Method of covulcanizing chlorinated low unsaturation rubbers with high unsaturation rubber

Abstract

Disclosed are chlorinated low unsaturation rubbers exhibiting improved adhesion properties and improved covulcanization ability with high unsaturation rubbers. Also disclosed is a method of preparing these rubbers which comprises reacting the chlorinated rubber with certain bromine and/or iodine containing compounds.

Description

BACKGROUND OF THE INVENTION

This invention relates to chlorinated low unsaturation rubbers having both improved adhesion properties and also improved covulcanizability with high unsaturation rubbers and a method for making same.

Chlorobutyl rubber possesses many desirable properties such as exceptionally good air impermeability, flex properties and especially good heat resistance and aging properties. The commercial success of chlorobutyl rubber is largely dependent on its application in such things as tire innerliners and sidewalls, conveyor or power transmission belting, steam hoses, wire insulation, etc. Chlorobutyl rubber has proved to be useful in applications inaccessible to butyl rubber owing to the fact that the chlorinated sites of chlorobutyl enhance covulcanization of chlorobutyl with high unsaturation rubbers. Even with this improved covulcanization, it has long been recognized that the degree of covulcanization of chlorobutyl with high unsaturation rubber was not complete enough to allow for the use of chlorobutyl with high unsaturation rubber in all of the applications where its desirable properties would be advantageous. The properties which had to be improved before chlorobutyl could be effectively covulcanized with certain high unsaturation rubber for such uses as high performance tire innerliners and sidewalls were (1) the adhesion of chlorobutyl vulcanizates to high unsaturation rubber vulcanizates, and (2) improved tensile strength and dynamic stability of covulcanizates of chlorobutyl with high unsaturation rubber.

It has long been known in the art that the adhesion of chlorobutyl to high unsaturation rubber could be improved by the addition of small amounts of bromobutyl rubber to chlorobutyl rubber. Such a technique is disclosed in U.S. Pat. No. 2,992,670, wherein a minor proportion of bromobutyl is blended with a major proportion of chlorobutyl in order to improve the adhesion properties of chlorobutyl with high unsaturation rubber.

Another technique for improving the adhesion properties of chlorobutyl with high unsaturation rubber is disclosed in U.S. Pat. No. 2,933,117, which teaches that a chlorinated butyl inner lining of a tubeless tire can be adhered to a carcass containing one or more high unsaturation rubbers by the introduction of an interposed layer containing an admixture of a high unsaturation rubber and a brominated butyl rubber.

Still another technique for adhering chlorobutyl to a high unsaturation rubber is disclosed in U.S. Pat. No. 2,975,816, wherein a laminated rubber structure was prepared which consisted of:

(1) AN INNER LINING OF CHLOROBUTYL AND A HIGH UNSATURATION RUBBER MODIFIED WITH CERTAIN N-bromo compounds;

(2) A CARCASS LAYER CONTAINING ONE OR MORE HIGH UNSATURATION RUBBERS MODIFIED WITH A N-bromo compound, and

(3) AN OUTER RUBBER LAYER CONTAINING AT LEAST ONE RUBBER POLYMER.

SUMMARY OF THE INVENTION

It has now surprisingly been found that the compatibility and covulcanizability of chlorobutyl with a high unsaturation rubber can be greatly improved without the need for blending a chlorobutyl rubber with a bromobutyl rubber. Such an improvement is accomplished by the addition of certain bromine or iodine-containing compounds. These bromine or iodine-containing compounds can be either inorganic or organic. If inorganic, they are preferably in the form of a Lewis acid, e.g., aluminum bromide. If organic, the bromine or iodine is preferably bonded to a carbon atom which in turn is bonded to one to three functional groups which are capable of stabilizing a positive charge at the bromine-bonded carbon. Illustrative of such groups are nitrile, carbonyl, aryl, vinyl, etc.

