Patent Description:
Ever more sophisticated rubber compositions including high filler contents, high molecular weight elastomers and functional elastomer require improved processing aids such as resins to improve processing and to improve tire performance.

The invention relates to a vulcanizable rubber composition in accordance with claim <NUM> or <NUM>, to a pneumatic tire in accordance with claim <NUM>, and to a manufactured item in accordance with claim <NUM>.

In a preferred aspect of the present invention, a vulcanizable rubber composition is disclosed comprising a vegetable oil derivative comprising the structure:
<CHM>
where R<NUM>, R<NUM> and R<NUM> are independently C15-C20 alkenyl, C15-C20 alkyl, and optionally containing aromatic groups; R is R is - O - C(=O) - R<NUM> where R<NUM> is phenyl, alkyl substituted phenyl, hydroxy-substituted phenyl, or terpenoid; each R is covalently bonded to a first carbon atom of one of R<NUM>, R<NUM> or R<NUM> wherein a second carbon atom is adjacent to the first carbon atom and the second carbon atom is substituted with an - OH group; and m is the number of R groups.

The invention is further directed to a pneumatic tire comprising the rubber composition.

There is disclosed a vulcanizable rubber composition comprising a vegetable oil derivative comprising the structure
<CHM>
where R<NUM>, R<NUM> and R<NUM> are independently C15-C20 alkenyl, C15-C20 alkyl, and optionally containing aromatic groups; R is R is - O - C(=O) - R<NUM> where R<NUM> is phenyl, alkyl substituted phenyl, hydroxy-substituted phenyl, or terpenoid; each R is covalently bonded to a first carbon atom of one of R<NUM>, R<NUM> or R<NUM> wherein a second carbon atom is adjacent to the first carbon atom and the second carbon atom is substituted with an - OH group; and m is the number of R groups.

The vegetable oil derivative may be produced by modification of an epoxidized vegetable oil.

In one embodiment, m ranges from <NUM> to <NUM>.

In one embodiment, R is selected from the group consisting of carboxylates of terpenoid carboxylic acids and carboxylates of aromatic carboxylic acids.

In one embodiment, R is selected from the group consisting of carboxylates of abietic acid, neoabietic acid, dehydroabietic acid, palustric acid, levopimaric acid, pimaric acid, and isopimaric acid.

In one embodiment, R is selected from the group consistings of carboxylates of benzoic acid, salicylic acid, para-t-butyl benzoic acid, salicylic acid, <NUM>-hydroxybenzoic acid, and <NUM>-hydroxybenzoic acid.

In one embodiment, each of R<NUM>, R<NUM>, and R<NUM> are independently at least one member selected from the group consisting of independently at least one member selected from the group consisting of stearyl, palymityl, oleyl, linoleyl, and linolenyl groups.

In another aspect, the invention is direction to a vulcanizable rubber composition comprising the vegetable oil derivative as the reaction product of an epoxidized vegetable oil and a carboxylic acid selected from the group consisting of terpenoid carboxylic acids and aromatic carboxylic acids.

In one embodiment, the epoxidized vegetable oil is selected from the group consisting of epoxidized soybean oil, epoxidized canola oil, epoxidized castor oil, epoxidized palm oil, epoxidized sunflower oil, epoxidized coconut oil, and epoxidized corn oil.

In one embodiment, the carboxylic acid is at least one member selected from the group consisting of abietic acid, neoabietic acid, dehydroabietic acid, palustric acid, levopimaric acid, pimaric acid, and isopimaric acid.

In one embodiment, the carboxylic acid is at least one member selected from the group consisting of benzoic acid, salicylic acid, para-t-butyl benzoic acid, salicylic acid, <NUM>-hydroxybenzoic acid, and <NUM>-hydroxybenzoic acid.

The vegetable oil derivative may be used in a vulcanizable rubber composition. In one embodiment, the vegetable oil derivative is used in an amount ranging from <NUM> to <NUM> phr.

