Flexible highly filled metal elastomer composite

Abstract

A material comprising a metal particulate having an interfacial modifier coating and a thermoplastic polyurethane polyester elastomer. The composite can be extruded with confidence that the production will continue smoothly. The composite can be made into a variety of cross- sectional shapes. A flexible adhesive wheel weight that can be used to rotationally balance vehicle wheels is one embodiment.

Description

[0001] 492.0078USP6 Patent Flexible Highly filled Metal Elastomer Composite Field The composite is a material comprising a metal particulate having an interfacial modifier (IM) coating and a thermoplastic elastomer. The highly filled composite can be melt processed into a variety of cross-sectional shapes having a variety of end uses. Background Composite materials have been made by combining a variety of IM coated particulate materials at varying proportions with thermoplastic polymers. In order to be useful, efficient blending and extruding the particulate and the polymer is needed to make a filled composite pellet. The pellet is then extruded into the shape desired in the end use. The ease of extrudability of the polymer and the composite is important. Composites have found a number of uses such as in ballasting balancing and in vehicle wheel weights. Composites are characterized by having sufficient density (greater than 5 or greater than 6 g-cm-3) such that adding the weight to the wheel and tire leads to rotationally balance, particularly at high highway RPM. In the absence of adequate balancing, the safety and comfort of the vehicle in operation would be seriously affected. Wheels are often rebalanced, with new weights, at such times as balance is lost, or with new tires. Wheel weights currently in use include conventional lead weights with an integral clip, adherent metal e.g., zinc or iron weights and composite flexible materials. Many available weights include lead or other materials of concern have obvious environmental problems, metal weights are inflexible, can often not be applied in the precise weight and often do not conform or adhere to the wheel geometry, often leading to a failure to balance. A substantial need exists to obtain an extrudable highly filled composite. Not all selections of polymer and IM coated metal particulate can be successfully extruded in commercial quantities. A flexible, adhesive wheel weight composite has extrudability, sufficient density, rheological and tensile properties, and environmental compatibility. The weight can be used at the precise amount to balance the wheel. The wheel weight must be produced efficiently, extrudable at useful temperatures, obtain sufficient flexibility such that the wheel weight can adhere to the rim with substantial adhesive (peel) strength. With flexibility and substantial adhesive bonding properties, the wheel weight can adhere to the correct location on the rim 492.0078USP6 Patent surface and establish and maintain rotational balance of a vehicle wheel during the lifetime of the tire or wheel. Brief Description We have found a highly filled composite that can be extruded into a pellet intermediate and into a final product is useful in a flexible wheel weight. The composite uses a metal particulate with a coating of an interfacial modifier combined with a carefully selected thermoplastic polyurethane polyester elastomer TPU. The particulate / polymer composite is efficiently manufactured, has excellent balancing properties and is environmentally safe. The weight is manufactured by extruding the composite in the correct rectangular or non-rectangular profile, coating a portion of the extrusion with adhesive, and then adding a release liner. Fifty to 300 meters of the assembly of the thus formed linear wheel weight can be stored on a reel for ease of use at the balance facility. The limit on reel size is the weight of the combined wheel weight and reel that can be efficiently handled in the balance facility. In use, a small portion (1 to 10 cm, or 2 to 6 cm) of the assembly is separated from the reel, in the precise amount that can attain balance to the wheel and tire. The release liner is removed from the separated portion and is adhered to the wheel at the precise location to achieve balance at assembly or on the road. The polyurethane polyester elastomer is formed into a composite with a modified metal particulate. The unique bonding structure between the interfacial modifier modification and the polymer promotes a high density but flexible wheel weight with a high packing concentration of metal in the composite. The wheel weight as made typically comprises a linear extrusion having a unique cross-sectional profile that can be easily adapted to and adhered to the differing geometries of the variety of manufacturers vehicle wheels / rims. Many rim geometries are known with different requirements for balancing. To ensure that the wheel weight can provide adequate balancing to a rotating wheel, the selected profile has a surface of the weight coated with an adhesive. Typically, a pressure- sensitive adhesive (PSA) is used. A PSA bonds with the application of light pressure. The bond forms because the adhesive can flow and wet to the adherend. PSAs are designed for either permanent or removable applications. Useful pressure-sensitive adhesives are manufactured in a 100% solid form. PSAs are made and applied using thermoplastic processing. A typical PSA comprises a thermoplastic polymer and a tackifier with optional materials including plasticizer, stabilizer, filler, and diluent. 492.0078USP6 Patent The adhesive must maintain the wheel weight in a precise location on the wheel rim for an extended period (typically the tire lifetime). This ensures that the wheel is balanced during any aspect of operation of the vehicle. In use, the composite material can be easily extruded and provided to a manufacturer in large capacity reels of materials having a useful profile. In use, a small proportion of the material in reel form can be selected to provide exactly the amount of weight required for appropriate balancing. To be successfully stored and used, the adhesive must be covered by a release liner to ensure that the adhesive is not contaminated during manufacture, use, storage, or application and that the adhesive does not cause the wheel weight to adhere to itself, thus ruining stored material. For this purpose, a release liner is typically applied to the surface of the adhesive after it is coated onto the wheel weight profile surface. For ease of use, it is typical to apply a release liner with an edge of the release liner exposed to the user, such that it can be easily grasped and then removed from the weight prior to application. The term “vehicle wheel / rim” means a metal structure that can be mated with a tire. The wheel is typically metal and often has a location on the periphery such that the wheel weight can be adhered for balancing purposes. The term tire is used in its conventional meaning. The term “highly filled” refers to a composite wherein the composite contains greater than 77 to 97 wt. % IM coated metal particulate or greater than 40 vol.