DETAILED DESCRIPTION

The expression "butyl rubber" as employed in this specification is well known in the art and is intended to include those copolymers made from a polymerization reaction mixture having therein from about 70 to about 99.5% by weight of an isoolefin, which has about 4 to about 7 carbon atoms (e.g., isobutylene) and about 30 to about 0.5% by weight of a conjugated multiolefin having from about 4 to about 14 carbon atoms, e.g., isoprene. The resulting copolymer contains about 85 to about 99.5% by weight of combined isoolefin and about 0.5 to about 15% of combined multiolefin. The preparation of butyl rubber is well known in the art, and therefore a detailed description of its preparation is not included in this specification. The preparation of butyl rubber is disclosed in U.S. Pat. No. 2,356,128 which is incorporated herein by reference.

The term "chlorobutyl" as used in the specification and claims means a halogenated butyl rubber wherein the halogen is chlorine. Chlorobutyl rubber is commercially available and may be prepared by chlorinating butyl rubber in a solution containing between 1 to 60% by weight of butyl rubber in a substantially inert C.sub.5 -C.sub.8 hydrocarbon solvent such as pentane, hexane, heptane, etc. and contacting this butyl rubber cement with chlorine gas for about 2 secs. to about 25 mins. whereby chlorobutyl rubber and hydrogen halide are formed, the polymer containing up to one or more halogen atoms per double bond initially present in the polymer. The preparation of chlorobutyl rubber is old in the art, see e.g. U.S. Pat. No. 3,099,644, which is incorporated herein by reference. This invention is not intended to be limited in any way by the manner in which butyl rubber is chlorinated.

In general any chlorobutyl rubber can be used. Illustrative of the chlorobutyl rubber used in this invention is a chlorinated butyl rubber which before chlorination analyzes 1.8 mole % unsaturation and a viscosity average molecular weight of about 450,000. The high molecular weight butyl rubber starting material contained from about 0.5 to about 6% of combined diolefin.

The term "high unsaturation rubber" as used in the specification and claims means those rubbers containing at least 30 mole % unsaturation. Illustrative of such rubbers are natural rubber, styrene-butadiene rubber, polybutadiene, polyisoprene, and polychloroprene and mixtures thereof.

It will be evident to those skilled in the art that the scope of this invention includes other chlorinated low unsaturation rubbers wherein the amount of unsaturation is less than 30 mole % and the viscosity average molecular weight is about 10,000 to 1,000,000. Illustrative of such an elastomer would be chlorinated EPDM. Methods for preparing chlorinated EPDM are well known in the art; said EPDM may be prepared by reacting an EPDM consisting of ethylene, an alpha-olefin other than ethylene and a small amount of non-conjugated diolefin with a chlorinated hydrocarbon such as carbon tetrachloride, chloroform, trichloroethylene, tetrachloroethylene or monochlorobenzene in the presence or absence of a free radical initiator, e.g., UV light, chemical initiators, etc.

Illustrative of a chlorinated EPDM suitable for use in this invention is one having the following properties: ethylene content, 48 wt. %; ethylene norbornene content, 9 wt. %; a chlorine content of 0.65 wt. % and having an iodine number of 18.6 and a Mooney Viscosity ML 260 of 67.

Organic bromine and iodine compounds suitable for use in this invention are preferably C.sub.1 to C.sub.30 and more preferably C.sub.1 to C.sub.20 compounds wherein the bromine or iodine is bonded to a carbon atom which also has bonded thereto, two or three additional groups wherein at least one of the groups is a functional group capable of stabilizing a positive charge at the halogen-bonded carbon. Illustrative of groups capable of stabilizing said positive charge and suitable for use in this invention include (but are not limited to) nitrile, carboxyl, aryl, vinyl and carbonyl. Groups other than the halogen and stabilizing groups which may also be attached to the halogen-bonded carbon may be any of the non-electron withdrawing groups. Illustrative of such groups suitable for use in this invention are aliphatic groups, double bonded oxygen, hydrogen and an additional bromine.

