Patent Application
20070037908
The invention relates to compositions containing improved tackifiers, as well as methods making and using the same.
In rubber technology, particular importance is attached to the assembly of unvulcanized blanks from prefabricated semi-finished products. The adhesion of the semi-finished product determines the cohesion and, above all, the dimensional stability of the “unvulcanized blank”. The desired dimensional stability of the material is not guaranteed if the tackiness of the superimposed layers is insufficient. Air pockets are likely to form, on the other hand, if the layers adhere too tightly to one another—when the blank is assembled—resulting in poor fusion of the layers in the vulcanization process. The defects due to deficient autohesion are often not recognized until after vulcanization, and in some cases not until the finished product is in use, with all the economic disadvantages that then entails, like economic loss.
There is little understanding of the workings of the methods applied by those involved in production processes to improve the tackiness of compounds. These methods, which are based for the most part on empirical experience, treat the surface by covering the compound slabs with interleaving film of fabric materials and use resins as so-called tackifier in compounds.
A particular use, among many, of such rubber compositions is for the creation of tires, such as those used in transportation, preferably automobiles. Among the many desirable attributes for tire tread compositions, a great resistance to abrasion is preferred. That is, rubber compositions that easily break down under frictional forces is not desirable because such compositions when used in a tire easily wear resulting in a short life. In addition, it is preferable that tires have very good web and/or dry grip. While dry grip is usually maintained by many rubber compositions, wet grip is not. Rubber compositions having good wet grip, thus improved wet skid resistance, is highly desirable for use in tires. Finally, it is highly desired to create a tire that helps increase the fuel economy in the transportation industry, for example in the automobile industry. One manner in which to increase fuel efficiency into a tire is to create the tire from a rubber composition that “likes” to roll. A rubber composition that “likes” to roll, in other words, has a reduced tendency to resist rolling. If a rubber composition has a reduced tendency to resist rolling, less energy is required to roll the tire. For example, less energy would be required out of the engine of an automobile if the automobile included tires made from, at least in part, rubber compositions that had a reduced tendency to resist rolling. While rubber compositions capable of being useful in tires and/or tire tread compositions are known, no such rubber composition having maximized abrasion resistance, maximized wet grip (e.g. wet skid resistance), and minimized resistance to rolling (e.g. maximizing fuel economy) is known to date.
An object of the invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin wherein the at least one resin is selected from the group consisting of a rosin ester, terpene phenolic resin, terpene phenol, pentaerythritol rosin ester, a modified terpene resin, terpene resin, a polyterpene, and a phenol modified copolymer of styrene and alpha methyl styrene.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having a softening point as determined by Ring & Ball of from 75 to 150° C.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having a softening point as determined by Ring & Ball of from 90 to 130° C.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having a softening point as determined by Ring & Ball of from 90 to 130° C. and the resin has an OH value of from 5 to 150.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having a softening point as determined by Ring & Ball of from 90 to 130° C. and the resin has an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 5 to 150.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50 and having a softening point as determined by Ring & Ball of from 75 to 150° C.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; a filler; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; a filler selected from the group consisting of silica, alumina, and carbon black; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; a coupling agent; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; a coupling agent containing silane; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50 and the composition has an abrasion resistance as measured the DIN Abrasion method ISO37 of from 80 to 100 mm3.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50 and the composition has an abrasion resistance as measured the DIN Abrasion method ISO37 of from 80 to 100 mm3, a tan δ at 70° C. of about 0.129 or less, and a tan δ at 20° C. of about 0.205 or more.
Another object of the present invention relates to a composition containing at least one polymer selected from the group consisting of a rubber polymer or copolymer; and an effective amount of at least one resin, wherein the resin is a terpene phenol resin having an OH value of from 30 to 50 and the composition has an abrasion resistance as measured the DIN Abrasion method ISO37 of from 80 to 100 mm3; a tan δ at 70° C. that is at least at least 5% less than the tan δ at 70° C. of a composition not containing any resin; and has a tan δ at 20° C. that is at least 5% greater than the tan δ at 20° C. of a composition not containing any resin.
Another object of the present invention relates to a tire containing any one or more of the objects mentioned above.
Another object of the present invention relates to a tire containing a tread composition wherein the tread composition contains at least one rubber polyer, at least one rubber copolymer, or mixtures thereof, and an effective amount of at least one terpene phenol resin having a softening point as determined by Ring & Ball of from 90 to 130° C. and having a OH value of from 30 to 50; the tread composition having an abrasion resistance as measured by the DIN Abrasion method ISO37 of from 80 to 100 mm3, a tan δ at 70° C. of about 0.129 or less, and a tan δ at 20° C. of about 0.205 or more, wherein
the tire has a reduced resistance to rolling and an increased wet skid resistance.