% of IM coated metal particulate. The term “particulate” refers to a collection of finely divided particles. The particulate has a range of sizes and morphologies. The maximum particle size is less than 400 microns. The particulate, coated with interfacial modifier, is dispersed into a thermoplastic polymer. The particulate can be a single particle size made up of a narrow range of particle sizes around a center size as commercial products are sold. A 100µ or 300µ particulate typically has some amount (e.g.) ± 20µ of a particle size distribution around the 100 µ or 300µ size. The wheel weight can be prepared with blends of two or more particulate products, with each product consisting of a distinct distribution of particles centered on a defined size. The term “wheel weight” as claimed in this application relates to an extruded composite material that can be adapted to conform to any of the varying geometries of commercial vehicle wheels. Herein, the wheel weight is used to balance a combination of a metal wheel and a tire during manufacture of the vehicle. This is often the last step in the assembly process and is automated in many assembly plants. In the term “wheel weight" the skilled person understands 492.0078USP6 Patent that the term refers to balancing the combination of wheel and tire, the flexible and viscoelastic nature of the composite makes it an ideal material in an automated process since it is easily adapted to automation and substantially reduces inventory requirements. The term “balance” refers to the rotational balance of a wheel and tire combination that is obtained to ensure that the wheel rim and tire rotate smoothly at highway speeds and can be used safely and in comfort. The term “extrudate” typically refers to a product of an extrusion process. In an extrusion process, a composite is typically heated to an appropriate temperature and passed through an extruder using the force applied from a rotating (blank). The warmed extrudate is then passed through a die that imparts a specific shape to the extrudate. The term “thermoplastic polyester urethane (TPU) polymer” means a polymer made by forming a polyester of an aliphatic diacid and an aliphatic diol and reacting that polyester with a diisocyanate. A number of embodiments can be made by combining varying proportions of monomer diacid, diol and diisocyanate, however, no residual reactivity can be had from the isocyanate content. In order to eliminate isocyanate activity, the polymer can be treated with a compound with an active hydrogen that is reacted with residual isocyanate. Active hydrogen groups include -OH, -SH, -COOH, and one example of such a compound is phenol comprising a benzene ring with a single -OH. Reactivity can be assessed by contacting the TPU polymer with a reactive polyol. The absence of reaction (recovering all polyol after test) is a test method. Varying the proportions of each of the monomers results in the variation in extrudability. Extrudability is measured by actual ease of maintaining cross sectional dimensions and density, (extrudability) of either a final pellet or final product. The term “elastomer” relates to a polymer material (not composite) with substantial viscoelasticity. The polymer has both viscosity characteristics and elasticity characteristics as known. Elastomers typically have a substantial property such that as it is placed under stress it will yield for a substantial amount of increase in its length under stress before it fails. For the claimed materials, the term elastomer typically refers to an amorphous polymer maintained above a glass transition temperature so that the polymer after extension can return to its initial geometry. Elastomers can be both thermosets requiring a cross-linking agent but can also be thermoplastic in nature. In both the types of thermoplastic elastomers the elasticity of the material arises within the long chains of the chains of the polymer that are randomly oriented in 492.0078USP6 Patent space. As the polymer is placed under stress, the polymer obtains more of a linear orientation of the polymer change but does not exceed its fracture strain. After release of the stress, the polymer substantially returns to its initial state from its extended form. The term “melt strength” is simply that the melt does not substantially change linear dimension in the melt after extrusion. The term “strain hardening” means the increase in stress that accompanies increase in strain in plastic deformation beyond the yield point. Such strain hardening depends on the network density of the composite (physical entanglements, Vander Waals bonding, hydrogen bonding and chemical cross-links, if any). With increasing temperature, the strain hardening effect decreases. In the claimed material, the polyurethane polyester elastomer polymer in the composite must strain harden at the use temperature of the weight in its use on the wheel. The term “block polymer” means a polymer that has separate regions in the polymer chain consisting of only one monomer. The balance of the polymer can be random placement of monomers or other blocks of monomers. Polymers that are not “block” polymers have randomly placed monomers along the polymer chain. The term “close association” generally refers to the packing of particles or particulate within the polymer matrix. The interfacial modifier coating provides a homogeneous surface on the particle even if the particles are dissimilar. Said surface, because of its inert character, permits high volume or weight fraction packing in the polymer matrix without a particle to particle or a particle to polymer reaction to provide the new composite material. This new composite material has the rheological properties of the underlying polymer that is seen in the composite’s melt flow during extrusion or injection molding or in other viscoelastic properties such as, for example, tensile elongation. The term “adhesive” is used in its conventional sense and is typically used as a PSA. The term “release liner” refers to a thin film material that can be attached to an adhesive surface film on the wheel weight, such that the release liner can be easily removed from the wheel weight revealing without damaging the adhesive layer such that the adhesive layer can form an adequate bond fixing the wheel weight on the rim. 492.0078USP6 Patent Brief Description of the Figures FIG.1 to 3 are views of an embodiment of a generally rectangular weight ready for installation. FIG.1 is a top plan view of the wheel weight and release liner. The extruded ferrous metal polyurethane polyester elastomer composite and revealed portion of the release liner is shown. The balance of the release liner is not shown. FIG.2 is a cross section at 2-2 of the article of FIG.1. FIG.3 is a side view of the article of FIG.1. FIGs.4-6 show a variation on the rectangular weight. This weight has three planar sides and one side with a curved aspect adapted to a curved surface of a metal wheel rim. FIGs.7 and 8 graphically represent the nature of a strain hardening elastomer polymer. In summary, an elastomer, after applying a force, strain hardens. Upon reaching a yield point stress hardening is seen as the polymer stress increases past the yield stress before fracture point. A yield point is seen in the stress / strain curve and is reached when the internal association of polymer molecules is disrupted (pulled apart) by force. A fracture is when the test article itself mechanically fails. FIG.9 is a spectrum showing the “fingerprint region’ within which the relevant IR peaks are found. FIG.10 establishes a baseline with which the heights of the relevant peaks can be established. FIG.11 is a representative FTIR spectra of six typical thermoplastic TPU. The peaks useful for predicting success in extrusion are listed below. FIGS.12 and 13 graphically represent the results of our data analysis of the FTIR spectral characteristics that are displayed by the selected thermoplastic polyester urethane (TPU) polymers also known as polyester urethane (PEU) polymers. These data techniques can be used to predict the success of extruding this class of thermoplastic polyester urethane (TPU) polymers.

