Methods of coating rubber with solventless crystalline polyolefin coatings

Abstract

A laminate useful for seals particularly for vehicle window seals that are flexible, wear resistant and have a low coefficient of friction, is provided. The laminate has a rubber substrate and a polyolefin coating disposed on and adherent to the rubber substrate. The invention also provides methods of making laminates, particularly seals. Such method includes the steps of providing a rubber substrate; then applying a powdered crystalline polyolefin to the rubber substrate, in an amount sufficient to form a continuous layer when melted; and then melting the powdered crystalline polyolefin to form a continuous polyolefin coating disposed on, and adherent to, the rubber substrate. The invention also relates to seals comprising: an polyolefin rubber body; and a continuous coating of fused polyolefin disposed on and adherent to the rubber seal. Preferably the continuous coating of fused polyolefin is disposed in the glass run channel in the rubber body.

Description

BACKGROUND OF THE INVENTION

Many vehicle seals are flexible to conform to vehicle glass to seal out the elements. The flexibility must be maintained over a wide range of temperatures. Moreover, the seal area in contact with glass requires a low coefficient of friction so that when glass is raised or lowered, the seal does not stick to the glass. While ethylene-propylene-diene monomer rubber (EPDM) has a suitable flexibility, it has a less than preferred coefficient of friction. In an attempt to reduce the coefficient of friction, the surface of ethylene-propylene-diene monomer rubber has been coated with polyurethane. However, the polyurethane coating is not particularly resistant to wear, which results in failure of the seal within a relatively short time. Attempts have been made to produce seals with polymeric coatings other than polyurethane; however such seals typically employ volatile organic solvents during the manufacturing process. Such volatile organic solvents have recently become the subject of governmental regulation.

It would be desirable to have a flexible, wear resistant seal, having a low coefficient of friction, and which is applied without volatile organic solvents.

SUMMARY OF THE INVENTION

The present invention provides novel laminate useful for seals, particularly for vehicle window seals that are both flexible and wear resistant and have a low coefficient of friction, preferably with an initial coefficient of friction below 0.5. The laminate comprises a rubber substrate and a polyolefin coating disposed on and adherent to the rubber substrate.

The invention also provides novel methods of making seals; such a-method comprises the following steps: providing a rubber substrate; then applying a powdered crystalline polyolefin to the rubber substrate, in an amount sufficient to form a continuous layer when melted; and then melting the powdered crystalline polyolefin to form a continuous polyolefin coating disposed on and adherent to the rubber substrate. The invention also relates to seals comprising: a polyolefin rubber substrate; and a continuous coating of fused polyolefin disposed on and adherent to the rubber substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the laminate, composed of the rubber substrate and the polyolefin coating disposed on the rubber substrate.

FIG. 2 shows an embodiment of a vehicle seal composed of the rubber substrate and the polyolefin coating disposed in the glass run channel.

FIG. 3 shows a another embodiment of a vehicle seal composed of the rubber substrate and the polyolefin coating disposed in the glass run channel.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 the coated substrate 10 is shown, which is composed to the rubber substrate 12 and the polyolefin coating 14 . Referring to FIG. 2 , a vehicle seal 110 is shown composed of rubber substrate, more specifically rubber body 112 and polyolefin coating 114 disposed in the glass run channel 116 . Referring to FIG. 3 , a vehicle seal 210 is shown composed of rubber substrate, more specifically rubber body 212 having glass run channel 216 . The polyolefin coating 214 is disposed on the channel face surface 218 of rubber body 212 and optionally on the glass-contacting surfaces 224 and 226 of lip 220 and lip 222 of the rubber body 212 . Glass G is shown in glass run channel 216 .

The coated rubber has an abrasion resistance preferably greater than 30 cycles/μm, more preferably greater than 100 cycles/μm, even more preferably greater than 200 cycles/μm, most preferably greater than 300 cycles/μm. The coating adheres well to the rubber. The coated rubber has a coefficient of friction preferably below 0.5, preferably less than 0.4, more preferably less than 0.3. Preferably the coefficient of friction is from 0.01 to 0.5, more preferably from 0.01 to 0.4, most preferably from 0.1 to 0.3.

The polyolefin coating preferably is preferably from 5 μm to 3mm, more preferably from 25μm to 0.9 mm, in average thickness.

Forming the Polyolefin Coating on the Rubber Substrate

The method involves coating a rubber with a crystalline polyolefin powder. The crystalline polyolefin powder is typically applied by conventional application techniques, such as, for example, by sprinkling, by dipping, by powder-dropping from a continuous feeder belt; by electrostatic spray; by running extrudate through a powder fluid bed; by drawing down by applicator, or by a powder-coating gun. Alternatively, a rubber substrate emerging from an extruder is passed through a crystalline polyolefin powder-inert gas bed. The crystalline polyolefin powder is applied to a rubber substrate, which substrate is preferably at a temperature of from −40° C. to 315° C. and may be applied to cured or uncured rubber substrate.

The layer of the crystalline polyolefin powder has an average thickness greater than 5 μm. Once the crystalline polyolefin powder is applied to the substrate, it is heated to melt and fuse the powder. Where the crystalline polyolefin polymer has a molecular weight of greater than about 3,000,000, the crystalline polyolefin powder typically incompletely fuses upon heating, and the crystalline polyolefin powder while still molten is preferably compressed by rolling such as with a glass or metal cylinder. However, during the rolling process care is to be taken to not shift the mass of heated polyolefin coating; such shift decreases the adhesion of the polyolefin coating when the coated substrate is cooled.