The rubber composition may include, in addition to the vegetable oil derivative, one or more rubbers or elastomers containing olefinic unsaturation. The phrases "rubber or elastomer containing olefinic unsaturation" or "diene-based elastomer" are intended to include both natural rubber and its various raw and reclaim forms as well as various synthetic rubbers. In the description of this invention, the terms "rubber" and "elastomer" may be used interchangeably, unless otherwise prescribed. The terms "rubber composition," "compounded rubber" and "rubber compound" are used interchangeably to refer to rubber which has been blended or mixed with various ingredients and materials and such terms are well known to those having skill in the rubber mixing or rubber compounding art. Representative synthetic polymers are the homopolymerization products of butadiene and its homologues and derivatives, for example, methylbutadiene, dimethylbutadiene and pentadiene as well as copolymers such as those formed from butadiene or its homologues or derivatives with other unsaturated monomers. Among the latter are acetylenes, for example, vinyl acetylene; olefins, for example, isobutylene, which copolymerizes with isoprene to form butyl rubber; vinyl compounds, for example, acrylic acid, acrylonitrile (which polymerize with butadiene to form NBR), methacrylic acid and styrene, the latter compound polymerizing with butadiene to form SBR, as well as vinyl esters and various unsaturated aldehydes, ketones and ethers, e.g., acrolein, methyl isopropenyl ketone and vinylethyl ether. Specific examples of synthetic rubbers include neoprene (polychloroprene), polybutadiene (including cis-<NUM>,<NUM>-polybutadiene), polyisoprene (including cis-<NUM>,<NUM>-polyisoprene), butyl rubber, halobutyl rubber such as chlorobutyl rubber or bromobutyl rubber, styrene/isoprene/butadiene rubber, copolymers of <NUM>,<NUM>-butadiene or isoprene with monomers such as styrene, acrylonitrile and methyl methacrylate, as well as ethylene/propylene terpolymers, also known as ethylene/propylene/diene monomer (EPDM), and in particular, ethylene/propylene/ dicyclopentadiene terpolymers. Additional examples of rubbers which may be used include alkoxy-silyl end functionalized solution polymerized polymers (SBR, PBR, IBR and SIBR), silicon-coupled and tin-coupled star-branched polymers. The preferred rubber or elastomers are polyisoprene (natural or synthetic), polybutadiene and SBR.

In one aspect, the at least one additional rubber is preferably of at least two of diene-based rubbers. For example, a combination of two or more rubbers is preferred such as cis <NUM>,<NUM>-polyisoprene rubber (natural or synthetic, although natural is preferred), <NUM>,<NUM>-polyisoprene rubber, styrene/isoprene/butadiene rubber, emulsion and solution polymerization derived styrene/butadiene rubbers, cis <NUM>,<NUM>-polybutadiene rubbers and emulsion polymerization prepared butadiene/acrylonitrile copolymers.

In one aspect of this invention, an emulsion polymerization derived styrene/butadiene (E-SBR) might be used having a relatively conventional styrene content of <NUM> to <NUM> percent bound styrene or, for some applications, an E-SBR having a medium to relatively high bound styrene content, namely, a bound styrene content of <NUM> to <NUM> percent.

By emulsion polymerization prepared E-SBR, it is meant that styrene and <NUM>,<NUM>-butadiene are copolymerized as an aqueous emulsion. Such are well known to those skilled in such art. The bound styrene content can vary, for example, from <NUM> to <NUM> percent. In one aspect, the E-SBR may also contain acrylonitrile to form a terpolymer rubber, as E-SBAR, in amounts, for example, of <NUM> to <NUM> weight percent bound acrylonitrile in the terpolymer.

Emulsion polymerization prepared styrene/butadiene/acrylonitrile copolymer rubbers containing <NUM> to <NUM> weight percent bound acrylonitrile in the copolymer are also contemplated as diene-based rubbers for use in this invention.

The solution polymerization prepared SBR (S-SBR) typically has a bound styrene content in a range of <NUM> to <NUM>, preferably <NUM> to <NUM>, percent. The S-SBR can be conveniently prepared, for example, by organo lithium catalyzation in the presence of an organic hydrocarbon solvent.

In one embodiment, cis <NUM>,<NUM>-polybutadiene rubber (BR) may be used. Such BR can be prepared, for example, by organic solution polymerization of <NUM>,<NUM>-butadiene. The BR may be conveniently characterized, for example, by having at least a <NUM> percent cis <NUM>,<NUM>-content.

The term "phr" as used herein, and according to conventional practice, refers to "parts by weight of a respective material per <NUM> parts by weight of rubber, or elastomer.