[0002] 492.0078USP6 Patent Detailed Discussion Novel composites are made by combining an interfacial modifier (IM) coated metal particulate and a selected thermoplastic elastomeric polymer having a set of specific properties. The metal particulate has a thin coating of an interfacial modifier that enhances the physical properties and processing efficiency of the composite. The combination of the thermoplastic elastomer and the modified metal particulate obtains a flexible, adhesive wheel weight composite that avoids any environmental impact and provides a precise and accurate balance weight when subsequently cut to a precise and accurate length. This combination can be efficiently manufactured, easily applied during balancing, and can survive the harsh conditions of highway traffic. Thermoplastic Elastomer Polymer Thermoplastic polyurethane polyester elastomers are substantially linear copolymers of a C2-4aliphatic diacid, C2-6aliphatic diol, and an aromatic diisocyanate. The polymer is made by a reaction between approximately equal molar amounts of an aromatic isocyanate and a C2-4 aliphatic diacid, C2-6 aliphatic diol polyester and are classified as a thermoplastic elastomer. Often a compound with active hydrogen can be added to the product to react with and eliminate any reactive isocyanate that is present or arises after manufacture. Polyester is useful in making elastomeric thermoplastic polyurethane (TPU). Polyester copolymers are prepared in a two-step procedure. Dicarboxylic acid is oligomerized with a diol / polyol or polyol. The resulting oligomer may be characterized by terminal hydroxyl group residues and internal -NH- residues, -C-C- residues, -CN- residues, carbonyl residues, aliphatic residues, or ester group residues. The oligomer is then reacted with a diisocyanate forming blocks of aromatic (aryl) of the diisocyanate and diol / polyol. In manufacture of the elastomeric TPU, the terminal hydroxyl groups of the polyester react with isocyanate compounds to form the final product. Additionally, ring opening polymerizations of cyclic acids such as lactones or cyclic carbonates can also be used to supply the hydroxy group for reaction with the isocyanate group. Typical hydroxy compounds used in making polyester materials include ethylene glycol, 1,2-propylene glycol, diethylene glycol, 1,4-butane diol, neopentyl glycol, 1,6-hexane diol, glycerol and trimethylolpropane. Aliphatic dicarboxylic acids used for the polyester reaction include adipic acid, glutaric acid, succinic acid, sebacic acid, and azelaic acid. These polymer 492.0078USP6 Patent residues interact within the polymer and between polymer molecules resulting in either an easy or difficult extrusion. Thermoplastic polyurethane polyester elastomer comprise a block copolymer consisting of “hard” and “soft” blocks. The hard block polymer is made by reacting a diisocyanate compound with a short-chain polyester diol. Soft block polymers are made by reacting a diisocyanate with long-chain polyester diol. The range of properties of the resulting material can vary depends on the type of diisocyanate, the type and size of polyester and the reaction ratios thereof. In somewhat greater detail, commercially, urethane chemistry can be tailored to specific end use requirements. Isocyanate compounds can react with hydroxyl groups to produce polyurethanes at reaction temperatures using a variety of polyester polyol materials producing biuret and isocyanate bonding. Polyurethanes can be considered as mixed amide esters of carbamic acid and possess properties of mixed polyester and polyamide chemistry. The basic reaction of an isocyanate with an active hydrogen compound occurs smoothly at ordinary reaction temperatures with the evolution of heat. Polyurethane elastomers can be prepared by two basic processes. The simplest and most obvious method is to mix a liquid higher molecular weight diol, a polyester polyol and a diisocyanate and to cast the mixture in a mold while liquid before curing. The typical product is a linear polyol polymer. A second method involves the reaction of a linear hydroxy terminated polyester polyol polymer with an excess of diisocyanate to form a linear isocyanate terminated pre polymer. The next step is chain extension and network formation with a small molecule weight molecular weight polyol called a chain extender component. Commercial manufacturers based primarily on the addition reactions of polyols with poly or diisocyanates. Monomeric and polymeric polyester diols typically produce linear polymers. The diisocyanate, polyol and other reactants affect the rate of reaction the type of reaction and it as well the properties of the final product in the final linear polymer. Control of water contamination is useful in making the useful TPUs and in extruding any pellet or product. The TPU or the composite materials should be compounded to contain as little water as possible to minimize polymer degradation. The water can be less than 300ppm, less than 200ppm or less than 100ppm or drier as needed for consistent operations. 492.0078USP6 Patent Polyol compounds used in polyurethane production are generally compounds with molecular weights in the range of 400-5000 Da (Daltons). The linear nature of the polyol and its increasing molecular weight creates soft segments and introduces elastomeric properties into the linear polymer structure. Polyurethane polyester copolymers are a type of thermoplastic polyurethane (TPU) that are composed of alternating sequences of hard and soft segments. The hard segments are formed by the reaction of diisocyanates with short-chain polyester diols, while the soft segments are formed by the reaction of diisocyanates with long-chain diols. The ratio, structure and molecular weight of the segments can be varied to produce different properties and applications of TPU. Linear aliphatic polyesters are common structures exemplified by poly(ethylene adipate) or poly(butylene adipate) made by reacting a diol such as ethylene glycol or butane diol and an aliphatic dicarboxylic acid such as an adipic acid. These polyols are used to provide elasticity and high strength to polyurethane elastomers. Polyester-based urethanes thermal behavior is dependent upon the concentration of ester groups on the polyester. Glass transition temperatures of polymers prepared with poly(1,4-butylene adipate) and poly(1,5-pentylene adipate) are significantly lower than that of the poly(ethylene adipate) elastomer. Some examples of polyester polyols are polyethylene adipate (PEA): made from ethylene glycol and adipic acid, polybutylene adipate (PBA): made from 1,4-butanediol and adipic acid, polycaprolactone (PCL): made from 1,6-hexanediol and caprolactone, polyethylene terephthalate (PET): made from ethylene glycol and terephthalic acid, Polybutylene terephthalate (PBT): made from 1,4- butanediol and terephthalic acid. While the composite can contain other materials and polymers that are compatible with the TPU, the composite cannot contain any fluorine compound such as a fluoropolymer. We have found that these TPU materials can be successfully extruded into pellets and into a final product using approximately 1:1 molar ratio of isocyanate to polyester. Polyester typically uses a small molar excess of diol to aliphatic acid. We have also found that control of moisture during the extrusion is important. The composite manufacture process is conducted such that the moisture content of the materials during compounding and production is less than about 200 ppm based on the polymer content. Diisocyanate The useful diisocyanates, are aromatic isocyanates such as toluene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI). Aliphatic isocyanates such as hexamethylene 492.0078USP6 Patent diisocyanate (HDI), isophorone diisocyanate (IPDI) or 4,4' dicyclohexyl diisocyanate (HMDI) are used to a much lesser extent, and only for special applications. TDI is commercialized using a mixture of the 2,4 and 2,6 isomers (TDI 80 / 20 having 80% 2,4 TDI and 20% 2,6 TDI and TDI 65 / 35 having 65% 2,4 TDI and 35% 2,6 toluene diisocyanate) or 2,4 TDI as pure isomer. Tri- isocyanates and higher functional isocyanates can be used if some degree of crosslinking is needed. MDI is preferred. Table 1 - The TPU polymers have the following properties: Tensile stress @ 100% elongation D792 < 5 Mpa Metal Particulate The useful substantially spherical particulate is a dense ( greater than 5 or 7 g-cm-3) metal, ferrous metal, or an alloy thereof. Typical materials include iron, iron alloys, steel, steel alloys, and other similar alloys with at least 50 wt. % iron. Both magnetic and non-magnetic metals can be used. The metal particles generally useful in the claimed materials typically have a particle size that ranges from about 2 to 500, 5 to 450, 10 to 425, 20 to 400, or 25 to 375 microns, 4 to 350 microns, and often 50 to 340, 75 to 330, or 75 to 415 microns. Composites can be made with a single particle size, two blended particle sizes, or three or more particle sizes in a blend. In a single particle composite the packing can be at least about 77 or about 78 to 98 %. Blended particles can attain higher packing levels. A combination of a larger and a smaller particle wherein there is about 0.1 to 50 wt.% of the smaller particle and about 99.9 to about 50 wt.% of larger particles can be used where the ratio of the diameter of the larger particles to the ratio of the smaller is about 1:1 to 4:1 or 2:1, 3:1, 4:1, 5:1, 6:1 or 7:1. In some embodiments there may be three or more components of particle sizes with size ratios such as about 50:7:1 or 350:50:7:1. In other embodiments there may be a continuous gradient of wide particle size distributions to provide higher packing densities or packing fractions. These percentages are 492.0078USP6 Patent based on the particulate. In some embodiments, there may be two or three or more components of particle sizes with specific size ratios. In two particulate blends, a first particulate that is greater than 200 microns is combined with a particulate that is less than 150 microns at a ratio of larger to smaller particulate of about 3-1 parts by weight of the larger to 1 part of the smaller. In three particulate blends, a first particulate that is greater than 200 microns is combined with a second particulate that is less than about 150 microns and a third particulate that is less than 100 microns at a ratio of first to second to third particulate of greater than about 10 parts by volume of the first to about 1 part of the second to less than about 5 of the third. These ratios will provide optimum self-ordering of particles within the polymer phase leading to maximum packing tunable particle fractions within the composite material. The self-ordering of the particles into a regular array is improved with the addition of interfacial modifier as a coating on the surface of the particle. The packing density or particle fraction of particles in the composite material varies to specifications required for the utility of the final shaped product as formed via injection molding. Values for packing density (ASTM B527-27), volume percent, may be greater than 40, 45, 50, 55, 65, 7075, 80, 85, 90, 95, or 99. The metal particle composition used in particle metallurgy typically includes many particulate size materials. The particles that are acceptable molding grade particulate include particle size, particle size distribution, particle morphology, including circularity index: Circularity = (perimeter)2 / 4π·Area and aspect ratio. Further, the flow rate of the particle mass, the green strength of the initial shaped object, the compressibility of the initial shaped object, the removability or ejectability of the shaped object from the mold, and the dimensional stability of the initial shape during processing is also important. These materials are not used as large metal particles, but are typically used as small metal particles, commonly called metal particulates. Such particulates have a relatively low aspect ratio and are typically less than about 1:3 aspect ratio. An aspect ratio is typically defined as the ratio of the greatest dimension of the particulate divided by the smallest dimension of the particulate. 