Where the rubber substrate is not fresh, for example the rubber substrate displays bloom, it is preferable that the surface of the rubber substrate is cleaned before applying the crystalline polyolefin powder. The bloom is typically the result of components such as sulfur, stearic acid or anti-oxidants and the like, migrating to the surface of the rubber substrate. Conventional cleaning techniques are suitable. Good results have been obtained by abrading pre-vulcanized rubber, such as with emery paper or by solvent cleaning such as by wiping with toluene or mineral spirits or by both abrading and solvent cleaning. Where the surface is abraded, it is preferred that fine particulates produced by the abrading process be removed such as by rinsing. Good results have been obtained by using toluene. Air jets or water jets are also suitable for such rinsing.

Where vehicle sealing strips are prepared by extrusion, the polyethylene powder is preferably applied to the moving rubber extrudate after it exits the extruder die, but before the rubber extrudate enters a curing oven. As the rubber extrudate is heated for curing, the powder fuses and adheres to the substrate rubber. An advantage of applying the powder polyolefin to fresh rubber from the extruder is that the rubber -does not require cleaning prior to the application of the powder.

Optionally, various textures, and colors are created in the polyolefin coating. Optionally, conventional pigments are added to the polyolefin coating prior to heating the coated substrate. Conventional pigments such as for example titanium dioxide, carbon black, and conventional colored pigments are suitable. Optionally, texture is imparted to the polyolefin coating by varying the powder particles size and molecular weight of the polyolefin polymer. Larger particle sizes and higher molecular weights tend to produce rougher surfaces. Optionally, texture is imparted to the surface of the coating by using a blend of differing molecular weight polyolefin polymers or different types of polyolefin polymers, such as for example a blend of LDPE and UHMWPE or LDPE and isotactic polypropylene. Optionally, texture is imparted to the surface of the coating by varying the amount of crystalline polyolefin powder initially applied to the rubber; areas with greater quantities will provide bumps whereas areas having less crystalline polyolefin powder will produce valleys. Alternatively, smooth rollers or textured rollers are impressed into the warm polyolefin coating to provide the polyolefin coating with a smooth surface or a textured surface.

The Rubber Substrate

The rubber substrate is flexible and comprises an aliphatic hydrocarbon polyolefin rubber. Preferably the polyolefin/aliphatic hydrocarbon rubber is unsaturated, preferably having a diene content of less than about 15 weight percent, preferably less than about 10 weight percent. Preferably, the rubber is a conventional rubber such as used in vehicle seals. Suitable rubbers are, for example, natural rubber, blends comprising a thermoplastic, crystalline polyolefin polymer and vulcanized hydrocarbon rubber particles as described in U.S. Pat. No. 4,130,534 to Coran, et al. issued Dec. 19, 1978; U.S. Pat. No. 4,130,535 to Coran, et al. issued Dec. 19, 1978; U.S. Pat. No. 4,311,628 to Abdou-Sabet, et al. issued Jan. 19, 1982; U.S. Pat. No. 4,594,390 to Abdou-Sabet, et al. issued Jun. 10, 1986; U.S. Pat. No. 5,397,832 to Ellul issued Mar. 14, 1995; and U.S. Pat. No. 5,290,880 to Moench, et al. issued May 1, 1994, synthetic polyisoprene rubber, polybutadiene rubber, ethylene propylene diene terpolymer (hereinafter “EPDM”), ethylene propylene rubber(hereinafter “EPR”), butyl rubber, (hereinafter “IIR”), chlorobutyl rubber, (hereinafter “CIIR”) and bromobutyl rubber, (hereinafter “BIIR”) The rubber polymer in the rubber substrate preferably has a weight average molecular weight of 50,000 to 2,000,000, g/mole, more preferably from 80,000 to 500,000 g/mole, most preferably from 100,000 to 300,000 g/mole.

The Crystalline Polyolefin Powder

The crystalline polyolefin powder comprises crystalline polyolefin polymer. The crystalline polyolefin polymer has a crystallinity X c of preferably from 20 wt. % to 100 wt. %, more preferably from 30 wt. % to 100 wt. %, even more preferably from 40 wt. % to 100 wt. %, most preferably from 40 wt. % to 88 wt. %, as estimated from the density of the crystalline polyolefin polymer. Thus: $$ X c = 100 × ( Ps - P ⁢   ⁢ α ) ( Pc - P ⁢   ⁢ α )

where Ps is the density of the sample, Pa is the pure crystal density (1.000) and Pc is the pure amorphous density (0.85).

The crystalline polyolefin powder preferably has an average particle diameter of 600 μm or greater, and preferably 5 μm or greater. Preferably, the crystalline polyolefin powder particle size is from 5μm to 600μm, more preferably from 10 m to 350 μm; most preferably from 90μm to 250 μm.

The crystalline polyolefin powder preferably has an maximum particle size of 1 mm or less, and preferably 600 μm or less. Preferably the maximum crystalline polyolefin powder particle size is from 10 to 1 mm, more preferably from 15μm to 600μm, even more preferably from 20μm to 500μm; most preferably from 25cm to 300 am.

The crystalline polyolefin powder preferably has a melt flow index at 190° C. under a load of 2 kg, from 0.0 to 100 g/10 minutes, more preferably from 0.0 to 50 g/10 minutes, and even more preferably from 0.0 to 25 g/10 minutes. The crystalline polyolefin powder preferably has a melt flow index at 190° C. under a load of 5 kg, from 0.0 to 200 g/10 minutes, more preferably from 0.0 to 100 g/10 minutes, and even more preferably from 0.5 to 50 g/10 minutes. The crystalline polyolefin powder preferably has a melt flow index at 190° C. under a load of 21.6 kg, from 0.0 to 500 g/10 minutes, more preferably from 5.0 to 250 g/10 minutes, and even more preferably from 10 to 100 g/10 minutes.