Another object of the present invention relates to a tire containing a tread composition wherein the tread composition contains at least one rubber polyer, at least one rubber copolymer, or mixtures thereof, and an effective amount of at least one terpene phenol resin having a softening point as determined by Ring & Ball of from 90 to 130° C. and having a OH value of from 30 to 50; the tread composition having an abrasion resistance as measured the DIN Abrasion method ISO37 of from 80 to 100 mm3; a tan δ at 70° C. that is at least at least 5% less than the tan δ at 70° C. of a composition not containing any resin; and has a tan δ at 20° C. that is at least 5% greater than the tan δ at 20° C. of a composition not containing any resin, wherein
the tire has a reduced resistance to rolling and an increased wet skid resistance.
The above objects and further objects such as methods of making and using the above objects are described hereinbelow. While the detailed description discussed below is meant to represent the specific objects and embodiments of the invention, they are meant to me non-limiting in so far as to exemplify the present invention.
This application is related to the fields of chemistry and rubber sciences which is described, for example, Harry Barron's “Modern rubber chemistry” (1948), Chemical Pub. Co, and Edward William Duck's “Plastics and rubbers, (Chemistry in modern industry series)”, (1971), Butterworths, and J. A Brydson's “Rubber chemistry”, (1978), Applied Science Publishers, which are hereby incorporated, in their entirety, herein by reference.
The inventor has surprisingly discovered a tackifier that, when applied to rubber containing compositions, improves the mechanical strength, tear resistance, and vulcanization thereof, without significantly diminishing other important physical characteristics important for end-use applications of rubber compositions. Further, the inventors have discovered a rubber composition containing a tackifier at effective amounts that maximize abrasion resistance, maximize wet grip (e.g. wet skid resistance), and minimize resistance to rolling (e.g. maximizing fuel economy), as well as tires and tire tread compositions containing the same.
The present invention relates to a composition, method of making the composition, and methods of using the composition. The composition is preferably a rubber containing composition. The rubber containing composition is preferably useful in tire production. Examples of rubber compositions useful in tire production can be found in U.S. Pat. Nos. 4,487,892; 5,877,249; 6,790,889; 6,525,118; 6,384,118; 6,384,117; 6,369,138; 6,348,531; 6,342,552; 6,228,908; 6,221,943; 6,180,710; and 5,994,448, as well as PCT published application WO2004013220 and WO2004013221 and United States Published Patent Application No. 2006/0167160, which are all hereby incorporated, in their entirety, herein by reference.
Although the rubber composition may be utilized for any article, preferably that article is a tire. Examples of such tires include, but are not limited to, tires useful in the transportation industry. Examples of such tires include those useful in the automobile industry. Further examples include tires such as pneumatic tires.
The composition of the present invention, when used to create the tire of the present invention, may be used to create the entire tire and/or just a portion thereof. For example, the rubber composition may be used to create the tire tread composition. Accordingly, the present invention further relates to a tire containing the rubber composition of the present invention. Any one or more parts of the tire may contain the rubber composition, including the tire tread.
The compositions according to the present invention contains a resin. The resin preferably provides tackiness to the composition. Thus the resin may function as a tackifier and/or a tackifying agent.
The resin may be any resin, but is not limited to a rosin ester, abietic acid, abietic acid ester, terpene resin, terpene-phenol resin, terpene phenol, pentaerythritol rosin ester, a modified terpene resin, a polyterpene, and a phenol modified copolymer of styrene and alpha methyl styrene or hydrocarbon resins.
Examples of polyterpenes, terpene phenol resins and hydrocarbon based resins can be found in U.S. Pat. Nos. 6,900,274; 6,562,888; 6,274,657; 5,504,152; 4,380,513; 6,160,083; 5,723,709; 6,121,392; 5,959,010; 5,854,367; 5,789,474; 5,723,709; 4,879,351; 4,052,549; 5,051,485; 4,879,351; 4,797,460 and 5,457,175; as well as United Stated Published Patent Application Numbers 20050054801 and 20030229178, which are all hereby incorporated, in their entirety, herein by reference. Commercial product include those terpene-phenolic resins, rosin esters, modified terpene resins, polyterpene resins, and phenol modified copolymer of styrene and alpha methyl styrene or hydrocarbon resins, but are not limited to, sold by Arizona Chemical Company such as: SYLVARES TP105; SYLVARES TP95; SYLVARES TP115; SYLVARES TP300; SYLVARES TP2019; SYLVARES TP2040HME; SYLVARES TP; SYLVARES 525; SYLVARES TR 5147; and SYLVARES RE104.
The composition may contain any amount of resin. The amount of the resin may be up to 50 phr, preferably up to 30 phr, more preferably up to 15 phr, and most preferably up to 10 phr. Also, the amount of the tackifier may be at least 0.1 phr, preferably at least 0.5 phr, more preferably at least 1 phr, most preferably at least 2 phr. The amount of tackifier may be 0.1, 0.2, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 15, 20, 25, 30, 40, and 50 phr, including any and all ranges and subranges therein.
