Hydrosilylation crosslinking

Abstract: An improved process for the preparation of thermoplastic elastomers by hydrosilylation crosslinking, in which a very low amount of a platinum containing hydrosilylation catalyst is used in combination with specific diene containing rubbers. In another variant of the invention, the hydrosilylation is carried out in the presence of process oil which is substantially free of materials having the chemical behavior of a Lewis base. A crosslinked rubber component is obtained in the thermoplastic elastomer composition.

Description: Field of the Invention This invention relates to thermoplastic elastomer compositions prepared using hydrosilylation crosslinking of the elastomer component of the composition. A thermoplastic elastomer is generally defined as a polymer or blend of polymers that can be processed and recycled in the same way as a conventional thermoplastic material, yet has properties and functional performance similar to that of vulcanized rubber at service temperatures. Blends or alloys of plastic and elastomeric rubber have become increasingly important in the production of high performance thermoplastic elastomers, particularly for the replacement of thermoset rubbers in various applications. High performance thermoplastic elastomers in which a highly vulcanized rubbery polymer is intimately dispersed in a thermoplastic matrix are generally known as thermoplastic vulcanizates. Description of the Related Art Polymer blends which have a combination of both thermoplastic and elastic properties are generally obtained by combining a thermoplastic resin with an elastomeric composition in a way such that the elastomer component is intimately and uniformly dispersed as a discrete particulate phase within a continuous phase of the thermoplastic. Early work with vulcanized rubber components is found in U.S.-A- 3,037,954 which discloses both static vulcanization of the rubber, as well as the technique of dynamic vulcanization wherein a vulcanizable elastomer is dispersed into a molten resinous thermoplastic polymer and the elastomer is cured while continuously mixing and shearing the blend. The resulting composition is a micro-gel dispersion of cured elastomer in an uncured matrix of thermoplastic polymer. In U.S.-A- 32,028 (reissued) polymer blends comprising an olefin thermoplastic resin and an olefin copolymer are described, wherein the rubber is dynamically vulcanized to a state of partial cure. The resulting compositions are reprocessible. U.S. -A- 4,130,534 and 4,130,535 further disclose thermoplastic vulcanizates comprising butyl rubber and polyolefin resin, and olefin rubber and polyolefin resin, respectively. The compositions are prepared by dynamic vulcanization and the rubber component is cured to the extent that it is essentially insoluble in conventional solvents. A range of crosslinking, or curing, agents for the vulcanization of the rubber are described in the early art, including peroxides, sulfurs, phenolic resins and radiation. U.S.-A- 4,803,244 generally discusses the use of multifunctional organosilicon compounds in conjunction with a catalyst as an agent for crosslinking the rubber component of a thermoplastic elastomer by hydrosilylation. Hydrosilylation involves the addition of a silicon hydride across a multiple bond, often with a transition metal catalyst. This patent describes a rhodium catalyzed hydrosilylation of EPDM rubber in a blend with polypropylene to produce thermoplastic elastomers having a gel content of up to 34% (after correction for the plastic phase). This degree of vulcanization was achieved only with a high level of catalyst. A further modification of hydrosilylation crosslinking of the rubber in a thermoplastic elastomer composition is disclosed in EP-A-651,009. A compatibilizing agent containing in the same molecule a component having an affinity for the rubber and a component having an affinity for the thermoplastic resin is incorporated into the composition, and is said to improve adhesion between the rubber and resin in order to prevent agglomeration. SUMMARY OF THE INVENTION The present invention relates to a process for the crosslinking of a blend of thermoplastic resin and an unsaturated rubber by dynamic vulcanization in the presence of a hydrosilylation agent, a platinum-containing hydrosilylation catalyst and an extender or processor oil which comprises employing an oil substantially free of materials having the chemical behavior of a Lewis base and from 0.01 to 4 parts per million, based on the weight of said rubber and expressed as platinum metal, of said platinum-containing hydrosilylation catalyst. Lewis base behavior may be generally defined as bond formation by donation of a pair of electrons. This embodiment of the invention requires a very low concentration of catalyst to achieve cure of the rubber, and the resulting thermoplastic elastomer product has excellent tensile properties and no undesirable color. In the instant invention no compatibilizer is required in order to produce compositions with excellent mechanical properties, not bubble formation and very good colorability, due to the extremely low levels of catalyst concentration. Good heat aging, ultraviolet stability and non-hygroscopic properties also result. In a further embodiment of the invention, additives which react with residual silicon hydride functionality in the thermoplastic elastomer are incorporated into the process. This results in a composition which has further