The crystalline polyolefin polymer preferably has a melting point greater than 100° C. but less than the decomposition point of the rubber substrate.

The polyolefin polymer is preferably a homopolymer or copolymer of polypropylene or of polyethylene or mixtures thereof.

Where the crystalline polyolefin powder comprises polyethylene, the crystalline polyolefin powder comprises at least one high density polyolefin polymer, having a weight average molecular weight of 30,000 to 10,000,000 g/mole, more preferably from 30,000 to 1,000,000 g/mole, even more preferably 100,000 to 600,000 g/mole, most preferably from 200,000 to 400,000 g/mole.

As used herein, the term “high density polyethylene” means conventional high density polyethylene polymers as well as conventional ultra-high molecular weight linear polyethylene polymers, and thus “high density polyethylene” as used herein includes linear polymers having a density of 0.94 to 0.97, as well as linear polymers having a molecular weight of 3,000,000 or higher, and having a density of 0.93 or higher.

As used herein, the term “low density polyethylene” means conventional low density polyethylene polymers as well as conventional medium density branched polyethylene polymers, and thus “low density polyethylene” as used herein includes branched polyethylene polymers having a density of 0.915 to 0.93, as well as branched polyethylene polymers having a density of 0.89 to 0.94.

High density polyethylene polymers having molecular weights above 3,000,000 tend to produce coatings which are incompletely fused and do not adhere well to the substrate. Preferably a second polyethylene polymer is therefore added to such ultra high molecular weight polyethylene polymer. Such second polyethylene polymer is either a low density polyethylene polymer having a weight average molecular weight of preferably from 30,000 to 150,000 g/mole or a high density polyethylene polymer having a weight average molecular weight of preferably from 10,000 to 2,000,000 g/mole, more preferably from 30,000 to 150,000 g/mole.

Where the polyolefin comprises polypropylene, the polypropylene is preferably isotactic and preferably has a density from 0.880 to 0.92 and a crystallinity preferably between 30% and 100% by weight.

In one preferred embodiment, the crystalline polyolefin powder comprises a blend of crystalline polyolefin powders; specifically the crystalline polyolefin powder comprises from 10 to 90 parts by weight of a powdered high-density polyethylene polymer having a weight-average molecular weight between 200,000 and 10,000,000 g/mol., and 90-10 parts by weight of a powdered high- or low-density polyethylene polymer, having a weight-average molecular weight between 30,000 and 150,000 g/mole.

In another preferred embodiment, the crystalline polyolefin powder comprises a blend of crystalline polyolefin powders; specifically the crystalline polyolefin powder comprises 25 to 75 parts by weight of a powdered high-density polyethylene polymer, having a weight-average molecular weight between 250,000 and 6,000,000 g/mol., and 75 to 25 parts by weight of powdered high density polyethylene polymer, having a weight average molecular weight between 40,000 and 150,000 g/mole.

Generally, where the crystalline polyolefin powder comprises only one crystalline polyolefin polymer, it is preferred that such polyolefin polymer is a high density polyethylene having a weight average molecular weight of from 30,000 to 3,000,000 g/mole, more preferably from 100,000 to 1,000,000 g/mole, even more preferably from 200,000 to 600,000 g/mole, most preferably from 200,000 to 400,000 g/mole.

Polyolefin polymers having a molecular weight below 30,000 g/mole tend to produce coatings displaying high wear rate, and are not preferred.

Examples of crystalline polyolefin polymers suitable alone or in a blend to form the polyolefin coating are listed in Tables IA, IB and 1C below.

TABLE IA
CRYSTALLINE POLYOLEFIN POWDERS
						HDPE
		Hostalen	Hostalen	Coathylene		Spectroscopy
	Hostalen	GHR 802C	GUR400F	HA 1931	Hostalen	Grade
	GHR 8110	UHMW	UHMW	LDPE	GUR X117	MP*:
	UHMWHDPE	HDPE	HDPE	Composite	UHMW HDPE	130-145° C.
Property	Ticona	Ticona	Ticona	Particles	Ticona	Aldrich
MFI A	—		—	2	—	—
MFI B	—	0.5	—	—	—	—
MFI C	0.8-1.6	14	<1		<1	—
Density	0.95	0.95	0.93	0.919	0.93	—
(g/cm 3 )
Crystalline	—	130-135	130-135	108-113	130-135	130-140
melting
range
(° C.)
Vicat	—	—	—	87	—	—
softening
point
(° C.)
Number		—	—	32,000	—	—
avg. mw
(g/mole)
Weight	600,000	300,000	more	730,000	4,400,000	—
avg. mw			than
(g/mole)			6,000,000
Max.	<500	—	125	75	125	—
particle
size (d)
micro-
meters
Mid-	120	210	c. 60	17	c. 60	—
range
particle
size
Mesh	—	—	—	200	—	—
size

TABLE IB
CRYSTALLINE POLYOLEFIN POWDERS
		UHMW
		PE	Coathylene	Coathylene	Coathylene	Coathylene
		Treated	NB6454	NC5374F	HA2454	HO1681
	UHMW PE	Surface	HDPE	HDPE	LDPE*	LDPE
Property	Aldrich	Aldrich	Clariant	Clariant	Clariant	Clariant
MFI A	—	—	8	20	7	70
MFI B	—	—	—	—	—	—
MFI C	—	—	—	—	—	—
Density	0.94	0.94	0.964	0.953	0.9244	0.916
(g/cm 3 )
Crystalline	138	138	128-134	126-133	108-113	102-109
melting
range
(° C.)
Vicat	—	—	127	124	91	70
softening
point
(° C.)
Number	—	—	25,000	18,000	30,000	21,000
avg. mw
(g/mole)
Weight	3,000,000-	—	80,000	60,000	67,000	295,000
avg. mw	6,000,000
(g/mole)
Max.	—	—	90	125	75	630
particle
size (d)
micro-
meters
Mid-range	—	180	30	75	17	305
particle
size
Mesh size	—	—	170	120	200	38

