IMPROVED RUBBER COMPOUND FOR TRACKED VEHICLE TRACK PADS

Abstract: A highly improved elastomeric-composition, process, and articles made thereof, wherein the novel composition is characterized by greatly increased wear longevity, thermomechanical stability, highly improved tear and tensile strength at high temperature useage, in addition to high resistance to burning in open flame, as well as high resistance to cutting, chipping, cracking and crack propagation particularly in product use for tank track pads and other related track system elastomeric component products; wherein the improved composition is a unique combination of its respective polymer, filler, curing and antidegradant systems, in which the polymer system either consists of about 100 parts by weight of highly saturated nitrile polymer or of various novel blends of the highly saturated nitrile usually in majority amounts together with minority amounts of carboxylated nitrile, with or without additional minority or near equal parts of nitrile rubber; and wherein the curing system may include various blends of from between about 1.5 to about 30 parts by weight of a metallic oxide, along with from between about 25 to about 50 parts by weight of a metallic methyl-methacrylate resin, together with from about 0.25 to about 3 parts by weight of a curative compound; which composition is further well suited for manufacture of various abutment and motion stop or limit members subjectable to repetitive engagement by moving mechanisms, and for various at least semi-flexible baffle or skirt-like members useable with various air cushion type vehicles or the like.

Description: This invention generally relates to an improved rubber compound, and more specifically relates to the improvement of the elastomeric components for tread pads of tracked vehicles, especially endless track military vehicles. Track laying vehicles wherein a continuous track is constantly layed down in the direction of movement of the associated vehicle are well known. Examples of such track laying devices are the military tanks and personnel carriers. Such devices have an endless track with a plurality of linked metal track shoes. These military tracked vehicles and other commercial type tracked vehicles are frequently equipped with rubber track pads, rubber blocks or endless-band rubber track to reduce shock, noise, wear and damage to road surfaces. These endless tracks render the vehicles operational in rough, uneven terrain when necessary under military manoeuvres. The vehicles, however, also travel over roads and hard surfaces and therefore the elastomeric components of the endless tracks should be of the type that wears well under abrasive rough terrain conditions. One example of a suitable track laying structure is disclosed in U.S. Pat. No. 3,078,128 issued Feb. 19, 1963 to the United States of America. Examples of previous tank tread pads and related compositions are well defined in various other prior U.S. patents such as No. 3,781,067; No. 4,279,448; No. 4,587,280; No. 4,461,516; and No. 4,470,641. Historically, field performance of these elastomeric track pad components has been poor, especially for the medium to heavy tonnage tracked vehicles, 40-60 Tonnes (Tons). The service life of these tank pads is affected not only by the terrain and environmental conditions but also by the speed, cornering, braking, weight of the vehicle, and the track tread design. While the operational life of the metal components is approximately 8000km (5000 miles) for vehicles of the 55 Tonne (Ton) weight class, the average life of the rubber pads is seldom more than 2400km (1500 miles under the best circumstances, and is usually less than 800km (500 miles) under the severest conditions. The elastomeric components of an endless track are affected in several ways depending upon service. Directly, it can cause cuts, tears, chunking, blow-outs and abrasive wear. Indirectly, it causes damage through hysteretic heating, environment convection and surface/terrain heating. Those skilled in the art are aware of the types of failures on rubber tank track pads, roadwheels and rubber blocks requiring frequent and costly replacement of the elastomeric components. Track pads for shoes presently are made from styrene-butadiene rubber (SBR). The widespread use of SBR in track pad applications appears to be based on cost, historical precedent and the fact that at times the United States Government has required that the materials used in their devices be available from sources within the United States to insure a continued supply. These factors in many ways are detrimental to the policy of continuing to use natural rubber for track pads and some shoe components, particulary since natural rubber is not available within the United States. Therefore, it is of the utmost importance to develop and use improved synthetic rubbers to improve the performance of tank track pads and shoes. To improve field or service performance of tank pads, one must first identify those properties that are most needed and then optimize these. This is by no means a trivial task. Those skilled in the art would agree that to improve performance of pads and shoes, properties such as cutting and chipping resistance, tear and tensile strength, crack growth resistance, abrasion resistance, hysteresis and thermomechanical stability all have to be improved. The primary object of the present invention is to overcome the aforementioned problems associated with prior track pads by providing an improved elastomeric composition which is particularly adaptable for fabricating track pads having improved resistance to cuts, tears, chunking, blowouts and abrasive wear. A further object of the present invention is to provide such a novel elastomeric composition of matter having many uses including for other related products such as road wheels, bushing members, gun abutment stops useful for association with tank track systems and other military armament/equipment. Other objects and advantages of this invention will become more apparent from the following detailed description, with the novel features, arrangements and combinations being clearly pointed out in the specification as well as in the appended claims. In accordance with the present invention, it has been found unexpectedly that the above objects and advantages are accomplished by our novel track pad composition by our novel selective use of polymers, fillers, the curing system and the proper processing thereof from which to make pads, shoes, bushings, solid rubber roadwheel surfaces and other items having greatly improved service life, as summarized in the following. Accordingly, in a first aspect, the present invention provides a vulcanizable elastomeric composition comprising a combination of respective polymer, filler, curing, and antidegradant systems, wherein (A) said polymer system is selected from a group including (a) about 100 parts by weight of highly saturated nitrile polymer; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of highly saturated nitrile polymer, and of from about 1 to a maximum of 5 parts of carboxylated polymer, and of from 5 to 