The rubber composition may also include up to <NUM> phr of processing oil. Processing oil may be included in the rubber composition as extending oil typically used to extend elastomers. Processing oil may also be included in the rubber composition by addition of the oil directly during rubber compounding. The processing oil used may include both extending oil present in the elastomers, and process oil added during compounding. Suitable process oils include various oils as are known in the art, including aromatic, paraffinic, naphthenic, vegetable oils, and low PCA oils, such as MES, TDAE, SRAE and heavy naphthenic oils. Suitable low PCA oils include those having a polycyclic aromatic content of less than <NUM> percent by weight as determined by the IP346 method. Procedures for the IP346 method may be found in <NPL>.

The rubber composition may include from <NUM> to <NUM> phr of silica. In another embodiment, from <NUM> to <NUM> phr of silica may be used.

The commonly employed siliceous pigments which may be used in the rubber compound include conventional pyrogenic and precipitated siliceous pigments (silica). In one embodiment, precipitated silica is used. The conventional siliceous pigments employed in this invention are precipitated silicas such as, for example, those obtained by the acidification of a soluble silicate, e.g., sodium silicate.

Such conventional silicas might be characterized, for example, by having a BET surface area, as measured using nitrogen gas. In one embodiment, the BET surface area may be in the range of <NUM> to <NUM> square meters per gram. In another embodiment, the BET surface area may be in a range of <NUM> to <NUM> square meters per gram. The BET method of measuring surface area is described in the <NPL>).

The conventional silica may also be characterized by having a dibutylphthalate (DBP) absorption value in a range of <NUM> to <NUM>, alternatively <NUM> to <NUM>.

Various commercially available silicas may be used, such as, only for example herein, silicas commercially available from PPG Industries under the Hi-Sil trademark with designations <NUM> and <NUM>; silicas available from Rhodia, with, for example, designations of Z1165MP and Z165GR; and silicas available from Degussa AG with, for example, designations VN2 and VN3.

Commonly employed carbon blacks can be used as a conventional filler in an amount ranging from <NUM> to <NUM> phr. In another embodiment, from <NUM> to <NUM> phr of carbon black may be used. Representative examples of such carbon blacks include N110, N121, N134, N220, N231, N234, N242, N293, N299, N315, N326, N330, N332, N339, N343, N347, N351, N358, N375, N539, N550, N582, N630, N642, N650, N683, N754, N762, N765, N774, N787, N907, N908, N990 and N991. These carbon blacks have iodine absorptions ranging from <NUM> to <NUM>/kg and DBP number ranging from <NUM> to <NUM><NUM>/<NUM>.

Other fillers may be used in the rubber composition including, but not limited to, particulate fillers including ultra-high molecular weight polyethylene (UHMWPE), crosslinked particulate polymer gels including but not limited to those disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; or <CIT>, and plasticized starch composite filler including that disclosed in <CIT>. Such other fillers may be used in an amount ranging from <NUM> to <NUM> phr.

In one embodiment, the rubber composition may contain a conventional sulfur containing organosilicon compound. In one embodiment, the sulfur containing organosilicon compounds are the <NUM>,<NUM>'-bis(trimethoxy or triethoxy silylpropyl) polysulfides. In one embodiment, the sulfur containing organosilicon compounds are <NUM>,<NUM>'-bis(triethoxysilylpropyl) disulfide and/or <NUM>,<NUM>'-bis(triethoxysilylpropyl) tetrasulfide.

In another embodiment, suitable sulfur containing organosilicon compounds include compounds disclosed in <CIT>. In one embodiment, the sulfur containing organosilicon compounds includes <NUM>-(octanoylthio)-<NUM>-propyltriethoxysilane, CH<NUM>(CH<NUM>)<NUM>C(=O) -S-CH<NUM>CH<NUM>CH<NUM>Si(OCH<NUM>CH<NUM>)<NUM>, which is available commercially as NXT™ from Momentive Performance Materials.

In another embodiment, suitable sulfur containing organosilicon compounds include those disclosed in <CIT>. In one embodiment, the sulfur containing organosilicon compound is Si-<NUM> from Degussa.

The amount of the sulfur containing organosilicon compound in a rubber composition will vary depending on the level of other additives that are used. Generally speaking, the amount of the compound will range from <NUM> to <NUM> phr. In one embodiment, the amount will range from <NUM> to <NUM> phr.