TABLE IC
CRYSTALLINE POLYOLEFIN POWDERS
		MICRO-
		SCRUB			Propyl-
		50	Co-	Co-	matte
	MDPE*	HMW*	athylene	athylene	31 powder
	MP*:	LDPE	PY0787F	PB0580	PP
	109-111	Micro	homo-PP*	homo-PP	Micro
Property	Aldrich	Powders	Clariant	Clariant	Powders
MFI A.	—	—	—	—	—
MFI B	—	—	60	100	—
MFI C.	—	—	—	—	—
Density	0.94	—	0.907	0.905	0.86
(g/cm 3 )
Crystalline	109-111	107-109	162-168	162-168	160-170
melting
range
(° C.)
Vicat	—	—	148	145	—
softening
point
(° C.)
Number avg.	—	—	—	—	—
mw
(g/mole)
Weight avg.	—	—	—	—	—
mw
(g/mole)
Max. particle	—	297	200	90	31
size (d)
micro-
meters
Mid-range	—	—	110	38	12
particle size
micro-meters
Mesh size	—	50	70	170
*MP - melting point melting range
MFI A - melt flow index (MI 190° C./2 kg) g/10 minutes
MFI B - melt flow index (MI 190° C./5 kg) g/10 minutes
MFI C - melt flow index (MI 190° C./21.6 kg) g/10 minutes
Manufacturer's designations:
HMW = high molecular weight,
UHMW = ultra-high molecular weight,
HDPE = high-density polyethylene,
MDPE = medium-density polyethylene
PE = polyethylene,
LDPE = low-density polyethylene
PP = isotactic polypropylene

The polyethylene polymer available as Vistomer HD 2800 from Composite Particles Inc. is coated with a proprietary adhesive by the manufacturer and has a melt flow index at 190° C. under a load of 21.6 kg, of less than 1 g/10 minutes, a density of 0.93 g/cm 3 , a crystalline melting range of 130-135, a weight average molecular weight of more than 6,000,000 a maximum particle size of 125 microns, a mid range particle size of c.60 and a mesh size of 8,000. The Vistomer HD 2800 polyethylene is less preferred particularly for use in a vehicle seal.

The following examples illustrate the invention and are not intended to be limiting.

The crystalline polyolefin powder was typically applied by one of two methods; by dipping or by drawing the crystalline polyolefin powder along the substrate with a tool. The dipping method involved placing the rubber substrate into the crystalline polyolefin powder to obtain about 0.2 to 2 mm layer of the powder on the substrate. The crystalline polyolefin powder was applied by dipping in Examples 3, 4, 6, 7, 18, 20-25, 33, 40 and 41.

Alternatively, about 1 gram of crystalline polyolefin powder was placed near one end of a 20 cm×2 cm rubber strip. A notched tool was used to draw down a strip of powder down the length of the strip. The tool, made from a sheet of a high-hardness rubber had a notch 1 cm wide and 2 mm deep. The tool applied a strip of crystalline polyolefin powder 2 cm wide and 1 to 2 mm thick and about 1 gram in weight, to the rubber substrate.

EXAMPLE 1

A coated substrate was prepared as follows. The surface of a piece of vulcanized, carbon black filled EPDM rubber was cleaning/roughening by abrading the surface by stroking the surface sheet about 20 times with emery paper. Then the surface was scrubbed with toluene for a short time and wiped dry. After a few minutes when the surface appeared to be dry by visual examination, the powder was applied.

The substrate was heated for 5 minutes at 230° C. in an air circulating oven. Then a layer of polyethylene powder sold under the trade name Hostalen GHR 8020 from Ticona, was applied by dipping the rubber substrate into the powder to form a layer of powder approximately 1 mm thick at the thickest points. The substrate was then placed in a 230° C. oven for 5 minutes and removed and cooled.

EXAMPLE 2

A coated substrate was prepared as in Example 1, except that after the coated substrate was removed from the oven, a room temperature glass cylinder or a steel cylinder was pressed and rolled over the molten polyolefin, by hand, for about 15 seconds. The cylinder was then removed; the resulting coated rubber was smooth and even.

EXAMPLE 3

A coated substrate was prepared as in Example 2, except that about one half the amount of crystalline polyolefin powder was used.

EXAMPLE 4

A coated substrate was prepared as in Example 3.

EXAMPLE 5

A coated substrate was prepared as in Example 2.

EXAMPLE 6

A coated substrate was prepared as in Example 1, except that the Polymatte 31 polypropylene was used instead of the GHR8020.

EXAMPLE 7

A coated substrate was prepared as in Example 6.

EXAMPLE 8

A coated substrate was prepared as in Example 2, except that the GURX117 polyethylene was used.

EXAMPLE 9

A coated substrate was prepared as in Example 1, except that Microscrub 50 polyethylene was used.

EXAMPLE 10

A coated substrate was prepared as in Example 1.

EXAMPLE 11

A coated substrate was prepared as in Example 2, except that Microscrub 50 polyethylene was used.

EXAMPLE 12

A coated substrate was prepared as in Example 2, except that a mixture of 60% by weight of the Microscrub 50 polyethylene and 40% by weight GHR 8020 polyethylene was used.