50 parts of nitrile rubber; and (B) said curing system comprises (a) from 1.5 to 30 parts by weight of a metallic oxide; selected from a group including at least zinc oxide and magnesium oxide; (b) from 25 to 50 parts by weight of a metallic methyl-methacrylate resin selected from a group including at least a zinc methyl-methyacrylate resin and a zinc dimethyl-methyacrylate resin; (c) a curative compound of from .25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals. It is to be understood that for the purpose of this invention, the term "vulcanize" is used in its broadest sense to include all means of cross-linking rubbery polymers both with and without the use of elemental sulfur. The improved composition tank pads should include at least one surface portion, preferably the portion which contacts the ground, made of an elastomeric material comprised of a combination of polymer, filler, curing and antidegradant systems in accordance with the first aspect of the invention. Thus, the polymer system may comprise a pure or a blend polymer system as aforesaid. The highly saturated nitrile polymers in the polymer system, preferably, have a degree of unsaturation ranging between 1% and 20%. The filler system may comprise from 15 to 25 parts of a highly reinforcing small particle carbon black such as any of those designated as N-110, N-121, N-220, or N-330 by ASTM D-1765; or it may alternatively comprise a medium processed channel black. The curing system relates to or embodies the ingredients which will be activated to achieve the cross-linking of the polymer chain in the compound and the antidegradant system, preferably, is comprised of at least one antioxidant which among others may comprise from 0.25 to 2 parts of a polymerized 1,2-dihydro-2,2,4-trimethyl-quinoline (TMQ). It is to be understood that for each of the foregoing four systems, that the stated parts are to be by weight per 100 parts of the selected polymer system. In a second aspect the present invention provides a process for preparation of a vulcanizable elastomeric composition comprising blending a mixture of A. about 100 parts by weight of highly saturated nitrile polymer; B. from 15 to 25 parts by weight of a highly reinforcing filler, C. a curative mixture comprising (a) from 1.5 to 30 parts by weight of a metallic oxide selected from a group including at least zinc oxide and magnesium oxide; (b) from 25 to 50 parts by weight of a metallic methy-methacrylate resin selected from a group including at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from 0.25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals; and D. an antidegradant mixture comprising from 0.25 to 2 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamine (PPD), and (c) hindered bisphenols. In a third aspect the invention provides a process for making a compression-molded track pad product which product includes an assembly with metal-mounting plates in combination with the vulcanizate obtained from a composition in accordance with the first aspect of the invention, said process including the steps of: A. making a predetermined size preform block of the vulcanizable composition; B. coating the metal mounting plates with a suitable heat-activated adhesive; C. preheating said preform block to about 82°C (180°F); D. preheating said metal mounting plates also to about 82°C (180°F); E. assembling said mounting plates and said preform into a mold which has been preheated to about 165°C (330°F)., which corresponds to a preset temperature of a compression press; F. closing said mold and said compression press, while maintaining the press temperature of about 177°C (350°F).; G. simultaneously maintaining a minimum pressure of about 13.8bar (200 p.s.i.) within said mold for a period of about 80 minutes; and H. thereafter removing said product from said press and compression mold. In a further aspect the present invention provides a vulcanizate product made by heating and compression molding a composition in accordance with the first aspect of the invention via the use of applicable molds and requisite related product inserts to which the vulcanizate is bonded, said vulcanizate product being of a predetermined size and shape to constitute a particular elastomeric component family member of a group of elastomeric family component members including track pads, road wheels, and bushing members all useable in conjunction with a tank track system. In a final aspect the invention provides a vulcanizable product member formed according to a process in accordance with the second aspect of the invention for which said product member may constitute any one of various elastomeric-containing family component members of various selected, respective family groups embodying (a) tank track components including at least track pads, road wheels, and related bushing members all useable with tank track systems; (b) various elastomeric abutment and stop or limit members repetitively engageable by moving mechanisms; and (c) various at least semi-flexible baffle and skirt family members useable with various air cushion type vehicles; said product member formation utilizing known compression molding equipment and subassembly procedures in conjunction with associated bondable metallic and non-metallic product components, and wherein for at least certain family members said elastomeric composition is suitable preformed as by extruding and shaping into predetermined size blocks which thereafter are respectively preheated and assembled with the respective associatable bondable product components, such as pad-mounting plates, wheel hub members and bushing sleeves, into a requisite shaped preheated mold, and wherein the vulcanizate end product is formed by requisite heating and compression molding procedures. The rubbery or elastomeric composition of the present invention can be prepared and compounded using any of the conventional compounding and mixing techniques using conventional rubber processing equipment such as a Banbury mixer or mixing mill. The unvulcanized rubbery composition is then pre-formed through a rubber extruder and larger amounts or thicknesses are pre-heated before assembling it with any applicable metal insert sub-assembly component or plate member together with a suitable heat-activatable adhesive which are then placed into a mold for the particular configuration article such as a tank track pad, bushing, shoe and/or solid tire or other product. A vulcanization temperature of at least 320 degrees Fahrenheit should be used to fully activate the peroxide curing system when making our highly improved tank track pads. Premature partial vulcanization must be avoided from the normal or inherent heat generated during the use of the mixing equipment. Therefore, mixing apparatus of a type provided with cooling means is preferably utilized. The track pads after vulcanization are of improved construction with the rubbery composition exhibiting a relatively high abrasion resistance, high cutting and chipping resistance, high tear and tensile strength at high temperature, decreased hysteresis, high resistance to fire and to cracking or crack propagation, and