Claims
- 1. A process for forming a masterbatch rubber having polymer bound functionality comprising the emulsion polymerization at a temperature ranging from about 40.degree. C. to 100.degree. C. of:
- (a) at least one functionalized monomer that contains a polymerizable vinyl group and has a moiety selected from the group consisting of antidegradants, metal deactivators, photosensitizers, pigments, synergists, catalysts, accelerators, or combinations thereof; with
- (b) at least one copolymerizable conjugated diene monomer selected from the group consisting of butadiene-1,3, 2-chlorobutadiene-1,3, isoprene, piperylene and conjugated hexadienes;
- wherein the polymerization is conducted in the presence of (1) from 2 to 30 parts by weight of an ionic surfactant per 100 parts by weight of organic components and (2) from about 10 to about 70 parts by weight of a plasticizer based on 100 parts by weight of total monomers and said plasticizer functions as the sole solvent and dispersing agent for said functionalized monomer during the polymerization other than the water and ionic surfactant in the emulsion and said copolymerizable conjugated diene; said plasticizer being selected from:
- (A) carboxylic acid esters selected from the group consisting of diesters of triethylene glycol, dibutoxy ethoxy ethyl formate, dialkyl diether glutarate, dibutoxyethyl adipate, dibutoxyethoxyethyl adipate, di-2-ethylhexyl adipate, tetraethylene glycol diheptanoate, propylene glycol dibenzoate, dipropylene glycol dibenzoate, triethylene glycol dibenzoate, butyl octyl phthalate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, dibutyoxy ethyl phthalate, di-2-ethylhexyl phthalate, tetraethylene glycol dioctoate, polyethylene glycol dioctoate, triethylene glycol di-2-ethylhexanoate, eteraethylene glycol di-2-ethylhexanoate, triethylene glycol caprate-caprylate, triethylene glycol di(caprate-caprylate), triethylene glycol dipelargonate, dibutyl sebacate, dibutoxyethyl sebacate, di-2-ethylhexyl sebacate, dioctyl sebacate, diethylene glycol mono-laurate and butoxyethyl oleate; or
- (B) phosphates selected from the group consisting of 2-ethylhexyl diphenyl phosphate, iso-decyldiphenyl phosphate, tri-n-butyl phosphate, tri(2-ethylhexyl) phosphate, tributoxyethyl phosphate, tricresyl phosphate, trixylenyl phosphate and trixylyl phosphate; or
- (C) formals selected from the group consisting of dibutoxyethoxy formal and di(butoxy-ethoxy-ethyl) formal; and
- (D) N-butylbenzene sulfonamide.
- 2. The process of claim 1 wherein the monomer charge ratio by weight of functionalized monomer to conjugated diene monomer ranges from about 0.10 to 99.9 to 99.9 to 0.10.
- 3. The process of claim 1 wherein in addition to said functionalized monomer and said copolymerizable conjugated diene monomer, at least one vinyl monomer is polymerized, said vinyl monomer being selected from the group consisting of styrene, .alpha.-methylstyrene, divinylbenzene, vinyl chloride, vinyl acetate, vinylidene chloride, methyl methacrylate, ethyl acrylate, vinylpyridine, acrylonitrile, methacrylonitrile, methacrylic acid, itaconic acid and acrylic acid.
- 4. The process of claim 3 wherein the weight ratio of functionalized monomer to conjugated diene monomer to vinyl monomer may range from 5:75:20 to 95:5:0 parts per hundred parts based on total monomer.