It is readily understood by those having skill in the art that the rubber composition would be compounded by methods generally known in the rubber compounding art, such as mixing the various sulfur-vulcanizable constituent rubbers with various commonly used additive materials such as, for example, sulfur donors, curing aids, such as activators and retarders and processing additives, such as oils, resins including tackifying resins and plasticizers, fillers, pigments, fatty acid, zinc oxide, waxes, antioxidants and antiozonants and peptizing agents. As known to those skilled in the art, depending on the intended use of the sulfur vulcanizable and sulfur-vulcanized material (rubbers), the additives mentioned above are selected and commonly used in conventional amounts. Representative examples of sulfur donors include elemental sulfur (free sulfur), an amine disulfide, polymeric polysulfide and sulfur olefin adducts. In one embodiment, the sulfur-vulcanizing agent is elemental sulfur. The sulfur-vulcanizing agent may be used in an amount ranging from <NUM> to <NUM> phr, alternatively with a range of from <NUM> to <NUM> phr. Typical amounts of tackifier resins, if used, comprise <NUM> to <NUM> phr, usually <NUM> to <NUM> phr. Typical amounts of processing aids comprise <NUM> to <NUM> phr. Typical amounts of antioxidants comprise <NUM> to <NUM> phr. Representative antioxidants may be, for example, diphenyl-p-phenylenediamine and others, such as, for example, those disclosed in <NPL>. Typical amounts of antiozonants comprise <NUM> to <NUM> phr. Typical amounts of fatty acids, if used, which can include stearic acid comprise <NUM> to <NUM> phr. Typical amounts of zinc oxide comprise <NUM> to <NUM> phr. Typical amounts of waxes comprise <NUM> to <NUM> phr. Often microcrystalline waxes are used. Typical amounts of peptizers comprise <NUM> to <NUM> phr. Typical peptizers may be, for example, pentachlorothiophenol and dibenzamidodiphenyl disulfide.

Accelerators are used to control the time and/or temperature required for vulcanization and to improve the properties of the vulcanizate. In one embodiment, a single accelerator system may be used, i.e., primary accelerator. The primary accelerator(s) may be used in total amounts ranging from <NUM> to <NUM>, alternatively <NUM> to <NUM>, phr. In another embodiment, combinations of a primary and a secondary accelerator might be used with the secondary accelerator being used in smaller amounts, such as from <NUM> to <NUM> phr, in order to activate and to improve the properties of the vulcanizate. Combinations of these accelerators might be expected to produce a synergistic effect on the final properties and are somewhat better than those produced by use of either accelerator alone. In addition, delayed action accelerators may be used which are not affected by normal processing temperatures but produce a satisfactory cure at ordinary vulcanization temperatures. Vulcanization retarders might also be used. Suitable types of accelerators that may be used in the present invention are amines, disulfides, guanidines, thioureas, thiazoles, thiurams, sulfenamides, dithiocarbamates and xanthates. In one embodiment, the primary accelerator is a sulfenamide. If a second accelerator is used, the secondary accelerator may be a guanidine, dithiocarbamate or thiuram compound.

The mixing of the rubber composition can be accomplished by methods known to those having skill in the rubber mixing art. For example, the ingredients are typically mixed in at least two stages, namely, at least one non-productive stage followed by a productive mix stage. The final curatives including sulfur-vulcanizing agents are typically mixed in the final stage which is conventionally called the "productive" mix stage in which the mixing typically occurs at a temperature, or ultimate temperature, lower than the mix temperature(s) than the preceding non-productive mix stage(s). The rubber composition may be subjected to a thermomechanical mixing step. The thermomechanical mixing step generally comprises a mechanical working in a mixer or extruder for a period of time suitable in order to produce a rubber temperature between <NUM> and <NUM>. The appropriate duration of the thermomechanical working varies as a function of the operating conditions, and the volume and nature of the components. For example, the thermomechanical working may be from <NUM> to <NUM> minutes.

The rubber composition may be incorporated in a variety of rubber components of the tire. For example, the rubber component may be a tread (including tread cap and tread base), sidewall, apex, chafer, sidewall insert, wirecoat or innerliner. In one embodiment, the component is a tread.

Alternatively, the rubber composition may be used in various manufactured items including tire treads, shoes, shoe soles, transmission belts, hoses, airsprings, conveyor belts, track belts, non-pneumatic tires, and vibration isolators.