improved long term heat aging characteristics. Preferred embodiments of the process of the present invention become apparent from the dependent claims. In a still further embodiment the present invention relates to a thermoplastic elastomer product obtainable by the process of the present invention. The compositions obtainable by the process according to the present invention have utility as replacements for thermoset rubber compounds in a variety of applications, particularly where molding or extrusion is involved and the combination of thermoplastic and elastomeric properties provides an advantage. Typical uses include molded articles for automobile underhood parts, engineering and construction materials, mechanical rubber goods, industrial parts such as hose, tubing and gaskets, electrical applications and household goods. DESCRIPTION OF THE PREFERRED EMBODIMENTS Thermoplastic elastomer compositions may generally be prepared by blending a thermoplastic resin and a rubber, then melting the thermoplastic component and mixing the melt until the blend is homogeneous. If a composition of vulcanized rubber in a thermoplastic matrix is desired, crosslinking agents (also referred to as curatives or vulcanizing agents) are added to the blend and crosslinking occurs during the mixing. This latter process is described as dynamic vulcanization. A wide range of thermoplastic resins and rubbers and/or their mixtures have been used in the preparation of thermoplastic elastomers, including polypropylene, HDPE, LDPE,VLDPE, LLDPE, cyclic olefin homopolymers or copolymers as well as olefinic block copolymers, polystyrene, polyphenylene sulfide, polyphenylene oxide and ethylene propylene copolymer (EP) thermoplastics, with ethylene propylene diene rubber (EPDM), acrylonitrile butadiene rubber (NBR) and natural rubber (NR) as the elastomers. When the elastomer component is crosslinked, agents such as sulfur, peroxide, phenolics and ionic compounds are often used. Hydrosilylation Agents Hydrosilylation has also been disclosed as a crosslinking method. In this method a silicon hydride having at least two SiH groups in the molecule is reacted with the carbon-carbon multiple bonds of the unsaturated (i.e. containing at least one carbon-carbon double bond) rubber component of the thermoplastic elastomer, in the presence of the thermoplastic resin and a hydrosilylation catalyst. Silicon hydride compounds useful in the process of the invention include methylhydrogen polysiloxanes, methylhydrogen dimethyl-siloxane copolymers, alkyl methyl polysiloxanes, bis(dimethylsilyl)alkanes and bis(dimethylsilyl)benzene. Preferred silicon hydride compounds may be described by the formula where each R is independently selected from the group consisting of alkyls comprising 1 to 20 carbon atoms, cycloalkyls comprising 4 to 12 carbon atoms and aryls. In formula (1) it is preferred that each R be independently selected from a group consisting of alkyls comprising 1 to 6 carbon atoms. Even more preferred is R = methyl. R' represents a hydrogen atom, an alkyl or alkoxy group having from 1 to 24 carbon atoms. R" represents R or a hydrogen atom. D represents the group D' represents the group T represents the group m is an integer having a value ranging from 1 to 50, n is an integer having a value ranging from 1 to 50, and p is an integer having a value ranging from 0 to 6. Particularly preferred polyorganosiloxanes are these in which the silicon atom of the silicon hydride functionality is bound by heteroatoms/atoms having lone pairs of electrons. The preferred polyorganosiloxanes may also be substituted with appropriate functionality permitting solubility in the reaction media. A type of this functionalization is described in U.S.-A- 4,046,930 which teaches alkylation of polyorganosiloxanes. Weight percent of alkylation should not exceed a level that does not permit adequate reaction rates due to steric constraints. The amount of silicon hydride compound useful in the process of the present invention can range from 0.1 to 10.0 mole equivalents of SiH per carbon-carbon double bond in the rubber, and preferably is in the range of 0.5 to 5.0 mole equivalents of SiH per carbon-carbon double bond in the rubber component of the thermoplastic elastomer. Thermoplastic Resins Thermoplastic resins useful in the compositions produced by the invention include crystalline polyolefin homopolymers and copolymers. They are desirably prepared from monoolefin monomers having 2 to 20 carbon atoms, such as ethylene, propylene, 1-butene, and 1-pentene, as well as copolymers derived from linear and cyclic olefins, with propylene being preferred. As used in the specification and claims the term polypropylene includes homopolymers of propylene as well as reactor copolymers of polypropylene which can contain 1 to 20 wt% of ethylene or an α-olefin comonomer of 4 to 20 carbon atoms, and mixtures thereof. The polypropylene can be crystalline, isotactic or syndiotactic polypropylene. Commercially available polyolefins may be used in the practice of the invention. Other thermoplastic resins which are substantially inert to the rubber, the silicon hydride and the hydrosilylation catalyst would also be suitable. Blends of thermoplastic resins may also be used. The amount of thermoplastic resin found to provide useful compositions is generally from about 5 to about 90 weight percent, based on the weight of the rubber and resin. Preferably, the thermoplastic resin content will range from 20 to 80 percent