EXAMPLE 13

A coated substrate was prepared as in Example 1, except that GHR 8020 polyethylene was applied to an uncured substrate and thus not pre-cleaned.

EXAMPLE 14

A coated substrate was prepared as in Example 2, except that the GUR 400F polyethylene applied to an uncured substrate and thus not pre-cleaned.

EXAMPLE 15

A coated substrate was prepared as in Example 2, except that GURX117 polyethylene was used.

EXAMPLE 16

A coated substrate was prepared as in Example 2.

EXAMPLE 17

A coated substrate was prepared as in Example 2, except that GHR 8110 polyethylene was used.

EXAMPLE 18

A coated substrate was prepared as in Example 2, except that a mixture of 60% by weight of the 8020 polyethylene and 40% by weight MS50 polyethylene was used.

EXAMPLE 19

A coated substrate was prepared as in Example 2, except that a mixture of 50% by weight of the 8020 polyethylene and 50% by weight MS50 polyethylene was used.

EXAMPLE 20

A coated substrate was prepared as in Example 1, except that a mixture of 50% by weight of the 8020 polyethylene and 50% by weight MS50 polyethylene was used.

EXAMPLE 21

A coated substrate was prepared as in Example 1, except that a mixture of 25% by weight of the 8020 polyethylene and 75% by weight MS50 polyethylene was used.

EXAMPLE 22

A coated substrate was prepared as in Example 22.

EXAMPLE 23

A coated substrate was prepared as in Example 1, except that a thin layer of an ultra high molecular weight polyethylene from Aldrich was used.

EXAMPLE 24

A coated substrate was prepared as in Example 1, except that “high density polyethylene” spectroscopy grade 130-145° C. from Aldrich was used.

EXAMPLE 25

A coated substrate was prepared as in Example 1, except that a “medium density polyethylene” melting point 109-111° C. from Aldrich was used.

EXAMPLE 26

A coated substrate was prepared as in Example 2, except that ultra high molecular weight polyethylene from Aldrich was used.

EXAMPLE 27

A coated substrate was prepared as in Example 2, except that ultra high molecular weight polyethylene, having a treated surface, from Aldrich was used.

EXAMPLE 28

A coated substrate was prepared as in Example 2, except Vistamer HD 2800 polyethylene coated with a manufacturer's proprietary adhesive, was used.

EXAMPLE 29

A coated substrate was prepared as in. Example 1, except Vistamer HD 2800 polyethylene, coated with a manufacturer's proprietary adhesive, was used.

EXAMPLE 30

A coated substrate was prepared as in Example 2, except that a the NC5374 Coathylene polyethylene was used.

EXAMPLE 31

A coated substrate was prepared as in Example 2, except that a the Coathylene NB6454 polyethylene was used.

EXAMPLE 32

A coated substrate was prepared as in Example 2, except Coathylene H01681 polyethylene with MFI of 70 was used.

EXAMPLE 33

A coated substrate was prepared as in Example 2, except that Coathylene HA2454 polyethylene was used.

EXAMPLE 34

A coated substrate was prepared as in Example 2, except that Coathylene HA1931 polyethylene from Clariant was used.

EXAMPLE 35

A coated substrate was prepared as in Example 2, except that Coathylene PB0580 polypropylene from Clariant was used.

EXAMPLE 36

A coated substrate was prepared as in Example 2, except that Coathylene PB0580 polypropylene from Clariant was used.

EXAMPLE 37

A coated substrate was prepared as in Example 2, except that Coathylene PY0787 polypropylene from Clariant was used.

EXAMPLE 38

A coated substrate was prepared as in Example 2, except that a mixture of 100 parts by weight of the 8020 polyethylene and 6.5 parts by weight molybdenum disulfide powder was used.

EXAMPLE 39

A coated substrate was prepared as in Example 1, except that a mixture of 100 parts of the MS50 polyethylene and 6.5 parts by weight molybdenum disulfide powder was used.

EXAMPLE 40

A coated substrate was prepared as in Example 2, except that a mixture of 50% by weight of the MS50 polyethylene and 50% by weight GHR 8020 polyethylene along with 6 parts molybdenum disulfide powder was used.

EXAMPLE 41

A coated substrate was prepared as in Example 2, except that a mixture of 25% by weight of the N6454 polyethylene and 75% by weight of the 8110 polyethylene was used.

EXAMPLE 42

A coated substrate was prepared as in Example 2, except that a mixture of 25% by weight of the N5374 polyethylene and 75% by weight GHR 8110 polyethylene was used.

EXAMPLE 43

A coated substrate was prepared as in Example 2, except that a mixture of 50% by weight of the N5374 polyethylene and 50% by weight GHR 8110 polyethylene was used.

EXAMPLE 44

A coated substrate was prepared as in Example 1, except that a mixture of 50% by weight of the N6454 polyethylene and 50% by weight of the 8110 polyethylene was used.

EXAMPLE 45

A coated substrate was prepared as in Example 1, except that a mixture of 75% by weight of the N5374 polyethylene and 25% by weight GHR 8020 polyethylene was used.

EXAMPLE 46

A coated substrate was prepared as in Example 1, except that the GHR 8110 polyethylene was used.

EXAMPLE 47

A coated substrate was prepared as in Example 1, except that a mixture of 25% by weight of the N5374 polyethylene and 75% by weight GHR 8110 polyethylene was used.

EXAMPLE 48

A coated substrate was prepared as in Example 1, except that a mixture of 38% by weight of the N5374 polyethylene and 62% by weight GHR 8110 polyethylene was used.

