Dynamically vulcanized compositions

Abstract

A dynamically vulcanized composition includes the reaction product of, based on a total weight of the dynamically vulcanized composition, a thermoplastic, a functionalized rubber, about 0.5 wt% to about 20 wt% of an aliphatic polyketone, and about 0.01 wt% to about 5 wt% of a crosslinking compound.

Description

DYNAMICALLY VULCANIZED COMPOSITIONSTECHNICAL FIELD

[0001] Embodiments of the present disclosure are generally related to vulcanized compositions. More particularly, dynamically vulcanized compositions include the reaction product of a thermoplastic, a functionalized rubber, an aliphatic polyketone, and a crosslinking compound.BACKGROUND

[0002] High temperature resistant thermoplastics are used in a wide variety of applications because they may withstand temperatures above 200 °C while also providing chemical resistance. However, such thermoplastics may not have the flexibility necessary for certain applications. While impact modified grades of thermoplastics may be formed by adding a relatively low weight percentage of rubber, increasing the rubber amount may result in a drop in chemical resistance and processability.

[0003] Accordingly, a continual need exists for improved vulcanized compositions having improved flexibility and improved chemical resistance.SUMMARY

[0004] Embodiments of the present disclosure are directed to dynamically vulcanized compositions including the reaction product of a thermoplastic, a functionalized rubber, an aliphatic polyketone, and a crosslinking compound.

[0005] According to some embodiments, a dynamically vulcanized composition is provided. The dynamically vulcanized composition includes the reaction product of, based on a total weight of the dynamically vulcanized composition, a thermoplastic, a functionalized rubber, about 0.5 wt% to about 20 wt% of an aliphatic polyketone, and about 0.01 wt% to about 5 wt% of a crosslinking compound.

[0006] Additional features and advantages of the embodiments described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilledin the art from that description or recognized by practicing the embodiments described herein, including the detailed description, which follows and the claims.DRAWINGS

[0007] FIG. 1 is a scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM EDX) image of an exemplary dynamically vulcanized composition, according to one or more embodiments described herein;

[0008] FIG. 2 is a SEM EDX image of an exemplary dynamically vulcanized composition, according to one or more embodiments described herein;

[0009] FIG. 3 is a SEM EDX image of a comparative composition;

[0010] FIG. 4 is a SEM EDX image of a comparative composition;

[0011] FIG. 5 is a photograph of a vertical burn test of an exemplary dynamically vulcanized composition, according to one or more embodiments described herein;

[0012] FIG. 6 is a photograph of the vertical bum test of the exemplary dynamically vulcanized composition of FIG. 5 after 10 seconds have elapsed; and

[0013] FIG. 7 is a photograph of the vertical burn test of the exemplary dynamically vulcanized composition of FIG. 5 after 60 seconds have elapsed.DETAILED DESCRIPTION

[0014] Reference will now be made in detail to various embodiments of dynamically vulcanized compositions.

[0015] The disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the subject matter to those skilled in the art.

[0016] Definitions

[0017] Unless otherwise expressly defined, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art. The terminology used in the disclosure herein is for describing particular embodiments only and is not intended to be limiting.

[0018] Unless otherwise expressly stated, it not intended that any method disclosed herein be construed as requiring that its steps be performed in a specific order, nor that any article set forth herein be construed as requiring specific orders or orientations to its individual components.

[0019] Unless otherwise expressly stated, it is intended that any composition or mixture disclosed herein may comprise, consist essentially of, or consist of the disclosed components.

[0020] As used herein, the singular form of a term is intended to include the plural form of the term, unless the context clearly indicates otherwise.

[0021] As used herein, numerical values are not strictly limited to the exact numerical value recited. Instead, unless otherwise expressly stated, each numerical value is intended to mean both the exact numerical value and “about” the numerical value, which encompasses a functionally equivalent range surrounding that numerical value, such that either possibility is contemplated as an embodiment disclosed herein.