shows good product uniformity and good thermo-mechanical stability, with supporting test results being described in the following detailed description. Preferred embodiments of the invention are described in the dependent sub-claims 2-12 (2-10), 14-23 (12-21), 27 (25) and 28 (26). The numbers in parenthesis identify the claims for contracting states DE, FR and GB. FIG. 1, 2 and 3 are a transverse cross-sectional views through various types of exemplary track shoes or pads made of our new composition; FIGS. 4 and 5 are top plan and cross-sectional views respectively for an M-60 form of track shoe utilizing our new composition and process; FIG. 6 is a diagrammatic fragmentary elevational view showing a large bore gun which utilizes a shock absorbing abutment which is comprised of our improved composition; FIG. 7 is a diagrammatic side view of an air cushion type of vehicle which can utilize flexible skirts made of our new composition. Referring in greater detail to FIG. 1, there is shown one illustrative form of a track shoe 10 of generally conventional overall design. This particular shoe includes three circular metal tubes 12, 14, and 16 extending between two metal end plates, not readily visible in the drawings. Each end plate has an upper flat edge 22, a lower flat edge 22 and two circular end edges 20. In practice, each track section comprises two track shoes 10 arranged in side-by-side relation, as shown for example in U.S. Pat. No. 4,165,906 to J.O. Fix. Non-illustrated connector pins and elastomeric bushings extend through tubes 12 and 16 into connector links to interconnect the track sections to adjacent track sections. The various track shoes 10 making up a complete endless track are structurally identical. These Figures 1 and 2 and much of their description are copied from U.S. Patent 4,461,516. In the illustrated track shoe the space between the two end plates is occupied by a resilient elastomeric pad 24 having a terrain-engagement surface 26. Upper surface 28 of the elastomeric pad is engaged by a non-illustrated road wheel carried on a swingable suspension road arm in conventional fashion. Our improved composition is particularly useful for making very substantively improved track pads of various forms and shapes. FIG. 2 illustrates a second type of track shoe with a pad 36 of our improved composition. The shoe comprises a metal casing 32 that includes a web 34 and two tubes 12 and 16 adapted to receive non-illustrated connector pins. The elastomeric pad 36 is removably received in a cavity on the lower face of web wall 34 between the tube outer surfaces. Retention of the improved pad 36 in the cavity is accomplished by a screw or stud 38 extending from a backing plate 46 into a nut 40. The upper surface of web wall 34 has a elastomeric member 42 molded thereon to provide a flat runway surface 44 for non-illustrated road wheel. The improved composition tank pads should include at least one surface portion, preferably the portion which contacts the ground, made of our improved elastomeric material comprised of a unique combination of a polymer system, a filler system, a curing system, and an antidegradant system. The polymer system may comprise a pure or a blend polymer system such as: (A) 100 parts of highly saturated nitrile polymer, or alternatively (B) a blend of from 80 parts to 90 parts of highly saturated nitrile, and from 10 parts to 20 parts of carboxylated nitrile; or still further alternatively (C) a blend of from 45 parts to 90 parts of highly saturated nitrile, and from 1 to a maximum of 5 parts of carboxylated nitrile, and from 5 to 50 parts of nitrile rubber. The filler system may comprise from 15 to 25 parts of a highly reinforcing small particle carbon black such as any of those designated as N-110, N-121, N-220, or N-330 by ASTM D-1765; or alternatively and preferably may comprise medium processed channel black. The carbon black filler system may also be blended to include parts of silica materials such as from 1 to 15 parts of fumed silica which silica contributes to the overall 15-25 parts by weight of the highly reinforcing filler material. The total filler system should not exceed the aforestated maximum of 25 parts by weight of 100 parts. The curing system herein relates to or embodies the ingredients which will be activated to achieve the cross-linking of the polymer chain in the compound. The curing system preferably includes from 1.5 to 30 parts of a metallic oxide such as zinc oxide or magnesium oxide; and further from 25 to 50 parts by weight of a metallic methyl-methacrylate resin which may be selected from a group including a least zinc methyl-methacrylate resin and zinc dimethyl-methacrylate resin; and still further includes a curative compound of from 0.25 parts to 3 parts by weight selected from a group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide, (iii) sulfur, and (iv) various sulfur donor chemicals. It is to be noted that any use of sulfur donor chemicals will depend upon the degree of saturation or unsaturation of the highly saturated nitrile. For example, when the formulation of claim 1 hereinafter includes highly saturated nitrile having degrees of unsaturation of approximately 5%, or of approximately only 2.5%, respectively, a curative compound may include one of various sulfur donor compounds. Two preferred examples thereof include (i) N- cyclo-hexyl-2- benzothiazole sulfenamide, and (ii) tetra-methyl-thiuram disulfide. The antidegradant system is comprised of from 0.25 to 2.0 parts by weight of at least one antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamines (PPD), and (c) hindered bisphenols. One preferred antioxidant will consist of from 0.25 to 2.0 parts by weight of polymerized 1,2, dihydro- 2,2,4-trimethylquinoline (TMQ). Another may comprise a substituted para-phenylenediamine (PPD) which is N-Isopropylphenyl - p - phenylene-diamine. A nitrile rubber may be defined as a straight chain copolymer of a diene and an unsaturated nitrile, the more common being the copolymer of butadiene and acrylonitrile. The majority of nitrile rubbers which are available today are made by copolymerizing these two monomers. Nitrile rubber is available in several standard grades of oil resistance based on the acrylonitrile content of the polymer ranging from 18 to 50%, with 34% being a common typical figure for a general purpose grade. Generally, the grades are referred as to very high, high, medium high, medium, medium low, and low acrylonitrile content. The following is a chemical representation of each of the two monomers separately, and of the resulting copolymer, nitrile rubber (NBR). The very high and high acrylonitrile polymers are used where the utmost in oil resistance, aromatic fuels, and solvent resistance is required. The medium grades are used in applications where greater swelling of the rubber is tolerable. The low and medium low acrylonitriles are used where low temperature flexibility is of greater importance. However the polymer used in this subject invention application rubber formulation is a highly hydrogenated nitrile copolymer with slight double bonds. Highly saturated nitrile