Illustrative of organic bromine-containing compounds suitable for use in this invention include (but is not limited to) .alpha.-bromoacetophenone, bromodiphenylmethane, 9-bromofluorene, diethyl bromomalonate, benzoyl bromide, cinnamyl bromide, 1,4-dibromo-2-butene, bromoacetic acid, 1,4-dibromo-2,3-butanedione, diethyl dibromomalonate, dibromoacetonitrile, tribromoacetaldehyde, .alpha.-bromoisobutyrophenone, ethyl 2-bromoisobutyrate, .alpha.,.alpha.,.alpha.',.alpha.' tetrabromo .sigma.-xylene and 9,10-dibromoanthracene. Preferred are diethyl bromomalonate, bromoacetic acid and cinnamyl bromide.

Organic iodine-containing compounds which are suitable for use in this invention include (but are not limited to) .alpha.-iodoacetophenone, iodoacetic acid, cinnamyl iodide.

Also within the scope of this invention are organic compounds similar to those above but which contain both iodine and bromine atoms.

It has also been found that certain types of bromine-containing inorganic compounds are suitable for use in this invention. Such inorganic compounds are preferably Lewis acids such as aluminum bromide and zinc bromide. When an inorganic bromine-containing compound is used which cannot be directly dispersed in the rubber blend because of the compound's high melting point, it is preferred that such a bromine containing compound be first dissolved in a suitable solvent before its introduction into the rubber blend. Illustrative of such suitable solvents would be water and oxygenated hydrocarbons such as ethers, esters and alcohols. An example of such a solution would be a 33% by weight solution of zinc bromide in isopropanol.

An advantage of this invention is that it increases the utility of chlorobutyl rubber so that it can be used in applications in which bromobutyl rubber has been advantageous because of its more rapid cure. One such application would be in molded products such as pharmaceutical stoppers. Often bromobutyl rubber as opposed to chlorobutyl rubber is used in the production of such stoppers to the fact that bromobutyl has a faster cure rate than chlorobutyl thus leading to a higher production rate. But by using bromobutyl rubber for such applications, an occupational hazard may also be created in view of the fact that bromine may be introduced into the working environment. By means of this invention one is able to obtain as fast a cure rate with the bromine modified chlorobutyl as with bromobutyl. The occupational hazard created by use of bromobutyl is also reduced owing to the fact that chlorobutyl dehydrochlorinates at a much slower rate than bromobutyl dehydrobrominates.

The compositions of this invention may be compounded by conventional compounding methods known in the art. In general the chlorinated low unsaturation rubber and/or high unsaturation rubber is mixed in a conventional mixer, although a banbury mixer is preferred, at about 75.degree. C. to about 250.degree. C. for about 1 to about 10 minutes. More preferred is a temperature of about 100.degree. C. to about 200.degree. C. for about 3 to about 8 minutes and most preferred is a temperature of about 150.degree. C. for about 6 minutes. The rubber composition is then milled with the bromine or iodine containing compound preferably at a temperature of about 0.degree. C. to about 100.degree. C. for a time long enough to completely mix the composition. More preferred is a temperature of about 20.degree. C. to about 50.degree. C. for about 1 to about 5 minutes.

The amount of bromine or iodine containing compound required will vary with the amount of chlorobutyl rubber. Preferably enough bromine or iodine containing compound is used so as to provide from about 0.125 moles of bromine or iodine to about 1 mole of bromine or iodine per mole of chlorine present in the chlorobutyl rubber. More preferred is about 0.250 moles to about 0.500 moles of bromine or iodine present per mole of chlorine.

It will also be evident to those skilled in the art that conventional rubber compounding materials may be used in the practice of this invention. Illustrative of such conventional compounding materials suitable for use in this invention would be fillers, oils, accelerators, etc.

Also within the scope of this invention is a method of improving the adhesion of chlorinated low unsaturated rubbers to high unsaturated rubbers wherein the interfacial surfaces of said rubbers are treated with a bromine or iodine containing composition. The bromine or iodine containing compounds are those previously described and may be applied in solution, paste or other appropriate means.