[0022] The amount of a component (e.g., thermoplastic, functionalized rubber, aliphatic polyketone, and crosslinking compound) in the reaction product is provided herein in weight percent (wt%), based on a total weight of the dynamically vulcanized composition (i.e., the reaction product), unless otherwise noted.

[0023] As used herein, “0 wt%” means that the composition is free of or does not include the given component.

[0024] As used herein, the term “average molecular weight” and “Mw” refer to the total weight of all chains in the polymer divided by the total number of chains, as measured according to gel permeation chromatography at 25 °C. The average molecular weight is given by the following formula:

[0025] As used herein, the term “tensile elongation at break” refers to the maximum strain, as a percentage that a material can withstand before ultimate failure, as measured according to ASTM D638 at 23 °C.

[0026] As used herein, the term “gel content” refers to a measure of the proportion of insoluble material in a composition, as measured through mass retention after a four hour exposure to xylene at reflux. The higher the gel content, the higher the crosslinking density of the composition.

[0027] As used herein, the term “improved tensile elongation at break” refers to the dynamically vulcanized composition having a tensile elongation at break, as measured in accordance to ASTM D638 at 23 °C, that is greater than the tensile elongation at break of a similar composition that is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and a crosslinking compound. Improved tensile elongation at break is indicative of improved flexibility.

[0028] As used herein, the term “improved gel content” refers to the dynamically vulcanized composition having a gel content, as measured through mass retention after a four hour exposure to xylene at reflux, that is greater than the gel content of a similar composition that is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and a crosslinking compound. Improved gel content is indicative of improved chemical resistance.

[0029] As used herein, the term “tensile modulus” refers to the ratio of the stress along an axis over the strain along that axis, as measured according to ASTM D638 at 23 °C and a rate of strain of 8.5 mm / s.

[0030] As used herein, the term “specific gravity” refers to the ratio of the density of a material to the density of water, as measured according to ASTM D792 at 23 °C.

[0031] Mooney viscosity is the shearing torque resisting rotation of a cylindrical metal disk or rotor embedded in rubber within a cylindrical cavity. As used herein, the term “Mooney viscosity” refers to the Mooney viscosity ML (1+4) at 100 °C, as measured according to ASTM D1646.

[0032] As used herein, the term “dynamically vulcanized” refers to a melt blending of rubber and a thermoplastic at a high temperature and then vulcanizing the rubber under the action of crosslinking during extrusion while the blend is in motion, thereby obtaining a vulcanized rubber phase.

[0033] As used herein, the term “formed from” (including related terms such as “forming”) refers to, with respect to an article (or component of an article) and a dynamically vulcanized composition, that the article (or component of the article) is extruded, molded, shaped, pressed, or otherwise made, in whole or in part, from the dynamically vulcanized composition under sufficient heating to enable such forming. As such, the term “formed from” (including related terms such as “forming”) means, in some embodiments, the article (or component of an article) can comprise, consist essentially of, or consist of, the composition; and, in other embodiments, the article (or component of an article) consists of the composition because the article (or component of an article) is, for example, made by an extrusion process or a molding process.

[0034] Usefulness

[0035] As discussed hereinabove, high temperature resistant thermoplastics, such as polyphenylene sulfide (PPS), are used in a wide variety of applications, such as gaskets, membranes, filters, and coolant systems, because they may withstand temperatures above 200 °C while also providing chemical resistance. However, such thermoplastics may not have the flexibility necessary for certain applications, such as hoses and vibration dampeners. While impact modified grades of thermoplastics may be formed by adding a low weight percentage (e.g., less than 20 wt%) of rubber, increasing the rubber amount may result in a drop in chemical resistance and processability.

[0036] Disclosed herein are dynamically vulcanized compositions. Specifically, the dynamically vulcanized compositions disclosed herein include the reaction product of a thermoplastic, a functionalized rubber, an aliphatic polyketone, and a crosslinking compound.Advantageously, the inclusion of the aliphatic polyketone and the crosslinking compound improves the compatibility between the thermoplastic and the functionalized rubber, thereby improving flexibility (e.g., improved tensile elongation at break) while improving chemical resistance (e.g., improved gel content).