If the resin is a phenol modified copolymer of styrene and alpha methyl styrene, the molar ratio of styrene to alpha methyl styrene is from 0.1 to 5, more preferably from a 0.2 to 2.0. The molar ratio of styrene to alpha methyl styrene may be 0.1, 0.2, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.5, 3, 3.5, 4, 4.5, and 5, including any and all ranges and subranges therein.
If the resin is a rosin ester, preferably the rosin portion of the ester is at least one rosin acid compound. The rosin acid compound may be selected from those natural resin-based acids, such as those obtained from residues of distillation of natural oils. The rosin acid compound may be also be derived. Since the rosin compound is an acid, the derivative may be any commonly known derivative of a carbonyl-containing compound known in general Organic Chemistry Textbooks, such as “Organic Chemistry”, 5th Edition, by Leroy G. Wade. Examples of such derivatives include, but is not limited to esters, amine carboxylates, and nitrile derivative of the rosin acid compound. The rosin acids may include those that may be isolated from black liquor skimmings, crude tall oil, tall oil pitch, and distilled tall oil. In addition rosin acids may be those found in tall oil rosin, gum rosin and wood rosin. These naturally occurring rosins may be suitably mixtures and/or isomers of monocarboxylic tricyclic rosin acids usually containing 20 carbon atoms. The tricyclic rosin acids differ mainly in the position of the double bonds. The rosin acid may be at least one of levopimaric acid, neoabietic acid, palustric acid, abietic acid, dehydroabietic acid, seco-dehydroabietic acid, tetrahydroabietic acid, dihydroabietic acid, pimaric acid, paulstric acid, and isopimaric acid, or mixtures, isomers, and/or derivatives thereof. The rosins derived from natural sources also include rosins, i.e. rosin mixtures, modified notably by polymerisation, isomerisation, disproportionation and hydrogenation. The rosin acids may include those mentioned in U.S. Pat. Nos. 6,875,842; 6,846,941; 6,344,573; 6,414,111; 4,519,952; and 6,623,554, which are hereby incorporated, in their entirety, herein by reference.
The composition may contain a rosin ester that is any ester of the above-mentioned rosin acids.
The resin may have a softening point, as determined by Ring & Ball, of from 75 to 150° C., preferably from 85 to 135° C., most preferably from 90 to 130° C. Therefore, the softening point is preferable less than 150° C. and greater than 75° C. The softening point may be 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, and 150° C., including any and all ranges and subranges therein.
In a preferred embodiment, the resin is a terpene-phenol resin. Examples of the terpene-phenol resin include commercial products (shown by the trade names) such as YS POLYSTAR T115, T145, S145, G150 and N125 of the YS POLYSTAR series manufactured by YASUHARA CHEMICAL Co., Ltd. Further examples include SYLVARES TP105; SYLVARES TP95; SYLVARES TP115; SYLVARES TP300; SYLVARES TP2019; SYLVARES TP2040HME; SYLVARES TP manufactured by Arizona Chemical Company.
When the resin is a terpene-phenol resin, the terpene-phenol resin may have any softening point mentioned above as determined by Ring & Ball. However, when the resin is a terpene-phenol resin, it may have a softening point less than 150° C., preferably less than 140° C., more preferably less than 130° C., and most preferably less than 120° C. Further, when the resin is a terpene-phenol resin, it may have a softening point greater than 75° C., preferably greater than 80° C., more preferably greater than 90° C., most preferably greater than 95° C. When the resin is a terpene-phenol resin, the softening point may be 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, and 150° C., including any and all ranges and subranges therein.
When the resin is a terpene-phenol resin, the terpene-phenol resin may have any OH value. The terpene-phenol resin has a OH value that is less than 150, preferably less than 100, more preferably less than 85, most preferably less than 50. The terpene-phenol resin has a OH value that is greater than 5, preferably greater than 10, more preferably greater than 20, most preferably greater than 30. The terpene-phenol resin has a OH value that is 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140 and 150, including any and all ranges and subranges therein.
The composition of the present invention may contain a rubber polymer or copolymer. The rubber or elastomer may be present in the composition at any amount. The amount of rubber or elastomer may be not more than 99 wt % and not less than 30 wt %, preferably not more than 90 wt % and not less than 40 wt %, more preferably not more than 85 wt % and not more than 45 wt %, most preferably not more than 80 wt % and not less than 50 wt %, based upon the total weight of the composition. The composition may contain 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 99 wt % of rubber or elastomer based upon the total weight of the composition, including any and all ranges and subranges therein.
The rubber polymer or copolymer may be any rubber polymer or copolymer, including compounding combinations thereof. The rubber polymer or copolymer may be any rubber, especially those used in compositions generally known to make tires for the transportation industry, more especially the automobile industry. Examples of the rubber polymer or copolymer, while being non-limiting, are styrene butadiene rubber, polybutadiene rubber, natural rubber, halogenated butyl rubber, butyl rubber, polyisoprene rubber, and styrene/isoprene/butadiene terpolymer rubbers.