EXAMPLE 49

A coated substrate was prepared as in Example 1, except that N5374 polyethylene was used.

EXAMPLE 50

A coated substrate was prepared as in Example, 1, except that a mixture of 75% by weight of the N5374 polyethylene and 25% by weight GHR 8100 polyethylene was used.

EXAMPLE 51

A coated substrate was prepared as in Example 1, except that a mixture of 50% by weight of the N5374 polyethylene and 50% by weight GHR 8100 polyethylene was used.

COMPARATIVE EXAMPLE A

An EPDM rubber strip without a coating was used as a control.

COMPARATIVE EXAMPLE

BAr EPDM rubber strip with a Versicoat® polyurethane as coating was prepared using conventional methods.

COMPARATIVE EXAMPLE C

A coated substrate was prepared as in Example 1, except that a thin layer less than 300μm of GHR 8020 polyethylene was used.

Evaluation

The coated rubbers of the Examples and the Comparative Example were evaluated for abrasion resistance, coefficient of friction and adhesion. After cooling, the test strips were tested by using the crockmeter. The coefficient of friction was recorded as a function of the number of crockmeter cycles. The typical average thickness of the films prepared was about 20 mils (about 0.5 mm).

The durability of the samples was determined by test method entitled General Motors Engineering Standards, Seals Abrasion Resistance GM9909P:R 1 :ETSSLN, January 1993. The abrasion resistance was measured by using the wear resistance testing apparatus, as shown in FIG. 1 of the General Motors Standards. A 4 mm thick piece of non-tempered glass having a radius on the edge of 2.5 to 6 mm, with satin finish edge was rubbed, under weight, back and forth across the coated substrate. The samples of the coated substrates of the examples, were cut to 200 mm in length and trimmed as needed. The samples were mounted to a mounting fixture which was then attached to the wear resistance testing apparatus. The mounting fixture was centered and tighten so that the mounting fixture remained stationary and straight during the test. A weight of 2.7 kilograms was applied and the wear resistance testing apparatus was set to 60 cycles per minute, where the stroke of the abrasion element, that is, the glass, is 150 mm with one back and forth movement as one cycle. The glass was loaded to the wear resistance tester as per profile print in FIG. 1 of the General Motors Engineering Standards.

The wear resistance test was performed and the samples were typically visually examined every 500 cycles. The glass was replaced every 5000 cycles.

In addition to visual examination, the depth of wear was determined by optical microscopy. Thus, the wear resistance is reported as number of cycles per micrometer (micron). The results are presented in Table II.

The coefficient of friction was determined by dividing lateral force to move the glass by the normal force 2.7 kg. this was done for each cycle and averages were taken. The polyolefin coatings of the Examples were evaluated for adhesion to the rubber substrate by visual examination and manual examination.