[0037] Accordingly, the dynamically vulcanized compositions disclosed herein may be used to form any article that requires both improved flexibility and improved chemical resistance. The dynamically vulcanized compositions are especially useful for forming articles in the automotive, industrial robotics, and chemical industries, such as hoses and vibration dampeners.

[0038] The dynamically vulcanized composition disclosed herein may generally be described as the reaction product of a thermoplastic, a functionalized rubber, an aliphatic polyketone, and a crosslinking compound.

[0039] Thermoplastic

[0040] The dynamically vulcanized composition described herein comprises a thermoplastic. The thermoplastic may impart improved chemical resistance to the dynamically vulcanized composition.

[0041] In embodiments, the thermoplastic may be a high temperature resistant thermoplastic that may withstand temperatures above 200 °C while also providing chemical resistance. For example, in embodiments, the thermoplastic may comprise a mer unit with a substituent that includes abenzene ring to ensure high temperature resistance. In embodiments, the thermoplastic may comprise polyamide, polyester, polyimide, polyphenylene sulfide, polyphenylene ether, polycarbonate, polystyrene, or any combination thereof.

[0042] In embodiments, the thermoplastic may have a melt flow rate (5.0 kg at 316 °C) less than or equal to about 750 g / 10 min such that the thermoplastic has a similar rheology as that of the functionalized rubber, thus leading to sufficient blending. In embodiments, the thermoplastic may have a melt flow rate (5.0 kg at 316 °C) less than or equal to about 750 g / 10 min, less than or equal to about 700 g / 10 min, less than or equal to about 650 g / 10 min, less than or equal to about 550 g / 10 min, or less than or equal to about 500 g / 10 min. In embodiments, the thermoplastic may have a melt flow rate (5.0 kg at 316 °C) greater than or equal to about 40 g / 10 min, greaterthan or equal to about 50 g / 10 min, greater than or equal to about 60 g / 10 min, greater than or equal to about 70 g / 10 min, or greater than or equal to about 80 g / 10 min. In embodiments, the thermoplastic may have a melt flow rate (5.0 kg at 316 °C) in the range of about 40 g / 10 min to about 750 g / 10 min, in the range of about 50 g / 10 min to about 700 g / 10 min, in the range of about 50 g / 10 min to about 650 g / 10 min, in the range of about 60 g / 10 min to about 600 g / 10 min, in the range of about 70 g / 10 min to about 550 g / 10 min, or in the range of about 80 g / 10 min to about 500 g / 10 min.

[0043] The dynamically vulcanized composition may include at least about 30 wt% of a thermoplastic to ensure improved chemical resistance. The amount of the thermoplastic may be limited (e.g., less than or equal to about 70 wt%) to ensure improved flexibility of the dynamically vulcanized composition. Accordingly, in embodiments, the dynamically vulcanized composition may comprise, based on the total weight of the dynamically vulcanized composition, about 30 wt% to about 70 wt% of a thermoplastic. In embodiments, the amount of the thermoplastic in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, greater than or equal to about 30 wt%, greater than or equal to about 35 wt%, greater than or equal to about 40 wt%, or even greater than or equal to about 45 wt%. In embodiments, the amount of the thermoplastic in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, less than or equal to about 70 wt%, less than or equal to about 65 wt%, less than or equal to about 60 wt%, or even less than or equal to about 55 wt%. In embodiments, the amount of the thermoplastic in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, from about 30 wt% to about 70 wt%, from about 30 wt% to about 65 wt%, from about 30 wt% to about 60 wt%, from about 30 wt% to about 55 wt%, from about 35 wt% to about 70 wt%, from about 35 wt% to about 65 wt%, from about 35 wt% to about 60 wt%, from about 35 wt% to about 55 wt%, from about 40 wt% to about 70 wt%, from about 40 wt% to about 65 wt%, from about 40 wt% to about 60 wt%, from about 40 wt% to about 55 wt%, from about 45 wt% to about 70 wt%, from about 45 wt% to about 65 wt%, from about 45 wt% to about 60 wt%, or even from about 45 wt% to about 55 wt%, or any and all subranges formed from any of these endpoints.