Examples of a styrene butadiene rubber are those copolymers containing any amount of styrene. For example the styrene butadiene rubber may contain greater or less than 50% by weight of styrene. When the composition contains a styrene butadiene copolymer, the styrene butadiene rubber may contain 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and 95% by weight of styrene, including any and all ranges and subranges therein.
Examples of polybutadiene rubbers may be any and may include those having a 1,4 configuration, 1,2 configuration, etc. Further the polybutadiene rubbers may contain any amount of those having 1,4 configuration and/or 1,2 configuration, etc.
Examples of polyisoprene rubber may be any and may include those having 1,4 configuration and/or cis-1,4 configuration, and/or 3,4 configuration, etc. The polyisoprene rubber may contain any amount of those having 1,4 configuration and/or cis-1,4 configuration, and/or 3,4 configuration, etc.
Further the rubber polymer or copolymer may be hydrogenated or partially hydrogenated. For example, a styrene butadiene copolymer may be fully hydrogenated or partially hydrogenated. When at least partially hydrogenated, the double bonds of the rubber polymer or copolymer may be more or less than 50% hydrogenated. For example, a styrene butadiene copolymer may contain double bonds that are more or less than 50% hydrogenated, for example, in the butadiene portion of the copolymer. The rubber polymer or copolymer may such that the double bonds are 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 100% hydrogenated, including any and all ranges and subranges therein.
The composition of the present invention may also contain pigments and fillers, preferably reinforcing fillers. Examples of such pigments and fillers include inorganic and organic fillers. Examples of fillers include silicon-containing compounds and/or aluminum containing compounds and/or carbon black and/or clay. Examples of silicon containing compounds include silaceous compounds, such as silaceous pigments. Further examples include fumed and/or pyrogenic and/or precipitated silaceous compounds (silica). Further examples of silica include wet silica (hydrated silicic acid), dry silica (anhydrous silicic acid), calcium silicate and aluminum silicate. Among these types of silica, wet silica which most remarkably exhibits the effect of improving the fracture resistance and simultaneously improving the road gripping property on wet roads and the low rolling resistance is more preferable.
Examples of aluminum containing compounds include alumina. Examples of alumina may include fumed and/or precipitated alumina. The above alumina can be any alumina. Examples of alumina include those represented by the following general formula: Al2O3.nH2O; where n represents a number preferably ranging from 0 to 3.
The fillers may have any size and shape. The fillers may have any BET surface area, as measure using nitrogen gas. The inorganic filler may have a BET surface area of 50 to 500, for example. The BET surface area of the inorganic filler may be 50, 60, 70, 80, 90, 100, 125, 150, 175, 200, 225, 250, 275, 300, 325, 350, 375, 400, 425, 450, 475, and 500 square meters per gram. The BET method of measuring surface area is described in the Journal of the American Chemical Society, Volume 60, page 304 (1930).
When the filler includes silica, the silica may have any specific surface area. It is preferable that the silica has a specific surface area in the range of 80 to 300 m.2/g and more preferably in the range of 10 to 220 m2/g as measured in accordance with the nitrogen adsorption method. When the specific surface area is 80 m2/g or greater, the sufficient reinforcing effect is exhibited. When the surface area is 300 m.2/g or smaller, no adverse effects on the processability are exhibited. In general, anhydrous silicic acid or hydrated silicic acid in the form of fine powder which is used as the white reinforcing filler of rubber is used. Examples of the silica include commercial products such as “NIPSIL” (manufactured by NIPPON SILICA KOGYO Co., Ltd.) having a specific surface area of about 200 m.sup.2/g and “ZEOSIL 1115MP” (manufactured by RHODIA Company) having a specific surface area of 117 m2/g.
When the inorganic filler is silica, various commercially available silicas may be considered for use in this invention such as, for example, only and without limitation, silicas commercially available from PPG Industries under the Hi-Sil trademark such as, for example, those with designations 210, 243, etc; silicas available from Rhone-Poulenc, with designations such as Zeosil 1165MP and silicas available from Degussa AG with designations such as VN2 and VN3, etc. The Rhone-Poulenc Zeosil 1165MP silica is reportedly characterized by having a BET surface area of about 160-170 and by a DBP value of about 250-290 and by having a substantially spherical shape.
The fillers may also contain metals. Examples of such metals include potassium, sodium, iron, aluminum, calcium, titanium, zirconium, and magnesium. Further, the fillers may halogen elements such as fluorine and/or groups such as NH4.