This invention will be more fully illustrated by the following examples.

EXAMPLE 1

Both chlorobutyl rubber and natural rubber were each compounded with fillers and plasticizers in a Banbury for 6 minutes at 149.degree. C. The compounds were then transferred to a rubber mill wherein zinc oxide, sulfur and accelerators were added and milled. The materials were then press cured for 30 minutes at 153.degree. C. Formulation data is found in Tables I and II below.

The chlorobutyl compound was tested by conventional means for % elongation, tensile strength and 300% modulus; the results are found at the end of Table I.

The two rubber compounds were adhered together and a strip adhesion test (ASTM D413-38) was performed; the results are listed in Table III below.

TABLE I______________________________________Chlorobutyl Rubber Compound Parts per Hundred______________________________________Chlorobutyl 100.0Regal 300 (HAF Block) 25.0MT (Medium Thermal Furnace Block) 75.0Stearic Acid 1.0Amberol ST 137 .times. (1) 4.0Flexon 840 oil (Plasticizer) 6.0Sunolite 127 Wax 2.0Zinc Oxide 5.0Sulfur 1.5Mercaptobenzothiazyl disulfide (MBTS) 1.0Properties300% Modulus, psi 800.0Tensile Strength, psi 1300.0Elongation, % 550.0Mooney Scorch at 132.degree. C. (minutesto 10 point rise) 10.2______________________________________ (1) phenol-formaldehyde resin TABLE II______________________________________Natural Rubber Blend Parts per Hundred______________________________________RSS No.1 (1) 100.0SRF Black 50.0Flexon 580 oil (Plasticizer) 5.0BLE-25 (2) 1.5Stearic Acid 1.5Zinc Oxide 5.0Santocure (3) 1.2Tetramethyl thiuram disulfide (TMTDS) 0.1Sulfur 2.5______________________________________ (1) Ribbed smoked sheet - natural rubber (2) High temperature reaction product of diphenylamino and acetone (3) N-cyclohexyl-2-benzo thiazolesulfenamide TABLE III______________________________________Adhesion of Chlorobutyl to Natural Rubber Blend______________________________________lbs/inch at 24.degree. C. 48 Interfacial separationlbs/inch at 121.degree. C. 5 Interfacial separation______________________________________

The above data illustrates the non-compatibility of chlorobutyl with a natural rubber blend. In view of the poor adhesion qualities of chlorobutyl with natural rubber, such a combination would be unacceptable for such uses as high performance tire construction.

EXAMPLES 2-9

A chlorobutyl rubber composition was prepared as in Example 1 except that bromine-containing compounds were introduced during the milling stage. The bromine-containing chlorobutyl was adhered to the natural rubber formulation of Example 1 and ASTM D413-38 strip-adhesion tests were performed. The following is a table illustrating some of the bromine-containing compounds suitable for use in this invention and their ability to enhance the compatibility of chlorobutyl with high unsaturated rubber compositions.