[0044] Suitable commercial embodiments of the thermoplastic are available from NHU Performance Materials, such as polyphenylene sulfide grade NHU 3508.

[0045] Functionalized Rubber

[0046] The dynamically vulcanized composition described herein comprises a functionalized rubber. In embodiments, the functionalized rubber may include a polymer chain with functional groups located along the polymer chain. The polymer chain may be linear or include one or more branches. A reactive group of the functionalized rubber may react with the aliphatic polyketone and / or the crosslinking compound and crosslink, thereby ensuring improved flexibility.

[0047] In embodiments, the functionalized rubber may have a glass transition temperature less than or equal to 23 °C.

[0048] In embodiments, the functionalized rubber may comprise a functionalized acrylic rubber, methacrylate rubber, acrylic acid rubber, methacrylic acid rubber, acrylonitrile-styrene- acrylate, ethylene propylene diene rubber, ethylene acrylic acid rubber, butadiene rubber, isoprene rubber, styrene-butadiene rubber, styrene-ethylene-butadiene rubber, a functionalized nitrile rubber, or any combination thereof. Those skilled in the art will appreciate that the functionalized rubber may be functionalized with a pendant functional group, as described herein, or may be functionalized on its own through its innate chemistry. In embodiments, the functionalized rubber may be hydrogenated.

[0049] In embodiments, the functionalized rubber may include a pendant functional group selected from the group consisting of epoxides, sulfur-containing groups, carboxyls, amides, maleic anhydride, maleic acid, alkenes, and alkynes.

[0050] In embodiments, the functionalized rubber may comprise a first functionalized rubber and a second functionalized rubber used in conjunction with the first functionalized rubber to further improve the flexibility of the resulting dynamically vulcanized composition. While not wishing to be bound by theory, a second functionalized rubber may improve miscibility and allow for further crosslinking, thereby improving flexibility. In embodiments, the first functionalized rubber may comprise a functionalized acrylic rubber, methacrylate rubber, acrylic acid rubber, methacrylic acid rubber, acrylonitrile-styrene-acrylate, ethylene propylene diene rubber, ethylene acrylic acid rubber, butadiene rubber, isoprene rubber, styrene-butadiene rubber, styrene-ethylene- butadiene rubber, a functionalized nitrile rubber, or any combination thereof, and the secondfunctionalized rubber may comprise acrylonitrile butadiene styrene, a core shell polymer of epoxy functional acrylic shell and butyl acrylate core, ethylene-acrylic ester-glycidyl methacrylate terpolymer, or any combination thereof. In embodiments including a core shell polymer, the functionalized rubber may be the shell of the core shell particle.

[0051] In embodiments, the functionalized rubber may comprise a Mooney viscosity greater than or equal to about 30 or even greater than or equal to about 34. In embodiments, the functionalized rubber may comprise a Mooney viscosity less than or equal to about 50 or even less than or equal to about 45. In embodiments, the functionalized rubber may comprise a Mooney viscosity from about 30 to about 50, from about 30 to about 45, from about 34 to about 50, or even from about 34 to about 45, or any and all subranges formed from any of these endpoints.

