Moisture curing of anhydride-functionalized polymers using polymeric epoxysilanes as crosslinkers
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- DOW GLOBAL TECHNOLOGIES LLC
- Filing Date
- 2022-12-14
- Publication Date
- 2026-07-02
AI Technical Summary
Existing thermoplastic curing chemistries, such as sulfur and peroxide curing, limit processability due to premature curing during extrusion, and polyurethane reactive (PUR) chemistry in hot melt adhesives is toxic and prone to gel formation, necessitating the need for environmentally friendly polymer formulations with improved curing control and high-temperature stability.
The use of anhydride-functionalized olefin-based polymers combined with polymeric epoxy silanes, which form crosslinks upon moisture curing, providing stable compositions with high-temperature resistance and controlled curing processes.
The compositions exhibit low viscosity and excellent thermal stability, with high Shear Adhesion Failure Temperatures (SAFT) and wide processing windows, suitable for high-temperature applications like hot melt adhesives.
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Abstract
Description
[Technical Field]
[0001] Thermoplastics typically require curing before use in high-temperature applications because temperatures above the plastic's melting point melt the plastic. Many curing chemistries have been developed, including sulfur curing, peroxide curing, and moisture curing. However, these curing chemistries limit the processability of thermoplastics to avoid undesired curing during processes such as extrusion. For example, to avoid premature curing (scorch) of polymers formulated with sulfur, peroxide, or moisture curing agents, the extrusion temperature must be reduced and / or the residence time in the extruder must be shortened during extrusion. Polymer formulations containing these curing agents are typically not stable at high temperatures for the time required to complete the process at hand. Therefore, there is a need for new polymer formulations with excellent curing efficiency and a wide processing window (stable even at processing temperatures above 100°C).
[0002] Additionally, there is a strong demand for long-term and high-temperature operating windows in hot melt adhesive (HMA) applications. The current curing chemistry for HMA is polyurethane reactive (PUR), which uses NCO chemistry. However, PUR has two major drawbacks: the toxicity of NCO and the gel problem due to the high reactivity of NCO. Therefore, there is a need to replace PUR with more environmentally friendly polymer formulations that provide better control of the curing process.
[0003] U.S. Patent No. 5,210,150 discloses moisture-curable, melt-processable adhesives obtained by reacting certain ethylene copolymers containing n-alkyl acrylates and carefully defined amounts of carboxylic acids with stoichiometric amounts of epoxy silanes (see Abstract). However, as shown in the present data (see Examples), acids tend to readily react with epoxies and catalyze the condensation of silanes to form crosslinks in polymer systems, especially at elevated temperatures.
[0004] U.S. Patent No. 9,562,149 discloses a release coating composition comprising a polyorganosiloxane (A) having alkenyl groups, a crosslinker (B) having organohydrogensiloxane groups, a catalyst for the hydrosilylation reaction between (A) and (B), and an adhesion additive to enhance adhesion of the composition to a polymeric film substrate. The adhesion additive is the reaction product of a liquid polyorganosiloxane (C) containing at least one alkenyl group and at least one silanol group and a hydrolyzable silane (D) containing at least one epoxide group. The curable silicone release coating composition can be applied to a substrate and cured. The substrate is known as the "liner" that holds the label; this liner can be, for example, paper or a polymeric film. See the Abstract.
[0005] Additional polymer formulations are disclosed in the following references: U.S. Pat. No. 8,399,571; U.S. Pat. No. 8,569,417; and U.S. Patent Application Publication No. 2020 / 0216730. However, as noted above, there remains a need for polymer formulations and associated curing processes that provide a wide processing window (long operating window at high temperatures). There is also a need for more environmentally friendly polymer formulations that provide better control of the curing process. These needs have been met by the following inventions. Summary of the Invention
[0006] At least the following components a and b: a) an anhydride-functionalized olefin-based polymer; b) a polymeric epoxy silane, wherein the polymeric epoxy silane comprises the following i) and ii): i) The following ia) to ic) ia)
[0007] [ka] [wherein R1, R2, and R3 are each independently H or alkyl; and * ) represents the remainder of the polymeric epoxy silane; ib)
[0008] [ka] wherein R and R are each independently H or alkyl; the term "ring" refers to a ring structure containing 5 or more carbon atoms; and the asterisk ( * ic) ia) and ib) represent the remainder of the polymeric epoxy silane; or ic) a combination of ia) and ib), ii) the following iia) to iic), iia)
[0009] [ka] [In the formula, X1 and X2 each independently represent an alkyl group or an alkoxy group, R represents an alkyl group, and an asterisk ( * ) represents the remainder of the polymeric epoxy silane; iib)
[0010] [ka] [In the formula, X1 is an alkyl group or an alkoxy group, R is an alkyl group, and each asterisk ( * iic) iia) and iib) independently represent the remainder of each of the polymeric epoxy silanes; or a combination of iic) iia) and iib);
[0011] A first composition, wherein the polymeric epoxy silane comprises two or more silicon atoms. DETAILED DESCRIPTION OF THE INVENTION
[0012] Novel compositions and crosslinking processes using same have been discovered that provide low-viscosity formulations with good thermal stability, excellent high-temperature operating windows (e.g., viscosities less than 75,000 mPa·s after 3 hours at 120°C and / or viscosities less than 12,000 mPa·s after 3 hours at 177°C), and high Shear Adhesion Failure Temperatures (SAFT) greater than 150°C or greater than 170°C after 7 days of curing at 35°C / 85% RH. In particular, high-temperature resistant hot melt adhesives (HMAs) have been discovered, along with their curing processes.
[0013] It has been discovered that when a polymeric epoxysilane is mixed with an anhydride-functionalized polymer, the anhydride does not react significantly with the epoxysilane at high temperatures. Therefore, the viscosity of the polymer composition remains stable at high temperatures for a long time. After the composition (physical blend) is prepared, it can be moisture-cured in a controlled manner. In the presence of moisture, the anhydride converts to a diacid form, and one acid group reacts with the epoxy to form a chemical bond between the polymer and the epoxysilane, while the other acid group acts as an in-situ catalyst to catalyze the hydrolysis / condensation reaction of the silane to form crosslinking sites. See, for example, Scheme 1 below. Furthermore, some moisture-curing catalysts, such as dibutyltin dilaurate (DBTDL, CAS: 77-58-7), may be added to improve curing.
[0014] [ka]
[0015] As described above, a first composition is provided comprising at least the following components a and b: a) an anhydride-functionalized olefin-based polymer as described above, and b) a polymeric epoxy silane as described above. The first composition may comprise a combination of two or more embodiments as described herein. Each component a and component b may independently comprise a combination of two or more embodiments as described herein.
[0016] As used herein, for polymeric epoxy silanes, R = R 1 , R2=R 2 , R3=R 3 Please note that RA=R A ,RB=R B and so on. With respect to the number of carbon atoms in a chemical group, for example, the designation "C1-C5" (where "1-5" represents the sequential numbers from 1 to 5) refers to "1 to 5 carbon atoms" that may be present in the chemical group. An "alkyl" group may be linear, branched, cyclic, or any combination thereof. An "alkenyl" group may be linear, branched, cyclic, or any combination thereof. A "hydrocarbylene" group may be linear, branched, cyclic, or any combination thereof. A "heterohydrocarbylene" group may be linear, branched, cyclic, or any combination thereof.
[0017] In one embodiment or a combination of two or more embodiments, each described herein, the polymeric epoxy silane comprises one of the following chemical groups a) to i): a)-(CR 1 R 2 -CR 3 R 4 )-[wherein R1, R2, R3, and R4 are independently H or alkyl, and further, R1, R2, R3, and R4 are the same, and further, R1=R2=R3-R4=H], b)-(SiR 1 R 2 -O)- [wherein R1 and R2 are each independently an alkyl, further R1 = R2, further R1 = R2 = C1-C5 alkyl group, further C1-C4 alkyl group, further C1-C3 alkyl group, further C1-C2 alkyl group, and further methyl group], c) -(Si(R)(CR 1 =CR 2 R 3))-[wherein R is alkyl, further a C1-C5 alkyl group, further a C1-C4 alkyl group, further a C1-C3 alkyl group, further a C1-C2 alkyl group, and further a methyl group; each of R1, R2, and R3 is independently H or alkyl; further, each of R1, R2, and R3 are the same; and further, R1=R2=R3=H], d)-(CR 1 R 2 -CR 3 (CR 4 =CR 5 R 6 ))- [wherein R1, R2, R3, R4, R5, and R6 are independently H or alkyl, and further wherein R1, R2, R3, R4, R5, and R6 are the same, and further wherein R1=R2=R3=R4=R5=R6=H], e) an amide, f) an ester, g) a urethane, h) -(CR1R2-CR3R4)- [wherein R1, R2, and R3 are independently H or alkyl, and further wherein R1, R2, and R3 are the same, and further wherein R1=R2=R3=H, R4 is an aryl group, and further wherein R4 is a phenyl group], or i) any combination thereof; Each chemical group is derived from one or more monomers, and when present, each chemical group is present in at least two repeat units within the polymeric epoxy silane. In further embodiments, the polymeric epoxy silane further comprises one or more of the following chemical groups: a)-d) or i).
[0018] In one embodiment or a combination of two or more embodiments, each described herein, the polymeric epoxy silane has the following structures T1a-T1c: T1a)
[0019] [ka] wherein D is hydrocarbylene or heterohydrocarbylene; E is hydrocarbylene or heterohydrocarbylene; A is —(CR1R2-CR3)— or —(O—SiR4)— (wherein R1, R2, R3 are each independently H or alkyl, and R4 is alkyl); B is —(CR5R6-CR7)— or —(O—SiR8)— (wherein R5, R6, R7 are each independently H or alkyl, and R8 is alkyl); at least one of D, E, A, or B contains at least one Si atom; R A is alkyl; L is a divalent linker group; and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane; T1b)
[0020] [ka] wherein R A, R B, R C and R D are each independently alkyl, and L is a divalent linker group; T1c) a combination of T1a and T1b.
[0021] In one embodiment or a combination of two or more embodiments, each described herein, for the T1a structure, L comprises C, Si, or a combination thereof. In one embodiment or a combination of two or more embodiments, each described herein, for the T1b structure, L comprises C, Si, or a combination thereof.
[0022] In one embodiment, or a combination of two or more embodiments, each described herein, the polymeric epoxy silane comprises structure T1a. In one embodiment, or a combination of two or more embodiments, each described herein, the polymeric epoxy silane comprises one of the following structures T3a1, T3a2, T3a3, T3a4, T3a5, or T3a6, each as described below (see section H2 below).