by weight of the total polymer. Rubbers Unsaturated rubbers useful to prepare thermoplastic elastomers according to the invention include monoolefin copolymer rubbers comprising non-polar, rubbery copolymers of two or more α-monoolefins, preferably copolymerized with at least one polyene, usually a diene. However, unsaturated monoolefin rubber such as EPDM rubber is more suitable. EPDM is a polymer of ethylene, propylene and one or more non-conjugated diene or non-conjugated dienes, and the monomer components may be polymerized using Ziegler-Natta or metallocene catalyzed reactions, among others. Satisfactory non-conjugated dienes include 5-ethylidene-2-norbornene (ENB); 1,4-hexadiene (HD); 5-methylene-2-norbornene (MNB): 1,6-octadiene; 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 1,3-cyclopentadiene; 1,4-cyclohexadiene; dicyclopentadiene (DCPD) and 5-vinyl-2-norbornene (VNB), or a combination thereof. In one embodiment of the invention, it has been found that rubber having a structure in which the diene monomer has carbon-carbon multiple bonds which are predominately unencumbered, i.e. bonds which are sterically unhindered such as terminal or pendant double bonds, provide a greatly improved rate of cure in the hydrosilylation curing process of the invention. Included in this embodiment are structures in which the bonds either normally are unencumbered or are easily isomerized to form a sterically unencumbered double bond, which is then rapidly hydrosilated, e.g. 1,4-hexadiene or ENB. This improvement is particularly significant where a fully cured rubber component is desired. The use of rubber in which the diene component is selected from the group consisting of 5-ethylidene-2-norbornene, 5-methyl-1,4-hexadiene, 1,4-hexadiene and 5-vinyl-2-norbornene is preferred. 5-vinyl-2-norbornene is particularly preferred as a diene component of such rubber. Butyl rubbers are also useful in the compositions of the invention. As used in the specification and claims, the term "butyl rubber" includes copolymers of an isoolefin and a conjugated monoolefin, terpolymers of an isooolefin, a conjugated monoolefin and divinyl aromatic monomers, and the halogenated derivatives of such copolymers and terpolymers. The useful butyl rubber copolymers comprise a major portion of isoolefin and a minor amount, usually less than 30 wt%, of a conjugated multiolefin. The preferred copolymers comprise 85-99.5 wt% of a C 4-7 isoolefin such as isobutylene and 15-0.5 wt% of a multiolefin of 4-14 carbon atoms, such as isoprene, butadiene, dimethyl butadiene, 4-methyl-1,4-pentadiene and piperylene. Commercial butyl rubber, useful in the invention, is a copolymer of isobutylene and minor amounts of isoprene. Other butyl co- and terpolymer rubbers are illustrated by the description in U.S.-A-4,916,180. Isobutylene/divinylbenzene is particularly preferred as an elastomer suitable for hydrosilylation crosslinking, as are the halogenated derivatives of butyl rubber such as chlorobutyl and bromobutyl. A further rubber suitable in the invention is natural rubber. The main constituent of natural rubber is the linear polymer cis-1,4-polyisoprene. It is normally commercially available in the form of smoked sheets and crepe. Synthetic polyisoprene can also be used with the particularly preferred synthetic polyisoprene elastomers being those that contain vinyl functionality pendant to the main polymer chain, i.e. 1,2-enchainments. Polybutadiene is also a suitable elastomer for hydrosilylation curing with polybutadienes that contain vinyl functionality being the most preferred. Blends of any of the above rubbers may also be employed, rather than a single olefinic rubber. In preparing the compositions of the invention, the amount of rubber generally ranges from 95 to 10 weight percent, based on the weight of the rubber and thermoplastic resin. Preferably, the rubber content will be in the range of from 80 to 20 weight percent of total polymer. Hydrosilylation Catalysts It has previously been understood that any catalyst, or catalyst precursor capable of generating a catalyst in situ, which will catalyze the hydrosilylation reaction with the carbon-carbon bonds of the rubber can be used. Such catalysts have included transition metals of Group VIII such as palladium, rhodium, and platinum, including complexes of these metals. Chloroplatinic acid has been disclosed as a useful catalyst in U.S. -A- 4,803,244 and EP-A- 0651,009, which further disclose that the catalyst may be used at concentrations of 5 to 10,000 parts per million by weight and 100 to 200,000 parts per million by weight based on the weight of rubber, respectively. It has been found in the process of the present invention that significantly lower concentrations of platinum-containing catalyst can be used, while obtaining improvement in both the speed of the reaction and the efficiency of the crosslinking. Concentrations of catalyst in the range of 0.01 to 4 parts per million by weight, expressed as platinum metal, are effective in rapidly and completely curing the rubber in the process of dynamically vulcanizing blends of thermoplastic resin and rubber. These low catalyst concentrations are particularly effective in combination with a diene-containing rubber having carbon-carbon multiple bonds which are predominately sterically unhindered. Catalyst concentrations of 0.1 to 4 parts per million by weight based on the weight of rubber, expressed as platinum metal, are particularly preferred. Platinum-containing catalysts which are useful in the process of the invention are described, for example, in U.S.