TABLE II
SUMMARY OF CROCKMETER AND WEAR RESULTS
							Abrasion
						Depth of	Resistance
				Cycles		Wear,	cycles/
	Powder	Initial	Avg.	To	Coating	micro-	micro-
Sample	Type	COF	COF	fail	Appearance	meters	meter
Comparative	Control	0.7027	0.6775	8640	None	—	—
Ex.
Comparative	Control	0.6584	0.62041	5000	None	—	—
Ex.
Comparative	HS-37-EX-2	0.3093	0.4262	1314	—	—	—
Ex.	(Versicoat
	PU)
Ex. 1	Hostalen	0.277	0.3461	16600	Moderately	WT	—
	GHR8020				heavy
	not rolled				uniform,
					rough
Ex. 2	Hostalen	0.3208	0.4351	3300	Medium	WT	—
	GHR8020				thick,
	rolled				uniform,
					rough
Ex. 3	Hostalen	0.4038	0.4497	430	Light,	52	8.3
	GHR8020				uniform,
	rolled				rough
Ex. 4	Hostalen	0.3714	0.3946	4835	Light to	75	64.5
	GHR8020				medium,
					slightly
					rough
Ex. 5	Hostalen	0.3171	0.3455	5000	Medium to	59	84.7
	GHR8020				heavy,
	rolled				slightly
					rough
Ex. 6	Polymatte	0.7354	0.7353	106	Moderate	WT	—
	31				to thin,
					smooth
Ex. 7	Polymatte	0.7758	0.7758	115	Moderate	WT	—
	31				to thin,
					smooth
Ex. 8	Hostalen	0.3168	0.4149	209	Medium	WT	—
	GURX117				thick
					uniform
					unfused
Ex. 9	Microscrub	0.4663	0.515	244	Aesthet-	WT	—
	50				ically
	not rolled				mottled
Ex. 10	Hostalen	0.2475	0.2823	20000	Thick,	153	130.7
	GHR8020				smooth,
	not rolled				trans-
					lucent
Ex. 11	Microscrub	0.4404	0.464	10000	Thick,	WT	—
	50				smooth,
	rolled				trans-
					lucent
Ex. 12	Microscrub	0.3657	0.3409	20000	Thick,	257	77.8
	50/Hostalen				smooth,
	GHR8020				trans-
	60/40				lucent
	rolled
Ex. 13	Hostalen	0.295	0.3061	20000	Thick,	62	322.6
	GHR8020#				smooth,
					trans-
					lucent
Ex. 14	Hostalen	0.2402	0.3186	20000	Smooth,	33	606.1
	GUR400#				white
	rolled				film, poor
					adhesion
Ex. 15	Hostalen	0.3322	0.3889	6675	Smooth,	20	333.8
	GURX117				white
	rolled				film; poor
					adhesion
Ex. 16	Hostalen	0.3593	0.3229	20000	Thick,	129	155.0
	GHR8020				smooth,
	rolled				trans-
					lucent
Ex. 17	Hostalen	0.2371	0.255	20000	Thick,	31	645.2
	GHR8110				trans-
	rolled				lucent
Ex. 18	GHR8020/	.05321	0.34	10000	White,	43	232.6
	Microscrub				moderately
	50 60/40				thick
	rolled
Ex. 19	Hostalen	0.4698	0.4563	4153	Moderately	96	43.3
	GHR8020/				thin,
	Microscrub				trans-
	50 50/50				lucent
	rolled
Ex. 20	Hostalen	0.3814	0.4364	2334	Medium	WT	—
	GHR8020/				thin
	Microscrub				rough,
	50 25/75				trans-
	not rolled				lucent
Ex. 21	Hostalen	0.3676	0.5592	1000	Medium	WT	—
	GHR8020/				thin
	Micro-				rough,
	scrub 50				trans-
	25/75 not				lucent
	rolled
Ex. 22	Hostalen	0.4782	0.4928	6146	Medium	WT	—
	GHR8020/				thin
	Microscrub				rough,
	50 25/75				trans-
	not rolled				lucent
Ex. 23	UHMW PE	1.1185	1.0854	59	Very thin,	WT	—
	(Aldrich)				milky
					white
Ex. 24	HDPE	0.4545	0.5719	246	Thin,	WT	—
	Spectroscopy				smooth
	Grade				trans-
	MP: 130-				parent
	145° C.,
	(Aldrich)
Ex. 25	Medium	0.5158	0.5588	2487	Medium	WT	—
	density PE				thickness,
	(MDPE)				trans-
	MP:				parent
	109-111,				bumpy
	(Aldrich)
Ex. 26	PE UHMW	0.4945	0.5439	121	Thick	32	3.8
	(Aldrich)				white
	rolled				film, poor
					adhesion
Ex. 27	PE UHMW	0.3007	0.3508	10000	Thick off-	34	294.1
	(Aldrich),				white
	treated				film, poor
	surface				adhesion
	not rolled
Comparative	Vistomer	0.3976	0.4096	85	Smooth,	40	2.1
Ex. 28	HD2800				thick
	rolled				trans-
					lucent
					film
Ex. 29	Vistomer	0.3667	0.381	5670	Smooth,	WT	—
	HD2800,				thick,
	rolled				trans-
					parent
					film
Ex. 30	Coathylene	0.22	0.2152	10000	Smooth,	97	103.1
	NC5374				trans-
	rolled				parent,
					cracks in
					groove
					after test
Ex. 31	Coathylene	0.2077	0.2134	10000	Smooth,	126	79.4
	NB6454				trans-
	rolled				parent
					puddles
Ex. 32	Coathylene	0.4499	0.5867	6390	Smooth,	WT	—
	HO1681				trans-
	rolled				parent,
					thin
Ex. 33	Coathylene	0.4486	0.4526	62	Smooth,	68	0.9
	HA2454				trans-
	rolled				parent,
					puddles
Ex. 34	Coathylene	0.3389	0.4275	1240	Smooth,	348	3.6
	HA1931				trans-
	rolled				parent,
					puddles
Ex. 35	Coathylene	0.3545	0.4016	4259	Fairly	140	30.4
	PB0580				thick,
	rolled				uniform,
					rough
Ex. 36	Coathylene	0.4386	0.4778	180	Smooth,	113	1.6
	PB0580				trans-
					parent
Ex. 37	Coathylene	0.2046	0.3029	3108	Smooth,	78	39.8
	PY0787				thick,
	rolled				trans-
					parent
					film
Ex. 38	Hostalen	0.296	0.3298	10000	Medium	87	114.9
	GHR8020/				thickness,
	MoS 2				uniform,
	100/6.5				rough
	rolled
Ex. 39	Microscrub	0.5217	0.5225	63	Thin,	59	1.1
	50/MoS 2				mottled
	100/6.5
Ex. 40	Microscrub	0.3884	0.3818	10000	Moderately	121	82.6
	50/				thin,
	Hostalen				trans-
	GHR8020/				lucent
	MoS 2
	rolled
Ex. 41	NB6454/	0.2061	0.2351	10000	Thick,	42	238.1
	GHR8110				uniform,
	25/75				rough
	rolled
Ex. 42	Coathylene	0.2438	0.2512	10000	Thick,	66	151.5
	NC5374/				uniform,
	GHR8110				rough
	25/75
	rolled
Ex. 43	Coathylene	0.2538	0.2613	10000	Thick,	89	112.4
	NC5374/				uniform,
	GHR8110				rough
	50/50
	rolled
Ex. 44	Coathylene	0.1945	0.217	10000	Thick,	40	250.0
	NB6454/				uniform,
	Hostalen				rough
	GHR8110
	50/50
	rolled
Ex. 45	Coathylene	0.2515	0.2816	10000	Thick,	83	120.5
	NC5374/				uniform,
	GHR8110				rough
	75/25 not
	rolled
Ex. 46	Hostalen	0.2724	0.2575	10000	Thick,	115	87.0
	GHR8110				uniform,
	not rolled				rough
Ex. 47	Coathylene	0.2227	0.2165	10000	Thick,	45	222.2
	NC5374/				uniform,
	GHR8110				rough
	25/75 not
	rolled
Ex. 48	Coathylene	0.2136	0.246	10000	Thick,	76	131.6
	NC5374/				uniform,
	GHR8110				rough
	38/62 not
	rolled
Ex. 49	Coathylene	0.3462	0.3431	5100	Bumpy	WT	—
	NC5374 not
	rolled
Ex. 50	Coathylene	0.2782	0.2847	10000	Thick,	209	47.8
	NC5374/				uniform,
	GHR8110				rough
	75/25 not
	rolled
Ex. 51	Coathylene	0.2136	0.2182	10000	Thick,	73	137.0
	NC5374/				uniform,
	GHR8110				rough
	50/50 not
	rolled
WT—worn through
#rubber substrate not cured at time crystalline polyolefin powder was applied