[0023] In one embodiment or a combination of two or more embodiments, each described herein, the polymeric epoxy silane comprises the structure T1b.
[0024] In one embodiment or a combination of two or more embodiments, each described herein, component a is an anhydride-functionalized ethylene-based polymer or an anhydride-functionalized propylene-based polymer. In one embodiment or a combination of two or more embodiments, each described herein, component a is an anhydride-functionalized ethylene-based polymer, as well as an anhydride-functionalized ethylene / alpha-olefin interpolymer, or as well as an anhydride-functionalized ethylene / alpha-olefin copolymer.
[0025] In one embodiment or a combination of two or more embodiments, each described herein, component a has a density of 0.860 g / cc or more, or 0.862 g / cc or more, or 0.864 g / cc or more, or 0.866 g / cc or more, or 0.868 g / cc or more, or 0.870 g / cc or more, or 0.872 g / cc or more, or 0.874 g / cc or more, and / or 0.920 g / cc or less, or 0.915 g / cc or less, or 0.910 g / cc or less, or 0.905 g / cc or less, or 0.900 g / cc or less, or 0.890 g / cc or less, or 0.888 g / cc or less, or 0.886 g / cc or less, or 0.884 g / cc or less, or 0.882 g / cc or less, or 0.880 g / cc or less, or 0.879 g / cc or less.
[0026] In one embodiment or a combination of two or more embodiments, each described herein, the first composition further comprises a tackifier (component c).
[0027] In one embodiment or a combination of two or more embodiments, each described herein, the weight ratio of component a to component b is 2.0 or more, or 4.0 or more, or 6.0 or more, or 8.0 or more, and / or 40 or less, or 38 or less, or 36 or less, or 34 or less.
[0028] In one embodiment or a combination of two or more embodiments, each described herein, the first composition has a sum of components a, b, and c of 80.0 wt. % or more, or 85.0 wt. % or more, or 90.0 wt. % or more, or 92.0 wt. % or more, or 94.0 wt. % or more, or 96.0 wt. % or more, or 98.0 wt. % or more, or 99.0 wt. % or more, or 99.2 wt. % or more, or 99.4 wt. % or more, and / or 100.0 wt. % or less, or 99.9 wt. % or less, 99.8 wt. % or less, or 99.7 wt. % or less, or 99.6 wt. % or less, based on the weight of the first composition.
[0029] In one embodiment or a combination of two or more embodiments, each described herein, the first composition has a sum of components a and b of 50.0 wt. % or more, or 55.0 wt. % or more, or 60.0 wt. % or more, or 62.0 wt. % or more, or 64.0 wt. % or more, or 66.0 wt. % or more, or 68.0 wt. % or more, or 70.0 wt. % or more, and / or 100.0 wt. % or less, or 95.0 wt. % or less, or 90.0 wt. % or less, or 85.0 wt. % or less, or 80.0 wt. % or less, or 78.0 wt. % or less, or 76.0 wt. % or less, or 74.0 wt. % or less, based on the weight of the first composition.
[0030] In one embodiment or a combination of two or more embodiments, each described herein, the first composition has a percent increase in melt viscosity at 120°C (Δη4% at 120°C) of 45% or less, or 40% or less, or 38% or less, or 36% or less, and / or 10% or more, or 15% or more, or 18% or more, where Δη4% at 120°C = [(η4 - η1) / η1] × 100, where η4 is the melt viscosity after 4 hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C.
[0031] In one embodiment or a combination of two or more embodiments, each described herein, the first composition has a SAFT value after 7 days in air at 22°C and 50% RH of 80°C or greater, or 82°C or greater, or 84°C or greater, or 86°C or greater, or 88°C or greater, or 90°C or greater, or 93°C or greater, or 95°C or greater, and / or 200°C or less.
[0032] In one embodiment or a combination of two or more embodiments, each described herein, the first composition has a SAFT value of 100°C or greater, or 105°C or greater, or 115°C or greater, or 120°C or greater, or 130°C or greater, or 140°C or greater, or 150°C or greater, or 160°C or greater, or 170°C or greater, and / or 250°C or less after 7 days in air at 35°C and 85% RH.
[0033] Also provided is a method for forming a composition comprising a crosslinked olefin-based polymer formed from a first composition of one embodiment or a combination of two or more embodiments, each described herein, the method comprising at least the following steps A) and B): A) mixing at least components a and b together to form the first composition; and B) exposing the first composition to moisture to form the crosslinked olefin-based polymer.
[0034] In one embodiment or a combination of two or more embodiments, each described herein, step A is performed at a temperature of 120° C. or more, or 130° C. or more, or 140° C. or more, or 150° C. or more, or 160° C. or more, or 165° C. or more, or 170° C. or more, or 175° C. or more, or 180° C. or more, and / or 220° C. or less, or 215° C. or less, or 210° C. or less, or 205° C. or less, or 200° C. or less. In one embodiment or a combination of two or more embodiments, each described herein, step A is performed at a relative humidity (%RH) of 10% or more, or 15% or more, or 20% or more, or 25% or more, or 30% or more, or 35% or more, and / or 60% or less, or 55% or less, or 50% or less, or 45% or less, or 40% or less.
[0035] In one embodiment or a combination of two or more embodiments, each described herein, step B is performed at a temperature of 20° C. or higher, or 21° C. or higher, or 22° C. or higher, or 24° C. or higher, or 26° C. or higher, or 28° C. or higher, or 30° C. or higher, or 32° C. or higher, or 34° C. or higher, and / or 100° C. or lower, or 90° C. or lower, or 80° C. or lower, or 70° C. or lower, or 60° C. or lower, or 50° C. or lower, or 45° C. or lower, or 40° C. or lower. In one embodiment or a combination of two or more embodiments, each described herein, step B is performed at a percent relative humidity (%RH) of 40% or higher, or 42% or higher, or 44% or higher, or 46% or higher, or 48% or higher, or 50% or higher, and / or 100% or lower, or 95% or lower, or 90% or lower, or 88% or lower, or 86% or lower, or 85% or lower.
[0036] Also provided are crosslinked compositions formed from the first composition of any one embodiment or combination of two or more embodiments, each described herein, or formed from the method of any one embodiment or combination of two or more embodiments, each described herein.
[0037] Also provided are articles comprising a first composition of any one embodiment or combination of two or more embodiments, each described herein. Also provided are articles comprising at least one component formed from a first composition of any one embodiment or combination of two or more embodiments, each described herein.
[0038] Anhydride-functionalized olefin-based polymers An "anhydride-functionalized olefin-based polymer" is an olefin-based polymer in which an anhydride moiety is attached to the olefin-based polymer chain (e.g., an anhydride moiety is grafted to an ethylene / α-olefin interpolymer chain or a propylene / ethylene interpolymer). Non-limiting examples of suitable anhydrides include maleic anhydride (MAH), as well as itaconic anhydride, citraconic anhydride, tetrahydrophthalic anhydride, bromomaleic anhydride, chloromaleic anhydride, nadic anhydride, methylnadic anhydride, and alkenylsuccinic anhydride.
[0039] Olefin-based polymers include, for example, ethylene-based polymers and propylene-based polymers. Non-limiting examples of suitable ethylene-based polymers include ethylene homopolymers, ethylene / alpha-olefin interpolymers, and ethylene / alpha-olefin copolymers. Non-limiting examples of suitable alpha-olefins include C3-C20 alpha-olefins, or C3-C10 alpha-olefins, or C3-C8 alpha-olefins. Representative alpha-olefins include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene. The distribution of the monomer units, particularly the alpha-olefins, can be random, block, uniform, heterogeneous, etc. Preferably, the interpolymer or copolymer is a random interpolymer or copolymer (i.e., the polymer is composed of a random distribution of the monomer components).
[0040] Non-limiting examples of suitable propylene-based polymers include propylene homopolymers, propylene / ethylene interpolymers and copolymers, and propylene / alpha-olefin interpolymers and copolymers. Non-limiting examples of suitable alpha-olefins include C4 to C20 alpha-olefins, or C4 to C10 alpha-olefins, or C4 to C8 alpha-olefins. Representative alpha-olefins include 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.
[0041] tackifier Tackifiers are known in the art and can be solid, semi-solid, or liquid at room temperature. Preferred tackifiers include aliphatic, cycloaliphatic, and aromatic hydrocarbons, modified hydrocarbons, and hydrogenated versions of such hydrocarbons.
[0042] wax Waxes include, but are not limited to, paraffin wax, microcrystalline wax, high-density low-molecular-weight polyethylene or polypropylene wax, pyrolysis wax, by-product polyethylene wax, and Fischer-Tropsch wax. The wax may be present in an amount of 0 wt.% or more, or 0.1 wt.% or more, or 1.0 wt.% or more, or 5.0 wt.% or more, and / or 40 wt.% or less, or 30 wt.% or less, or 20 wt.% or less, based on the weight of the first composition.
[0043] Additives and Applications The first composition may include one or more additives. Additives include, but are not limited to, curing catalysts, fillers, pigments, UV stabilizers, antioxidants, processing aids, and solvents. In one embodiment, the additives are present in an amount of 0.01 wt. % or more, or 0.02 wt. % or more, or 0.05 wt. % or more, or 0.10 wt. % or more, or 0.20 wt. % or more, and / or 2.0 wt. % or less, or 1.5 wt. % or less, or 1.0 wt. % or less, or 0.90 wt. % or less, or 0.80 wt. % or less, or 0.70 wt. % or less, or 0.60 wt. % or less, or 0.50 wt. % or less, or 0.40 wt. % or less, or 0.30 wt. % or less, based on the weight of the first composition. The solvent may be present in an amount of 1.0 to 10 wt. % based on the weight of the first composition.
[0044] The first composition can include one or more polymers different from the anhydride-functionalized olefin-based polymer (component a), such as a polar copolymer, such as a polar copolymer of acrylate and vinyl acetate with ethylene, or a polymer blend of a polar copolymer with a non-polar olefin-based polymer. In one embodiment, the additional polymer or polymer blend is present in an amount of 0.5 wt.% or more, or 1.0 wt.% or more, or 2.0 wt.% or more, or 3.0 wt.% or more, or 4.0 wt.% or more, and / or 10 wt.% or less, or 9.0 wt.% or less, or 8.0 wt.% or less, or 7.0 wt.% or less, or 6.0 wt.% or less, or 5.0 wt.% or less, based on the weight of the first composition.