rubbers, HSN, are presently produced by the selective and controlled hydrogenation of nitrile rubber, NBR. Examples of such copolymers are disclosed in U.S. Patent 4,337,327; 4,384,081; 4,464,515; 4,503,196; and German Patents 2,539,132 and 2,913,992. At least three companies are known to produce highly saturated nitrile copolymers useful in the practice of this invention and having with various degrees of hydrogenation. Mobay Corporation in Pittsburg, Pa. 15205-9741, produces at least two grades of HSN's under the commercial name of "THERBAN". Polysar Ltd. in Akron, Ohio, 44313, produces at least three grades of HSN's under the trade name of "TORNAC". Nippon Zeon Co., Ltd. in New York City, 10017, produces at least three grades of HSN's under the trade name of "ZETPOL". Grades determined by degree of unsaturation of the HSN, typically 5%, 2.5%, and 1%, respectively. A carboxylated nitrile copolymer, XNBR, is the resulting polymer from the modification of a nitrile copolymer, NBR, to include carboxylic groups in the copolymer chain. This type of polymer contains in addition to acrylonitrile and butadiene, one or more acrylic-type acids as part of the comonomer system. The polymerization of these monomers produces a chain similar to a normal nitrile rubber except for the carboxyl groups which are distributed along the chain with a frequency of about 1 to every 100 to 200 carbon atoms. This type of polymer is unique in that it can be vulcanized by reactions of the carboxylic group as well as conventional sulfur-type vulcanization. This polymer has been used in a blend with HSN's in the rubber formulation subject of this invention because the carboxy modification exhibits much higher tensile strength and modulus, lower elongation, higher hardness, much improved hot tear and tensile strength, better low-temperature brittleness, improved ozone resistance, and better retention of properties after air aging at high temperatures, all important properties for tank pad performance. Carboxylated nitriles, XNBR, suitable for the practice of the invention are produced by most nitrile rubber, NBR, manufacturers. B.F. Goodrich Co. produces XNBR'S under the commercial trade name of "HYCAR" while the Goodyear Co. produces XNBR'S under the name of "CHEMIGUM". Both companies; have business locations in Akron, Ohio. Up to 50% of total nitrile component of the inventive composition can be of a standard grade of nitrile copolymer, i.e., not highly saturated nitrile, without significant degradation of performance as a track pad material. This can significantly reduce the cost of the pad. Recommended quantities are from 5 parts to 50 parts standard nitrile rubber per 100 parts total nitrile copolymer in the inventive composition. One preferred and fully tested composition contains 100 parts of HSN as the polymer system. The following example is a representative comparison of our newly developed composition versus commercially procured pads which were field tested on a military M-60 tank and on a much heavier experimental military vehicle known as a Counter Obstacle Vehicle (COY). The tests for the COY were conducted at the Ft. Belvoir, Virginia Engineering Proving Grounds, more particularly to measure for thermal buildup, abrasion resistance, adhesion resistance, chunking and chipping, and all terrain mobility. The M-60 tank tests were conducted at the Yuma, Arizona Proving Grounds and more particularly directed to operation on paved roads, hilly cross-country terrain, and various overall terrain combination tests. EXAMPLE A rubbery composition was prepared and compounded according to the present invention by mixing in a basically conventional manner 100.0 parts of highly saturated nitrile polymer (HSN), 2.0 parts zinc oxide, 0.5 parts 1,2-dihydro-2,2,4-trimethylquinoline (TMQ), 20.0 parts carbon black, 30.0 parts zinc methyl-methacrylate resin, and 1.3 parts dicumyl peroxide. The unvulcanized rubbery composition was then preformed through a rubber extruder, preheated to 82°C (180°F), placed in the desired mold, and vulcanised at about 165°C (330°F) for 80 minutes. The HSN Polymer was obtained commercially from Goldsmith Eggleton, Akron, Ohio with the trade name "ZETPOL 2020". The TMQ antioxidant was obtained commercially from R.T. Vanderbilt in Norwalk, CT. with the name "AGERITE RESIN D". The carbon black was obtained commercially from Summit Chemical Co. under a trade name known as "MPC BLACK". The zinc methyl-methacrylate resin was obtained commercially from Yardley Ball Corp. in Yardly, Pa. with the trade name "Z-MAX MA". The dicumyl peroxide curative was obtained commercially from the Hercules Co. in Akron, Ohio, with the trade name "DI CUP R". In order to form the sample test track pads, the extruded preheated rubber was assembled with applicable metal inserts and a heat-activated adhesive into a mold where vulcanization was carried out in a heated press. The physical properties of the resulting new pads were measured and are presented and are compared in Table 1 below to those of standard commercial pads as tested. The track pads designated STD. T-107 and STD T-142 tested were standard stock pads for the Army's experimental Counter Obstacle Vehicle (COV), and the M-60 tank respectively, made from styrene-butadiene rubber (SBR) and are of the type presently employed on military tracked vehicles. The specific formulation of the standard pads is proprietary to the manufacturer and not known by the inventors, but it can be characterized as a common type of styrene-butadiene vulcanizate. The above tests were carried out according to accepted Industry Standards as listed in Tables 2 below: Some of the more important properties for track pad applications are: 1. Cutting and chipping resistance. 2. Tear strength, (ambient and high temperature). 3. Crack growth resistance, (ambient and high temperature). 4. Fatigue life under compressive stresses. 5. Low heat build-up and high abrasion resistance. The statistics set forth hereinabove in Table 1 show the superiority in the properties of our improved elastomeric compound over that use in the standard production pads. Data depicted in Table 1 is the result of tests conducted in the laboratory from molded T-107 and T-142 tank pads, COV and M-60 respectively. The geometry of both type of pads is different. Therefore, curing characteristics and polymer flow patterns during vulcanization may produce small differences in the physical properties between the two types of pads. Analysis of the data depicted in Tables 1 and 2 show that the tensile strength of our improved elastomeric compound is 32% higher as used the T-107 pads and 40% higher for the T-142 pads. The retention of tensile strength after heat aging was 100% for the T-107's and T-142's. The standard production pads retained only 45% of the tensile strength for the T-107's and 57% for the T-142 pads. The rebound and elongation was about the same for our improved pad as for standard compound. The hardness of the improved material is 22% higher for our improved composition in the T-107 pads and 13% higher for the T-142 pads. The increase in hardness produced a 95% improvement in the load bearing