The coatings of the Examples show reduced coefficients of friction in comparison to the comparative Example. In particular, the coatings of Examples 9, 10, 11, 13, 14b,14/18, 15-17, 19 21, 22, 23b, have significantly reduced coefficients of friction and show good wear characteristics. When the Versicoat® polyurethane control coating is fresh, the wear resistance is typically about 400 cycles/micron. However, with weathering, the wear resistance typically drops to about 10 cycles/micr6n, and the coefficient of friction greatly increases.

Thus, a reduced coefficient of friction is obtained with the coated substrates of the present invention. The wear resistance of the coating containing a polyethylene polymer having a molecular weight of 300,000 and higher, Examples 13 to 17 is greater than coatings containing polyethylene with a molecular weight below 300,000, such as Examples 30 and 31 However, the adhesion of the ultra high molecular weight HDPE to the substrate is typically not as strong as with the other HDPE.

Surprisingly, the coating which is a mixture of the of ultra-high molecular weight HDPE and the lower-molecular-weight HDPE has improved wear resistance and satisfactory adhesion to the substrate.

The coated substrate prepared in example 14, employed a polyethylene polymer having a molecular weight in excess of 6,000,000, GUR 400F. The resulting laminate had poor adherence making it less preferred for a vehicle seal but useful for a laminate having a temporary or easily removable polyolefin coating.

Crystalline polyolefin powders were also applied to rubber substrates having a temperature in the range of 20° C. to 260° C.; the coatings were satisfactory based on visual evaluation.

Claims

1. A method of coating polyolefin rubber substrate comprising the following steps:a. providing a crystalline polyolefin powder comprising a crystalline polyolefin polymer having weight average molecular weight of from 30,000 to 10,000,000 and a degree of crystallinity of 20 wt. % to 100 wt. %; b. applying the crystalline polyolefin powder, to the polyolefin rubber substrate, in an amount sufficient to form a continuous layer when melted; and c. then melting the crystalline polyolefin powder to form a continuous, fused, polyolefin coating disposed on, and adherent to, the polyolefin rubber substrate.

2. The method of 1, further comprising the step of:compressing the molten polyolefin coating.

3. The method of 1, wherein the polyolefin polymer has a an average particle diameter of from 5 to 600 μm and a melt flow index above from 0.0 to 500 g/10 minutes, at 190° C. under a load of 21.6 kg., and the rubber substrate is. selected from the group consisting of: ethylene propylene diene terpolymer, ethylene propylene rubber, butyl rubber, chlorobutyl rubber, and bromobutyl rubber, and mixtures thereof.

4. The method of claim 3, wherein the crystalline polyolefin powder comprises a powdered polyethylene comprising at least one high density polyethylene polymer.

5. The method of claim 3, wherein the crystalline polyolefin powder comprises a powdered polypropylene polymer.

6. The method of 3, wherein, wherein the crystalline polyolefin polymer comprises isotactic polypropylene.

7. The method of claim 3, wherein the crystalline polyolefin powder comprises:from 10 to 90 parts by weight of powdered high-density polyethylene polymer, having a weight-average molecular weight from 300,000 to 10,000,000 g/mol.; and from 10 to 90 parts by weight of powdered high-density polyethylene polymer, having a weight-average molecular weight from 40,000 to 150,000 g/mol.

8. The method of claim 6, wherein the rubber substrate is ethylene propylene diene terpolymer.

9. The method of claim 3, wherein the crystalline polyolefin powder comprises:from 25 to 75 parts by weight, of the powdered high-density polyethylene polymer, having a weight-average molecular weight from 600,000 to 6,000,000 g/mol.; and from 25 to 75 parts by weight of powdered high-density polyethylene polymer, having a weight-average molecular weight from 40,000 to 150,000 g/mole.

10. The method of claim 4, wherein the average particle diameter of the crystalline polyolefin powder is from 30 to 350 μm.

11. The method of 4, wherein the polyolefin polymer has a weight average molecular weight of from 30,000 to 6,000,000.

12. The method of claim 9, wherein the rubber substrate is ethylene propylene diene terpolymer.

13. The method of claim 3, wherein the rubber substrate has a glass run channel therethrough and the crystalline polyolefin powder is disposed in the glass run channel and the polyolefin coating has an average coefficient of friction against glass of less than 0.5 and a wear resistance of at least 30 cycles per micrometer as measured using glass having with satin edge, under a 2.7 kg load.

14. The method of claim 13, wherein the polyolefin coating has an average coefficient of friction against glass of less than 0.4 and a wear resistance of at least 100 cycles/μm as measured by using glass with satin edge, under a 2.7 kg load.

15. The method of claim 14, wherein the average particle diameter of the powdered polyolefin is from 90 to 250 μm.

16. The method of claim 14, wherein the polyolefin coating has a wear resistance of at least 200 cycles/μm as measured by using glass with satin edge, under a 2.7 kg load.

17. The method of claim 14, wherein the polyolefin coating has a wear resistance of at least 300 cycles/μm as measured by using glass with satin edge, under a 2.7 kg load.

18. The method of claim 14, wherein the polyolefin coating has an average thickness of 10 μm to 3 mm.