[0045] The components of the first composition can be mixed at high temperature in an extruder or mixing vessel, as is typical in the hot melt adhesive industry. The order of addition of the components can be further optimized to ensure the most stable compounding results. For example, all components can be added to one mixing vessel, or if more appropriate, the anhydride-functionalized polymer and epoxy silane can be mixed separately first and then mixed with the remaining components in a separate step.
[0046] The excellent stability and crosslinking characteristics of the present compositions make them well suited for adhesive applications. The compositions are suitable for applications requiring a long open time, such as woodworking or bookbinding applications. Many other applications would benefit from the delayed curing of the compositions.
[0047] definition Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percentages are by weight and all test methods are current as of the filing date of this disclosure.
[0048] As used herein, the term "composition" includes a mixture of materials, including the composition and reaction products and decomposition products formed from the materials of the composition. Any reaction or decomposition products are typically present in trace or residual amounts.
[0049] As used herein, the term "polymer" refers to a polymeric compound prepared by polymerizing multiple monomers, whether of the same or different types. Thus, the generic term polymer includes the term homopolymer (used to refer to a polymer prepared from only one type of monomer, with the understanding that trace amounts of impurities may be incorporated into the polymer structure), and the term interpolymer, as defined below. Trace amounts of impurities, such as catalyst residues, may be incorporated into and / or within the polymer. Typically, polymers are stabilized with very small amounts ("ppm" amounts) of one or more stabilizers (e.g., antioxidants).
[0050] As used herein, the term "interpolymer" refers to a polymer prepared by the polymerization of at least two different types of monomers. Thus, the term interpolymer includes the term copolymer (used to refer to a polymer prepared from two different types of monomers) and polymers prepared from three or more different types of monomers.
[0051] As used herein, the term "olefin-based polymer" refers to a polymer that, in polymerized form, comprises 50 weight percent or a majority weight percent (based on the weight of the polymer) of an olefin, such as ethylene or propylene, and may optionally contain one or more comonomers.
[0052] As used herein, the term "ethylene-based polymer" refers to a polymer that, in polymerized form, contains at least 50 weight percent or majority weight percent ethylene (based on the weight of the polymer), and may optionally contain one or more comonomers.
[0053] As used herein, the term "ethylene / alpha-olefin interpolymer" refers to an interpolymer that comprises, in polymerized form, 50 weight percent or a majority weight percent (based on the weight of the interpolymer) ethylene and an alpha-olefin.
[0054] As used herein, the term "ethylene / alpha-olefin copolymer" refers to a copolymer that, in polymerized form, contains 50% or a majority weight percent ethylene (based on the weight of the copolymer) and an alpha-olefin as the only two monomer types.
[0055] As used herein, the term "propylene-based polymer" refers to a polymer that, in polymerized form, comprises a majority weight percent propylene (based on the weight of the polymer) and may optionally include one or more comonomers.
[0056] As used herein, the term "propylene / alpha-olefin interpolymer" refers to an interpolymer that, in polymerized form, comprises a majority weight percent of propylene (based on the weight of the interpolymer) and an alpha-olefin. As used herein, the term "propylene / alpha-olefin copolymer" refers to a copolymer that, in polymerized form, comprises a majority weight percent of propylene (based on the weight of the copolymer) and an alpha-olefin as the only two monomer types.
[0057] As used herein, the term "propylene / ethylene interpolymer" refers to an interpolymer that, in polymerized form, comprises a majority weight percent of propylene and ethylene (based on the weight of the interpolymer). As used herein, the term "propylene / ethylene copolymer" refers to a copolymer that, in polymerized form, comprises a majority weight percent of propylene and ethylene (based on the weight of the copolymer) as the only two monomer types.
[0058] As used herein, the term "anhydride-functionalized olefin-based polymer" refers to an olefin-based polymer that includes an anhydride group attached to the olefin-based polymer. See previous discussion. Such anhydride groups may be derived from maleic anhydride or other anhydride compounds. The anhydride groups may be converted to carboxylic acid groups by reaction with water.
[0059] As used herein, the phrase "major weight percent" with respect to a polymer (or interpolymer or copolymer) refers to the amount of monomer that is present in the greatest amount in the polymer.
[0060] As used herein, the phrase "crosslinked olefin-based polymer" is understood by those skilled in the art and refers to a polymer having a network structure resulting from the formation of chemical bonds between polymer chains. The extent (or degree) of the network structure is determined by the SAFT failure temperature. The higher this temperature, the greater the extent of the network (or the greater the amount of crosslinking present in the crosslinked olefin-based polymer).
[0061] As used herein, the phrase "a crosslinked olefin-based polymer formed from the first composition," or similar phrases, refers to crosslinking (or curing) an "anhydride-functionalized polymer" with at least one polymeric epoxy silane to form a "crosslinked polymer."
[0062] As used herein, the term "polymeric epoxy silane" refers to a polymer or oligomer comprising a chemical repeating unit, at least one epoxy group, and at least one siloxane group (see claim 1). Optionally, a repeating unit (e.g., designated "A") may be separated from other similar repeating units by one or more intervening repeating units (e.g., designated "B," "C," or "D") of different chemical structure. For example, -ABABBA- or -ABACDAAA-.
[0063] The term "percent relative humidity (%RH)" is the amount of water vapor present in the air, expressed as a percentage of the amount required for saturation at the same temperature. %RH can be measured using humidity meters such as hygrometers and humidity gauges, which measure the relative humidity in air, respectively.
[0064] As used herein, the phrase "exposing the first composition to moisture" refers to contacting the first composition with an atmosphere containing water, typically in a gaseous state. Such exposure can be carried out, for example, in air or in an air oven set to a particular %RH.
[0065] The term "heteroatom" refers to an atom other than hydrogen or carbon (eg, Si, O, N, or P, typically Si or O).
[0066] The term "heteroatomic group" refers to a chemical group that contains a heteroatom or one or more heteroatoms.
[0067] As used herein, the terms "hydrocarbon," "hydrocarbyl group," and similar terms refer to chemical compounds or groups that contain only carbon and hydrogen atoms, respectively.
[0068] As used herein, the terms "heterohydrocarbon," "heterohydrocarbyl group," and similar terms refer to carbon, hydrogen-containing compounds or chemical groups, etc., in which one or more carbon atoms are independently replaced with a heteroatom group (e.g., Si, O, N, or P).
[0069] The terms "hydrocarbylene," "hydrocarbylene group," and similar terms used herein refer to a divalent hydrocarbon or divalent hydrocarbon group, and the like.
[0070] The terms "heterohydrocarbylene," "heterohydrocarbylene group," and similar terms used herein refer to a divalent hydrocarbylene or divalent hydrocarbylene group in which one or more carbon atoms are independently replaced with a heteroatom group.
[0071] As used herein, the term "divalent linker group" refers to a divalent chemical group that contains at least two atoms.
[0072] As used herein, the phrases "heat treated," "heat treatment," and similar phrases with respect to a first composition refer to increasing the temperature of the composition, for example, by application of heat and / or radiation. Note that the temperature at which the heat treatment is carried out refers to the temperature of the composition (e.g., the melting temperature of the composition).
[0073] The terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional component, step, or procedure, whether or not it is specifically disclosed. For the avoidance of doubt, all compositions claimed through the use of the term "comprising" may include, for example, any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term "consisting essentially of" excludes any other component, step, or procedure from any succeeding list, excepting those that are not essential to operability. The term "consisting of" excludes any component, step, or procedure not specifically delineated or listed.
[0074] List of Selected Features of Compositions and Methods A] at least the following components a and b: a) an anhydride-functionalized olefin-based polymer; b) a polymeric epoxy silane, wherein the polymeric epoxy silane comprises the following i) and ii): i) The following ia) to ic) ia)
[0075] [ka] [wherein R1, R2, and R3 are each independently H or alkyl; and * ) represents the remainder of the polymeric epoxy silane; ib)
[0076] [ka] wherein R and R are each independently H or alkyl; the term "ring" refers to a ring structure containing 5 or more carbon atoms; and the asterisk ( * ic) ia) and ib) represent the remainder of the polymeric epoxy silane; or ic) a combination of ia) and ib), ii) the following iia) to iic), iia)
[0077] [ka] [In the formula, X1 and X2 each independently represent an alkyl group or an alkoxy group, R represents an alkyl group, and an asterisk ( * ) represents the remainder of the polymeric epoxy silane; iib)
[0078] [ka] [In the formula, X1 is an alkyl group or an alkoxy group, R is an alkyl group, and each asterisk ( * iic) iia) and iib) independently represent the remainder of each of the polymeric epoxy silanes; or a combination of iic) iia) and iib); A first composition, wherein the polymeric epoxy silane comprises two or more silicon atoms.
[0079] B] The first composition according to A] above, wherein for structure ib), the ring structure contains 6 or more carbon atoms, even 6 carbon atoms.
[0080] C] The first composition according to A] or B] above, wherein for structure ib), the ring structure contains 10 or fewer, or 9 or fewer, or 8 or fewer, or 7 or fewer carbon atoms.
[0081] D] The first composition according to any one of A] to C] above, wherein the polymeric epoxy silane contains 3 or more, or 4 or more, or 5 or more, or 6 or more, or 8 or more, or 10 or more Si atoms.
[0082] E] The polymeric epoxy silane is provided with the following chemical groups a) to i): a)-(CR 1 R 2 -CR 3 R 4 )-[wherein R1, R2, R3, and R4 are independently H or alkyl, and further, R1, R2, R3, and R4 are the same, and further, R1=R2=R3-R4=H], b)-(SiR 1 R 2 -O)- [wherein R1 and R2 are each independently an alkyl, further R1 = R2, further R1 = R2 = C1-C5 alkyl group, further C1-C4 alkyl group, further C1-C3 alkyl group, further C1-C2 alkyl group, and further methyl group], c) -(Si(R)(CR 1 =CR 2 R 3 ))-[wherein R is alkyl, further a C1-C5 alkyl group, further a C1-C4 alkyl group, further a C1-C3 alkyl group, further a C1-C2 alkyl group, and further a methyl group; each of R1, R2, and R3 is independently H or alkyl; further, each of R1, R2, and R3 are the same; and further, R1=R2=R3=H], d)-(CR 1 R2 -CR 3 (CR 4 =CR 5 R 6 ))- [wherein R1, R2, R3, R4, R5, and R6 are independently H or alkyl, and further wherein R1, R2, R3, R4, R5, and R6 are the same, and further wherein R1=R2=R3=R4=R5=R6=H], e) an amide, f) an ester, g) a urethane, h) -(CR1R2-CR3R4)- [wherein R1, R2, and R3 are independently H or alkyl, and further wherein R1, R2, and R3 are the same, and further wherein R1=R2=R3=H, R4 is an aryl group, and further wherein R4 is a phenyl group], or i) any combination thereof; The first composition according to any one of A] to D] above, wherein each chemical group is derived from one or more monomers, and when present, each chemical group is present in at least two repeat units within the polymeric epoxy silane.
