of a vulcanizing agent. The rubber composition as claimed in claim 5, wherein the hydrogenation ratio [A] of the selectively, partially hydrogenated butadiene polymer is 3 to 60% and hydrogenation ratio [B] of the selectively, partially hydrogenated butadiene polymer is 30% or more. The rubber composition as claimed in claim 5, containing the selectively partially hydrogenated butadiene polymer of claim 3. Claims for the following Contracting State : ES Process for preparing a selectively partially hydrogenated butadiene polymer by selectively, partially hydrogenating a butadiene polymer comprising: (1) a bound styrene content [S] of 0 to 40% by weight, said styrene being bound at random; (2) a vinyl linkage content [V] of 1 to 80% at the butadiene portion; (3) a weight average molecular weight (Mw) of 10,000 to 1,000,000; and (4) a molecular weight distribution (Mw/Mn) of 1.2 to 5.0; wherein the selectively, partially hydrogenated butadiene polymer is obtained from said butadiene polymer by selective partial hydrogenation in the presence of a catalyst under a partial hydrogen pressure of 9.8 bar or less within a temperature range of from 0 to 100 °C, the obtained polymer having (5) a hydrogenation ratio [A] of 3 to 85% of the total butadiene portion; and (6) a hydrogenation ratio [B] of 20% or more at the vinyl linkage moiety of the butadiene portion; said [A], [B], [S] and [V] satisfying the relationships of: (7) [A]/([S] + [V]) 1/2 which is 2 to 8; and (8) [B]·[V] 1/2 /[A] which is 10 to 16. Process for preparing the selectively partially hydrogenated butdiene polymer as claimed in claim 1, wherein the hydrogenation ratio [A] is 3 to 60% and the hydrogenation ratio [B] is of 30% or more. Process for preparing the selectively, partially hydrogenated butadiene polymer as claimed in claim 1, wherein the butadiene polymer being partially hydrogenated comprises: (1) a bound styrene content [S] of 0 to 30% by weight; (2) a vinyl linkage content [V] of 5 to 60% by weight at the butadiene portion; (3) a weight average molecular weight (Mw) of 50,000 to 800,000; and (4) a molecular weight distribution (Mw/Mn) of 1.5 to 3.0. Process for preparing the selectively partially hydrogenated butadiene polymer as claimed in claim 1, wherein the butadiene polymer being hydrogenated is a butadiene homopolymer, or a styrene-butadiene copolymer having a styrene content of 30% by weight or less, said styrene being bound at random. A rubber composition suitable for use in tire manufacture comprising 100 parts by weight of a starting material rubber containing at least 30% by weight of the selectively partially hydrogenated butadiene polymer prepared by the process of one of claims 1 to 4, 10 to 150 parts by weight of carbon black, and 0.1 to 10 parts of a vulcanizing agent. The rubber composition as claimed in claim 5, wherein the hydrogenation ratio [A] of the selectively, partially hydrogenated butadiene polymer is 3 to 60% and hydrogenation ratio [B] of the selectively, partially hydrogenated butadiene polymer is 30% or more. Process for preparing a rubber composition suitable for use in tire manufacture, wherein 100 parts by weight of a starting material rubber containing at least 30% by weight of the selectively partially hydrogenated butadiene polymer prepared by the process of one of claims 1 to 4 are intimately mixed with 10 to 150 parts by weight of carbon black and 0.1 to 10 parts by weight of a vulcanization agent.

Inventors: HATTORI YASUO, KITAGAWA YUICHI, HATTORI, YASUO, KITAGAWA, YUICHI
Applicants: ASAHI CHEMICAL IND, ASAHI KASEI KOGYO KABUSHIKI KAISHA
Application year: 1988
Main classification: C08C19
IPC codes: C08C19