492.0078USP6 Patent Generally, spherical particulates are commonly used; however, sufficient packing densities can be obtained from relatively uniformly shaped particles in a dense structure. In some embodiments, the particles may be ball milled to provide mostly round particles. In some instances, the ball-milled particle can have some flat spots. Using the interfacial modifier coating enables the part or shaped article to be extruded from the die with less force than a part or article that is not coated with the interfacial modifier. Interfacial Modifier Organo-metallic interfacial modifiers used in the application fall into broad categories from about 1 to about 3 ligands comprising hydrocarbyl groups, phosphate esters and / or hydrocarbyl sulfonate esters and about 1 to 3 hydrocarbyl ligands which may further contain unsaturation and heteroatoms such as oxygen, nitrogen, and sulfur. In one embodiment, the interfacial modifier that can be used is a type of organo-metallic material such as organo-cobalt, organo-iron, organo-boron, organo-nickel, organo-titanate, organo-aluminate, organo-strontium, organo-neodymium, organo-yttrium, organo-zinc, or organo-zirconate. The specific type of organo-titanate, organo-aluminates, organo-boronate, organo-strontium, organo-neodymium, organo-yttrium, organo-zirconates which can be used, and which can be referred to as organo-metallic compounds are distinguished by the presence of at least one hydrolysable group and at least one organic moiety. Mixtures of organo-metallic materials may be used. Certain of these types of compounds may be defined by the following general formula: M (R1)n(R2)m wherein M is a central atom selected from such metals as, for example, Ti, Al, and Zr and other metal centers including, preferably M is Ti, or Zr; R1can be a hydrolysable group; R2is a group consisting of an organic moiety, preferably an organic group that is non-reactive with polymer or other film former; wherein the sum of m+n must equal the coordination number of the central atom and where n is an integer ≥ 1 and m is an integer ≥1. R1may be an alkoxy group (-O-alkyl) having less than 12 carbon atoms. Other useful groups are those alkoxy groups, which have less than 9 carbons, and C1-8 linear, branched, cyclic, or aromatic alkoxy groups. R2 is an organic group including between 6-30, preferably 10-24 carbon atoms optionally including one or more hetero atoms selected from the group consisting of N, O, S and P. R2is a group consisting of an 492.0078USP6 Patent organic moiety, which is not easily hydrolyzed and is often lipophilic and can be a C5 to 30chain of an alkyl, ether, ester, saturated, unsaturated, polyunsaturated, branched, (etc.) C8-30 fatty acid, phospho-alkyl, phospho-alkyl, phospho-lipid, or phospho-amine. The phosphorus may be present as phosphate, pyrophosphato, or phosphito groups. Furthermore, R2may be linear, branched, cyclic, or aromatic. R2 is substantially unreactive, i.e., not providing attachment or bonding, to other particles. Titanates provide antioxidant properties and can modify or control cure chemistry. One titanium-based IM can be expressed as Ti (O-iPr)n(stearate)mwherein n is 1-3 and m is 1-3 and n+m = 4. The use of an interfacial modifier results in workable viscosity and improved structural properties in a final use such as a structural member or shaped article. Minimal amounts of the modifier can be used including about 0.005 to 10 wt.-%, about 0.01 to 6 wt.-%, about 0.02 to 5 wt.-%, or about 0.03 to 4 wt.% based on the weight final composite. The IM coating, with no other components, can be formed as a coating of a dimension equal to at least 3 molecular layers of IM. A substantially complete IM coating has a thickness of less than 1500 Angstroms often less than 200 Angstroms, and commonly 100 to 5000 Angstroms (Å) 50 to 1000 Angstroms (Å) or 10 to 500 Angstroms (Å). A composite is more than a simple admixture with properties that can be predicted by the rule of mixtures. A composite is defined as a combination of two or more substances at various percentages, in which each component results in properties of the composite material that are in addition to or superior to those of its constituents. In a simple admixture, the mixed material has little interaction and little property enhancement. In a composite material, at least one of the materials can be chosen to increase stiffness, strength, or density. The atoms and molecules in the components of the composite can form bonds with other atoms or molecules using several mechanisms. Such bonding can occur between the electron cloud of an atom or molecular surfaces including molecular-molecular interactions, atom- molecular interactions, and atom-atom interactions. Each bonding mechanism involves characteristic forces and dimensions between the atomic centers even in molecular interactions. The important aspect of such bonding force is strength and the variation of bonding strength over distance and directionality. The major forces in such bonding include ionic bonding, covalent bonding, and the van der Waals' (VDW) types of bonding. 492.0078USP6 Patent Ionic radii and bonding occur in ionic species such as Na+Cl-, Li+F-. Such bonding is substantial, often substantially greater than 100 kJ-mol-1often greater than 250 kJ-mol-1. Further, the interatomic distance for ionic radii tend to be small and can be 1-3 Å. Covalent bonding results from the overlap of electron clouds surrounding atoms forming a direct covalent bond between atomic centers. The covalent bond strengths are substantial, are roughly equivalent to ionic bonding and tend to have somewhat smaller interatomic distances. The varied types of van der Waals' forces are different than covalent and ionic bonding. These van der Waals' forces tend to be forces between molecules, not between atomic centers. In the composites of the claimed materials strong covalent or ionic bonding is avoided. Reactive coupling agents that bond polymer to ferrous particle are not used. The blended ferrous particle polymer composite as shown in the embodiments is formed with van der Waals bonding as modified and reduced by the IM coating. Such VDW forces, because of the nature of the fluctuating polarization of the molecule, tend to be low in bond strength, typically 50 kJ mol-1or less. Further, the range at which the force becomes attractive is also substantially greater than ionic or covalent bonding and tends to be about 3-10 Å. In the interfacial modifier (IM) modified van der Waals composite materials, we have found that the unique combination materials result in the creation of a unique van der Waals' bonding. The van der Waals' forces arise between coated particles, molecules / aggregates / crystals and are created by the combination of ferrous particle size, polymer, and interfacial modifiers in the composite. The claimed materials are characterized by a composite having intermolecular forces between ferrous particles less than about 30 kJ-mol-1and a bond dimension of 3-10 Å. An interfacially modified metal has a substantially complete coating of an interfacial modifier (IM) with a thickness of less than 1500 Angstroms, often less than 200 Angstroms, and commonly 10 to 500 Angstroms (Å) or 100 to 1500 Angstroms (Å). The process and physical property benefits of utilizing the coating becomes evident when packing to a significant proportion of the maximum packing fraction; this value is typically greater than approximately 75, 77, 85, 90, 95 or 98 weight % of the coated particulate phase in the composite. In contemporary materials maximum packing is less than 50 wt. %. 492.0078USP6 Patent Pigments The pigments can be used to add to or modify color to the products. The pigments used in preparing the composite are heat stable to 250°C and include inorganic and organic pigments, small particle metal pigments. Specific examples of metal pigments include powdered iron, copper powder, aluminum flake, etc. Also, complex oxide-based black pigments, iron oxide black pigments, titanium oxide-based black pigments, azomethine-azo-based black pigments, and titanium oxide-based pigments can be used. Other specific examples of the inorganic filler include, but are not particularly limited to, carbon, mica-based pigments, natural minerals, silica. Specific examples of the organic pigments are pigments of quinacridone, anthraquinone, phthalocyanine blue-based, phthalocyanine green-based, indigo / thiol indigo, dioxazine-based, quino phthalone, nickel azo, azo-based pigments, carbon black pigments, Strain hardening, in an elastomer that strain hardens, after applying a force, is seen in the increase in stress in the test material until a yield point. A yield point is seen in a change in the stress / strain curve of a material and is reached when the internal association of polymer molecules is disrupted (pulled apart) by force. At a fracture, seen as change in the curve, the test article itself mechanically fails. Typically, after a yield point, the max strain hardening strength is at a higher strain. A yield point is seen in the stress / strain curve is reached when the internal association of polymer molecules is disrupted (pulled apart) by force. Melt strength can be described as the resistance of a polymer melt to change in the linear dimensions of the extruded material as it leaves an extruder and is then placed under stress as it is processed down line from extrusion. Often after extrusion, the extruded material is passed through mechanical equipment that maintains a specific tension on the material in order to promote and control downstream processing. Accordingly, for appropriate manufacturing, the melt material should not change substantially in length after exiting the extrusion die. The polymer properties specifically involved in melt strength include molecular weight, molecular weight distribution, molecular branching, and polymer entanglement. As each of these characteristics increases, the melt strength is improved in the melt at low shear rates. The molecular weight of the polymer and the resistance of the polymer to resist any change in their relative position or entanglements one placed under strain after extrusion. The melt strength of the material typically is important until the polymer cools sufficiently that the resistance to dimensional change significantly increases after solidification. While there are methods of 492.0078USP6 Patent measuring melt strength, the specific analytical number relating to melt strength is less important than simply visually inspecting the extruded polymer composite as in a melt form before solidification after extrusion. If needed, one method to measure melt strength is the Goettfert / Rheotens device wherein a mold extrudate or fiber strand is pulled between two powered rollers as it leaves a downward extruding orifice. As the speed of rollers increases, the tension created in the strand is measured by the device and the loss modulus (G’’) and the storage modulus (G’) cross over, as a measure of oscillatory rheometer has become useful for estimating melt strength, if that effort is necessary. For commercial polymers, data such as melt strength can often be obtained directly from suppliers without additional testing necessary. These material companies often use tests such as melt strength for internal quality control. In the instance that manufacturers of a composite material or the composite object, changing materials from one polymer to another in the composite often requires changes to the extruder and the extruder die to compensate for differences in melt strength.