[0083] F] The polymeric epoxy silane is selected from the group consisting of the following chemical groups a) to d) or i): a)-(CR 1 R 2 -CR 3 R 4 )-[wherein R1, R2, R3, and R4 are independently H or alkyl, and further, R1, R2, R3, and R4 are the same, and further, R1=R2=R3-R4=H], b)-(SiR 1 R 2 -O)- [wherein R1 and R2 are each independently an alkyl, further R1 = R2, further R1 = R2 = C1-C5 alkyl group, further C1-C4 alkyl group, further C1-C3 alkyl group, further C1-C2 alkyl group, and further methyl group], c) -(Si(R)(CR 1 =CR 2 R 3))-[wherein R is alkyl, further a C1-C5 alkyl group, further a C1-C4 alkyl group, further a C1-C3 alkyl group, further a C1-C2 alkyl group, and further a methyl group; each of R1, R2, and R3 is independently H or alkyl; further, each of R1, R2, and R3 are the same; and further, R1=R2=R3=H], d)-(CR 1 R 2 -CR 3 (CR 4 =CR 5 R 6 ))- wherein each of R1, R2, R3, R4, R5, and R6 is independently H or alkyl, and further wherein each of R1, R2, R3, R4, R5, and R6 is the same, and further wherein R1 = R2 = R3 = R4 = R5 = R6 = H; or i) any combination thereof; The first composition according to any one of A] to E] above, wherein each chemical group is derived from one or more monomers, and when present, each chemical group is present in at least two repeat units within the polymeric epoxy silane.
[0084] G] The first composition according to any one of A] to F] above, wherein for structure iia), R is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0085] H] The first composition according to any one of A] to G] above, wherein in structure iia), X1 and X2 are each independently an alkoxy group, further X1 = X2, further X1 = X2 = OR, and further R is a C1 to C5 alkyl group, further C1 to C4 alkyl group, further C1 to C3 alkyl group, further C1 to C2 alkyl group, or further methyl group.
[0086] I] The first composition according to any one of A] to H] above, wherein for structure iib), R is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0087] J] The first composition according to any one of A] to I] above, wherein in structure iib), X1 is an alkoxy group, and further X1 = OR, and further R is a C1-C5 alkyl group, further C1-C4 alkyl group, further C1-C3 alkyl group, further C1-C2 alkyl group, and further methyl group.
[0088] K] The first composition according to any one of A] to J] above, wherein for structure ia), R1, R2 and R3 are each H.
[0089] L] The first composition according to any one of A] to K] above, wherein for structure ib), R1 and R3 are each H.
[0090] M] polymeric epoxy silanes having the following structures T1a-T1c: T1a)
[0091] [ka] wherein D is hydrocarbylene or heterohydrocarbylene; E is hydrocarbylene or heterohydrocarbylene; A is —(CR1R2-CR3)— or —(O—SiR4)— (wherein R1, R2, R3 are each independently H or alkyl, and R4 is alkyl); B is —(CR5R6-CR7)— or —(O—SiR8)— (wherein R5, R6, R7 are each independently H or alkyl, and R8 is alkyl); at least one of D, E, A, or B contains at least one Si atom; R A is alkyl; L is a divalent linker group; and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane; T1b)
[0092] [ka] wherein R A, R B, R C and R D are each independently alkyl, and L is a divalent linker group; The first composition according to any one of A] to L] above, comprising at least one of T1c) a combination of T1a and T1b.
[0093] N] The first composition of M] above, wherein the T1a structure (as shown) has a molecular weight of 500 g / mol or more, or 600 g / mol or more, or 700 g / mol or more, or 800 g / mol or more, or 900 g / mol or more, or 1000 g / mol or more, and / or 50,000 g / mol or less, or 40,000 g / mol or less, or 30,000 g / mol or less, or 20,000 g / mol or less, or 10,000 g / mol or less, or 9,000 g / mol or less, or 8,000 g / mol or less, or 7,000 g / mol or less, or 6,000 g / mol or less, or 5,000 g / mol or less.
[0094] O] The first composition according to M] or N] above, wherein for component A of the T1a structure, R1=R2=R3, and further R1=R2=R3=H.
[0095] P] The first composition according to any one of the above M] to O], wherein for component A of the T1a structure, R4 is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0096] Q] A first composition according to any one of the above M] to P], wherein for component B of the T1a structure, R5=R6=R7, and further R5=R6=R7=H.
[0097] R] The first composition according to any one of the above M] to Q], wherein for component B having the T1a structure, R8 is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0098] S] The first composition according to any one of M] to R] above, wherein for the T1a structure, component D comprises at least one of the following groups: -CH2-, -Si(R)2-, -Si(R)2-O-, or any combination thereof, and further wherein each R is independently a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, or further a methyl group.
[0099] T] A first composition according to any one of the above M] to S], wherein for the T1a structure, component E comprises at least one of the following groups: -CH2-, -Si(R)2-, or any combination thereof, and further wherein R is independently a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, or further a methyl group.
[0100] U] The first composition according to any one of the above M] to T], wherein, for the T1a structure, L contains 4 or more atoms, or 6 or more atoms.
[0101] V] The first composition of any one of M] to U] above, wherein for the T1a structure, L comprises C, Si, or a combination thereof. Further, L comprises one or more of the following units: -(CH2-CHR)-, where R is H, alkyl, or alkenyl, -(OSi(R)2)-, where R is alkyl, -(SiRR')-, where R is alkyl and R' is alkyl or alkenyl, or any combination thereof.
[0102] W] The first composition according to any one of M] to V] above, wherein the T1b structure has a molecular weight of 500 g / mol or more, or 600 g / mol or more, or 700 g / mol or more, or 800 g / mol or more, or 900 g / mol or more, or 1000 g / mol or more, and / or 50,000 g / mol or less, or 40,000 g / mol or less, or 30,000 g / mol or less, or 20,000 g / mol or less, or 10,000 g / mol or less, or 9,000 g / mol or less, or 8,000 g / mol or less, or 7,000 g / mol or less, or 6,000 g / mol or less, or 5,000 g / mol or less.
[0103] X] The first composition according to any one of the above M] to W], wherein, in the T1b structure, RA is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0104] Y] The first composition according to any one of the above M] to X], wherein, in the T1b structure, RB is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0105] Z] The first composition according to any one of the above M] to Y], wherein, in the T1b structure, R C is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0106] A2] The first composition according to any one of the above M] to Z], wherein, in the T1b structure, RD is a C1 to C5 alkyl group, further a C1 to C4 alkyl group, further a C1 to C3 alkyl group, further a C1 to C2 alkyl group, and further a methyl group.
[0107] B2] The first composition according to any one of the above M] to A2], wherein in the T1b structure, RA = RB = RC = RD, and each is a C1 to C5 alkyl group, a C1 to C4 alkyl group, a C1 to C3 alkyl group, a C1 to C2 alkyl group, or a methyl group.
[0108] C2] The first composition according to any one of the above M] to B2], wherein, in the T1b structure, L contains 4 or more atoms, or 6 or more atoms.
[0109] D2] The first composition of any one of M] to C2] above, wherein for the T1b structure, L comprises C, Si, or a combination thereof. Further, L comprises one or more of the following units: -(CH2-CHR)-, where R is H, alkyl, or alkenyl, -(OSi(R)2)-, where R is alkyl, -(SiRR')-, where R is alkyl and R' is alkyl or alkenyl, or any combination thereof.
[0110] E2] The first composition according to any one of M] to D2] above, wherein the polymeric epoxy silane comprises the structure T1a.
[0111] F2] A first composition described in any one of the above M] to E2], wherein for structure T1a, A is -(CR1R2-CR3)- [wherein R1, R2, and R3 are each independently H or alkyl] and B is -(CR5R6-CR7)- [wherein R5, R6, and R7 are each independently H or alkyl].
[0112] G2] A first composition described in any one of the above M] to E2], wherein for structure T1a, A is -(O-SiR4)-, R4 is alkyl, B is -(O-SiR8)-, and R8 is alkyl.
[0113] H2] the polymeric epoxy silane has the following structure T3a1, T3a2, T3a3, T3a4, T3a5 or T3a6:
[0114] [ka] T3a1) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane;
[0115] [ka] T3a2) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane;
[0116] [ka] T3a3) [wherein b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and each of x, y, z and k is independently a number from 1 to 300],
[0117] [ka] T3a4) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane;
[0118] [ka] T3a5) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represent each remainder of the polymeric epoxy silane;
[0119] [ka] T3a6) [wherein b is a number of 1 to 20, m is a number of 1 to 10, n is a number of 1 to 10, and x, y, z, and k are each independently a number of 1 to 300].
[0120] I2] The first composition according to any one of M] to D2] above, wherein the polymeric epoxy silane comprises the structure T1b.
[0121] J2] The first composition of any one of M]-D2] or H2] above, wherein the polymeric epoxy silane comprises structures T1a and T1b.
[0122] K2] The first composition according to any one of A] to J2] above, wherein the polymeric epoxy silane has a viscosity (25°C) of 1000 mPa·s or less, or 800 mPa·s or less, or 600 mPa·s or less, and / or 50 mPa·s or more, or 100 mPa·s or more, or 150 mPa·s or more, or 200 mPa·s or more.
[0123] L2] The first composition according to any one of A] to K2] above, wherein the molar ratio of epoxy groups in the polymeric epoxy silane to anhydride groups in the "anhydride-functionalized olefin-based polymer" is 0.10 or more, or 0.15 or more, or 0.20 or more, or 0.25 or more, or 0.30 or more, or 0.35 or more, or 0.40 or more, or 0.45 or more, or 0.50 or more, or 0.52 or more, and / or 2.00 or less, or 1.80 or less, or 1.60 or less, or 1.40 or less, or 1.20 or less, or 1.15 or less, or 1.10 or less.
[0124] M2] The first composition according to any one of A] to L2] above, wherein component a is an anhydride-functionalized ethylene-based polymer or an anhydride-functionalized propylene-based polymer.
[0125] N2] The first composition described in any one of A] to M2] above, wherein component a is an anhydride-functionalized ethylene-based polymer, further an anhydride-functionalized ethylene / alpha-olefin interpolymer, further an anhydride-functionalized ethylene / alpha-olefin copolymer.