TABLE IV__________________________________________________________________________Effects of Selected Bromine-Containing Compoundson the Compatability of Chlorobutyl with NaturalRubber__________________________________________________________________________ Mole of 300% Tensile Br to Modulus Strength Elonga- Adhesion to Adhesion to Mooney ScorchEx. Bromine Compound Mole of Cl psi psi tion % NR at 24.degree. C. NR at 121.degree. C. at 132.degree. C. (2)__________________________________________________________________________2 1,4-dibromo-2,3-butanedione 0.5 950 1100 350 52T 38T 2.6 0.25 1000 1250 400 70I 43T 3.8 0.125 1000 1300 450 90T 9I 5.03 Diethyl Bromomalonate 0.5 550 1000 600 120T 68T 6.6 0.25 700 1100 600 170T 80T 7.1 0.125 780 1200 500 70I,T 4-I 6.44 .alpha.-bromoacetophenone 0.5 650 1000 600 165T 75T 5.4 0.25 850 1200 550 125T 80T 6.2 0.125 880 1250 500 80I,T 9-I 7.05 Bromoacetic Acid 0.5 750 1000 500 118T 65T 4.8 0.25 850 1100 550 90I 58T 5.2 0.125 930 1200 500 73T 4I 7.86 Cinnamyl bromide 0.5 900 1150 400 105T 50T 1.7 0.25 950 1300 530 75I 50T 4.8 0.125 930 1330 400 90I,T 13I,T 4.87 1,4-dibromo-2-butene 0.5 1000 1250 450 82T 60T 7.0 0.25 900 1200 500 120T 38T 9.4 0.125 1000 1330 500 44I 7I 8.48 Zinc bromide(1) 0.5 1200 1350 400 -- -- <2.0 0.25 1050 1300 450 130-T 50-T 2.0 0.125 880 1380 500 95I,T 6-I 5.89 Aluminum Bromide 0.5 950 1250 450 105T 60T 2.0__________________________________________________________________________ (1) dissolved in isopropanol to give a 33% by weight solution; (2) minute to 10 point rise I = Interfacial separation (not desirable) T = Stock Tearing (desirable)

The above table shows that the compatibility of chlorobutyl with high unsaturation rubber compositions can be increased with the use of selected bromine-containing organic and inorganic compounds. The above table also illustrates that as the mole ratio of bromine to chlorine in the chlorobutyl is decreased, the adhesion property of bromine-containing chlorobutyl to natural rubber decreases. As shown above, it is preferred that the mole ratio of bromine to chlorine not fall substantially below 0.125 mole of bromine per mole of chlorine.

Also indicated by this table is the fact that the addition of bromine-containing compounds to chlorobutyl significantly decreases the Mooney Scorch time. This shows that the addition of these bromine-containing compounds gives a faster cure rate than chlorobutyl alone.

EXAMPLE 10

Rubber compositions were prepared according to Example 2 except that an iodine-containing compound as opposed to a bromine-containing compound was reacted with the chlorobutyl during milling. The following is a table illustrating the suitability of one such iodine compound for use in the present invention.

TABLE V______________________________________Effect of Iodoacetic Acid on the Compatibilityof Chlorobutyl with Natural Rubber0.25 Moles of Iodine per Mole of Chlorine______________________________________300% Tensile Adhesion to Adhesion toModulus Strength Elongation NR at 24.degree. C. NR at 121.degree. C.psi psi % lbs/inch lbs/inch______________________________________750 1200 500 65-T 25-T______________________________________ T = stock tearing

EXAMPLE 11

A vulcanizate of chlorobutyl/natural rubber was prepared according to the procedure of Example 1. The formulation for such a rubber blend is found in Table VI. Tensile strength and dynamic stability of this rubber blend were measured by conventional means, and the data set forth in Table VII below.

TABLE VI______________________________________Formulation of Chlorobutyl/Natural Rubber Vulcanizate______________________________________ Parts per Hundred______________________________________Chlorobutyl 50.0RSS No.1 (natural rubber) 50.0HAF Black 35.0Circosol 4240 oil 5.0Age Rite Stalite (1) 1.0Stearic Acid 1.5ZnO 5.0Sulfur 1.5MBTS 1.0______________________________________ Press cured for 30 minutes at 153.degree. C. (1) Mixture of alkylated diphenylamines TABLE VII______________________________________Tensile Strength and Dynamic Stability of Chlorobutyl/Natural Rubber Vulcanizate______________________________________300% Modulus, psi 990Tensile Strength, psi 1850Elongation % 500Kilocycles to rupture.sup.1 31______________________________________ .sup.1 Monsanto fatigue-to-fatigue test at a nominal 140% extension.