- 5. A process according to claim 1 wherein at least one functionalized monomer is from the group consisting of (a) amides having the structural formula: ##STR11## wherein R.sup.6 is an aryl radical, R.sup.3 and R.sup.4 are selected from the group consisting of hydrogen, alkyl radicals having from 1 to 4 carbon atoms and alkoxy radicals having from 1 to 4 carbon atoms, R.sup.5 is selected from the group consisting of hydrogen, alkyl radicals having from 1 to 4 carbon atoms, alkoxy radicals having from 1 to 4 carbon atoms and a radical having the following structural formula: ##STR12## wherein R.sup.7 is selected from the group consisting of alkyl radicals having from 1 to 12 carbon atoms, cycloalkyl radicals having from 5 to 12 carbon atoms, aryl radicals having from 6 to 12 carbon atoms and aralkyl radicals having from 7 to 13 carbon atoms and R.sup.8 is selected from the group consisting of hydrogen and alkyl radicals having from 1 to 12 carbon atoms and wherein R.sup.9 and R.sup.10 are hydrogen or alkyl radicals having from 1 to 4 carbon atoms, R.sup.11 is selected from the group consisting of hydrogen, methyl and ethyl; and R.sup.12 is hydrogen or phenyl; and (b) imides selected from the group consisting of (1) compounds having the following structural formula: ##STR13## wherein R.sup.3, R.sup.4, R.sup.5, R.sup.9 and R.sup.10 are as previously defined herein under structural formula II and wherein R.sup.13 and R.sup.14 are selected from the group consisting of hydrogen and alkyl radicals having from 1 to 14 carbon atoms and (2) compounds having the following structural formula: ##STR14## wherein R.sup.3, R.sup.4, R.sup.5, R.sup.6, R.sup.9 and R.sup.10 are as previously defined herein under structural formula I and wherein R.sup.15 and R.sup.16 are selected from the group consisting of hydrogen and alkyl radicals having from 1 to 4 carbon atoms.
- 6. A process according to claim 1 wherein the functionalized monomer is selected from the group of compounds represented by the structural formula: ##STR15## wherein R.sup.17 and R.sup.18 is a tert-alkyl radical having from 4 to 8 carbon atoms, R.sup.19 is selected from the group of radicals: ##STR16## wherein R.sup.20 is hydrogen or methyl and m is 0 to 3; and compounds with the structural formula: ##STR17## wherein R.sup.21 and R.sup.22 are selected from n-alkyl radicals having from 1 to 18 carbon atoms and secondary alkyl radicals having from 3 to 18 carbon atoms and t-alkyl radicals having from 4 to 8 carbon atoms; R.sup.24 is H, CH.sub.3 or C.sub.2 H.sub.5 and A is selected from the radicals: ##STR18## and compounds with this structural formula: ##STR19## wherein each of R.sup.24 and R.sup.25 are alkyl radicals of 1 to 4 carbon atoms, R.sup.26 is hydrogen or methyl and R.sup.23 is hydrogen or phenyl.
- 7. The process of claim 1 wherein 15 to 50 parts by weight of plasticizer per 100 parts by weight of total monomer is used.
- 8. The process of claim 1 wherein an ionic surfactant is used and is present in an amount ranging from about 2 to 30 parts by weight of ionic surfactant per 100 parts by weight of organic components.
- 9. The process of claim 8 wherein the amount of ionic surfactant is present in an amount ranging from about 5 to 12 parts by weight of ionic surfactant per 100 parts by weight of organic components.
- 10. The process of claim 1 wherein said functionalized monomer has an antidegradant moiety.
- 11. The process of claim 1 wherein said carboxylic acid ester is selected from the group consisting of polyethylene glycol dioctoate and a diester of triethylene glycol.
- 12. The process of claim 1 wherein said phosphate is tributoxyethyl phosphate.
- 13. The process of claim 1 wherein the polymerization is at a temperature ranging from about 45.degree. C. to 85.degree. C.
Parent Case Info
This is a Continuation-in-Part Application of application Ser. No. 07/784,091, filed on Oct. 24, 1991, now abandoned, which is a File Wrapper Continuation of application Ser. No. 07/562,062, filed on Aug. 2, 1990, now abandoned.
US Referenced Citations (3)
Number |
Name |
Date |
Kind |
3725332 |
Carrock |
Apr 1973 |
|
3950294 |
Connelly et al. |
Apr 1976 |
|
4701507 |
Mate et al. |
Oct 1987 |
|
Foreign Referenced Citations (1)
Number |
Date |
Country |
59-227934 |
Jun 1983 |
JPX |
Continuations (1)
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Number |
Date |
Country |
Parent |
562062 |
Aug 1990 |
|
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
784091 |
Oct 1991 |
|