[0126] O2] The first composition described in any one of A] to N2] above, wherein component a is an anhydride-grafted ethylene-based polymer, further an anhydride-grafted ethylene / alpha-olefin interpolymer, further an anhydride-grafted ethylene / alpha-olefin copolymer.
[0127] P2] The first composition according to N2] or O2] above, wherein the alpha olefin is a C3 to C20 alpha olefin, further selected from propylene, 1-butene, 1-pentene, 1-hexene or 1-octene, further selected from propylene, 1-butene, 1-hexene or 1-octene, further selected from propylene, 1-butene or 1-octene, further selected from 1-butene or 1-octene, further selected from 1-octene.
[0128] Q2] The first composition according to any one of A] to M2] above, wherein component a is an anhydride-functionalized propylene-based polymer, further an anhydride-functionalized propylene / ethylene interpolymer or an anhydride-functionalized propylene / alpha-olefin interpolymer, further an anhydride-functionalized propylene / ethylene copolymer or an anhydride-functionalized propylene / alpha-olefin copolymer.
[0129] R2] The first composition described in any one of A] to M2] or Q2] above, wherein component a is an anhydride-grafted propylene-based polymer, further an anhydride-grafted propylene / ethylene interpolymer or an anhydride-grafted propylene / alpha-olefin interpolymer, further an anhydride-grafted propylene / ethylene copolymer or an anhydride-grafted propylene / alpha-olefin copolymer.
[0130] S2] The first composition according to Q2] or R2] above, wherein the alpha-olefin is a C4 to C20 alpha-olefin, further selected from 1-butene, 1-pentene, 1-hexene or 1-octene, further selected from 1-butene, 1-hexene or 1-octene, further selected from 1-butene or 1-octene, further selected from 1-octene.
[0131] T2] Component a is 0.860 g / cc or more, or 0.862 g / cc or more, or 0.864 g / cc or more, or 0.866 g / cc or more, or 0.868 g / cc or more, or 0.870 g / cc or more, or 0.872 g / cc or more, or 0.874 g / cc or more, and / or 0.920 g / cc or less, or 0.915 g / cc or less, or 0.910 g / cc or less, or 0.905 g / cc or less, or 0.900 g / cc or less, or 0.890 g / cc or less, or 0.888 g / cc or less, or 0.886 g / cc or less, or 0.884 g / cc or less, or 0.882 g / cc or less, or 0.880 g / cc or less, or 0.879 g / cc or less (1 cc = 1 cm 3The first composition according to any one of A] to S2] above, having a density of
[0132] U2] Component a has a viscosity of 100,000 mPa·s or less, or 80,000 mPa·s or less, or 60,000 mPa·s or less, or 50,000 mPa·s or less, or 40,000 mPa·s or less, or 30,000 mPa·s or less, or 25,000 mPa·s or less, or 20,000 mPa·s or less, or 18,000 mPa·s or less, or 16, The first composition according to any one of A] to T2] above, having a melt viscosity (177°C) of 1,000 mPa·s or less, or 14,000 mPa·s or less, and / or 1,000 mPa·s or more, or 2,000 mPa·s or more, or 4,000 mPa·s or more, or 6,000 mPa·s or more, or 8,000 mPa·s or more, or 10,000 mPa·s or more.
[0133] V2] The first composition described in any one of A] to U2] above, wherein component a has a melt index (I2) of 200 or more, or 300 or more, or 400 or more, or 500 or more, or 550 dg / min or more, and / or 2,000 or less, or 1,500 or less, or 1,000 or less, or 900 or less, or 800 or less, or 700 dg / min or less.
[0134] W2] The first composition described in any one of A] to V2] above, wherein component a has a melting point (Tm) of 50°C or higher, or 55°C or higher, or 60°C or higher, or 65°C or higher, and / or 120°C or lower, or 110°C or lower, or 100°C or lower, or 90°C or lower, or 80°C or lower, or 75°C or lower, or 70°C or lower.
[0135] X2] The first composition according to any one of A] to W2] above, wherein component a has a glass transition temperature (Tg) of -70°C or higher, or -68°C or higher, or -66°C or higher, or -64°C or higher, or -62°C or higher, or -60°C or higher, and / or -40°C or lower, or -45°C or lower, or -48°C or lower, or -50°C or lower, or -52°C or lower, or -55°C or lower.
[0136] Y2] A first composition described in any one of A] to X2] above, wherein component a has a percent crystallinity of 10% or more, or 12% or more, or 14% or more, or 16% or more, or 18% or more, and / or 40% or less, or 35% or less, or 30% or less, or 28% or less, or 26% or less, or 24% or less, or 22% or less.
[0137] Z2] The first composition according to any one of A] to Y2] above, wherein component a has a weight average molecular weight Mw of 10,000 g / mol or more, or 20,000 g / mol or more, or 30,000 g / mol or more, or 32,000 g / mol or more, or 34,000 g / mol or more, or 35,000 g / mol or more, and / or 60,000 g / mol or less, or 50,000 g / mol or less, or 48,000 g / mol or less, or 45,000 g / mol or less, or 42,000 g / mol or less, or 40,000 g / mol or less.
[0138] A3] The first composition according to any one of A] to Z2] above, wherein component a has a number average molecular weight Mn of 6,000 g / mol or more, or 8,000 g / mol or more, or 10,000 g / mol or more, or 12,000 g / mol or more, and / or 50,000 g / mol or less, or 40,000 g / mol or less, or 30,000 g / mol or less, or 28,000 g / mol or less, or 26,000 g / mol or less, or 24,000 g / mol or less, or 22,000 g / mol or less, or 20,000 g / mol or less.
[0139] B3] The first composition according to any one of A] to A3] above, wherein component a has a molecular weight distribution (Mw / Mn) of 2.00 or more, or 2.10 or more, or 2.20 or more, or 2.30 or more, or 2.40 or more, and / or 3.50 or less, or 3.40 or less, or 3.30 or less, or 3.20 or less, or 3.10 or less, or 3.00 or less, or 2.90 or less, or 2.80 or less, or 2.70 or less, or 2.60 or less, or 2.50 or less.
[0140] C3] The first composition according to any one of A] to B3] above, wherein component a contains, based on the weight of component a, 0.1 wt. % or more, or 0.2 wt. % or more, or 0.4 wt. % or more, or 0.6 wt. % or more, or 0.8 wt. % or more, or 1.0 wt. % or more, or 1.1 wt. % or more, and / or 20 wt. % or less, or 15 wt. % or less, or 10 wt. % or less, or 5.0 wt. % or less, or 4.0 wt. % or less, or 3.5 wt. % or less, or 3.0 wt. % or less, or 2.5 wt. % or less, or 2.0 wt. % or less, or 1.8 wt. % or less, or 1.6 wt. % or less, or 1.4 wt. % or less of anhydride groups.
[0141] D3] The first composition according to any one of A] to C3] above, wherein the anhydride of the anhydride-functionalized olefin-based polymer is derived from maleic anhydride.
[0142] E3] The first composition according to any one of A] to D3] above, further comprising a tackifier (component c).
[0143] F3] The first composition described in E3] above, wherein component c has a number average molecular weight Mn of 50 g / mol or more, or 70 g / mol or more, or 100 g / mol or more, or 200 g / mol or more, and / or 1,000 g / mol or less, or 800 g / mol or less, or 600 g / mol or less, or 500 g / mol or less.
[0144] G3] The first composition described in E3] or F3] above, wherein component c has a molecular weight distribution (Mw / Mn) of 1.2 or more, or 1.4 or more, or 1.6 or more, and / or 2.2 or less, or 2.0 or less, or 1.8 or less.
[0145] H3] The first composition according to any one of E3] to G3] above, wherein component c is selected from a hydrocarbon resin, a silane-modified hydrocarbon resin, or a combination thereof.
[0146] I3] The first composition according to any one of the above E3] to H3], wherein component c is a hydrocarbon resin, further a hydrogenated hydrocarbon resin.
[0147] J3] The first composition according to any one of the above E3] to H3], wherein component c is a silane-modified hydrocarbon resin.
[0148] K3] The first composition according to any one of the above E3] to J3], wherein the weight ratio of component a to component c is 1.00 or more, or 1.20 or more, or 1.40 or more, or 1.60 or more, or 1.80 or more, or 2.00 or more, or 2.10 or more, or 2.20 or more, and / or 3.00 or less, or 2.80 or less, or 2.60 or less, or 2.50 or less, or 2.40 or less.
[0149] L3] The first composition according to any one of A] to K3] above, wherein the weight ratio of component a to component b is 2.0 or more, or 4.0 or more, or 6.0 or more, or 8.0 or more, and / or 40 or less, or 38 or less, or 36 or less, or 34 or less.
[0150] M3] The first composition according to any one of A] to L3] above, wherein component a is, based on the weight of the first composition, 15 wt% or more, or 20 wt% or more, or 30 wt% or more, or 40 wt% or more, or 50 wt% or more, or 55 wt% or more, or 60 wt% or more, or 62 wt% or more, and / or 99 wt% or less, or 95 wt% or less, or 90 wt% or less, or 85 wt% or less, or 80 wt% or less, or 75 wt% or less, or 70 wt% or less.
[0151] N3] A first composition according to any one of A] to M3] above, wherein component b is, based on the weight of the first composition, 0.50 wt % or more, or 1.0 wt % or more, or 1.5 wt % or more, or 2.0 wt % or more, and / or 20 wt % or less, or 15 wt % or less, or 12 wt % or less, or 10 wt % or less, or 8.0 wt % or less.
[0152] O3] The first composition according to any one of A3] to N3] above, wherein component c is, based on the weight of the first composition, 5.0 wt % or more, or 10 wt % or more, or 15 wt % or more, or 20 wt % or more, or 22 wt % or more, or 24 wt % or more, or 26 wt % or more, and / or 50 wt % or less, or 45 wt % or less, or 40 wt % or less, or 38 wt % or less, or 36 wt % or less, or 34 wt % or less, or 32 wt % or less, or 30 wt % or less.
[0153] P3] A first composition according to any one of the above E3] to O3], wherein the sum of components a, b and c is 80.0 wt.% or more, or 85.0 wt.% or more, or 90.0 wt.% or more, or 92.0 wt.% or more, or 94.0 wt.% or more, or 96.0 wt.% or more, or 98.0 wt.% or more, or 99.0 wt.% or more, or 99.2 wt.% or more, or 99.4 wt.% or more, and / or 100.0 wt.% or less, or 99.9 wt.% or less, 99.8 wt.% or less, or 99.7 wt.% or less, or 99.6 wt.% or less, based on the weight of the first composition.