capabilities of our improved composition pads. Another significant improvement was achieved on tear resistance with a 69% improvement for our improved composition in the T-107s and 45% for T-142's at ambient temperature. Tear strength at high temperature produced improvement of 54% for our improved T-107 pads and double the tear resistance for our improved T-142 pads. Abrasion resistance is a very important property and was measured by two methods, Taber abrasion and Pico index, respectively. Both test methods indicated an improvement of 24 times better on Taber and 9 times better on Pico for our improved composition T-142 pads while for our improved T-107 pads the Taber was 20 times better but the Pico indicated a 12.5% decrease. The observed mode of failure for tank pads during crosscountry operations is chunking and chipping. This property was measured with the B.F. Goodrich Cutting and Chipping machine and both diameter and weight loss of the specimens were recorded. Test results for diameter and weight loss were in excellent agreement producing the same degree of improvement for both types of our improved composition test pads. Our improved composition pads exhibited a 76% improvement for T-107 pads and 34% better for the T-142's. The improved elastomeric tank pads exhibited a higher internal temperature when tested for heat build-up as well as during field testing. However, the unique combination of the highly saturated nitrile rubber and zinc-methylmethacrylate with the peroxide cure, produces an unparalleled heat resistance that prevents premature failure. Crack growth resistance relates to the ability of a rubber compound to deter crack propagation once the rubber has been cut as happens during cross-country operations. Crack propagation deteriorates into tear and eventually chunking and chipping. Crack growth was measured using a Ross tester. Specimens were tested at ambient temperature and after being heat aged at 121°C (250°F). In addition the resistance to crack initiation was measured. Resistance to crack growth was 400% better at ambient temperatures for both our improved composition T-107 and T-142 elastomeric pads. At high temperature the crack growth resistance of our T-107's was improved 22 times while for the T-142's it was improved 36 times over the standard production compounds. Two performance test programs were carried out using appropriately formed tank pads to compare the performance of pads of the standard styrene-butadiene composition to the inventive nitrile rubber composition on actual tracked vehicles. Two types of vehicles were employed to carry out the field tests, a Counter-Obstacle-Vehicle (COV) which is an engineering type tracked vehicle, weighing about 72 tonnes (tons), and an M-60 battle tank weighing about 40 tonnes (tons). The testing of the COV pads, (T-107's) was performed over a severe course designed to combine all possible operational and terrain factors deemed relevant for the application. The test plan for the M-60 field test was designed to include three phases consisting of a (2000 mile) 3200km paved surface course, (900 mile) 1440km hilly cross-country course and a (1000 mile) 1600km combination course. All these tests were successfully completed by tank pads made from our improved composition which is the subject of this invention. Complete results of the COV T-107 track pad field test and results from field test on the T-142 tank pads from the M-60 tank confirm that a distinct technological breakthrough in tracked vehicle pad performance has been achieved. The COV was initially tested for a total of (1600 miles) 2560km including portions in hard track and all type terrain. The wear of the pads with our new rubber formulation was significantly less than the conventional rubber used for tank pads. Additional tests have confirmed the greatly improved performance beyond (3000 miles) 4800km with still no indication of failure, although some abrasive wear is evident. Projected results indicate that the pads with the new formulation will have a service life in excess of about 3500 miles while the standard production pads exhibit an average service life of (1200 miles) 1920km under similar testing conditions. During the paved course portion of the M-60 field test, standard production pads failed on the average of (1200 miles) 1920km. The pads with our disclosed improved rubber formulation were tested for (2000 miles) 3200km, the maximum duration allocated in the test plan for the paved course. At the end of the test the limited wear of the new formulation pads indicated a projected service life of (3,400 miles) 5440km, a service level never before achieved by any conventional rubber pad. Subsequent actual field tests have proven continued good useful life at over (3000 miles) 4800km on the same paved course. The above results show the superior service life of our improved elastomeric compound over that used in the standard pads. The service life of our improved composition pads on paved road is three times better than the standard pads. In the more severe cross-country operations the improved pads exhibit a service life of 2.5 longer than the standard pads. It should be pointed out that there is the significant difference in weight between the M-60 and the COV; the M-60 weighs approximately 45 Tonnes (Tons) as opposed to the 72 tonnes (Tons) for COV. This weight difference by itself can account for the difference in pad performance between the two vehicles but the fact remains that for either vehicle our improved formulation exhibits up to more than double the service life of a standard production tank pad. It is to be understood that because the highly saturated nitrile exhibited distinguishing characteristics of inherent ozone, heat and weather resistance which precluded deterioration both in the field and in storage, there was no need to include a separate antiozonant for precluding ozone attack. To add such an ingredient would be a wasteful, useless exercise. Additionally, the improved rubber formulation exhibited self extinguishing characteristics when subjected to an open flame. It also exhibits resistance to chemical warfare agent decontaminants. Exhibiting a tensile strength retention over 90% after immersion in a DS-2 fluid for 24 hours. DS-2 is a U.S. Army general purpose decontaminant fluid for chemical warfare agents. From the foregoing detailed description, it is apparent that a greatly improved elastomeric composition has been developed which achieves all the objects and has the advantages set forth hereinabove. While some specific test examples have been described more particularly for tank track pad applications, it is to be understood that other variations in the composition, and other potential uses such as abutments or stops for large bore guns, and flexible elastomeric skirts for air cushion type vehicles, are contemplated to be within the spirit of the invention. Accordingly, reference should be made to the appended claims for the governing scope hereof inasmuch as those skilled in the art may make various changes and modifications and other uses without departing from the spirit and scope of this invention.

