Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1999-08-12
2001-11-20
Cain, Edward J. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S394000
Reexamination Certificate
active
06319969
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
FIELD OF THE INVENTION
The present invention pertains to certain novel compositions containing an &agr;-olefin/vinyl or vinylidene interpolymer, an organic acid and optionally one or more coupling agents and optionally one or more fillers. The interpolymers contained in the compositions of the claimed inventions may further contain polymerizable ethylenically unsaturated monomers, or may be blended with additional polymers. The present invention also pertains to the use of such compositions in sound management.
BACKGROUND OF THE INVENTION
The generic class of materials of &agr;-olefin/vinyl or vinylidene monomer substantially random interpolymers, including materials such as substantially random (&agr;-olefin/vinyl aromatic monomer interpolymers, and their preparation, are known in the art, such as described in U.S. Pat. No. 5,703,187 (EP416,815 A2), and in U.S. Pat. No. 5,872,201 the entire contents of which are incorporated herein by reference.
These materials offer a wide range of material structures and properties that make them useful for varied applications. Examples of useful applications for these substantially random interpolymers include their use as asphalt modifiers or compatibilizers for blends of polyethylene and polystyrene, as described in U.S. Pat. No. 5,460,818. Also, materials containing &agr;-olefin/vinyl or vinylidene substantially random interpolymers display good elastic properties and energy dissipation capacities, and thus are also useful in adhesive systems, as described in U.S. Pat. No. 5,244,996.
Although useful in these and other applications, industry is constantly seeking to broaden and improve the applicability of &agr;-olefin/vinyl or vinylidene interpolymer containing materials. To perform well in certain applications, it may be desirable to modify the properties of interpolymer-containing materials. For example, it is desired to extend the range of temperatures in which these interpolymers may be utilized. Other properties which are desirable to modify include processing and/or fabrication characteristics, glass transition temperatures (T
g
), modulus, hardness, viscosity, elongation, fire retardation, density, melt index (MI), tensile strength, compatibility with other materials in composition, and virtually any other property. Industry is also interested in achieving modifications of various physical parameters without detrimentally effecting other preferred polymer properties. Any advantageous modifications are especially useful if achieved in a cost-effective manner.
Development of interpolymers that can be highly filled is sought, in particular, for sound management applications. Prior attempts to formulate compositions particularly useful for sound management applications use highly filled ethylene-vinylacetate copolymers (EVA). These highly filled blends are deficient, however, in that they possess physical properties that restrict available fabrication techniques. For example, EVA-based formulations must be kept at processing temperatures below 185° C. to prevent degradation.
Thus, there is a need for other materials without these restrictions. For example, there is a need for materials based on &agr;-olefin/vinyl or vinyledene monomer substantially random interpolymers with superior performance characteristics to unmodified polymers and the prior art. In particular, there is a great need for economic forms of this class of materials, which are highly processable.
SUMMARY OF THE INVENTION
The compositions disclosed and claimed herein provide industry with economical and advantageous forms of materials effective, in particular, for applications requiring sound management. The compositions provided by the present inventions are typically effective for both sound blocking and vibration damping.
The compositions generally display excellent physical properties amenable to a wide range of fabrication techniques, and are often recyclable, thus may be re-used or re-applied to various applications.
The present invention pertains to compositions comprising a substantially random interpolymer comprising polymer units derived from ethylene and/or at least one C
3-20
&agr;-olefin with at least one vinyl or vinylidene aromatic monomer, or at least one sterically hindered aliphatic or cycloaliphatic vinyl or vinylidene monomer, or a combination of at least one vinyl or vinylidene aromatic monomer and at least one sterically hindered aliphatic or cycloaliphatic vinyl or vinylidene monomer. The interpolymer component of the disclosed compositions may also further comprise polymer units derived from additional and different ethylenically unsaturated polymerizable monomers. The interpolymer component of the disclosed compositions may even be blended with a one or more other polymers.
The composition still further comprises, in addition to the interpolymer, an organic acid. They composition may also comprise a processing agent, a filler, or both, as well as other additives.
In additional embodiments, the present invention provides a process for making the disclosed compositions. In still other embodiments, the present invention provides products made from the disclosed compositions, and products made by the disclosed processes. Further additional embodiments provide sound management compositions fabricated with the disclosed compositions and according to the disclosed processes.
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Betso Stephen R.
Clayfield Timothy E.
Hoenig Stephen M.
Walther Brian W.
Cain Edward J.
The Dow Chemical Company
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