[0154] Q3] The first composition according to any one of A] to P3] above, wherein the total of components a and b is, based on the weight of the first composition, 50.0 wt% or more, or 55.0 wt% or more, or 60.0 wt% or more, or 62.0 wt% or more, or 64.0 wt% or more, or 66.0 wt% or more, or 68.0 wt% or more, or 70.0 wt% or more, and / or 100.0 wt% or less, or 95.0 wt% or less, or 90.0 wt% or less, or 85.0 wt% or less, or 80.0 wt% or less, or 78.0 wt% or less, or 76.0 wt% or less, or 74.0 wt% or less.
[0155] R3] The first composition according to any one of A] to Q3] above, having a melt viscosity (η1) after 1 hour at 120°C of 5,000 mPa·s or more, or 10,000 mPa·s or more, or 15,000 mPa·s or more, or 20,000 mPa·s or more, or 25,000 mPa·s or more, or 30,000 mPa·s or more, or 32,000 mPa·s or more, or 34,000 mPa·s or more, or 36,000 mPa·s or more, and / or 80,000 mPa·s or less, or 75,000 mPa·s or less, or 70,000 mPa·s or less, or 68,000 mPa·s or less, or 66,000 mPa·s or less, or 64,000 mPa·s or less.
[0156] S3] A first composition according to any one of the above A] to R3], wherein the percent increase in melt viscosity at 120°C (Δη2% at 120°C) is 35% or less, or 30% or less, or 28% or less, or 26% or less, or 24% or less, or 22% or less, or 20% or less, and / or 1.0% or more, or 2.0% or more, or 3.0% or more, or 4.0%, wherein Δη2% at 120°C = [(η2 - η1) / η1] × 100, where η2 is the melt viscosity after 2 hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C.
[0157] T3] A first composition described in any one of the above A] to S3], wherein the percentage increase in melt viscosity at 120°C (Δη3% at 120°C) is 35% or less, or 30% or less, or 28% or less, or 26% or less, or 24% or less, and / or 1.0% or more, or 5.0% or more, or 8.0% or more, or 10%, or 12%, and Δη3% at 120°C = [(η3 - η1) / η1] × 100, where η3 is the melt viscosity after 3 hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C.
[0158] U3] A first composition described in any one of the above A] to T3], wherein the percentage increase in melt viscosity at 120°C (Δη4% at 120°C) is 45% or less, or 40% or less, or 38% or less, or 36% or less, and / or 10% or more, or 15% or more, or 18% or more, and Δη4% at 120°C = [(η4 - η1) / η1] × 100, where η4 is the melt viscosity after 4 hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C.
[0159] V3] The first composition according to any one of A] to U3] above, which has a SAFT value of 80°C or higher, or 82°C or higher, or 84°C or higher, or 86°C or higher, or 88°C or higher, or 90°C or higher, or 93°C or higher, or 95°C or higher, and / or 200°C or lower, after 7 days in an air atmosphere at 22°C and 50% RH.
[0160] W3] The first composition according to any one of A] to V3] above, which has a SAFT value of 90°C or higher, or 92°C or higher, or 94°C or higher, or 96°C or higher, or 98°C or higher, or 100°C or higher, or 105°C or higher, or 110°C or higher, and / or 200°C or lower after 16 days in an air atmosphere at 22°C and 50% RH.
[0161] X3] The first composition according to any one of A] to W3] above, which has a SAFT value of 150°C or higher, or 155°C or higher, or 160°C or higher, or 165°C or higher, or 170°C or higher, and / or 250°C or lower, after 21 days in an air atmosphere at 22°C and 50% RH.
[0162] Y3] A first composition according to any one of A] to X3] above, which has a SAFT value of 100°C or higher, or 110°C or higher, or 115°C or higher, or 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher, or 160°C or higher, or 170°C or higher, and / or 250°C or lower, after 7 days in air at 35°C and 85% RH.
[0163] Z3] The first composition according to any one of A] to Y3] above, further comprising at least one additive, and further at least one antioxidant.
[0164] A4] The first composition described in any one of A] to Z3] above, further comprising a polymer that differs from component a in one or more characteristics, such as the type of monomer(s), the distribution of monomers, the melt viscosity (177°C), the density, or any combination thereof.
[0165] B4] The first composition according to any one of A] to A4] above, which contains 0.50 ppm or less, or 0.20 ppm or less, or 0.10 ppm or less, or 0.05 ppm or less, or 0.02 ppm or less, or 0.01 ppm or less of peroxide, or even contains no peroxide.
[0166] A5] A method for forming a composition containing a crosslinked olefin-based polymer formed from the first composition according to any one of A] to B4] above, comprising at least the following steps A) and B): A) mixing together at least components a and b to form a first composition; B) exposing the first composition to moisture to form a crosslinked olefin-based polymer.
[0167] B5] The method according to A5] above, wherein step A is carried out at a temperature of 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher, or 160°C or higher, or 165°C or higher, or 170°C or higher, or 175°C or higher, or 180°C or higher, and / or 220°C or lower, or 215°C or lower, or 210°C or lower, or 205°C or lower, or 200°C or lower.
[0168] C5] The method according to A5] or B5] above, wherein step A is carried out at a relative humidity (%RH) of 10% or more, or 15% or more, or 20% or more, or 25% or more, or 30% or more, or 35% or more, and / or 60% or less, or 55% or less, or 50% or less, or 45% or less, or 40% or less.
[0169] D5] The method according to any one of A5] to C5] above, wherein step B is carried out at a temperature of 20°C or higher, or 21°C or higher, or 22°C or higher, or 24°C or higher, or 26°C or higher, or 28°C or higher, or 30°C or higher, or 32°C or higher, or 34°C or higher, and / or 100°C or lower, or 90°C or lower, or 80°C or lower, or 70°C or lower, or 60°C or lower, or 50°C or lower, or 45°C or lower, or 40°C or lower.
[0170] E5] The method according to any one of A5] to D5] above, wherein step B is carried out at a temperature of 20°C or higher, or 30°C or higher, or 40°C or higher, or 50°C or higher, or 60°C or higher, or 70°C or higher, or 80°C or higher, and / or 150°C or lower, or 140°C or lower, or 130°C or lower, or 120°C or lower, or 100°C or lower.
[0171] F5] The method described in any one of A5] to E5] above, wherein step B is carried out at a relative humidity percent (%RH) of 40% or more, or 42% or more, or 44% or more, or 46% or more, or 48% or more, or 50% or more, and / or 100% or less, or 95% or less, or 90% or less, or 88% or less, or 86% or less, or 85% or less.
[0172] G5] The method according to any one of A5] to F5] above, wherein the composition comprises either a crosslinked ethylene-based polymer derived from an anhydride-functionalized ethylene-based polymer or a crosslinked propylene-based polymer derived from an anhydride-functionalized propylene-based polymer.
[0173] H5] The method of any one of A5]-G5] above, wherein the composition comprises a crosslinked ethylene-based polymer derived from an anhydride-functionalized ethylene-based polymer.
[0174] I5] A crosslinked composition formed by the method described in any one of A5]-H5] above.
[0175] A6] A crosslinked composition formed from the first composition described in any one of A] to B4] above.
[0176] B6] The first composition according to any one of the above A] to B4], which is an adhesive, further a hot melt adhesive.
[0177] C6] An article comprising the first composition according to any one of A] to B4].
[0178] D6] An article comprising at least one component formed from the first composition described in any one of A] to B4].
[0179] E6] An article comprising the crosslinked composition of I5] or A6].
[0180] An article comprising at least one component formed from a crosslinked composition according to F6]I5] or A6].
[0181] G6] An article according to any one of C6] to F6] above, wherein the composition bonds two surfaces of the article.
[0182] H6] An article according to any one of C6] to F6] above, which is furniture, a book or a container.
[0183] Test Method Melt viscosity of the polymer and the first composition Melt viscosities were measured according to ASTM D3236 using a Brookfield viscometer (Model DV0III, Version 3) and an SC-31 hot melt viscometer spindle at the following temperatures: a) 177°C for the anhydride-functionalized olefin-based polymer (component a) and b) 120°C for the first composition. This method can also be used to measure the viscosity of tackifiers (160°C) or polymeric epoxy silanes (25°C). The sample was poured into an aluminum disposable tubular chamber, which was inserted into a Brookfield Thermosel and secured in place. The sample chamber had a notch in the bottom that fit the bottom of the Brookfield Thermosel, ensuring that the chamber could not rotate when the spindle was inserted and rotating. The sample (approximately 8-10 grams) was heated to the required temperature until the molten sample was 1 inch below the top of the sample chamber. The viscometer apparatus was lowered, submerging the spindle in the center of the sample chamber. The spindle was prevented from touching the sides of the chamber. The downward movement continued until the viscometer bracket was aligned on the Thermosel. The viscometer was turned on and set to operate at a steady shear rate that resulted in a torque reading within the range of 40-60 percent of the full torque capacity, based on the rpm output of the viscometer. Readings were taken every minute for 15 minutes or until the value stabilized, at which point the final reading was recorded.
[0184] Differential Scanning Calorimetry (DSC) Unless otherwise specified, differential scanning calorimetry (DSC) is used to measure Tm, Tc, Tg, and crystallinity in ethylene-based (PE) and propylene-based (PP) samples, as discussed below. Each sample (0.5 g) is compression molded into a film at 190°C for 10-15 seconds at 25,000 psi. Approximately 5-8 mg of film sample is weighed and placed in a DSC pan. A lid is crimped onto the pan to ensure a sealed atmosphere. The sample pan is then placed in a DSC cell and heated at a rate of approximately 10°C / min to a temperature of 180°C for PE (230°C for PP). The sample is held at this temperature for 3 minutes. The sample is then cooled at a rate of 10°C / min to -90°C for PE (-60°C for PP) and held isothermally at that temperature for 3 minutes. The sample is then heated at a rate of 10°C / min (second heat) until completely melted. Unless otherwise noted, the melting point (Tm) and glass transition temperature (Tg) of each polymer sample are determined from the second heat curve, and the crystallization temperature (Tc) is determined from the first cooling curve. The Tg and the respective peak temperatures of the Tm are recorded. The percent crystallinity can be calculated by dividing the heat of fusion (Hf) determined from the second heat curve by the theoretical heat of fusion of 292 J / g for PE (165 J / g for PP) and multiplying this amount by 100 (e.g., % crystallinity = (Hf / 292 J / g) × 100 for PE).
[0185] density The density of the polymer is measured by preparing a polymer sample according to ASTM D1928 and then measuring the density according to ASTM D792, Method B within one hour of sample pressing.