Specific examples of the fillers include alumina hydrate (Al.2O3H2O), aluminum hydroxide [Al(OH)3] such as gibbsite and bayerite, aluminum carbonate [Al2(CO3)2], magnesium hydroxide (Mg(OH)2), magnesium oxide (MgO), magnesium carbonate [MgCO3], talc (3MgO.4SiO2.H2O), attapulgite (5MgO.8SiO2.9H2O), titanium white (TiO2), titanium black (TiO2n−1), calcium oxide (CaO), calcium hydroxide [Ca(OH)2], aluminum magnesium oxide (MgO.Al2O3), clay (Al2O3.2SiO2), kaolin (Al2O3.2SiO2.2H2O), pyrophillite (Al2O3.4SiO2.H2O), (Al2O3.4SiO2.2H2O), aluminum silicate (Al2SiO5, Al4.3SiO4.5H2O and the like), magnesium silicate (Mg2SiO4, MgSiO3 and the like), calcium silicate (Ca2SiO.4 and the like), aluminum calcium silicate (Al2O3.CaO.2SiO2 and the like), magnesium calcium silicate (CaMgSiO4), calcium carbonate (CaCO3), zirconium oxide (ZrO2), zirconium hydroxide [ZrO(OH)2.nH2O], zirconium carbonate [Zr(CO.3).2], various types of zeolite, feldspar, mica and montmorillonite.
Among the above inorganic fillers, at least one filler selected from carbon black, silica, various types of alumina and various types of clay is preferable as the filler used in the present invention.
Carbon black is not particularly limited. For example, SRF, GPF, FEF, HAF, ISAF and SAF can be used. Carbon black having an iodine adsorption (IA) of 60 mg/g or greater and a dibutyl phthalate absorption (DBP) of 80 ml/100 g or greater is preferable. The effect of improving the road gripping property and the fracture resistance is increased by using carbon black. HAF, ISAF and SAF providing excellent abrasion resistance are more preferable.
The carbon black may have any outer surface area. The carbon black may have an outer surface area in the range of 130 to 200 m2/g as measured in accordance with the CTAB adsorption method is preferable.
The filler may have any diameter. The filler may have a diameter of 50 μm or smaller, preferably 25 μm or smaller, more preferably 10 μm or smaller, most preferably 3 μm or smaller. When the diameter of the inorganic filler is 10 μm or smaller, the fracture resistance and the abrasion resistance of the vulcanized rubber composition may be kept improved. The diameter of the filler may be 0.001, 0.01, 0.1, 0.5, 1, 2, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50 μm, including any and all ranges and subranges therein.
The composition may contain the filler at any amount. The composition contains from 5 to 250 phr, preferably from 10 to 150 phr, more preferably from 40 to 120 phr, most preferably from 60 to 120 phr of the inorganic filler. The composition may contain 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240 and 250 phr, including any and all ranges and subranges therein.
In the present invention, the filler, such as those exemplified above, may be used singly or in combination of two or more.
The composition of the present invention may contain a coupler or coupling agent. In many cases there tends to be a lack of, or at least an insufficient degree of, physical and/or chemical bonding and/or interaction between the filler and the rubber polymer or copolymer mentioned above so as to enable the filler to become a reinforcing filler for the rubber polymer and/or copolymer. While various solutions, treatments and procedures have been devised to overcome such deficiencies, compounds capable of enhancing the degree of physical and/or chemical bonding and/or interaction between the filler and the rubber polymer or copolymer are generally known as coupling agents, or couplers.
Examples of couplers include any coupler that is generally known in the art to the skilled artisan to enhance the degree of physical and/or chemical bonding and/or interaction between the filler and the rubber polymer or copolymer. In the case of a when silica is used as a filler, such coupling agents may generally be composed of a silane which has a constituent component, or moiety, (the silane portion) capable of reacting with the silica surface and, also, a constituent component, or moiety, capable of interacting with the rubber, particularly a sulfur vulcanizable rubber which contains carbon-to-carbon double bonds, or unsaturation. In this manner, then the coupler may act as a connecting bridge between the silica and the rubber and thereby enhances the rubber reinforcement aspect of the silica.
This ideal can be used by the skilled artisan so as to be applied to any filler although the specific chemical groups and chemistry may change according to the selection of the filler.
In one aspect, the silane of the coupling agent apparently forms a bond to the silica surface, possibly through interaction with silanol groups on the silica surface, and the rubber interactive component of the coupling agent apparently interacts with the rubber. Usually the rubber interactive component of the coupler is temperature sensitive and may tend to combine with the rubber during the higher temperature sulfur vulcanization of the rubber composition and after the silane group of the coupler has reacted with the silica. However, partly because of typical temperature sensitivity of the coupler, some degree of interaction may occur between the rubber-interaction component of the coupler and the rubber during initial rubber/silica/coupler mixing stage(s) and, thus, prior to the subsequent vulcanization of the rubber composition.
The rubber-interactive reactive group component of the coupler may be, for example, one or more of groups such as mercapto, amino, vinyl, epoxy, and sulfur groups, preferably a sulfur or mercapto moiety and more preferably sulfur.