[0003] 492.0078USP6 Patent Table 2 - Exemplary Composites Component Useful Useful amounts amounts Table 3 - Properties of the composite Property ASTM Minimum Range of Units 492.0078USP6 Patent We have found a selection of polyester TPU elastomers suitable for flexible wheel weight application. We have found that the nature of the hydrogen bonding within a polymer and between the oxygen containing portion of separate polyester blocks is a useful predictor of the utility of the elastomer in this application in extrusion. Thermoplastic Highly filled Composite Extrudability We developed an analysis of Fourier Transfer InfraRed spectra (FTIR) to determine of extrudability in highly filled composites (metal particulate greater than 77 wt. %) of blended particles (particle size of 90 to 350 micron). We find that seemingly similar TPU-ARESs exhibit markedly different behaviors when extruded. We have discovered that the ability to be readily extruded into a successful composite shape can be predicted based on certain features in the FTIR spectra of the neat resins. This method is developed for aliphatic polyesters and aromatic diisocyanate but can easily be adapted for aromatic polyesters and aliphatic diisocyanate compounds through a selection of relevant peaks in the IR spectrum. We selected neat resins that are understood by this industry to be “the same,” in that, they are based on an adipate / butane diol polyester reacted with a diphenyl methane diisocyanate. The selection of a number of resins was based on published product specifications. In a first experimental cut, based on properties including melt strength, tensile, and elongation at break, Avalon 90AB, Covestro 385A, Elastolon 898A 15, Estane 58277, and Covestro 292AE were tested. Each polymer was trialed and given a score from A to E based on comparison of melt strength, edge and surface imperfections, consistent weight per unit length, and dimensional stability. The initial ranking are: Table 4 - Rankings of tested thermoplastic TPU’s TPU polymer Ranking 492.0078USP6 Patent The better polymers were extruded at commonly used and reasonable extruder conditions of rate, temperature, and pressure. We have found that while these TPUs are believed to be somewhat chemically similar, they extrude differently due to differences in extra monomers, various monomer proportions, impurities, additives, and molecular weight. These differences have a major impact on extrudability. In order to evaluate candidate polymers now and in future, we investigated the FTIR spectra of each and used a data analysis of spectral peaks to discriminate between resins in order to predict success in selection. The absorption of 12 peaks in the fingerprint region (FIG.9) (1800 to1000 cm-1) of the spectra were identified and the absorption measured by defining a baseline (see FIG.10) and then using the corrected height. The infrared spectra of neat resins (FIG.11) were measured utilizing an ATR-FTIR spectroscopy. The spectral dimensions were then normalized to each other using the dimension of the vC-C phenyl ring (1413 cm-1).(ref-height). In greater detail, we selected certain peaks that are characteristic of the polymer structure and properties. These peaks are attributed to, for example, terminal hydroxyl group residues - OH, and internal -NH- residues, -C-C- residues, -C-N- residues, carbonyl residues, aliphatic residues, ester group residues etc., as shown below in Table 5. We have found that the nature of the polymer / polymer association, bonding of residues within a polymer and between the residues of separate polyester blocks is a useful predictor of the utility of the elastomer in this application in extrusion and production efficiency. These interactions are best seen in the infra-red spectra. The dimensions of the peak absorbances from the stretch and flex bonds of urethane residues and polyester groups are seen at wavenumbers (cm-1): 1726.6 (cm-1) for polyurethane / polyester carbonyl, 1703.3 (cm-1) for polyurethane hydrogen bonding, 1596.1 (cm-1) for polyurethane aromatic carbon bonding, 1528.3 (cm-1) for polyurethane N-H and C-N bonds, 1413.2 (cm-1) for polyurethane C-C bond , 1309.1 (cm-1) for polyurethane N-H and C-N bonds, 1250.9 (cm-1) for polyester ester oxygen and methylene bonds, 1218.4 (cm-1) for polyurethane N-H and C-N bonds, 1168.9 (cm-1) for polyester oxygen bonding, 1140.8 (cm-1) for polyurethane / polyester carbonyl and methylene oxygen bonding, 1069.5 (cm-1) for polyurethane / polyester oxygen bonding, and 1018.0 (cm-1) for polyurethane / polyester aryl oxygen bonding. See FIGs 9, 10 and 11 for representative examples of the infrared spectral peaks characterize the relevant peaks in the TPU spectra. 492.0078USP6 Patent Visual comparison of the normalized peaks did not immediately yield obvious patterns or groupings. We can, however, distinguish groupings in a 12-coordinate space. Each IR peak corresponds to one coordinate axis in this space. This can be facilitated with the aid of two known and standard multivariant data methods, Hierarchical Cluster Analysis (HCA), and Principal Components Analysis (PCA). In the HCA method samples are intercompared based on their multivariate distance in 12 coordinate space. The distance between the responses for each sample is calculated and then plotted as a dendrogram. The following HCA analysis was performed on the data set utilizing the R project for statistical computing. Information on The R Project for Statistical Computing can be found at: https: / / www.r-project.org / . R is a language and environment for statistical computing and graphics. It is a GNU project which is similar to the S language and environment which was developed at Bell Laboratories (formerly AT&T, now Lucent Technologies) by John Chambers and colleagues. R can be considered as a different implementation of S. R provides a wide variety of statistical (linear and nonlinear modelling, classical statistical tests, time-series analysis, classification, clustering, …) and graphical techniques, and is highly extensible. The S language is often the vehicle of choice for research in statistical methodology, and R provides an open-source route to participation in that activity. R is available as Free Software under the terms of the Free Software Foundation’s GNU General Public License in source code form. It compiles and runs on a wide variety of UNIX platforms and similar systems. The IR spectra yielded the following data set: Table 5, Data with peak assignment before normalizing to the υ(C-C) phenyl ring of the MDI residue Avalon 90AB Avalon 90AE Covestro 385A Ellastolan Estane 58277 Covestro F n ti nl Gr A+ A B+ 890A 15 C+ D- 292AE F 323 354 105 276 134 120 128 364 233 154 215 067 492.0078USP6 Patent In a first HCA data analysis, these data were then read and analyzed by the following code sequence. #HCA analysis f <- read.table("FTIR_ONLY.txt", header = TRUE) # read in the data fs <- scale(f) # scale the data (abs - mean abs) / stdev fse <- dist(fs, method = "euclidean") # the "euclidian" straight line distance is calculated fses.hca <- hclust(fse, method = "single") # using single-linkage method plot(fses.hca, cex = 1, hang = 0.03, main = "") # plot the data In the following breakdown the vertical scale represents the Euclidian distance between the polymer candidates. The larger the number the better the extrusion performance. The important number is on the vertical axis and the tree is organized as seen simply for ease of reading. We found that the Euclidean distance predicts ease of extrudability. Avalon 90 AB with an A+ rating has a Euclidean of about 4.4 while poorer performing polymers scored less than 3.6. See Fig.12. The letter grades attached to the resin names were obtained by physically compounding the composite for each candidate and gauging the actual ease of maintaining cross sectional dimensions and density. In a second data PCA analysis, the candidates are uniformly separated in extrudability with the extrudability based on an assignment on a 12-point grading scale. PCA analysis transforms the 12-coordinate space to coordinates that are determined as containing the most information (variance) in the data set. In the same manner Principal Component Analysis was performed on the same data set. #PCA analysis script fs.pca <- prcomp(f, scale = TRUE) biplot(fs.pca, col=c("black", "red"), cex=c(.7, .7), xlim=c(-1, 1), 492.0078USP6 Patent main="", xlab="", ylab="", expand= 1.1, arrow.len=.1) The transformed data projection scores are plotted below showing that the five PE-PU resins were distinct in extrudability, with no overlapping properties. See FIG.13. In FIG.13 the value of the principle component #1 is represented in the Graphic as set by the horizontal axis. The important parameter is the value associated with the Principle component #1 the Value of the Principle component #2 is less helpful in selecting workable polymers. In FG.13, this analysis shows that the Avalon 90 AB ranked A+ and the Covestro 385A ranked B+ both had a principle component #1 value less than zero. The others scored greater than zero and were found to be much less suitable for extrusion in this claimed material. Adhesive The claimed material can be available as an indeterminate length of the extrudate, an adhesive and a release liner. An adhesive is used on balancing weight material to hold the weight in place in rotational balancing. The adhesive typically comprises a hot melt adhesive, typically a PSA. The hot melt adhesive uses a thermoplastic polymer such as an ethylene-vinyl acetate copolymer, acrylate copolymers, olefin polymers polyethylene, polypropylene, polybutene, and its copolymers, thermoplastic urethanes, styrene block polymers, polycarbonates, silicones, etc. Preferred are pressure sensitive adhesives that can be typically formulated by combining a polymer with a tackifying agent and other components such as plasticizers, dyes, stabilizers, etc. Release liner A release liner is made of a 50 to 150 micron polymer film or sheet used to prevent the adhesive surface of the weight from contamination from the use environment or from prematurely adhering before it can be applied in wheel balancing. The liner film can be coated with a release agent, which provides or enhances ease of removal without damage to the adhesive layer. Release liners are available in different colors, with or without printing under the 492.0078USP6 Patent low surface energy coating or on the backside of the liner. The release liner is placed on or covers the adhesive used to adhere the weight to the wheel. In use, the wheel weight is obtained from an inventory such as length of the material. The inventory, such as a roll inventory, of the extrudate and release liner. The material can be stored on rolls that can contain sufficient inventory to be useful but not so much that the roll is too heavy to handle. In rotational balancing, the balancer machine calculates the weight necessary to rationally balance the wheel and tire along with the placement of the weight. The exact weight in grams or ounces is then cut form the inventory, the release liner is removed, and the weight article is placed on the rim at the exact location needed. If needed, the operator can confirm the balance. Detailed Description of the Figures The wheel weight article as claimed comprises an extruded polymer composite having a removable release liner adhesively adhered thereto. The composite extrudate comprises a substantially rectangular extrudate with a width substantially greater than its thickness. The release liner is adhered to the weight using an adhesive layer. The release liner is sized and configured such that a small portion of the release liner overlaps and extends past the edge of the wheel