Claims: Claims for the following Contracting States : DE, FR, GB A vulcanizable elastomeric composition comprising a unique combination of respective polymer, filler, curing, and antidegradant systems, wherein: A. said polymer system is selected from a group including (a) about 100 parts by weight of highly saturated nitrile polymer; (b) a blend of from 80 to 90 parts by weight of said highly saturated nitrile polymer and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of said highly saturated nitrile polymer, and of from 1 to a maximum of 5 parts of carboxylated polymer, and of from 5 to 50 parts of nitrile rubber; and B. said curing system comprises (a) from 1.5 to 30 parts by weight of a metallic oxide selected from a group including at least zinc oxide and magnesium oxide; (b) from 25 to 50 parts by weight of a metallic methyl-methacrylate resin selected from a group consisting of at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from .25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals; C. said filler system comprises from 15 to 25 parts by weight of a highly reinforcing filler material, said filler material being selectable from the group including (a) medium processed channel black; and (b) carbon black particles of the type selected from a subgroup including N-110, N-121, N-220, and N-330 as designated by ASTM D-1765. The composition of claim 1, wherein said antidegradant system comprises from 0.25 to 2.0 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamines (PPD's), and (c) hindered bisphenols. A vulcanizable elastomeric composition including a combination of respective polymer, filler, curing, and antidegradant systems, comprising: A. said polymer system is selected from a group including (a) about 100 parts by weight of highly saturated nitrile polymer; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of highly saturated nitrile polymer, of from 1 to a maximum of 5 parts of carboxylated nitrile polymer, and of from 5 to 50 parts of nitrile rubber; B. said filler system comprising from 15 to 25 parts by weight of a highly reinforcing filler material; C. said curing system comprising (a) from 1.5 to 30 parts by weight of a metallic oxide selected from a group including at least zinc oxide and magnesium oxide; (b) from 25 to 50 parts by weight of a metallic methyl-methacrylate resin selected from a group consisting of at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from .25 parts to 3 parts selected from the group consisting of: (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals; and D. said antidegradant system comprises from 0.25 to 2.0 parts by weight of an antioxidant selected from the group consisting of antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamines (PPD's), and (c) hindered bisphenols. The composition of claim 1, wherein said filler system is modified to include a blend of said carbon black particles together with from 1 to 15 parts of fumed silica contributing to said overall 15-25 parts by weight of said highly reinforcing filler. The composition of claim 2, wherein said antidegradant system consists of from 0.25 to 2 parts by weight of polymerized 1,2 dihydro-2,2,4 trimethyl-quinoline antioxidant (TMQ). The composition of claim 2, wherein said antidegradant system consists of from 0.25 parts to 2 parts by weight of a substituted paraphenylenediamine (PPD). The composition of claim 2, wherein said antidegradant system comprises a substituted para-phenylenediamine (PPD) which is N-isopropyl phenyl-p-phenylenediamine. The composition of any of claims 1, 2 or 3 in which said highly saturated nitrile polymer in paragraph A has a degree of unsaturation ranging between 2.5% and 5%; and wherein said curative compound consists of a tetra-methylthiuram disulfide. The composition of any of claims 1, 2 or 3 which includes highly saturated nitrile rubber, having a degree of unsaturation ranging between 1% to 20%, and in which said curative compound consists of dicumyl peroxide. A vulcanizable elastomeric composition, as claimed in claim 1, wherein said polymer system consists of about 100 parts by weight of a highly saturated nitrile polymer. A process for preparation of a vulcanizable elastomeric composition comprising blending a mixture of A. about 100 parts by weight of highly saturated nitrile polymer; B. from 15 to 25 parts by weight of a highly reinforcing filler, C. a curative mixture comprising (a) from 1.5 to 30 parts by weight of a metallic oxide selected from the group including at least zinc oxide and magnesium oxide (b) from 20 to 50 parts by weight of a metallic methyl-methacrylate resin selected from the group including at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from 0.25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals; and D. An antidegradant mixture comprising from 0.25 to 2 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamines (PPD), and (c) hindered bisphenols; and The process of claim 11, wherein the mixing of the polymer recited in A alternatively includes blending of from 80 parts to 90 parts of the highly saturated nitrile, with from 10 parts to 20 parts of a carboxylated nitrile. The process of claim 11, wherein the mixing of the polymer recited in A alternatively includes blending of from 45 parts to 90 parts of the highly saturated nitrile, with from 1 to a maximum of 5 parts of a carboxylated nitrile, and further with from 5 to 50 parts of a nitrile rubber. The process of claim 11, wherein the blending of the filler material in B includes selecting the stated amounts of filler from a group including (a) medium processed channel black; and (b) carbon black particles selected from a subgroup consisting of N-110, N-121, N-220, and N-330 as designated by ASTM D-1765. The process of claim 14, wherein the filler material is modified or further blended to include a blend of said carbon black particles together with from 1 to 15 parts of fumed silica contributing to said overall 15-25 parts by weight of said highly reinforcing material. The process of claim 11, wherein said antioxidant is polymerized 1,2 dihydro - 2,2,4 trimethylquinoline (TMQ) antioxidant (TMQ). The process of claim 11, wherein said antioxidant is para - phenylenediamine (PPD). The process of claim 11, wherein said antioxidant is known as N-Isopropyl phenyl-p-phenylene-diamine. The process of claim 11, wherein the mixing with the polymer recited in A includes using a polymer having a degree of unsaturation ranging between 2.5% and 5%; and further using a curative compound which consists of a sulfur donor N-cyclo-hexyl-2-benzothiazole sulfenamide. The process of claim 11, wherein the mixing with the polymer recited in A includes using a polymer having a degree of unsaturation ranging between 2.5% and 5%; and further using a curative compound which consists of tetra-methylthiuram disulfide. The process of any one of claims 11-20 in which the polymer material of A includes all grades of highly saturated nitrile; and in which the