Numerous coupling agents may be used to combine silica and rubber polymer or copolymer, such as, for example, silane coupling agents containing a polysulfide component, or structure such as, for example, bis-(trialkoxysilyalkyl) organosilane polysulfides containing from 2 to about 8 sulfur atoms in a polysulfide bridge such as, for example, bis-(3-triethoxysilylpropyl)tetrasulfide, trisulfide or disulfide. In the case of the disulfide, if in a high purity form, some free sulfur, or sulfur donor, may desirably be added with the coupler in a rubber mixing step to enhance an overall effect of interaction with the elastomer, or rubber.
The composition of the present invention may also contain other synthetic rubbers, and may further contain various chemicals conventionally used in the rubber industry such as process oils, antioxidants, vulcanizing agents, vulcanization auxiliary agents, vulcanization accelerators and scorch inhibitors.
The composition of the present invention may also contain at least one antioxidant. Representative antioxidants may be, for example, diphenyl-p-phenylenediamine and others, such as, for example, those disclosed in the Vanderbilt Rubber Handbook (1978), pages 344-346.
The composition of the present invention may also contain a wax, preferably a paraffinic wax.
The composition of the present invention may also contain a fatty acid. An example of a fatty acid is a stearic acid.
The composition of the present invention may also contain other additives that traditionally and optionally may be present in rubber containing compositions, including those compositions specifically intended for use in tires. An example of these other additives include sulfur and inorganic oxides, such as zinc oxides.
The composition of the present invention has a Hardness Shore A as measured by DIN 53505 ranging from 50 to 100, preferably from 60 to 85, most preferably from 65 to 80. The Hardness Shore A may be 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100, including any and all ranges and subranges therein.
The composition of the present invention has a DIN Abrasion as measured by ISO 37 method of less than 110 mm3, preferably less than 100 mm3. The DIN abrasion of the composition may be greater than 50 mm3. The composition may have a DIN abrasion of 50, 60, 70, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 105, and 110 mm3, including any and all ranges and subranges therein.
The composition of the present invention has a tensile strength as measured by DIN 53504 of from 10 to 30, preferably from 15 to 25, most preferably from 17 to 21 Mpa. The tensile strength of the composition may be 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 Mpa, including any and all ranges and subranges therein.
The composition of the present invention has an elongation at break as measured by DIN 53504 of from 200 to 450, preferably from 250 to 425%, most preferably from 300 to 400%. The elongation at break may be 200, 250, 300, 325, 350, 355, 360, 365, 370, 375, 380, 385, 390, 395, 400, 410, 425, and 450%, including any and all ranges and subranges therein.
The composition of the present invention has a Tension at 300% elongation as measured by DIN 53504 of from 10 to 30, preferably from 12 to 20 Mpa. The Tension at 300% elongation may be 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 Mpa, including any and all ranges and subranges therein.
The composition of the present invention has a tear resistance as measured by DIN 53507 of greater than 5, preferably greater than 10, most preferably greater than or equal to about 15 N/mm. The tear resistance of the composition may be less than 50. Preferably the tear resistance is in the range of from about 15 to about less than 25 N/mm. The tear resistance may be 5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, and 25 N/mm, including any and all ranges and subranges therein.
The composition of the present invention has a tear resistance that is preferably about equal or at least 5% greater than that of a composition that does contain the above-mentioned resin or when compared to compositions containing equivalent amounts of Koresin, for example.
The composition of the present invention has any Tg The composition of the present invention has a Tg less than 0° C., preferably less than 10° C., most preferably less than 20° C., and most preferably from −50° C. to −25° C. The Tg may be −50, −45, −40, −35, −30, −25, −20, −15, −10, −5 and −1° C., including any and all ranges and subranges therein.
The composition of the present invention has preferably and/or improved vulcanization when containing the above-mentioned tackifier as compared to those compositions that do not contain the resin of the present invention and/or that of those compositions containing Koresin.
When the composition of the present invention has or improved vulcanization as measure by tan δ described below and in the attached report, the improvement is at least 5% that of those compositions that do not contain the resin of the present invention and/or that of those compositions containing Koresin
The presence of the resin with a rubber polymer and/or copolymer in the composition of the present invention is considered herein to be beneficial because of observed viscoelastic properties of the composition such as complex and storage modulus, loss modulus tan δ and loss compliance at different temperature/frequency/strain as hereinafter generally described.
The properties of complex and storage modulus, loss modulus, tan δ and loss compliance are understood to be generally well known to those having skill in such art. They are hereinafter generally described.
The viscoelastic properties of the present invention when used for a compounded rubber blend, such as for a tire tread application, are considered herein as being important. For example, a tan δ property is the ratio of the viscous contribution to the elastic contribution for a viscoelastic rubber subjected to a dynamic deformation. Such properties are typically represented in a form of a curve(s) as a plot of tan δ values versus temperature.