weight, while covering the adhesive layer on the surface of the wheel weight below the release liner. The extended portion enables the removal of the liner in the installation process. In use, a portion of a wheel weight extruded composite is selected with a weight appropriate for its balancing purpose. The release liner is then removed from the surface of the wheel weight and the wheel weight is adhered to the rim of the wheel, using the revealed adhesive material. The adhesive is substantially strong enough such that the wheel weight is semi-permanently attached to the wheel, which attachment is further enhanced using a magnetic ferrous metal in the wheel weight, in combination with a wheel that can bond to magnetic materials. FIG.1 is a view of a portion of the wheel weight, adhesive and release liner with the extruded ferrous metal elastomer composite 101. In use the release liner is removed, and the adhesive is used to bond the weight to the wheel rim. FIG.1, there is shown a wheel weight 100 comprising the extruded composite 101 comprising the extruded ferrous metal elastomer composite. The wheel weight has weight 101, and the release liner 102 on the opposite side. A 492.0078USP6 Patent portion of the release layer 102 extends from opposite side of the weight 101 adhered thereto using a PSA layer 103. FIG.2 is a view of a cross section at 2-2 of the article of FIG.1. In FIG.2, there is shown a wheel weight comprising the extruded composite wheel weight 101, the release liner 102. As can be seen, the thickness of the composite is substantially greater than the thickness of the release liner. The release liner 102 is adhered to the weight with adhesive layer 103. The release liner 102 extends 102a past the weight body 101. Fig.3 is a side view of the article of FIG.1. In FIG.3, there is shown a side view of a portion of the wheel weight that is sized and configured to be directly applied to a wheel. The length of the extruded weight is determined by estimating the weight in grams, or ounces, which provides the exact weight as required to balance the wheel. This length is cut from a supply of the wheel weight roll to roll supply. Like the previous figures, article 300 in FIG.3 shows the extruded weight 101, the release liner 102, and the adhesive layer 103 positioned there between. FIGs.4 to 6 show a variation to a substantially rectangular weight. This weight has three planar sides and one side with a curved aspect adapted to a curved surface on a wheel rim. FIG.4 shows an isometric view a wheel weight 400 having an extruded portion 101, a release liner 102a and an adhesive placed there between. Figs.5 and 6 shows a cross section of weight 104. In fig. 5 the release liner and adhesive covers the planar portion of the weight and in FIG.6 the release liner and adhesive covers the curved portion of the weight. FIGs.7 and 8 graphically represent the nature of two typical aspects of a strain hardening elastomer polymer. In summary, in an elastomer that strain hardens, after applying a force, the test material yields proportionally to yield point ^. A yield point is seen in the stress / strain curve of FIG.7 and is reached when the internal association of polymer molecules is disrupted (pulled apart) by force. At fracture at ^, the test article itself mechanically fails. In FIG.7, the yield point is at ^, the max strain hardening strength is at ^. After the test material necks and fails at ^. A yield point ^ is seen in the stress / strain curve of FIG.8 and is reached when the internal association of polymer molecules is disrupted (pulled apart) by force. At fracture at ^, the test article itself mechanically fails. In FIG.7, the yield point is at ^, the max strain hardening strength is between ^ and fracture at ^. After the test material necks and fails at ^. FIG.9 is a spectrum showing the “fingerprint region’ within which the relevant IR peaks are found. 492.0078USP6 Patent FIG.10 establishes a baseline with which the heights of the relevant peaks can be established. FIG.11 is a representative FTIR spectra with baseline of the typical thermoplastic TPU. The peaks useful for predicting success in extrusion are listed on page 23. FIGS.12 and 13 graphically represent the results of our data analysis of the FTIR spectral characteristics than are displayed by the thermoplastic polyester urethane (TPU) polymers also known as poly ester urethane (PEU) polymers. These data techniques can be used to predict the success of extruding this class of thermoplastic polyester urethane (TPU) polymers. Table 6 - Numerical Indicia in FIGs.1-3. Indicia Identification Discussion 100 Wheel weight View -Extrudate with rectangular Table 7 – D mens ons n s. - . d1 Width Release Liner Composite Width composite plus at least 1 mm 492.0078USP6 Patent d8 Possible length of 0.5 to 10 cm or 1-5 cm weight for installation Pellet The composite can be made from a pellet through extrusion through a shaping die. Pellets are commonly made by extruding the compounded material through a pelleting die and cutting the pellets to size as they emerge from the die. Such a pellet made of the composite can be used as an intermediate between the compounding of the composite and the manufacturing of the final wheel weight product. A pellet can comprise the composite comprising the components in use concentration of components designed to be directly converted or used in making a useful article. Alternatively, the pellet can comprise a master batch composition with increased amounts, e.g., about 2 to 10 times the amount of ferrous particle such that the pellet can be combined with polymer in proportions that result in producing use concentrations. The pellet is a roughly cylindrical object that can be fed into an extruder input. The pellet is typically 1 to 50, 1 to 60, 1 to 70, 1 to 80, 1 to 90, or 1 to 100 mm in length and 1 to 5, 1 to 10, 1 to 15, or 1 to 20 mm in diameter. A pellet weighs about 10 to 100 mg,10 to 80 mg, 10 to 70 mg, 10 to 60 mg, 10 to 50 mg, 20 to 50 mg, 20 to 60 mg, 20 to 70 mg, 20 to 80 mg. The metal polymer composites can be applied as sound damping, sound insulation or sound isolation structures. These structures can take the form of panels or sound absorbing elements with various shapes, such as wedges, cones, or other projections, which can be attached to a surface to reduce or eliminate sound transmission. Metal polymer composites can be used as gaskets or seals for internal combustion engines. These materials can withstand the high temperatures and pressures of different types of engines, such as diesel, gasoline, rotary, turbine, or jet engines. These materials have viscoelastic properties that enhance their sealing performance and sound attenuation capabilities. Specifically, the invention can be used for apex seals in rotary engines where the rotating part contacts the engine casing. Metal polymer 492.0078USP6 Patent composites that have viscoelastic properties that enable them to absorb or prevent the propagation of low or high frequency vibrations through a structure. When two structural components are joined together, the material of the invention can be placed between them and act as a vibration isolator or dampener. Additionally provided are metal polymer composites that can be combined with a foamed thermoplastic material to create a multi-layer structure that has various applications. One layer consists of a foamed polymer layer and another layer consists of the claimed material. These tape materials are conformable to simple or complex curves due to their viscoelastic properties, especially their modulus. The composites can also be used as shielding materials for radiation protection. For example, composites can be molded into plates, bricks, tiles, or other shapes that can be used to build walls, floors, ceilings, or containers that can block or reduce the penetration of harmful radiation such as gamma rays, x-rays, or neutrons. Composites of known shielding metals can also be incorporated into clothing, suits, vests, helmets, or other wearable items that can provide personal protection for workers or civilians who are exposed to radiation sources. Composites can also be used to coat or wrap pipes, cables, wires, or other conduits that carry radioactive materials or fluids. Composites can offer advantages over conventional shielding materials such as tungsten, lead, steel, or concrete in terms of weight, flexibility, durability, environment, and cost. The weighted balance strip for the boat propeller is a linear extrudate of the composite composition for rotational balancing with a uniform cross section and a variable length that can be adjusted to achieve the optimal weight for balancing the propeller at different speeds. The weight can be cut from a long extrudate to obtain the exact weight needed for each propeller. The weighted balance strip can have a colored or decorative layer on the outside for aesthetic or informative purposes. The weight of the strip can vary from 1 to 250 grams, or 2 to 100 grams, depending on the size of the propeller. The upper cross section of the strip is curved to match the inner circumference of the propeller hub, which improves the adhesion of the strip to the hub. The cross section also has shaped corners and edges to reduce water turbulence and cavitation around the propeller. The smooth edges help to maintain a low Reynolds number, which means a stable laminar flow of water over the propeller surface. A high Reynolds number would cause more turbulence, cavitation, and vibration, which would affect the performance and 492.0078USP6 Patent durability of the propeller. The larger dimension of the rectangular cross section of the strip is pressed against the inner diameter of the propeller hub to increase the contact area and adhesion. The larger dimension can range from 1 mm to 5 cm, depending on the propeller size. Experimental section Example 1 An amount of 300µ and 100µ stainless steel powders in a proportion of 3 parts by weight larger particles to 1 part by weight of smaller particles were placed in a process container and combined with 0.41 parts by weight of an organo-titanium interfacial modifier. The container was agitated until the combined steel particles were fully coated with IM. The coated stainless steel was combined with 0.8 parts by weight of aluminum pigment. The mixture above was extruded in a compounding extruder at a temperature of 200°C that varied from the first half of the compounder to a temperature of 140°C with the Avalon AB at a rate of 1,200 pounds per hour through a pelletizing die at to make a composite pellet that was made-up of the following formulation. Table 7 – Exemplary formulation Component Wt. % The composite pellet was then extruded in a production extruder at a temperature between 190°C and 180°C through a die at 150°C to 175°C to form a dog bone test object. The 492.0078USP6 Patent dog bone test object (density 5.66 g-cm-3)was tested under ASTM D638 and exhibited a maximum tensile strength of 3.7 mPa (540 psi) and a tensile elongation at break of.840% The claims may suitably comprise, consist of, or consist essentially of, or be substantially free or free of any of the disclosed or recited elements. The claimed technology is illustratively disclosed herein can also be suitably practiced in the absence of any element which is not specifically disclosed herein. The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Various modifications and changes may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims. While the above specification shows an enabling disclosure of the composite technology, other embodiments may be made with the claimed materials. Accordingly, the disclosed wheel weight is embodied solely in the claims hereinafter appended.