[0186] Gel Permeation Chromatography - Ethylene-Based Polymers The chromatography system consisted of a PolymerChar GPC-IR (Valencia, Spain) high-temperature GPC chromatograph equipped with an internal infrared detector (IR5). The autosampler oven compartment was set to 160 °C, and the column compartment was set to 150 °C. The columns were four Agilent "Mixed A" 30 cm, 20 micron tandem mixed-bed columns. The chromatography solvent was 1,2,4-trichlorobenzene containing 200 ppm butylated hydroxytoluene (BHT). The solvent source was nitrogen sparged. The injection volume was 200 microliters, and the flow rate was 1.0 milliliters / minute.
[0187] Calibration of the GPC column set was performed using 21 narrow molecular weight distribution polystyrene standards with molecular weights ranging from 580 to 8,400,000 g / mol, arranged in six "cocktail" mixtures with at least a 10-fold separation between individual molecular weights. The standards were purchased from Agilent Technologies. The polystyrene standards were prepared in 0.025 grams in 50 milliliters of solvent for molecular weights equal to or greater than 1,000,000 and 0.05 grams in 50 milliliters for molecular weights less than 1,000,000. The polystyrene standards were dissolved at 80°C with gentle agitation for 30 minutes. The peak molecular weights of the polystyrene standards were converted to polyethylene molecular weights using Equation 1 (as described in Williams and Ward, J. Polym. Sci., Polym. Let., 6, 621 (1968)): M ポリエチレン =A×(M ポリスチレン ) B (EQ1) where M is the molecular weight, A has a value of 0.4315, and B is equal to 1.0.
[0188] A fifth-order polynomial is used to fit each polyethylene-equivalent calibration point. A small adjustment (approximately 0.375 to 0.445) is made to A to correct for column resolution and band broadening effects, such that a linear homopolymer polyethylene standard is obtained at 120,000 MW.
[0189] A total plate count of the GPC column set is performed using decane (prepared in 0.04 g in 50 milliliters of TCB and dissolved for 20 minutes with gentle agitation). The plate count (Equation 2) and symmetry (Equation 3) are calculated using the following equations for a 200 microliter injection:
[0190]
number
[0191]
number
[0192] Samples were prepared semi-automatically using PolymerChar "Instrument Control" software to target a sample weight of 2 mg / ml, and the solvent (containing 200 ppm BHT) was added via the PolymerChar high-temperature autosampler to a pre-nitrogen-sparged septum-capped vial. Samples were dissolved at 160°C for 2 hours under "slow" shaking.
[0193] Calculations of Mn(GPC), Mw(GPC), and Mz(GPC) are based on GPC results using the internal IR5 detector (measurement channel) of the PolymerChar GPC-IR chromatograph according to Equations 4-6 using PolymerChar GPCOne™ software, a baseline-subtracted IR chromatogram at each equally spaced data collection point (i), and the polyethylene equivalent molecular weight obtained from a narrow standard calibration curve at point (i) from Equation 1. Equations 4-6 are as follows:
[0194]
number
[0195] To monitor deviations over time, a flow marker (decane) is introduced into each sample via a micropump controlled by the PolymerChar GPC-IR system. This flow marker (FM) is used to linearly correct the pump flow rate (Flow Rate (Nominal)) for each sample by aligning the RV of each decane peak in the sample (RV(FM Sample)) with the RV of the decane peak in the narrow standard calibration (RV(FM Calibrated)). This assumes that any change in the time of the decane marker peak is related to a linear shift in flow rate (Flow Rate (Effective)) for the entire run. To facilitate the highest accuracy in measuring the RV of the flow marker peak, a least-squares fit is used to fit the peaks in the flow marker concentration chromatogram to a quadratic equation. The first derivative of the quadratic equation is then used to solve for the true peak position. After calibrating the system based on the flow marker peak, the effective flow rate (relative to the narrow standard calibration) is calculated as in Equation 7: Flow Rate (Effective) = Flow Rate (Nominal) × (RV(FM Calibrated) / RV(FM Sample)) (EQ7). Processing of flow marker peaks is performed by PolymerChar GPCOne™ software. Acceptable flow corrections are those that result in an effective flow rate within + / - 0.7% of the nominal flow rate.
[0196] Gel Permeation Chromatography (GPC) - Propylene-Based Polymers A high-temperature gel permeation chromatography (GPC) system equipped with a robotic assistant deliverer (RAD) system for sample preparation and injection is used. The concentration detector is an infrared detector (IR4) manufactured by Polymer Char Inc. (Valencia, Spain). Data collection is performed using a Polymer Char DM100 data acquisition box. The system is equipped with an online solvent degasser manufactured by Agilent. The column compartment is operated at 150 °C. The columns are four Mixed A LS 30 cm, 20 micron columns. The solvent is nitrogen (N2)-purged 1,2,4-trichlorobenzene (TCB) containing approximately 200 ppm of 2,6-di-t-butyl-4-methylphenol (BHT). The flow rate is 1.0 mL / min, and the injection volume is 200 μl. A sample concentration of 2 mg / mL was prepared by dissolving the sample in N 2 purged and preheated TCB (containing 200 ppm BHT) at 160° C. for 2.5 hours with gentle stirring.
[0197] A GPC column set is calibrated by running 20 narrow molecular weight distribution polystyrene (PS) standards. The molecular weights (MW) of the standards range from 580 to 8,400,000 g / mol, and the standards are contained in six "cocktail" mixtures. Each standard mixture has at least a 10-fold difference between the individual molecular weights. The polypropylene-equivalent molecular weight of each PS standard is calculated using the Mark-Houwink coefficients reported for polypropylene (T. G. Scholte, N.L. J. Meijerink, H.M. Schoffeleers, and A.M.G. Brands, J. Appl. Polym. Sci., 29, 3763-3782 (1984)) and polystyrene (E.P. Tocka, R.J. Roe, N.Y. Hellman, P.M. Muglia, Macromolecules, 4, 507 (1971)) using the following equation (1):
[0198]
number
[0199] [Table 1]
[0200] Logarithmic molecular weight calibrations are generated using a fourth-order polynomial fit as a function of elution volume. Number-average and weight-average molecular weights are calculated according to the following equations:
[0201]
number
[0202] Melt Index The melt index (I2) of ethylene-based polymers is measured according to ASTM D-1238, condition 190°C / 2.16 kg. The melt flow rate (MFR) of propylene-based polymers is measured according to ASTM D-1238, condition 230°C / 2.16 kg.
[0203] Shear Adhesion Failure Temperature (SAFT) Shear adhesive failure temperature (SAFT) was measured according to ASTM D4498 using a Chem Instruments OSI-8 programmable oven with a 500 gram weight. Each test specimen was first equilibrated in the oven at 40°C for 10 minutes, and the oven temperature was increased at an average rate of 0.5°C / min. The temperature at which the adhesive bond failed was recorded. Each test specimen was in a shear mode configuration with a 500 gram weight.
[0204] Each SAFT test specimen was prepared using two sheets of 60 g / m² kraft paper. Each sheet measured 6 inches by 12 inches (152 mm by 305 mm). Two 1.75-inch or 2-inch (45 mm or 51 mm) wide strips of single-sided pressure-sensitive tape, such as masking tape, were adhered to the bottom sheet, parallel to each other, with a 1-inch (25 mm) gap between them. The two strips of tape were positioned so that the 1-inch gap ran lengthwise down the center of the bottom sheet.
[0205] The adhesive composition to be tested (first composition) was heated to 170°C (338°F) and then evenly dispensed into the center of the "1-inch gap" formed between the two strips of tape. A bonded paper template was then quickly formed before the composition could thicken too much, as follows: A rod was quickly slid onto the bottom sheet to flatten the adhesive composition in the gap. This rod was shimmed with identical strips of tape on both sides of the gap. After the first rod had passed, a second piece of kraft paper was aligned with the bottom sheet and placed on top of it, and a second rod was quickly slid onto this top sheet to form the bonded paper template. Overall, the first rod evenly spread the composition into the gap area between the tape strips, and the second rod evenly pressed the second sheet, which covered the top of the gap area and the top of the tape strips. Within the bonded paper template, a single 1-inch (25.4 mm) wide strip of adhesive composition bonded the bottom and top paper sheets. The paper template was cut crosswise into 1-inch (25.4 mm) wide by 3-inch (76.2 mm) long strips to form the test specimens. Each test specimen had a 1-inch by 1-inch adhesive bond in the center, with a bond thickness of approximately 8 to 10 mils (0.008 to 0.010 inch). Each test specimen was cured in air using one of two cure profiles: either room temperature (see a) or a humid atmosphere (see b): a) 22°C, 50% RH cure for 7, 16, or 21 days or more; or b) 35°C, 85% RH cure for 7 days. Each cured test specimen was then subjected to the SAFT test described above. For each cured composition, two test specimens were tested, and the average failure temperature was recorded. [Example]
[0206] Reagents and Polymers The reagents and polymers are listed in Table 1.
[0207] [Table 2]
[0208] For AFFINITY GA 1000R polymer, after prolonged storage in air, all or most of the anhydride groups typically convert to acid groups, as seen by FTIR. Therefore, AFFINITY GA 1000R was heat-treated at 180°C for 15-20 minutes with stirring to completely convert the acid groups to anhydride groups (anhydride treatment). The conversion can be monitored by FTIR. In the following table, "AFFINITY GA 1000R-acid" refers to AFFINITY GA 1000R without anhydride treatment, and "AFFINITY GA 1000R-anhydride" refers to the polymer after anhydride treatment.
[0209] Preparation of polymeric epoxy silanes The preparation of four polymeric epoxy silanes is provided below. See also U.S. Patent No. 9,562,149.
[0210] Polymer-based epoxy silane 1 (P-ES1) Viscosity is 20mm 2 A silanol-terminated methylvinylsiloxane-dimethylsiloxane copolymer (80 wt%) containing primarily α,ω-hydroxy-terminated siloxanes with some α-hydroxy-ω-methoxy-terminated siloxanes was reacted with 20 wt% 3-glycidoxypropyltrimethoxysilane in the presence of potassium silanolate at 100°C for 1 hour to produce a reaction product containing at least one epoxy group, at least one alkenyl group, and at least one alkoxy group in the molecule. At least 80% (mol) of the epoxy groups from the glycidoxypropyltrimethoxysilane were incorporated into the reaction product, which also contained the siloxane chains of the silanol-terminated polysiloxane.