The pneumatic tire of the present invention may be a race tire, passenger tire, aircraft tire, agricultural, earthmover, off-the-road or truck tire. In one embodiment, the tire is a passenger or truck tire. The tire may also be a radial or bias.

Vulcanization of the pneumatic tire of the present invention is generally carried out at conventional temperatures ranging from <NUM> to <NUM>. In one embodiment, the vulcanization is conducted at temperatures ranging from <NUM> to <NUM>. Any of the usual vulcanization processes may be used such as heating in a press or mold, heating with superheated steam or hot air. Such tires can be built, shaped, molded and cured by various methods which are known and will be readily apparent to those having skill in such art.

This invention is illustrated by the following examples. Unless specifically indicated otherwise, parts and percentages are given by weight.

Epoxidized soybean oil was generously supplied by Arkema under the tradename Vikoflex® <NUM>. <NUM>-tert-butylbenzoic acid was purchased from Sigma Aldrich. Gum rosin (Rosin) and <NUM>,<NUM>-diazabicyclo[<NUM>. <NUM>]octane (DABCO) were purchased from Beantown Chemical. All materials were used without further purification. <NUM> and 13C NMR analyses were performed with a Bruker <NUM> NMR.

<NUM>-<NUM> (<NUM> eq) of epoxidized soybean oil (ESBO) was weighed into a resin kettle, followed by <NUM>-<NUM> eq of the desired carboxylic acid. The mixture was stirred prior to DABCO (<NUM>-<NUM> wt% versus ESBO) being added. The mixture was heated at <NUM>-<NUM> for <NUM>-<NUM>. After the reaction was complete, the reaction vessel was carefully opened to high vacuum while still being heated to remove the DABCO by sublimation. The resultant product was subjected to <NUM> and 13C NMR to confirm identity and purity. The product was used without further purification.

<NUM> (<NUM> eq, <NUM> epoxides per triglyceride) of ESBO, <NUM> (<NUM> eq) of gum rosin, and <NUM> of DABCO were added to a resin kettle. The mixture was heated to <NUM> for <NUM>, at which time it was opened to high vacuum to remove the DABCO by sublimation. The amber product was transferred hot to storage containers. Tg = - <NUM>; m. = <NUM>-<NUM>.

<NUM> (<NUM> eq, <NUM> epoxides per triglyceride) of ESBO, <NUM> (<NUM>. 2eq) of gum rosin, and <NUM> of DABCO were added to a resin kettle. The mixture was heated to <NUM> for <NUM>, at which time it was opened to high vacuum to remove the DABCO by sublimation. The amber product was transferred hot to storage containers. Tg = <NUM>.

<NUM> (<NUM> eq, <NUM> epoxides per triglyceride) of ESBO, <NUM> (<NUM>. 1eq) of tert-butylbenzoic acid, and <NUM> of DABCO were added to a resin kettle. The mixture was heated to <NUM> for <NUM>, at which time it was opened to high vacuum to remove the DABCO by sublimation. The amber product was transferred hot to storage containers. Tg = -<NUM>.

<NUM> (<NUM> eq, <NUM> epoxides per triglyceride) of ESBO, <NUM> (<NUM> eq) of tert-butylbenzoic acid, and <NUM> of DABCO were added to a resin kettle. The mixture was heated to <NUM> for <NUM>, at which time it was opened to high vacuum to remove the DABCO by sublimation. The amber product was transferred hot to storage containers. Cools to opaque tan semi-solid < <NUM>. Tg = -<NUM>.

Three rubber compounds were prepared in a multistep mix procedure following the formulations in Table <NUM>, where all amounts are in phr. Rubber compounds were cured following a standard cure cycle and tested for various properties as given in Table <NUM>.

Claim 1:
A vulcanizable rubber composition comprising a vegetable oil derivative comprising the structure
<CHM>
where R<NUM>, R<NUM> and R<NUM> are independently selected from a C15 to C20 alkenyl or a C15 to C20 alkyl, and optionally contain aromatic groups; R is - O - C(=O) - R<NUM> where R<NUM> is a phenyl, an alkyl substituted phenyl, a hydroxy-substituted phenyl, or a terpenoid; wherein each R is covalently bonded to a first carbon atom of one of R<NUM>, R<NUM> or R<NUM>; wherein a second carbon atom is adjacent to the first carbon atom and the second carbon atom is substituted with an -OH group; and m is the number of R groups.