[0052] The dynamically vulcanized composition may include at least about 30 wt% of a functionalized rubber to ensure improved flexibility. The amount of functionalized rubber may be limited (e.g., less than or equal to about 70 wt%) to ensure improved chemical resistance and to maintain processability of the dynamically vulcanized composition. Accordingly, in embodiments, the dynamically vulcanized composition may comprise, based on a total weight of the dynamically vulcanized composition, about 30 wt% to about 70 wt% of a functionalized rubber. In embodiments, the amount of the functionalized rubber in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, greater than or equal to about 30 wt%, greater than or equal to about 33 wt%, or even greater than or equal to about 35 wt%. In embodiments, the amount of the functionalized rubber in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, less than or equal to about 70 wt%, less than or equal to about 65 wt%, less than or equal to about 60 wt%, less than or equal to about 55 wt%, less than or equal to about 50 wt%, or even less than or equal to about 45 wt%. In embodiments, the amount of the functionalized rubber in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, from about 30 wt% to about 70 wt%, from about 30 wt% to about 65 wt%, from about 30 wt% to about 60 wt%, from about 30 wt% to about 55 wt%, from about 30 wt% to about 45 wt%, from about 33 wt% to about 70 wt%, from about 33 wt% to about 65 wt%, from about 33 wt% to about 60 wt%, from about 33 wt% to about 55 wt%, from about 33 wt% to about 45 wt%, from about 35 wt% to about 70 wt%, from about 35 wt% to about 65 wt%, fromabout 35 wt% to about 60 wt%, from about 35 wt% to about 55 wt%, or even from about 35 wt% to about 45 wt%, or any and all subranges formed from any of these endpoints.

[0053] Suitable commercial embodiments of the functionalized rubber are available under the HYTEMP brand from Zeon Corporation, such as functionalized polyacrylate grade AR212HR; under the BLENDEX brand from Galata Chemicals, such as acrylonitrile butadiene styrene grade 338; under the PARALOID brand from Dow, such as a core shell polymer of epoxy functional acrylic shell and butyl acrylate core grade EXL-2314; and under the LOTADER brand from SK Functional Polymer, such as ethylene-acrylic ester-glycidyl methacrylate terpolymer grade AX8900.

[0054] Aliphatic Polyketone

[0055] The dynamically vulcanized composition described herein comprises an aliphatic polyketone. By way of a non-limiting example, as compared to an aromatic polyketone, an aliphatic polyketone may have a relatively lower glass transition temperature and a relatively lower melting temperature. A functionalized rubber, such as those described herein, may not survive the process temperatures at which an aromatic polyketone is melted. Those skilled in the art will appreciate that aliphatic polyketones include polymers prepared from carbon monoxide and at least one olefin. In embodiments, a molar ratio of carbon monoxides to olefin in the aliphatic polyketone may be in the range of 1.2: 1 to 1 : 1.2, 1.1 : 1 to 1 : 1.1, or 1.05:1 to 1 : 1.05. Suitable olefins for use in an aliphatic polyketone include ethylene and propylene. In embodiments, the aliphatic polyketone may be a copolymer of carbon monoxide and ethylene. In embodiments, the aliphatic polyketone may be a copolymer of carbon monoxide, ethylene, and a second olefin, having at least 3 carbon atoms. In embodiments, the aliphatic polyketones may be a terpolymer of carbon monoxide, ethylene, and propylene. In some embodiments where the olefin content of the aliphatic polyketone is ethylene and propylene, the weight percent of the total olefin content may be up to 20 wt%, 15 wt%, 10 wt%, or 5 wt% propylene, with the balance of the olefin content being ethylene.

[0056] Inclusion of aliphatic polyketones may result in improved properties as compared to conventional polyolefin and polyamide thermoplastic vulcanizates. In particular, the aliphatic polyketone has ketone functionalities on repeat units of the base polymer which allows forcrosslinking at multiple locations along the polymer, leading to improved compatibility between the thermoplastic and the functionalized rubber, thereby improving flexibility and chemical resistance. In contrast, polyamide only couples at the ends of the polymer. In embodiments, the dynamically vulcanized composition may be free of polyamide polymer.