For a tire with good wet skid resistance, a tread rubber with a tan δ maximization (a maximization of a tan δ value of a tan δ vs temperature curve) is desired in a temperature range, or region, of about −45° C. to about +10° C. Also, for a tire to have good wet grip, wet skid resistance, it is desired that the composition have a high tan δ between the temperatures of from about 0 to about 30° C. Further, for a tire to have low resistance to rolling and thus provide better gas mileage as discussed above, it is desired that the composition have a low tan δ between the temperatures of from about 60 to about 80° C.
The composition of the present invention has any tan δ from about 60 to about 80° C. The tan δ from about 60 to about 80° C. is less than 0.1400, preferably less than 0.13, more preferably less than about 0.12 and most preferably less than 0.11. For example, at any temperature from about 60 to about 80° C. (including about 60, 65, 70, 75, and 80° C.), it is preferable that the tan δ of the composition be less than 0.1400, preferably less than 0.13, more preferably less than about 0.12 and most preferably less than 0.11. In a preferred embodiment, the composition contains a terpene phenol resin and has a tan δ at about 60° C. of about 0.139 or less, preferably about 0.135 or less, more preferably about 0.128 or less, most preferably about 0.112 or less. In another preferred embodiment, the composition contains a terpene phenol resin and has a tan δ at about 70° C. of about 0.129 or less, preferably about 0.125 or less, more preferably about 0.120 or less, most preferably about 0.115 or less.
The composition of the present invention has any tan δ from about 0 to about 30° C. The tan δ from about 0 to about 30° C. is greater than about 0.16, preferably greater than about 0.165, more preferably greater than about 0.17 and most preferably greater than about 0.175. For example, at any temperature from about 0 to about 30° C. (including about 0, 5, 10, 15, 20, 25 and 30° C.), it is preferable that the tan δ of the composition be greater than 0.1600, preferably greater than 0.165, more preferably less than about 0.17 and most preferably greater than 0.175. In a preferred embodiment, the composition contains a terpene phenol resin and has a tan δ at about 0° C. of about 0.205 or more, preferably about 0.21 or more, more preferably about 0.22 or more, most preferably about 0.23 or more. In another preferred embodiment, the composition contains a terpene phenol resin and has a tan δ at about 20° C. of about 0.166 or more, preferably about 0.169 or more, more preferably about 0.171 or more, most preferably about 0.174 or more.
The composition of the present invention may have a reduced or increased tan δ at 70° C. as compared to a composition not containing any resin according to the present invention and/or to a composition containing Koresin in the place of the resin according to the present invention. However, it is preferable that the composition of the present invention has a tan δ at 70° C. that is at least 3%, preferably at least 4%, more preferably at least 5%, most preferably at least 10% less than the tan δ at 70° C. of a composition not containing any resin according to the present invention and/or to a composition containing Koresin in the place of the resin according to the present invention.
The composition of the present invention may have a reduced or increased tan δ at 20° C. as compared to a composition not containing any resin according to the present invention and/or to a composition containing Koresin in the place of the resin according to the present invention. However, it is preferable that the composition of the present invention has a tan δ at 20° C. that is at least 2%, preferably at least 7%, more preferably at least 10%, most preferably at least 15% greater than the tan δ at 20° C. of a composition not containing any resin according to the present invention and/or to a composition containing Koresin in the place of the resin according to the present invention.
The composition of the present invention may contain an effective amount of the resin. An effective amount means, for the purposes of herein, an amount of resin that is capable of allowing the composition to obtain any of the above-mentioned preferable performance and physical characteristics. More preferably, an effective amount of resin in the composition allows the composition to attain the above-mentioned abrasion resistance and tan δ values. Further, a composition containing the effective amount of resin, when incorporated into a tire according to the present invention, bestows upon the tire an increased abrasion resistance, an decreased resistance to rolling, and an increased wet skid resistance or wet grip.
The term “phr” where used herein, and according to conventional practice, refers to parts of a respective material per 100 parts by weight of rubber, or elastomer.
The presence of the tackifier mentioned above with a rubber blend is considered herein to be beneficial because of observed viscoelastic properties of the tread rubber composition such as complex and storage modulus, loss modulus tan.delta and loss compliance at different temperature/frequency/strain as hereinafter generally described.
The properties of complex and storage modulus, loss modulus, tan.delta and loss compliance are understood to be generally well known to those having skill in such art. They are hereinafter generally described.
The present invention is explained in more detail with the aid of the following embodiment examples.
I. Raw Materials
Alpha pinene, phenol, boron trifluoride, xylene, water, sodium carbonate, and sodium hypophosphite.