Claims

492. 0078USP6 Patent We claim:

1. A metal polymer composite, comprising: (i) about 90 to 97 wt. % of a metal particle coated with 0.05 to 0.4 wt. % of an interfacial modifier, the particulate is a blend having a particle size range of 1 to 150 microns and 200 to 400 microns and the interfacial modifier coating having a thickness of less than 1500 Å, and (ii) 3 to 10 wt. % of a thermoplastic polyurethane polyester elastomeric polymer, the wt. % based on the composite; wherein the composite has a density of greater than 5 g-cm-3. 2.The composite of claim 1 wherein the polyester is an adipic acid polyester.

3. The composite of claim 2 wherein the polyester is a butanediol polyester.

4. The composite of claim 1 wherein the interfacial modifier coating thickness is less than 2 nm.

5. The composite of claim 1 wherein the composite comprises equimolar amounts of adipic acid and butanediol.

6. The composite of claim 5 wherein the composite is free of fluoropolymer and isocyanate reactivity and contains less than 200 ppm water .

7. The composite of claim 5 wherein the polymer exhibits strain hardening.

8. The composite of claim 5 wherein the composite exhibits melt strength.

9. The composite of claim 4 wherein the composite comprises about 91 to 95 wt. % of the metal particle and the metal particle is a blend of a larger particle and a smaller particle at a ratio of between 1:1 to 4:1 larger: smaller.

10. The composite of claim 4 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

11. The composite of claim 4 wherein the particle is coated with less than a 500 Å coating of 0.1 to 2 wt. % a titanium or zirconium organo metallic interfacial modifier, the wt. % based on the coated particle.

12. The composite of claim 9 wherein the particulate is a blend having a particle size of 5 to 100 microns and 150 to 350 microns.

13. The composite of claim 1 wherein the composite has an HCA value of greater than 3.

14. The composite of claim 1 wherein the composite has an HCA value of greater than 3.5.492.0078USP6 Patent 15. The composite of claim 1 wherein the composite has a Principle Component #1 value of less than 0.

0. The composite of claim 1 wherein the composite has a Principle Component #1 value of less than 0.

4.

16. A metal polymer composite, comprising: about 90 to 97 wt. % of a metal particle coated with 0.1 to 0.5 wt. % of an interfacial modifier, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 1500 Å and 3 to 10 wt. % of a thermoplastic polyurethane polyester elastomeric polymer comprising the polymerization product of diphenyl methane diisocyanate and a polyester comprising adipic acid and 1,4 -butane diol, the wt. % based on the composite; wherein the composite has an elongation at break (ASTM D636) of about 400 % (ASTM D638) and a maximum tensile strength (ASTM D638) greater than about 6 MPa and the linear extrudate has a density of greater than 5 g-cm-3.

17. The composite of claim 16 wherein the interfacial modifier coating thickness is less than 2 nm.

18. The composite of claim 17 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

19. The composite of claim 18 wherein the composite is free of fluoropolymer and of isocyanate reactivity and contains less than 200 ppm water.

20. The composite of claim 18 wherein the polymer exhibits strain hardening.

21. The composite of claim 18 wherein the composite exhibits melt strength.

22. The composite of claim 17 wherein the composite comprises about 91 to 95 wt. % of the metal particle.

23. The composite of claim 16 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

24. The composite of claim 18 wherein the particle is coated with 0.1 to 2 wt. % of a titanium or zirconium organometallic interfacial modifier the wt. % based on the coated particle.

25. The composite of claim 24 wherein the particulate having a particle size of 5 to 150 microns a coating thickness of less than 500 Å.

26. The composite of claim 16 wherein the composite has an HCA value of less than 3.

27. The composite of claim 16 wherein the composite has an HCA value of less than 3.5.492.0078USP6 Patent 28. The composite of claim 16 wherein the composite has a Principle Component #1 value of less than 0.

0.

29. The composite of claim 16 wherein the composite has a Principle Component #1 value of less than 0.

4.

30. A wheel weight composite comprising a metal polymer composite, and adhered thereto, a layer of adhesive and a release liner, wherein: (i) the composite, free of fluoropolymer, comprises 90 to 97 wt. % of a metal particle coated with 0.05 to 0.4 wt. % of a titanium or zirconium organo metallic interfacial modifier, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 500 Å and 3 to 10 wt. % a thermoplastic polyurethane polyester elastomeric polymer, the wt. % based on the composite, the polymer having an elongation at break of greater than 350 % (ASTM D638), a tensile modulus of greater than 2 MPa (ASTM D638), the composite is a linear extrudate having a rectangular cross section, a width of about 10 to 30 mm and a thickness of about 1 to 5 millimeters, (ii) the adhesive layer a 90° peel strength of greater than 3 kg per inch width and (iii) a release liner having a thickness of 50 to 150 microns, the release liner width is at least one millimeter greater than that of the linear extrudate. and the linear extrudate has a density of greater than 5 g-cm-3.

31. The wheel weight of claim 30 wherein the polyester is an adipic acid polyester .

32. The wheel weight of claim 31 wherein the polyester is a butanediol polyester. .

33. The wheel weight of claim 30 wherein the interfacial modifier coating thickness is less than 2 nm.

34. The wheel weight of claim 30 wherein the composite elongation at break (ASTM D636) of about 400 % (ASTM D638) and a maximum tensile strength (ASTM D638) greater than about 3.1 MPa .

35. The composite of claim 30 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

36. The wheel weight of claim 35 wherein the composite is free of fluoropolymer and free of isocyanate reactivity.

37. The wheel weight of claim 35 wherein the polymer exhibits strain hardening.

38. The wheel weight of claim 30 wherein the composite exhibits melt strength.492.0078USP6 Patent 39. The wheel weight of claim 30 wherein the composite comprises about 91 to 95 wt. % of the metal particle.

40. The wheel weight of claim 30 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

41. The wheel weight of claim 40 wherein the particle is coated with 0.1 to 2 wt. % of an interfacial modifier.

42. The wheel weight of claim 30 wherein the particulate having a particle size of 1 to 400 microns a coating thickness of less than 5 nm.

43. The wheel weight of claim 30 wherein the composite has an HCA value of less than 3.

44. The wheel weight of claim 30 wherein the composite has an HCA value of less than 3.

5.

45. The wheel weight of claim 30 wherein the composite has a Principle Component #1value of less than 0.

0.

46. The wheel weight of claim 30 wherein the composite has a Principle Component #1 value of less than 0.

4.

47. A wheel weight composite comprising a metal polymer composite, and adhered thereto, a layer of adhesive and a release liner, wherein: (i) the composite comprises 90 to 97 wt. % of a metal particle coated with 0.05 to 0.4 wt. % of an interfacial modifier, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 5 nm and 3 to 10 wt. % of a thermoplastic polyurethane polyester elastomeric polymer comprising the polymerization product of diphenyl methane diisocyanate and a polyester comprising adipic acid and 1,4-butane diol, the composite is a linear extrudate having a rectangular cross section, a width of about 20 to 25 mm and a thickness of about 3 to 4 millimeters, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 500Å; (ii) ) the adhesive layer having a 90° peel strength of 3 kg per inch-width and (iii) a release liner having a width of about 23 to 25 mm and a thickness of 50 to 150 microns, the release liner width is at least one millimeter greater than that of the linear extrudate; wherein the composite an elongation at break (ASTM D636) of about 350 % (ASTM D638) and a maximum tensile strength (ASTM D638) greater than about 6 MPa and the linear extrudate has a density of greater than 5 g-cm-3.492.0078USP6 Patent 48. The wheel weight of claim 47 wherein the interfacial modifier coating thickness is less than 2 nm.

49. The wheel weight of claim 47 wherein the composite is free of fluoropolymer and of isocyanate reactivity.

50. The composite of claim 47 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

51. The wheel weight of claim 50 wherein the polymer exhibits strain hardening.

52. The wheel weight of claim 50 wherein the composite exhibits melt strength.

53. The wheel weight of claim 49 wherein the composite comprises about 91 to 95 wt. % of the thermoplastic polyurethane polyester elastomeric polymer and about 5 to 9 wt. % of the metal particle.

