Claims
- 1. An ebonite preform comprising a single component mixture having low modulus, high elongation and substantially tack free surface, the single component mixture comprising:
a) unsaturated polymers with mass parts of 100; b) a sulfur vulcanization agent with mass parts of approximately 15-50; c) a vulcanization activator with mass parts of approximately 5-35; d) a solubilizer with mass parts of approximately 1.5-6 for the sulfur vulcanization agent; and e) a vulcanization accelerator of mass parts of approximately 3-5, wherein the unsaturated polymers contain sufficient unsaturation in the backbones for forming linkage with the sulfur vulcanization agent and wherein the mixture gels at ambient condition.
- 2. The ebonite preform of claim 1, wherein the preform is characterized as a tape, block, brick, insert, sheet or laminate.
- 3. The ebonite preform of claim 1, wherein the unsaturated polymers are selected from the group consisting of polybutadiene, polyisoprene, and poly(butadiene-co-acrylonitrile).
- 4. The ebonite preform of claim 3, wherein the unsaturated polymers do not contain functional groups.
- 5. The ebonite preform of claim 3, wherein the unsaturated polymers contain functional groups.
- 6. The ebonite preform of claim 5, wherein the unsaturated polymers are partially epoxidized.
- 7. The ebonite preform of claim 5, wherein the functional groups are selected from the group consisting of hydroxyl, epoxy, anhydride and acrylic.
- 8. The ebonite preform of claim 1, wherein the mass parts of the sulfur vulcanization agent in the mixture is approximately 30-50.
- 9. The ebonite preform of claim 1, wherein the solubilizer contains polyamine.
- 10. The ebonite preform of claim 9, wherein the polyamine is selected from the group consisting of aliphatic, cycloaliphatic, amidoamide, and polyamide amine.
- 11. The ebonite preform of claim 1, wherein the vulcanization accelerator is selected from the group consisting of thiuram disulfide, diphenlguanidine, diorthotolylguanidine, mercaptobenzothiazoles, benzothiazo-2-sulfenmides, metal dialkyldithiocarbamides, thioureas, thiurams, xanthates, and thiadiazines.
- 12. The ebonite preform of claim 11, wherein the thiuram disulfide is selected from the group consisting of tetramethylthiuram disulfide, tetraethylthiuram disulfide, tetrabutylthiuram disulfide, tetraisobutylthiuram disulfide, tetraaklylthiuram and tetrabenzylthiuram disulfide.
- 13. The ebonite preform of claim 1, wherein the solubilizer contains polyamine and the vulcanization accelerator contains thiuram disulfide, which reacts with the polyamine, causing the mixture to gel at ambient condition.
- 14. The ebonite preform of claim 1, wherein the vulcanization activator is selected from the group consisting of zinc oxide, magnesium oxide, and zinc stearate.
- 15. The ebonite preform of claim 1, wherein the mixture further comprises a viscosity reducer with mass parts of approximately 0-30 for adjusting viscosity of the mixture and surface tack of the ebonite preform, the viscosity reducer is thermodynamically compatible with the unsaturated polymers.
- 16. The ebonite preform of claim 15, wherein the viscosity reducer is a liquid rubber having a viscosity lower than that of an unsaturated liquid rubber.
- 17. The ebonite preform of claim 15, wherein the viscosity reducer is non-volatile so that no significant weight loss occurs during vulcanization.
- 18. The ebonite preform of claim 1, wherein the mixture further comprises a thixotropic agent with mass parts of approximately 0-10.
- 19. The ebonite preform of claim 18, wherein the thixotropic agent is selected from the group consisting of fume silica and bentonite.
- 20. The ebonite preform of claim 1, wherein the mixture further comprises a reinforcing agent with mass parts of approximately 0-10.
- 21. The ebonite preform of claim 20, wherein the reinforcing agent comprises carbon black.
- 22. The ebonite preform of claim 1, wherein the ebonite preform is characterized as an ebonite tape and wherein the mixture is mixed and cast on a release paper at ambient conditions.
- 23. The ebonite preform of claim 22, wherein the release paper is selected from the group consisting of silicone release paper, polypropylene release paper, and polyethylene terephthalate release paper.
- 24. The ebonite preform of claim 22, wherein the ebonite preform is wrapped around a substrate and baked at elevated temperature for vulcanization, whereby a coating is formed on the substrate.
- 25. The ebonite preform of claim 1, wherein the mixture gels in approximately four days and turns into a soft elastic ebonite tape.
- 26. The ebonite preform of claim 25, wherein the ebonite tape has a tensile strength at 100% elongation less than 100 psi.
- 27. The ebonite preform of claim 25, wherein the ebonite tape has an elongation greater than 50%.
- 28. The ebonite preform of claim 1, wherein the ebonite preform is cast in a mold at ambient temperature.
- 29. The ebonite preform of claim 28, wherein the ebonite preform gels in 1 to 7 days and can be removed cleanly from the mold while retaining a molded shape.
- 30. The ebonite perform of claim 29, wherein the ebonite preform can stand alone in an oven and can be vulcanized at elevated temperature without significant distortion of the molded shape.
- 31. The ebonite preform of claim 30, wherein the ebonite preform is vulcanized by gradually raising temperature from ambient temperature to 115° C. at approximately less than 1° C./min and held at 115° C. for at least 4 hours.
- 32. The ebonite preform of claim 31, wherein the ebonite preform is characterized as having a thickness of greater than 0.030 inch and substantially free of porosity.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part patent application of U.S. patent application Ser. No. 09/724,715, filed Nov. 28, 2000, now allowed. This application is related to U.S. patent application Ser. No. 09/724,698, filed Nov. 28, 2000, now allowed, which is incorporated herein by reference.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09724715 |
Nov 2000 |
US |
Child |
10269839 |
Oct 2002 |
US |