selected curative compound of C(c) of claim 11 is dicumyl peroxide. A process for making a compression-molded track pad product which product includes assembly with metal mounting plates in combination with the vulcanizate obtained from any of the compositions defined in claims 1-10, said process including the steps of: A. making a predetermined size preform block of the vulcanizable composition; B. coating the metal mounting plates with a suitable heat-activated adhesive; C. preheating said preform block to about 82°C (180°F); D. preheating said metal mounting plates also to about 82°C (180°F); E. assembling said mounting plates and said preform into a mold which has been preheated to about 165°C (330°F.), which corresponds to a preset temperature of a compression press; F. closing said mold and said compression press, while maintaining the press temperature of about 177°C (350°F.); G. simultaneously maintaining a minimum pressure of about 13.8bar (200 p.s.i.) within said mold for a period of about 80 minutes; and H. thereafter removing said product from said press and compression mold. A vulcanizate product made by heating and compression molding of the compositions defined in any of claims 1-10 via the use of applicable molds and requisite related product inserts to which the vulcanizate is bonded, said vulcanizate product being of a predetermined size and shape to constitute a particular elastomeric component family member of a group of elastomeric family component members including track pads, road wheels, and bushing members all useable in conjunction with a tank track system; A vulcanizable product member formed according to the process of any of claims 11-21, for which said product member may constitute any one of various elastomeric - containing family component members of various selected, respective family groups embodying (a) tank track components including at least track pads, road wheels, and related bushing members all useable with tank tract systems; (b) various elastomeric abutment and stop or limit members repetitively engageable by moving mechanisms; and (c) various at least semi-flexible baffle and skirt family members useable with various air cushion type vehicles; said product member formation utilizing known compression molding equipment and subassembly procedures in conjunction with associated bondable metallic and non-metallic product components, and wherein for at least certain family members said elastomeric composition is suitable preformed as by extruding and shaping into predetermined size blocks which thereafter are respectively preheated and assembled with the respective associatable bondable product components, such as pad-mounting plates, wheel hub members and bushing sleeves, into a requisite shaped preheated mold, and wherein the vulcanizate end product is formed by requisite heating and compression molding procedures. The composition of claim 1 wherein said polymer system is selected from the group consisting of: (a) about 100 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blending of from 45 to 90 parts of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 1 to a maximum of 5 parts of carboxylated nitrile polymer, and of from 5 to 50 parts of nitrile rubber. The process of claim 11, wherein said polymer system is selected from the group consisting of: (a) about 100 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blending of from 45 to 90 parts of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 1 to a maximum of 5 parts of carboxylated nitrile polymer, and of from 5 to 50 parts of nitrile rubber. Claims for the following Contracting States : AT, SE A vulcanizable elastomeric composition. comprising a combination of respective polymer, filler, curing, and antidegradant systems, wherein (A) said polymer system is selected from a group including (a) about 100 parts by weight of highly saturated nitrile polymer; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of highly saturated nitrile polymer, and of from 1 to a maximum of 5 parts of carboxylated polymer, and of from 5 to 50 parts of nitrile rubber; and (B) said curing system comprises (a) from 1.5 to 30 parts by weight of a metallic oxide; selected from a group including at least zinc oxide and magnesium oxide; (b) from 25 to 50 parts by weight of a metallic methyl-methacrylate resin selected from a group including at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from .25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals. The composition of claim 1, wherein said filler system comprises from 15 to 25 parts by weight of a highly reinforcing filler material. The composition of claim 2, wherein said filler system is selectable from a group including (a) medium processed channel black; and (b) carbon black particles of the type selected from a subgroup including N-110, N-121, N-220, and N-330 as designated by ASTM D-1765. The composition of claim 1, wherein said antidegradant system comprises from 0.25 to 2.0 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamine (PPD), and (c) hindered bisphenols. A vulcanizable elastomeric composition as claimed in claim 1, wherein said filler system comprises from 15 to 25 parts by weight of a highly reinforcing filler material; and said antidegradant system comprises from 0.25 to 2.0 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamine (PPD), and (c) hindered bisphenols. The composition of claim 3, wherein said filler system is modified to include a blend of said carbon black particles together with from 1 to 15 parts of fumed silica contributing to said overall 15-25 parts by weight of said highly reinforcing filler. The composition of claim 4, wherein said antidegradant system consists of from 0.25 to 2 parts by weight of polymerized 1,2 dihydro - 2,2,4 trimethyl - quinoline antioxidant (TMQ). The composition of claim 4, wherein said antidegradant system consists of from 0.25 parts to 2 parts by weight of a substituted paraphenylenediamine (PPD). The composition of claim 4, wherein said antidegradant system comprises a substituted paraphenylenediamine (PPD) which is N-Isopropyl phenyl-p-phenylene-diamine. The composition of any of claims 1, 2, 3, 4 and 5 in which said highly saturated nitrile polymer in paragraph A has a degree of unsaturation ranging between 2.5% and 5%; and wherein said curative compound consists of a tetra-methyl-thiuram disulfide. The composition of any of claims 1, 2, 3, 4 and 5 which includes highly saturated nitrile rubber having a degree of unsaturation ranging between 1% and 20%, and in which said curative compound consists of dicumyl peroxide. A vulcanizable elastomeric composition as claimed in claim 1, wherein said polymer system consists of about 100 parts by weight of a highly saturated nitrile polymer. A process for preparation of a vulcanizable elastomeric composition comprising blending a mixture of A. about 100 parts by weight of highly saturated nitrile polymer; B. from 15 to 25 parts by weight of a