EXAMPLES 12-19

Chlorobutyl/natural rubber compositions of Example 11 were prepared except that certain bromine-containing compounds were introduced during the milling stage. After curing, tensile strength and dynamic stability data were obtained by conventional means, and the data for these bromine-containing compositions are found in Table VIII below.

TABLE VIII__________________________________________________________________________Effect of Selected Bromine Containing Compoundson Tensile Strength and Dynamic Stability ofChlorobutyl/Natural Rubber Blend__________________________________________________________________________ Tensile Moles of Br to 300% Strength Elongation Kilocycles toEx. Bromine Compound Moles of Cl Modulus, psi psi % Rupture__________________________________________________________________________12 1,4-dibromo-2,3-butanedione 0.50 850 2250 550 71 0.25 1100 2400 550 57 0.125 1000 2000 500 4913 Diethyl Bromomalonate 0.50 900 2550 650 121 0.25 1000 2700 600 57 0.125 950 2050 500 4714 .alpha.-bromoacetophenone 0.50 600 2500 650 202 0.25 950 2500 600 45 0.125 800 2250 600 4715 Bromoacetic Acid 0.50 500 2350 700 206 0.25 1050 2500 570 55 0.125 1000 2350 550 5016 Cinnamyl Bromide 0.50 850 2750 650 74 0.25 950 2500 500 53 0.125 830 2000 500 5517 1,4-dibromo-2-butene 0.50 900 2500 600 88 0.25 1100 2400 550 50 0.125 930 1880 500 2718 Zinc Bromide (1) 0.50 1100 2700 550 49 0.25 1200 2550 500 46 0.125 1000 2180 550 4619 Aluminum Bromide 0.50 1000 2550 550 60__________________________________________________________________________ (1) dissolved in isopropanol to give a 33% by weight solution

The above table shows that tensile strength and dynamic stability of a blend of chlorobutyl with natural rubber is improved by the addition of the bromine-containing compounds of this invention. It is also apparent from this data that as the mole % of bromine to chlorine decreases, the compatibility of chlorobutyl to natural rubber decreases.

EXAMPLE 20

A vulcanizate of claim 11 was prepared, except an iodine-containing compound was added to the composition during the milling stage. The rubber composition was also cured for 30 minutes at 153.degree. C. The following table shows the ability of an iodine compound of this invention to increase the compatibility of chlorobutyl to natural rubber

TABLE IX______________________________________Effect on Tensile Strength and Dynamic Stabilityby Addition of Iodoacetic Acid in Chlorobutyl/ -Natural Rubber______________________________________BlendsMoles ofIodine 300% Tensile Kilo-per mole Modulus, Strength, Elonga- cycles toof Chlorine psi psi tion % Rupture______________________________________0.25 930 2450 550 64______________________________________ It is to be understood that this invention is not restricted to the foregoing examples which serve only to illustrate the present invention. Numerous variations may be devised without departing from the scope of this invention.

Claims

1. A laminated composition of matter comprising one layer of chlorobutyl rubber and a halogen-containing organic compound, wherein the halogen is bonded to a carbon atom which is in turn bonded to 1 to 3 functional groups capable of stabilizing the positive charge at the halogen-carbon bond, and wherein the halogen is selected from the group consisting of bromine and iodine; and another layer comprising a high unsaturation rubber wherein the unsaturation is at least 30 mole %.

2. The composition of claim 1 wherein the halogen-containing compound is selected from the group consisting of diethylbromomalonate, .alpha.-bromoacetophenone, bromoacetic acid, cinnamyl bromide, 1,4-dibromo-2-butene and iodoacetic acid.

3. The composition of claim 1 wherein said composition contains at least 0.125 moles of halogen per mole of chlorine.

4. The composition of claim 1 wherein the functional group is selected from the group consisting of nitrile, carboxyl, aryl, vinyl, and carbonyl.

5. The composition of claim 1 wherein the high unsaturated rubber is selected from the group consisting of natural rubber, styrene butadiene rubber, polybutadiene, polyisoprene, polychloroprene, and mixtures thereof.