II. Procedure
II-A. Dehydration of Solvent and Phenol:
Transfer the resin solution to a tared 4-neck round bottom flask. Equip the flask with an agitator, a condenser via a 3-way take-off adapter, a thermocouple assembly, and a sparge tube for nitrogen sparging. Insert the sparge tube below the surface of the solution and beging nitrogen sparge (˜2000 cc/min.) Begin agitation and start heating using an electric heating mantle. Distill off the solvent between 140 and 170° C., and continue heating to 245° C. When the contents reach 245° C., terminate the sparge and maintain a nitrogen purge. Lower heating mantle and draw out a sample (1-2 mL) of the hot resin for softening point. Obtain a softening point (base s.p.) and resume heating and nitrogen sparge. Continue sparging at 245° C. to strip out residual terpene-phenol dimers (residual in the TP resin), and sample as needed for s.p. measurements till target s.p. (112-118° C.) is reached. At target s.p., lower mantle, discontinue nitrogen sparge and pour sample out for color, final softening point, and obtain a final resin yield.
A typical synthesis affords a resin with a softening point of 115° C., a neat color of 6-7 Gardner at an overall yield of 85-90%
The following Commercial Products: Koresin (from BASF); Sylvalite RE 104 (from Arizona Chemical Company); SLYVARES TR5147 (from Arizona Chemical Company); SLYVARES TP 105 (from Arizona Chemical Company); and SLYVARES 525 (from Arizona Chemical Company), were tested according the DIN standard listed in the table below (DIN Nos: 53505, 53504, 53507), all of which are hereby incorporated, in their entirety, herein by reference, to test the physical properties thereof (see Table 1 below) when formulated in a rubber composition according to attached report. The tan d (e.g. tan δ) analysis is described in the report attached hereto. The difference between the vulcanization presented below and the vulcanization in the attached report is that the vulcanization was performed under conditions where the 2 mm thick fims have been cured for 17 minutes at 160° C. in a hot platen press.
The compositions of Table 1 are exactly set forth as in the formulation of Table 3, except that a BR Buna® CB 24 is replaced with BR Buna® CB 10.
The tan d (or tan δ) reported above comes from the curve in
Various Terpene Phenol resins have been compared below in a silica tread rubber compound by mechanical and visco-elastic data. When applied in quantities of 4 parts resin on 100 part rubber, the Mooney viscosity, the vulcanization behaviour and most of the mechanical do not change significantly. There are significant differences in the visco-elastic behaviour. TP115 shows the best modification of the rubber compound in increasing damping for braking and reducing damping for rolling resistance. While TP95 increases damping in both relevant temperature zones, TP resins with high OH value such as TP300 and TP2040 HME exhibit higher rolling resistance without improving wet braking whereas TP2019 does not show any effect. Average SP of around 105 to 115 with low OH value seems to be an optimum in regard to dynamic tyre properties while high polarity is detrimental especially combined with high softening point.
In addition, the compound containing TP2040HME shows significantly better abrasion resistance than the other resins and the reference.
Surprisingly it was found that a lower softening point Terpene Phenol resin (Sylvares TP105) was performing similar to an AMS type resin. Terpene phenol resins are known in the industry as tackifier resins, however with much less tackification effect than Alkylphenol Novolaks and are applied in various compounds for sidewall, innerliners, or Apex. They are not known as compound modification resin like aliphatic, naphthenic or aromatic (modified) Hydrocarbon resins from fossil or renewable resources.
In order to verify the effect, a series of terpene phenol resins have been selected and subjected to a comparative study in which a typical silica tread compound was used as matrix and the mechanical data and the visco-elastic data were generated. The resin selection criteria were softening point and polarity expressed by their OH value (See Table.2)
Experimental:
Compound Preparation:
The compounds were prepared in 4 steps with a laboratory internal mixer from Werner&Pfleiderer GK 1.5 E with intermeshing geometry and a laboratory 2 roll mill of Berstorff (150×350 mm). The process parameters were as followed:
From 0′ to 1′ polymers (s-SBR+Br)
Tmax(display): approx. 140° C.
Tmax Step2 (Display): approx. 130-135° C.
Tmax Step3(Display): approx. 120-125° C.
Vulcanisation was carried out at 160° C. up to t90 in a platen press.
Test Methods
All methods were carried out by standardized methods (see table 4 for names of methods)
Results:
In Table. 4 all the relevant data characterising the process-ability (Mooney viscosity and Vulcametry), mechanical data and data concerning the heat build up and the durability (Flexometer) are shown.
Viscoelastic Properties (DMA Measurements)
In
For better clarity the relevant values of tan δ are tabulated in Table 5 which are represented in values at selected temperatures of silica tread compounds
As used throughout, ranges are used as a short hand for describing each and every value that is within the range, including all subranges therein.
Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.
All of the references, as well as their cited references, cited herein are hereby incorporated by reference with respect to relative portions related to the subject matter of the present invention and all of its embodiments
The present invention is related to, and claims the benefit of 119(e) priority to U.S. provisional patent application Ser. No. 60/706,861; entitled “RUBBER COMPOSITIONS CONTAINING IMPROVED TACKIFIERS”, which was filed on Aug. 9, 2005, and is hereby incorporated, in its entirety, herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60706861 | Aug 2005 | US |