highly reinforcing filler, C. a curative mixture comprising (a) from 1.5 to 30 parts by weight of a metallic oxide selected from a group including at least zinc oxide and magnesium oxide (b) from 25 to 50 parts by weight of a metallic methy-methacrylate resin selected from a group including at least a zinc methyl-methacrylate resin and a zinc dimethyl-methacrylate resin; (c) a curative compound of from 0.25 parts to 3 parts selected from the group including (i) dicumyl peroxide, (ii) derivatives of dicumyl peroxide; (iii) sulfur, and (iv) sulfur donor chemicals; and D. An antidegradant mixture comprising from 0.25 to 2 parts by weight of an antioxidant selected from the group including at least the antioxidants from the respective families of (a) quinolines, (b) substituted para-phenylenediamine (PPD), and (c) hindered bisphenols. The process of claim 13, wherein the mixing of the polymer recited in A alternatively includes blending of from 80 parts to 90 parts of the highly saturated nitrile, with from 10 parts to 20 parts of a carboxylated nitrile. The process of claim 13, wherein the mixing of the polymer recited in A alternatively includes blending of from 45 parts to 90 parts of the highly saturated nitrile, with from 1 to a maximum of 5 parts of a carboyxlated nitrile, and further with from 5 to 50 parts of a nitrile rubber. The process of claim 13, wherein the blending of the filler material in B includes selecting the stated amounts of filler from a group including (a) medium processed channel black; and (b) carbon black particles of the type selected from a subgroup including N-110, N-121, N-220, and N-330 as designated by ASTM D-1765. The process of claim 16, wherein the filler material is modified or further blended to include a blend of said carbon black particles together with from 1 to 15 parts of funed silica contributing to said overall 15-25 parts by weight of said highly reinforcing material. The process of claim 13, wherein said antioxidant is polymerized 1,2 dihydro - 2,2,4 trimethylquinoline antioxidant (TMQ). The process of claim 13, wherein said antioxidant is para - phenylenediamine (PPD). The process of claim 13, wherein said antioxidant is known as N-Isopropyl phenyl-p-phenylenediamine. The process of claim 13, wherein the mixing with the polymer recited in A includes using a polymer having a degree of unsaturation ranging between 2.5% and 5%; and further using a curative compound which consists of a sulfur donor N-cyclo-hexyl-2-benzothiazole sulfenamide. The process of claim 13, wherein the mixing with the polymer recited in A includes using a polymer having a degree of unsaturation ranging between 2.5% and 5%; and further using a curative compound which consists of tetra-methyl-thiuram disulfide. The process of any of claims 13-22 in which the polymer material of A includes all grades of highly saturated nitrile; and in which the selected curative compound of C(c) of claim 13 is dicumyl peroxide. A process for making a compression-molded track pad product which product includes assembly with metal-mounting plates in combination with the vulcanizate obtained from any of the compositions defined in claims 1-12, said process including the steps of: A. making a predetermined size preform block of the vulcanizable composition; B. coating the metal mounting plates with a suitable heat-activated adhesive; C. preheating said preform block to about 82°C (180°F); D. preheating said metal mounting plates also to about (180°F) 82°C; E. assembling said mounting plates and said preform into a mold which has been preheated to about 165°C (330°F.), which corresponds to a preset temperature of a compression press; F. closing said mold and said compression press, while maintaining the press temperature of about 177°C (350°F.); G. simultaneously maintaining a minimum pressure of about 13.8bar (200 p.s.i.) within said mold for a period of about 80 minutes; and H. thereafter removing said product from said press and compression mold. A vulcanizate product made by heating and compression molding of the compositions defined in any of claims 1-12 via the use of applicable molds and requisite related product inserts to which the vulcanizate is bonded, said vulcanizate product being of a predetermined size and shape to constitute a particular elastomeric component family member of a group of elastomeric family component members including track pads, road wheels, and bushing members all useable in conjunction with a tank track system. A vulcanizable product member formed according to the process of any of claims 13-23, for which said product member may constitute any one of various elastomeric-containing family component members of various selected, respective family groups embodying (a) tank track components including at least track pads, road wheels, and related bushing members all useable with tank track systems; (b) various elastomeric abutment and stop or limit members repetitively engageable by moving mechanisms; and (c) various at least semi-flexible baffle and skirt family members useable with various air cushion type vehicles; said product member formation utilizing known compression molding equipment and subassembly procedures in conjunction with associated bondable metallic and non-metallic product components, and wherein for at least certain family members said elastomeric composition is suitable preformed as by extruding and shaping into predetermined size blocks which thereafter are respectively preheated and assembled with the respective associatable bondable product components, such as pad-mounting plates, wheel hub members and bushing sleeves, into a requisite shaped preheated mold, and wherein the vulcanizate end product is formed by requisite heating and compression molding procedures. The composition of Claim 1 wherein said polymer system is selected from the group consisting of: (a) about 100 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 1 to a maximum of 5 parts of carboxylated nitrile polymer, and of from 5 to 50 parts of nitrile rubber. The process of Claim 13 wherein said polymer system is selected from the group consisting of: (a) about 100 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%; (b) a blend of from 80 to 90 parts by weight of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, and of from 10 to 20 parts by weight of carboxylated nitrile; and (c) a blend of from 45 to 90 parts of highly saturated nitrile polymer having a degree of unsaturation ranging between 1% to 5%, of from 1 to a maximum of 5 parts of carboxylated nitrile polymer, and of from 5 to 50 parts of nitrile rubber.

Inventors: BUTLER, DANIEL PATRICK, CRAWFORD, DAWN MARIE, FEUER, HENRY OTTO, FLANAGAN, DAVID PAUL, GATZA, PAUL EDWARDS, RODRIGUEZ, GUMERSINDO JR., TEETS, ALAN ROY, TOUCHET, PAUL
Applicants: US ARMY, THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY, UNITED STATES DEPARTMENT OF COMMERCE
Application year: 1989
Main classification: C08L15
IPC codes: B62D55, C08K13, C08L15