-A-4,578,497; U.S.-A-3,220,972; and U.S.-A-2,823,218 all of which are incorporated herein by this reference. These catalysts include chloroplatinic acid, chloroplatinic acid hexahydrate. complexes of chloroplatinic acid with sym-divinyltetramethyldisiloxane, dichloro-bis(triphenylphosphine) platinum (II), cis-dichloro-bis(acetonitrile) platinum (II), dicarbonyldichloroplatinum (II), platinum chloride and platinum oxide. Zero valent platinum metal complexes such as Karstedt's catalyst are particularly preferred, as described in U.S.-A- 3,775,452; U.S.-A-3,814,730; and U.S.-A-4,288,345. In order for the catalyst to function most efficiently in the dynamic vulcanization environment, it is important that it is inherently thermally stable, or that its activity is inhibited to prevent too rapid a reaction or catalyst decomposition. Appropriate catalyst inhibitors that are suitable to stabilize the platinum catalyst at high temperatures include 1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasiloxane and its higher analogs such as vinyl cyclic pentamer. However, other olefins that are stable above 165° C are also useful. These include maleates, fumarates and the cyclic pentamer. It is also particularly preferred in the invention to use a catalyst that remains soluble in the reaction medium. Additives The thermoplastic elastomer may contain conventional additives, which can be introduced into the composition in the thermoplastic resin, the rubber, or in the blend either before, during or after the hydrosilylation and curing. Examples of such additives are antioxidants, processing aids, reinforcing and nonreinforcing fillers, pigments, waxes, rubber processing oil, extender oils, antiblocking agents, antistatic agents, ultraviolet stabilizers, plasticizers (including esters), foaming agents, flame retardants and other processing aids known to the rubber compounding art. Such additives may comprise from 0.1 to 300 percent by weight based on the weight of the final thermoplastic elastomer product. Fillers and extenders which can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide and carbon black. Additives, fillers or other compounds which may interfere with the hydrosilylation should be added after curing reaches the desired level. In another embodiment, it has been found that the heat aging properties of compositions prepared according to the invention can be greatly improved by the addition of a metal chelating agent to the blend. This effect is believed to be due to the fact that the hydrosilylation catalyst is in an active valence state. This form of the platinum metal accelerates degradation of the thermoplastic elastomer, particularly under conditions of elevated temperature over an extended time. Chelation prevents the metal from causing degradation. Typical chelating agents useful for this purpose include materials such as 1,2-bis(3,5-di-ter-butyl-4-hydroxyhydrocinnamoyl)hydrazine. Surprisingly, these agents may be incorporated into the composition prior to or after the hydrosilylation curing . Amounts of chelating agent ranging from 0.025 parts per hundred parts of rubber (phr) to 10 phr have been found to be useful, and amounts in the range of 0.1 phr to 2 phr are preferred. In a further embodiment of the invention, it has been demonstrated that reducing residual or unreacted silicon hydride functionality in the thermoplastic elastomer products results in compositions which have improved heat stability. Unreacted silicon hydride may be reduced or eliminated by reacting the silicon hydride with compounds containing active hydrogen, carbon-carbon multiple bonds, carbon-oxygen double bonds or carbon-nitrogen double bonds. The residual silicon hydride reacts with these compounds to eliminate silicon hydride functionality and form silicon-oxygen or carbon-silicon bonds. Typical compounds useful for this purpose are silica and water. These agents are incorporated into the composition after the hydrosilylation cure is complete. Water may be introduced as steam anytime after cure in a single or two pass operation. Amounts of such compounds may be estimated by measuring residual silicon hydride and adding a stoichiometric amount of the compound. One may also desire to add a stoichiometric excess if necessary to eliminate a sufficient amount of the residual silicon hydride in order to realize the desired improvement in heat aging properties. Amounts of such compounds ranging from one mole equivalent to 10 mole equivalents have been found to be useful, and amounts in the range of 1 to 3 mole equivalents are preferred. Extender Oil The rubber processing or extender oils used in thermoplastic elastomers generally are paraffinic, naphthenic or aromatic oils derived from petroleum fractions. The type will be that ordinarily used in conjunction with the specific rubber or rubbers present in the composition, and the quantity based on the total rubber content of the thermoplastic elastomer may range from zero to several hundred parts per hundred rubber. Important to the efficiency of the catalyst is that the oils and other additives contain no or very low concentrations of compounds that are catalyst inhibitors or that interfere with the activity of the catalyst. These compounds include phosphines, amines, sulfides, thiols or other compounds that may be classified as Lewis bases. Lewis bases, or other compounds that have a pair of electrons