[0057] In embodiments, the aliphatic polyketone may have a melt flow rate (2.16 kg at 240 °C) greater than or equal to about 1 g / 10 min. In embodiments, the aliphatic polyketone may have a melt flow rate (2.16 kg at 240 °C) less than or equal to about 300 g / 10 min. In embodiments, the aliphatic polyketone may have a melt flow rate (2.16 kg at 240 °C) greater than or equal to about 1 g / 10 min, greater than or equal to about 3 g / 10 min, greater than or equal to about 5 g / 10 min, greater than or equal to about 10 g / 10 min, greater than or equal to about 25 g / 10 min, or even greater than or equal to about 50 g / 10 min. In embodiments, the aliphatic polyketone may have a melt flow rate (240 °C / 2.16 kg) less than or equal to about 300 g / 10 min, less than or equal to about 200 g / 10 min, less than or equal to about 150 g / 10 min, less than or equal to about 100 g / 10 min, less than or equal to about 50 g / 10 min, less than or equal to about 25 g / 10 min, or even less than or equal to about 10 g / 10 min. In embodiments, the aliphatic polyketone may have a melt flow rate (2.16 kg at 240 °C) from about 1 g / 10 min to about 300 g / 10 min, from about 1 g / 10 min to about 200 g / 10 min, from about 1 g / 10 min to about 150 g / 10 min, from about 1 g / 10 min to about 100 g / 10 min, from about 1 g / 10 min to about 50 g / 10 min, from about 1 g / 10 min to about 25 g / 10 min, from about 1 g / 10 min to about 10 g / 10 min, the aliphatic polyketone may have a melt flow rate (2.16 kg at 240 °C) from about 3 g / 10 min to about 300 g / 10 min, from about 3 g / 10 min to about 200 g / 10 min, from about 3 g / 10 min to about 150 g / 10 min, from about 3 g / 10 min to about 100 g / 10 min, from about 3 g / 10 min to about 50 g / 10 min, from about 3 g / 10 min to about 25 g / 10 min, from about 3 g / 10 min to about 10 g / 10 min, from about 5 g / 10 min to about 300 g / 10 min, from about 5 g / 10 min to about 200 g / 10 min, from about 5 g / 10 min to about 150 g / 10 min, from about 5 g / 10 min to about 100 g / 10 min, from about 5 g / 10 min to about 50 g / 10 min, from about 5 g / 10 min to about 25 g / 10 min, from about 5 g / 10 min to about 10 g / 10 min, from about 10 g / 10 min to about 300 g / 10 min, from about 10 g / 10 min to about 200 g / 10 min, from about 10 g / 10 min to about 150 g / 10 min, from about 10 g / 10 min to about 100 g / 10 min, from about 10 g / 10 min to about 50 g / 10 min, from about 10 g / 10 min to about 25 g / 10 min, from about 25 g / 10 min to about 300 g / 10 min, from about 25 g / 10 min to about 200 g / 10 min, from about 25 g / 10 min to about 150 g / 10 min, from about 25 g / 10 min to about 100 g / 10 min, fromabout 25 g / 10 min to about 50 g / 10 min, from about 50 g / 10 min to about 200 g / 10 min, from about 50 g / 10 min to about 150 g / 10 min, or even from about 50 g / 10 min to about 100 g / 10 min, or any and all subranges formed from any of these endpoints.

[0058] In embodiments, the aliphatic polyketone may have a tensile modulus greater than or equal to about 750 MPa, greater than or equal to about 1000 MPa, or even greater than or equal to about 1250 MPa. In embodiments, the aliphatic polyketone may have a tensile modulus less than or equal to about 2000 MPa, less than or equal to about 1750 MPa, or even less than or equal to about 1500 MPa. In embodiments, the aliphatic polyketone may have a tensile modulus from about 750 MPa to about 2000 MPa, from about 750 MPa to about 1750 MPa, from about 750 MPa to about 1500 MPa, from about 1000 MPa to about 2000 MPa, from about 1000 MPa to about 1750 MPa, from about 1000 MPa to about 1500 MPa, from about 1250 MPa to about 2000 MPa, from about 1250 MPa to about 1750 MPa, or even from about 1250 MPa to about 1500 MPa, or any and all subranges formed from these endpoints.