54. The wheel weight of claim 48 wherein the particle is coated with 0.1 to 2 wt. % an interfacial modifier.

55. The wheel weight of claim 54 wherein the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 500 Å.

56. The wheel weight of claim 47 wherein the composite has an HCA value of less than 3.

57. The wheel weight of claim 47 wherein the composite has an HCA value of less than 3.

5.

58. The wheel weight of claim 47 wherein the composite has a Principle Component #1 value of less than 0.

0.

59. The wheel weight of claim 47 wherein the composite has a Principle Component #1 value of less than 0.

4.

60. A method of making a highly filled and large particle composite, the method comprises: processing a thermoplastic polyurethane polyester elastomeric polymer to contain less than about 200 ppm water to form a dried polymer, combining 3 to 10 wt.% of the dried polymer with about 90 to 97 wt. % of a metal particle having a particle size about 5 to 150 micron and a 10 to 500 Å coating of about 0.1 to 2 wt. % of an interfacial modifier in an extruder to form a melt composite; and extruding the melt composite to form a solid product.

61. The method of claim 60 wherein the polyester is an adipic acid and 1,4 butanediol polyester.

62. The method of claim 60 wherein the composite is free of fluoropolymer and of isocyanate reactivity.492.0078USP6 Patent 63. The method of claim 60 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

64. The method of claim 63 wherein the polymer exhibits strain hardening.

65. The method of claim 63 wherein the composite exhibits melt strength.

66. The method of claim 60 wherein the composite comprises about 91 to 95 wt. % of the metal particle.

67. The method of claim 61 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

68. The method of claim 66 wherein the particle is coated with 0.1 to 2 wt. % an interfacial modifier with a coating thickness of less than 500 Å.

69. The method of claim 68 wherein the particulate having a particle size of 1 to 400 microns 70. The method of claim 60 wherein the composite has an HCA value of less than 3.

71. The method of claim 60 wherein the composite has an HCA value of less than 3.

5.

72. The method of claim 60 wherein the composite has a Principle Component #1 value of less than 0.

0.

73. The method of claim 60 wherein the composite has a Principle Component #1 value of less than 0.

4.

74. A method of making a highly filled particle composite, the method comprises: processing a thermoplastic polyurethane polyester elastomeric polymer comprising the polymerization product of diphenyl methane diisocyanate and a polyester comprising adipic acid and 1,4 -butane diol to contain less than about 100 ppm water to form a dried polymer, combining 3 to 10 wt.% of the dried polymer with about 90 to 97 wt. % of a metal particle having a particle size about 1 to 400 micron and a 10 to 500 Å coating of about 0.1 to 2 wt. % of an interfacial modifier in an extruder to form a melt composite; and extruding the melt composite to form a solid product.

75. The method of claim 74 wherein the interfacial modifier coating thickness is less than 2 nm.

76. The method of claim 74 wherein the composite is free of fluoropolymer and of isocyanate reactivity.

77. The method of claim 76 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

78. The method of claim 77 wherein the polymer exhibits strain hardening492.0078USP6 Patent 79. The method of claim 77 wherein the composite exhibits melt strength 80. The method of claim 74 wherein the composite comprises about 91 to 95 wt. % of the metal particle 81. The method of claim 77 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer 82. The method of claim 80 wherein the particle is coated with 0.1 to 2 wt. % of an interfacial modifier 83. The composite of claim 80 wherein the particulate having a particle size of 1 to 400 microns a coating thickness of less than 500 Å.

84. The method of claim 74 wherein the composite has an HCA value of less than 3.

85. The method of claim 74 wherein the composite has an HCA value of less than 3.

5.

86. The method of claim 74 wherein the composite has a Principle Component #1 value of less than 0.

0.

87. The method of claim 74 wherein the composite has a Principle Component #1 value of less than 0.

4.

88. A metal polymer composite, comprising: about 90 to 97 wt. % of a metal particle coated with 0.1 to 0.5 wt. % of an interfacial modifier, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 1500 Å and 3 to 10 wt. % of a thermoplastic polyurethane polyester elastomeric polymer comprising the polymerization product of diphenyl methane diisocyanate and a polyester comprising adipic acid and 1,4 -butane diol, the wt. % based on the composite; wherein the composite has an elongation at break (ASTM D636) of about 400 % (ASTM D638) and a maximum tensile strength (ASTM D638) greater than about 6 MPa and the linear extrudate has a density of greater than 5 g-cm-3.

89. The composite of claim 88 wherein the interfacial modifier coating thickness is less than 2 nm.

90. The composite of claims 88-89 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

91. The composite of claims 88-90 wherein the composite is free of fluoropolymer and of isocyanate reactivity and contains less than 200 ppm water.

92. The composite of claim 88-91 wherein the polymer exhibits strain hardening.492.0078USP6 Patent 93. The composite of claim 88-92 wherein the composite exhibits melt strength.

94. The composite of claim 88-93 wherein the composite comprises about 91 to 95 wt. % of the metal particle.

95. The composite of claim 88-94 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

96. The composite of claim 88-94 wherein the particle is coated with 0.1 to 2 wt. % of a titanium or zirconium organometallic interfacial modifier the wt. % based on the coated particle.

97. The composite of claim 88-96 wherein the particulate having a particle size of 5 to 150 microns a coating thickness of less than 500 Å.

98. The composite of claim 88-97 wherein the composite has an HCA value of less than 3.

99. The composite of claim 88-98 wherein the composite has an HCA value of less than 3.

5.

100. The composite of claim 88-100 wherein the composite has a Principle Component #1 value of less than 0.

0.

101. The composite of claim 88-101 wherein the composite has a Principle Component #1 value of less than 0.

4.

102. A wheel weight composite comprising a metal polymer composite, and adhered thereto, a layer of adhesive and a release liner, wherein: (i) the composite, free of fluoropolymer, comprises 90 to 97 wt. % of a metal particle coated with 0.05 to 0.4 wt. % of a titanium or zirconium organo metallic interfacial modifier, the particulate having a particle size of 1 to 400 microns and a coating thickness of less than 500 Å and 3 to 10 wt. % a thermoplastic polyurethane polyester elastomeric polymer, the wt. % based on the composite, the polymer having an elongation at break of greater than 350 % (ASTM D638), a tensile modulus of greater than 2 MPa (ASTM D638), the composite is a linear extrudate having a rectangular cross section, a width of about 10 to 30 mm and a thickness of about 1 to 5 millimeters, (ii) the adhesive layer a 90° peel strength of greater than 3 kg per inch width and (iii) a release liner having a thickness of 50 to 150 microns, the release liner width is at least one millimeter greater than that of the linear extrudate. and the linear extrudate has a density of greater than 5 g-cm-3.

103. The wheel weight of claim 102 wherein the polyester is an adipic acid polyester .492.0078USP6 Patent 104. The wheel weight of claim 101-103 wherein the polyester is a butanediol polyester.

105. The wheel weight of claim 101-104 wherein the interfacial modifier coating thickness is less than 2 nm.

106. The wheel weight of claim 101-105wherein the composite elongation at break (ASTM D636) of about 400 % (ASTM D638) and a maximum tensile strength (ASTM D638) greater than about 3.1 MPa .

107. The composite of claim 101-106 wherein the composite comprises equimolar amounts of adipic acid and 1,4 butane diol.

108. The wheel weight of claim 101-107 wherein the composite is free of fluoropolymer and free of isocyanate reactivity.

109. The wheel weight of claim 101-108 wherein the polymer exhibits strain hardening.

110. The wheel weight of claim 101-109 wherein the composite exhibits melt strength.

111. The wheel weight of claim 101-110 wherein the composite comprises about 91 to 95 wt. % of the metal particle.

112. The wheel weight of claim 101-111 wherein the composite comprises about 5 to 9 wt. % of the thermoplastic polyurethane polyester elastomeric polymer.

113. The wheel weight of claim 101-112 wherein the particle is coated with 0.1 to 2 wt. % of an interfacial modifier.

114. The wheel weight of claim 101-113 wherein the particulate having a particle size of 1 to 400 microns a coating thickness of less than 5 nm.

115. The wheel weight of claim 101-114 wherein the composite has an HCA value of less than 3.

116. The wheel weight of claim 101-115 wherein the composite has an HCA value of less than 3.

5.

117. The wheel weight of claim 101-116 wherein the composite has a Principle Component #1value of less than 0.

0.

118. The wheel weight of claim 101-117 wherein the composite has a Principle Component #1 value of less than 0.4.

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