available for donation, will react with the platinum catalyst, effectively neutralizing its activity. It has been discovered that the presence of such compounds has a surprisingly detrimental impact on hydrosilylation curing in the process of dynamic vulcanization of the rubber component of the thermoplastic elastomer compositions. If the concentration of compounds which have the chemical reactivity of Lewis bases, such as compounds containing sulfur or nitrogen, is maintained at or below a level which provides less than 1000 ppm and 300 ppm of sulfur and nitrogen respectively, then the amount of platinum catalyst required to promote efficient hydrosilylation curing in dynamic vulcanization can be substantially reduced, usually to the range of about 4 ppm or less, without impact on the cure state of the rubber or the tensile properties of the thermoplastic elastomer product. Concentrations of sulfur and nitrogen below 500 and 200 ppm respectively are more preferred, and concentrations of less than 30 ppm sulfur and less than 100 ppm nitrogen are most preferred. It has been discovered that, even at catalyst concentrations as low as 0.25 ppm, full cure of the elastomer can be achieved if the concentration of sulfur and nitrogen is within the most preferred ranges. Most paraffinic petroleum oils for the rubber industry are derived from a crude oil distillation stream. A typical refining history would include some type of dewaxing to reduce the pour point, a solvent extraction to physically remove aromatic compounds and a hydrotreating process to chemically modify aromatic structures. Both extraction and hydrotreating result in a net increase in the total concentration of saturated hydrocarbon structures and a net decrease in the total aromatic, sulfur and nitrogen-containing compound concentration. The degree of reduction in concentration of these compounds in the oil is dependent upon the type and severity of the refining employed, and the nature of the crude oil. White and paraffinic oils have been treated more extensively than aromatic and napthenic oils and would contain a smaller concentration of aromatic, sulfur and/or nitrogen compounds. It is difficult to elucidate the exact chemical structure of these compounds due to their complexity. The tendency of an oil to interfere with platinum catalyzed hydrosilylation is directly related to the concentration of sulfur and nitrogen containing compounds, as well as compounds which contain phosphorus, tin, arsenic, aluminum and iron. Processing The rubber component of the thermoplastic elastomer is generally present as small, i.e. micro-size, particles within a continuous thermoplastic resin matrix, although a co-continuous morphology or a phase inversion is also possible depending upon the amount of rubber relative to plastic and the degree of cure of the rubber. The rubber is desirably at least partially crosslinked, and preferably is completely or fully crosslinked. It is preferred that the rubber be crosslinked by the process of dynamic vulcanization. As used in the specification and claims, the term "dynamic vulcanization" means a vulcanization or curing process for a rubber blended with a thermoplastic resin, wherein the rubber is vulcanized under conditions of shear at a temperature at which the mixture will flow. The rubber is thus simultaneously crosslinked and dispersed as fine particles within the thermoplastic resin matrix, although as noted above other morphologies may exist. Dynamic vulcanization is effected by mixing the thermoplastic elastomer components at elevated temperatures in conventional mixing equipment such as roll mills, Banbury mixers, Brabender mixers, continuous mixers and mixing extruders. The unique characteristic of dynamically cured compositions is that, notwithstanding the fact that the rubber component is partially or fully cured, the compositions can be processed and reprocessed by conventional plastic processing techniques such as extrusion, injection molding and compression molding. Scrap or flashing can be salvaged and reprocessed. The terms "fully vulcanized" and "fully cured" or "fully crosslinked" as used in the specification and claims means that the rubber component to be vulcanized has been cured or crosslinked to a state in which the elastomeric properties of the crosslinked rubber are similar to those of the rubber in its conventional vulcanized state, apart from the thermoplastic elastomer composition. The degree of cure can be described in terms of gel content, or conversely, extractable components. Gel content reported as percent gel (based on the weight of crosslinkable rubber) is determined by a procedure which comprises determining the amount of insoluble polymer by soaking the specimen for 48 hours in organic solvent at room temperature, weighing the dried residue and making suitable corrections based upon knowledge of the composition. Thus, corrected initial and final weights are obtained by subtracting from the initial weight the weight of soluble components, other than rubber to be vulcanized, such as extender oils, plasticizers and components of the composition soluble in organic solvent, as well as that rubber component of the product which is not intended to be cured. Any insoluble polyolefins, pigments and fillers are subtracted from both the initial and final weights. The rubber component can be described as fully cured when less than 5%, and preferably less than 3%, of the rubber which is capable of being cured by hydrosilylation is extractable from the thermoplastic elastomer product by a solvent for that rubber. Alternatively the degree of cure may be expressed in terms of crosslink density. All of these descriptions are well known in the art, for example in U.S.