[0211] Polymer-based epoxy silane 2 (P-ES2) A silanol-terminated methylvinylsiloxanedimethylsiloxane copolymer (80 wt %) having a viscosity of 20 centistokes and containing an α,ω-hydroxy-terminated siloxane and an α-hydroxy-ω-methoxy-terminated siloxane was reacted with 20 wt % methyl-(3-glycidoxypropyl)diethoxysilane in the presence of potassium silanolate at 100°C for 1 hour to produce a reaction product containing at least one epoxy group, at least one alkenyl group, and at least one alkoxy group in the molecule.
[0212] Polymer-based epoxy silane 3 (P-ES3) Viscosity is 20mm 2 A silanol-terminated methylvinylsiloxanedimethylsiloxane copolymer (50 wt %) containing an α,ω-hydroxy-terminated siloxane and an α-hydroxy-ω-methoxy-terminated siloxane was reacted with 50 wt % β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane in the presence of potassium silanolate at 100°C for 1 hour at 1 / s to produce a reaction product containing at least one epoxy group, at least one alkenyl group, and at least one alkoxy group in the molecule.
[0213] Polymeric Epoxy Silane 4 (P-ES4) Viscosity is 20mm 2 A silanol-terminated methylvinylsiloxanedimethylsiloxane copolymer (45.5 wt %) containing an α,ω-hydroxy-terminated siloxane and an α-hydroxy-ω-methoxy-terminated siloxane was reacted with 45.5 wt % 3-glycidoxypropyltrimethoxysilane and 9 wt % methylvinyldimethoxysilane in the presence of potassium silanolate at 100°C for 1 hour at 1 / s to produce a reaction product containing at least one epoxy group, at least one alkenyl group, and at least one alkoxy group in the molecule.
[0214] First Composition The first composition is shown in Table 2 below.
[0215] Preparation of a first composition containing "AFFINITY GA 1000R - Anhydrous" For each composition, the corresponding ingredients shown in Table 2, excluding the crosslinker (epoxy silane or polymeric epoxy silane), were weighed into a stainless steel container (250 mL), which was placed in an oven and heated at 180°C (oven temperature) for 30-60 minutes until the composition was melted. The composition was then melt-blended for 15 minutes at 180-200°C using a "Paravisc-style" mixhead operating at 90-150 revolutions per minute (rpm). The crosslinker was added, and the composition was stirred at 180-200°C for 10 minutes.
[0216] The viscosity stability of each first composition (uncured) was investigated by measuring the melt viscosity of the composition over time. The compositions were also cured and examined by SAFT. The results are shown in Table 2.
[0217] Preparation of a First Composition Containing "AFFINITY GA 1000R-Acid" The ingredients of composition (CE3) shown in Table 2 were weighed into a stainless steel container and melt blended for 15 minutes at a temperature of 180-200°C using a "Paravisc style" mixhead operating at 90-150 revolutions per minute (rpm). The composition gelled during this mixing stage.
[0218] Curing of the First Composition (See CE1, CE2, and IE1-IE5 in Table 2) SAFT test specimens were prepared for each composition (see Test Methods section above). Each first composition was cured in air using one of two cure profiles: room temperature (see a) or humid atmosphere (see b): a) 22°C, 50% RH for 7, 16, or 21 days or more; b) 35°C, 85% RH for 7 days. The cohesive strength of each crosslinked composition was determined using the SAFT test. The results are shown in Table 2. For the above humid cure, the oven temperature is represented as 35°C, but the test specimens quickly equilibrated to the oven temperature in less than 10 minutes. The 22°C temperature was the temperature of air in a controlled laboratory environment. The %RH in the oven was controlled by a built-in humidity monitoring device, and the %RH at 22°C was also controlled by a similar device.
[0219] Summary of results The results showed that Examples IE1, IE2, IE3, IE4, and IE5, which contained a polymeric epoxy silane as a crosslinker, had excellent high-temperature viscosity stability after 4 hours at 120°C. In Example CE3, the acid groups reacted with the epoxy silane to form a gel, indicating that the anhydride was necessary for the high-temperature stability of the first composition. Compared to the benchmark (CE1), Examples IE-IE5 showed significant improvements in SAFT after both wet curing and room-temperature curing, suggesting a high degree of crosslinking in each cured composition. Furthermore, Examples IE1-IE5 are more environmentally friendly than Example CE2, which is labeled as "may be irritating to the skin or eyes" (due to the epoxy silane). Therefore, the compositions of the present invention are well suited for hot-melt adhesive (HMA) applications.
[0220] [Table 3] Gel - Viscosity approached infinity. No viscosity stability. (Δη(t)%) = [(η(t) - η1) / η1] × 100, where η(t) is the melt viscosity after t hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C. WARNING - May cause skin / eye irritation.
Claims
1. At least the following components a and b, a) Anhydrous functionalized olefin polymers, b) A first composition comprising a polymer-based epoxysilane, wherein the polymer-based epoxysilane is the following i) and ii), i) the following ia) to ic), ia) 【Chemistry 1】 [In the formula, R1, R2 and R3 are each independently H or alkyl, and the asterisk ( * ) represents the remainder of the polymer-based epoxysilane. ib) 【Chemistry 2】 [In the formula, R1 and R3 are each independently H or alkyl, and the term "ring" represents a ring structure containing five or more carbon atoms, and the asterisk ( * ) represents the remainder of the polymer-based epoxysilane, or A combination of ic) ia) and ib), at least one epoxy group selected from, ii) The following iia) to iiic), iia) 【Transformation 3】 [In the formula, X1 and X2 are each independently an alkyl group or an alkoxy group, R is an alkyl group, and an asterisk ( * ) represents the remainder of the polymer-based epoxysilane. iib) 【Chemistry 4】 [In the formula, X1 is an alkyl group or alkoxy group, R is an alkyl group, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes, or A combination of ii)iia) and iib), comprising at least one siloxane group selected from, A first composition wherein the polymer-based epoxysilane contains two or more silicon atoms.
2. The polymer-based epoxysilane has the following chemical groups a) to i): a) -(CR 1 R 2 -CR 3 R 4 )-(wherein each of R1, R2, R3, and R4 is independently H or alkyl), b) -(SiR 1 R 2 -O)-(wherein each of R1 and R2 is independently alkyl), c) -(Si(R)(CR 1 =CR 2 R 3 ))-(wherein R is alkyl and each of R1, R2, and R3 is independently H or alkyl), d) -(CR 1 R 2 -CR 3 (CR 4 =CR 5 R 6 ))-(wherein each of R1, R2, R3, R4, R5, and R6 is independently H or alkyl), e) amide, f) ester, g) urethane, h) -(CR1R2 - CR3R4)-(wherein each of R1, R2, and R3 is independently H or alkyl and R4 is an aryl group), or i) any combination thereof, and further includes one or more of The first composition according to claim 1, wherein each chemical group is derived from one or more monomers, and if present, each chemical group is present in at least two repeating units within the polymeric epoxysilane.
3. The polymer-based epoxysilane has the following structures T1a to T1c, T1a) 【Transformation 5】 [In the formula, D is hydrocarbylene or heterohydrocarbylene, E is hydrocarbylene or heterohydrocarbylene, A is -(CR1R2-CR3)- or -(O-SiR4)- (in the formula, R1, R2, and R3 are each independently H or alkyl, and R4 is alkyl), B is -(CR5R6-CR7)- or -(O-SiR8)- (in the formula, R5, R6, and R7 are each independently H or alkyl, and R8 is alkyl), at least one of D, E, A, or B contains at least one Si atom, RA is alkyl, L is a divalent linker group, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes. T1b) 【Transformation 6】 [In the formula, RA, RB, RC, and RD are each independently alkyl groups, and L is a divalent linker group.] The first composition according to claim 1, comprising at least one of the following: T1c) a combination of T1a and T1b.
4. The polymer-based epoxysilane has the following structures T3a1, T3a2, T3a3, T3a4, T3a5, or T3a6, 【Transformation 7】 T3a1) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes. 【Transformation 8】 T3a2) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes. 【Chemistry 9】 T3a3) [wherein b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and x, y, z, and k are each independently a number from 1 to 300]. 【Chemistry 10】 T3a4) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes. 【Chemistry 11】 T3a5) [In the formula, b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and x, y, z, and k are each independently a number from 1 to 1000, and each asterisk ( * ) independently represents the remainder of each of the polymer-based epoxysilanes. 【Chemistry 12】 The first composition according to claim 1, comprising one of T3a6) [wherein b is a number from 1 to 20, m is a number from 1 to 10, n is a number from 1 to 10, and each of x, y, z, and k is independently a number from 1 to 300].
5. The first composition according to claim 1, wherein component a is an anhydrous-functionalized ethylene polymer or an anhydrous-functionalized propylene polymer.
6. The first composition according to claim 1, wherein component a is an anhydrous functionalized ethylene polymer.
7. The first composition according to claim 1, wherein component a has a density of 0.860 g / cc to 0.920 g / cc.
8. The first composition according to claim 1, wherein the first composition further comprises a tackifier (component c).
9. The first composition according to claim 1, wherein the weight ratio of component a to component b is 2.0 to 40.
10. The first composition according to claim 8, wherein the first composition comprises the sum of components a, b, and c in an amount of 80.0% to 100.0% by weight based on the weight of the first composition.
11. The first composition according to claim 1, wherein the first composition comprises the sum of components a and b, which are 50.0% to 100.0% by weight based on the weight of the first composition.
12. The first composition according to claim 1, wherein the first composition has a percentage increase in melt viscosity at 120°C (Δη4% at 120°C) of 10% to 45%, where η4 is the melt viscosity after 4 hours at 120°C and η1 is the melt viscosity after 1 hour at 120°C.
13. The first composition according to claim 1, wherein the first composition has a SAFT value of 80°C to 200°C after 7 days in air at 22°C and 50% RH.
14. The first composition according to claim 1, wherein the first composition has a SAFT value of 100°C to 250°C after 7 days in air at 35°C and 85% RH.
15. A method for forming a composition comprising a crosslinked olefin polymer formed from the first composition described in claim 1, comprising at least the following steps A) and B), A) A step of mixing at least components a and b together to form the first composition, B) A method comprising the step of exposing the first composition to moisture to form the crosslinked olefin polymer.
16. The method according to claim 15, wherein step A is performed at a temperature of 120°C to 200°C.
17. The method according to claim 15, wherein step A is performed at a relative humidity (%RH) of 10% to 60%.
18. The method according to claim 15, wherein step B is performed at a temperature of 20°C to 100°C.
19. The method according to claim 15, wherein step B is performed at a relative humidity percentage (%RH) of 40% to 100%.
20. An article comprising at least one component formed from a first composition according to any one of claims 1 to 14.