-A- 4,593,062, 5,100,947 and 5,157,081. The following general procedure was used in the preparation of thermoplastic elastomers by the process of the invention, as set forth in the examples. The thermoplastic resin and oil extended rubber were placed in a heated internal mixer, with the hydrosilylation agent and hydrosilylation catalyst. The hydrosilylation agent and catalyst can be incorporated into the composition by any suitable technique, for example by injection as solutions in oil or as neat components, although a dilute catalyst solution is preferred. Additives such as antioxidants, ultraviolet stabilizers and fillers may also be added as a slurry in oil. Masterbatches of the components may also be prepared to facilitate the blending process. The mixture was heated to a temperature sufficient to melt the thermoplastic component, and the mixture was masticated, with added processing oil if desired, until a maximum of mixing torque indicated that vulcanization had occurred. Mixing was continued until the desired degree of vulcanization was achieved. The order of addition of the hydrosilylation agent and hydrosilylation catalyst was found to be important. Maximum catalyst efficiency was obtained when the hydrosilylation agent was added first to the blend, followed by the hydrosilylation catalyst. The mechanical properties of the thermoplastic elastomer products, as well as the degree of cure, were improved when this order of addition was followed. The invention will be better understood by reference to the following examples. In the examples, the following test methods were used to determine the properties of the thermoplastic elastomer products. Hardness (Shore A/D) ASTM D 2240 Ultimate tensile strength (UTS MPa (psi)) ASTM D 412 Ultimate elongation (UE - %) ASTM D 412 Modulus at 100/300% elongation (M1 or M3 MPa (psi)) ASTM D412 Tension set (TS - %) ASTM D 412 Oil swell (OS - %) ASTM D 471 Heat aging ASTM D 573 The rubber component used in the compositions prepared according to the examples are further identified as follows. Rubber "A" EPDM - 2.1% ENB; 52% ethylene Rubber "B" EPDM - 5% HD; 55% ethylene Rubber "C" EPDM - 3% VNB; 64% ethylene Rubber "D" EPDM - 1.6% VNB; 50% ethylene Rubber "E" EPDM - 0.9% VNB; 72% ethylene Rubber "F" EPDM - 3% VNB; 55% ethylene Rubber "I" EPDM - 4.2% ENB; 0.3% VNB; 58% ethylene Rubber "K" EPDM - 1.1% VNB; 64% ethylene Rubber "L" EPDM - 0.7% VNB; 62.6 % ethylene PREPARATION EXAMPLE 1 (not according to the invention) Compositions were prepared by the method of the invention as generally described above, using polypropylene resin and EPDM rubber containing ENB (Rubber "A") as the diene component. The plastic and rubber components were melt mixed in a Brabender mixer at 180°C until the polypropylene was melted. Silicone hydride (alkylated methyl hydrogen polysiloxane) was added dropwise to the melt mix, followed by addition of an oil solution containing platinum [platinate (II) hexachloro, dihydrogen reaction product with 2,4,6,8-tetraethenyl-2,4,6,8-tetramethyl cyclotetrasiloxane]. The rubber was dynamically vulcanized by mixing the blend until the maximum torque was reached. The product was removed from the mixer, then returned to the mixer and masticated at 180°C for an additional minute. Plaques were prepared by compression molding the products of the dynamic vulcanization at 200° C to a thickness of 1.524 mm of (60 mil) and cooling under pressure, and the physical properties were determined using these plaques. All of the products were elastomeric, as defined by ASTM D1566, i.e. all had tension set values of less than 50%. EXAMPLE 2 Compositions were prepared as in Preparation Example 1, using EPDM rubber containing 1,4-hexadiene as the diene termonomer. Platinum (as in Preparation Example 1) was used as the hydrosilylation catalyst. Plaques were prepared from the products and physical properties were determined. The results are set forth in Table I. Again for the purposes of comparison with a rhodium-catalyzed hydrosilylation, example 7 of U.S. -A- 4,803,244 is set forth. In this comparative example, a blend of polypropylene and EPDM (containing hexadiene) was dynamically vulcanized by hydrosilylation using the equivalent of 35 ppm of rhodium metal as the catalyst. Composition- D E Pat. Ex. 7 PP (parts) 67 67 50 Rubber "B" (parts) 100 100 100 Si-H (phr) 3 3 6.7 Rhodium (ppm) -- -- 35 Platinum (ppm) 3.3 1.8 0 Hardness(D) 39 37 25 UTS MPa (psi) 14.27 (2070) 12.06 (1750) 8.82 (1280) UE (%) 340 160 180 M1 1580 1620 -- TS (%) 25 26 14 Gel (%) 91 88 34 As demonstrated by the data set forth above, EPDM rubber containing 1,4-hexadiene as the diene termonomer is crosslinked more efficiently and completely using a platinum catalyst in conjunction with a hydrosilating agent, as compared to a rhodium catalyst. The dynamic vulcanizates prepared using the platinum catalyst have substantially higher gel content and better tensile properties, even at catalyst concentrations which are orders of magnitude lower than those required for rhodium catalyst. The rate of crosslinking was also much faster using the platinum catalyst at low concentration, in comparison to the rhodium catalyst at higher concentrations. EXAMPLE 3 Compositions were prepared using a twin-screw extruder as the mixing means for carrying out the dynamic vulcanization. EPDM rubbers containing either 5-vinyl-2-norbornene or 5-ethylidene-2-norbornene as the diene component were used, and were dynamically vulcanized by hydrosilylation with the platinum catalyst of Preparation Example 1. Plaques were prepared from the thermoplastic elastomer products and physical properties were determined. The results are set forth in Table II. Composition - F G Polypropylene (parts) 41 41 Rubber "F" (parts) 100 100 Rubber "G" (parts) -- -- Si-H (phr) 2.2 2.2 Platinum (ppm) 4 2 Hardness (A) 69 69 UTS MPa (psi) 7.45 (1080) 7.16 (1039) UE (%) 211 211 M1 636 606 Gel (%) 99 99 Compositions F and G, which utilized VNB/EPDM, had very high crosslinking levels even though the amounts of both hydrosilylation agent and catalyst were very low. Composition H (ENB/EPDM) had a lower, but still acceptable level of crosslinking. EXAMPLE 4 In order to study the effect of extender oil, compositions were prepared as generally described above using polypropylene resin and EPDM rubber. Masterbatches of rubber were prepared containing three different extender oils with progressively lower aromatic fractions and lower sulfur and nitrogen concentrations. The masterbatch composition was 100 parts rubber, 100 parts extender oil, 42 parts clay, 2 parts zinc oxide and 5 parts wax. The polypropylene (41 parts) was added to this masterbatch of rubber "K" and mixed in a Brabender mixer at 180°C until the polypropylene was melted. Silicone hydride (3 phr) was added dropwise to the mix, followed by addition of an oil solution containing platinum catalyst at various levels. The rubber was dynamically vulcanized by mixing the blend until maximum torque was reached. Additional processing oil (30 parts) was added after the cure. The product was removed from the mixer, then returned to the mixer and masticated at 180° C for an additonal minute. Test specimens were prepared by compression molding the products at 200° C, and the oil swell properties were determined by the test method of ASTM D471, using IRM 903 oil at 125°C for 24 hours. The results, expressed as percent swell (or weight gain) of the specimen, are set forth in Table III. Pt Catalyst Extender Oil A Extender Oil B Extender Oil C OS S:Pt N:Pt OS S:Pt N:Pt OS S:Pt N:Pt 0.25 ppm 339 14300 8942 - - - 119 24 55 0.5 285 7150 4471 105 227 2808 92.3 12 23 1.0 222 3575 2236 86.4 114 1404 85.3 6 12 1.9 140 1882 1177 85.8 60 739 85.6 3.2 6 2.4 98 1490 932 93.4 48 585 - - - The relative degree of swelling in oil is representative of the crosslink density of the vulcanized rubber, i.e. higher crosslink density in the rubber results in lower oil swell values. The data in Table III clearly shows that materials prepared using extender oil which has low amounts of sulfur and nitrogen, and where the mole ratio of sulfur or nitrogen to the platinum in the catalyst is low, results in a thermoplastic elastomer product which is much more effectively crosslinked by hydrosilylation. This effect is seen even at extremely low concentrations of catalyst. EXAMPLE 5 Compositions were prepared using masterbatches of rubber with two different extender oils, under the conditions described in Example 4. The physical properties of the products were evaluated and are set forth in Table IV. Extender Oil C A C A C A Pt Catalyst (ppm) 0.22 0.23 0.45 0.59 1.03 1.08 Hardness (A) 62 55 60 57 62 62 TS (%) 8 14 6 12 6 8 UTS MPa (psi) 6.55 (950) 2.62 (380) 6.20 (900) 4.61 (670) 6.07 (880) 6.41 (930) M1 400 220 420 280 410 370 UE (%) 390 440 320 490 290 450 OS (%) 101.7 258.5 93.2 165.7 93.6 109.9 The use of extender oil "C", which contained very low levels of materials which have the chemical behavior of a Lewis base, resulted in thermoplastic elastomer products having excellent tensile properties and a high degree of crosslinking of the elastomer, even at catalyst levels as low as 0.2 parts per million. In contrast, products prepared with extender oil "A", which contained higher levels of sulfur and nitrogen containing compounds, required the use of about five times more catalyst in the reaction to achieve similar properties. EXAMPLE 6 Thermoplastic elastomer compositions were prepared using a rubber which had been extended with oil, blended to have an increasing concentration of sulfur compounds. The thermoplastic elastomers were prepared as described in Example 4, using a masterbatch of rubber "I". The properties of the products are set forth in Table V. S content of oil (mg) 0.02 15.12 30.24 45.35 N content of oil (mg) 0.02 1.39 2.76 4.13 Pt catalyst (ppm)/ (mg) 3.7/ .07 3.8/.07 3.7/.07 3.7/.07 S:Pt mole ratio 0.9:1 1316:1 2633:1 3948:1 N:Pt mole ratio 3.7:1 276:1 548:1 821:1 Hardness(A) 58 55 57 55 TS (%) 6.5 6 8.5 9 UTS MPa (psi) 5.51 (800) 5.24 (760) 5.96 (865) 5.51 (800) M1 MPa (psi) 2.76 (400) 2.48 (360) 2.48 (360) 2.07 (300) UE (%) 290 330 330 560 Gel (%) 97.5 97.9 97.8 97.9 OS (%) 91 100 121 126 The effect of increasing sulfur and nitrogen content in the extender (processing) oil on cure state can be seen by the sharp increase in oil swell which occurs when the S:Pt mole ratio is above 4000:1 and the N:Pt mole ratio is above 800:1. The mole ratio of total material having the chemical behavior of a Lewis base to the platinum catalyst is desirably less than 5000:1, and the preferred mole ratios of sulfur and nitrogen to platinum are less than 2000:1 and 600:1, respectively. The most preferred mole ratios are less than 1000:1 S:Pt and less than 100:1 N:Pt.

Claims: A process for the crosslinking of a blend of thermoplastic resin and an unsaturated rubber by dynamic vulcanization in the presence of a hydrosilylation agent, a platinum-containing hydrosilylation catalyst and an extender or processing oil which comprises employing an oil substantially free of materials having the chemical behavior of a Lewis base and from 0.01 to 4 parts per million, based on the weight of said rubber and expressed as platinum metal, of said platinum-containing hydrosilylation catalyst. The process of claim 1 wherein said oil is substantially free of materials which contain sulfur, phosphorus, tin, nitrogen or arsenic. The process of claim 1 wherein the molar ratio of materials having the chemical behavior of a Lewis base to the platinum is less than 5000:1. The process of claim 1 wherein the thermoplastic resin is a polyolefin resin and the rubber contains a diene monomer having predominately sterically unhindered carbon-carbon double bonds. The process of claim 4 wherein the polyolefin resin is polypropylene and the rubber is EPDM rubber containing 5-vinyl-2-norbornene as a diene monomer. The process of claim 1 wherein after dynamic vulcanization the rubber is in the form of discrete particles in a matrix of the thermoplastic resin, and is crosslinked to the extent that less than 5 percent by weight of the crosslinkable rubber can be extracted from the thermoplastic elastomer product by a rubber solvent. The process of claim 1 wherein said oil is a paraffinic white oil containing less than 30 parts per million of sulfur and less than 100 parts per million of nitrogen. The process according to anyone of claims 1 to 7 comprising the steps of: a)mixing the thermoplastic resin and the unsaturated rubber containing the extender oil which is substantially free of materials having the chemical behavior of a Lewis base, b) adding the hydrosilylation agent to the mixture from (a), c) blending the mixture from (b) at a temperature sufficient to cause the mixture to flow, d) optionally incorporating into the mixture a processing oil substantially free of materials having the chemical behavior of a Lewis base, e) incorporating into the mixture the platinum-containing hydrosilylation catalyst in an amount ranging from 0.01 to 4 parts per million parts of rubber, expressed as platinum metal, and f) masticating the mixture from (e) under conditions of heat and shear until the rubber is crosslinked. A process for the hydrosilylation crosslinking of a composition comprising a blend of a thermoplastic resin and an unsaturated rubber by dynamic vulcanization comprising/employing a hydrosilylation crosslinking agent and from 0.01 to 4 parts per million, based on the weight of said rubber and expressed as platinum metal, of a platinum-containing hydrosliylation catalyst in combination with an EPDM rubber containing 5-vinyl-2-norbornene as a diene monomer, whereby a crosslinked rubber is obtained in a matrix of thermoplastic resin. The process of claim 9 wherein the thermoplastic resin is a polyolefin resin. The process of claim 9 wherein after dynamic vulcanization the rubber is in the form of discrete particles in a matrix of the thermoplastic resin, and is crosslinked to the extent that less than 5 percent by weight of the crosslinkable rubber can be extracted from the thermoplastic elastomer product by a rubber solvent. The process of claim 1 or 9 wherein the platinum-containing hydrosilylation catalyst is selected from the group consisting of chloroplatinic acid, complexes of chloroplatinic acid with symdivinyltetramethyldisiloxane, and dichloro-bis(triphenylphosphine) platinum(II). The process of claim 9 which further comprises incorporating into the thermoplastic elastomer a metal chelating agent. The process of claim 9 which further comprises incorporating into the thermoplastic elastomer a compound which reacts with residual silicon hydride. The process according to claim 10 wherein the polyolefin resin is polypropylene and the dynamic vulcanization is carried out in the presence of a paraffinic white oil containing less than 30 parts per million of sulfur and less than 100 parts per million of nitrogen. The process according to claim 9 comprising the steps of: a) mixing the thermoplastic resin and the EPDM rubber containing 5-vinyl-2-norbornene as the diene monomer, b) adding the hydrosilylation agent to the mixture from (a), c) blending the mixture from (b) at a temperature sufficient to cause the mixture to flow, d) incorporating into the mixture the platinum-containing hydrosilylation catalyst in an amount ranging from 0.01 to 4 parts per million parts of rubber, expressed as platinum metal, and e) masticating the mixture from (d) until the rubber is crosslinked. A thermoplastic elastomer product obtainable by the process of anyone of claim 1 to 16.

Inventors: GILBERTSON GARY, MEDSKER ROBERT EUGENE, PATEL RAMAN, ZHAO JIANQUN, GILBERTSON, GARY, MEDSKER, ROBERT EUGENE, PATEL, RAMAN, ZHAO, JIANQUN
Applicants: ADVANCED ELASTOMER SYSTEMS, ADVANCED ELASTOMER SYSTEMS, L.P.
Application year: 1996
Main classification: C08L23
IPC codes: C08L101, C08K5, C08L21, C08L23, C08J3