[0059] In embodiments, the aliphatic polyketone may have a specific gravity greater than or equal to about 1.1 or even greater than or equal to about 1.2. In embodiments, the aliphatic polyketone may have a specific gravity less than or equal to about 1.4 or even less than or equal to about 1.3. In embodiments, the aliphatic polyketone may have a specific gravity from about 1.1 to about 1.4, from about 1.1 to about 1.3, from about 1.2 to about 1.4, or even from about 1.2 to about 1.3, or any and all subranges formed from any of these endpoints.

[0060] The dynamically vulcanized composition may include at least 0.5 wt% aliphatic polyketone to ensure improved compatibility between the thermoplastic and the functionalized rubber, thereby improving flexibility and chemical resistance. Accordingly, in embodiments, the dynamically vulcanized composition may comprise, based on a total weight of the dynamically vulcanized composition, about 0.5 wt% to about 20 wt% of an aliphatic polyketone. In embodiments, the amount of the aliphatic polyketone in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, greater than or equal to about 0.5 wt%, greater than or equal to about 1 wt%, greater than or equal to about 3 wt%, greater than or equal to about 5 wt%, or even greater than or equal to about 7 wt%. In embodiments, the amount of the aliphatic polyketone in the dynamically vulcanized compositionmay be, based on a total weight of the dynamically vulcanized composition, less than or equal to about 20 wt%, less than or equal to about 17 wt%, less than or equal to about 15 wt%, or even less than or equal to about 13 wt%. In embodiments, the amount of the aliphatic polyketone in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, from about 0.5 wt% to about 20 wt%, from about 0.5 wt% to about 17 wt%, from about 0.5 wt% to about 15 wt%, from about 0.5 wt% to about 13 wt%, from about 1 wt% to about 20 wt%, from about 1 wt% to about 17 wt%, from about 1 wt% to about 15 wt%, from about 1 wt% to about 13 wt%, from about 3 wt% to about 20 wt%, from about 3 wt% to about 17 wt%, from about 3 wt% to about 15 wt%, from about 3 wt% to about 13 wt%, from about 5 wt% to about 20 wt%, from about 5 wt% to about 17 wt%, from about 5 wt% to about 15 wt%, from about 5 wt% to about 13 wt%, from about 7 wt% to about 20 wt%, from about 7 wt% to about 17 wt%, from about 7 wt% to about 15 wt%, or even from about 7 wt% to about 13 wt%, or any and all subranges formed from any of these endpoints.

[0061] Suitable commercial embodiments of the aliphatic polyketone are available from Hyosung Corporation, such as grade M630S or grade M630F.

[0062] Crosslinking Compound

[0063] The dynamically vulcanized composition described herein comprises a crosslinking compound. The crosslinking compound is capable of reacting with the ketone groups of the aliphatic polyketone, the functional groups of the functionalized rubber, and the thermoplastic. Accordingly, the crosslinking compound may form crosslinks between aliphatic polyketones, between functionalized rubbers, between thermoplastics, between a functionalized rubber and an aliphatic polyketone, between a thermoplastic and an aliphatic polyketone, and between a thermoplastic and a functionalized rubber. As described herein, the crosslinking compound improves the compatibility between the thermoplastic and the functionalized rubber, thereby improving the flexibility and chemical resistance of the resulting dynamically vulcanized composition. The crosslinking compound may be present in an article formed from the dynamically vulcanized composition.

[0064] Because the dynamically vulcanized compositions described herein may result from relatively quick crosslinking (e.g., within an extruder), a crosslinking compound having arelatively high average molecular weight (e g., greater than or equal to about 100 g / mol) may be used. A compound having a relatively high average molecular weight may be relatively less volatile at the processing temperatures. In embodiments, the crosslinking compound may have an average molecular weight greater than or equal to about 100 g / mol, greater than or equal to about 250 g / mol, greater than or equal to about 500 g / mol, greater than or equal to about 750 g / mol, or even greater than or equal to about 1,000 g / mol. In embodiments, the crosslinking compound may have an average molecular weight less than or equal to about 10,000 g / mol, less than or equal to about 5,000 g / mol, less than or equal to about 1,000 g / mol, or even less than or equal to about 500 g / mol. In embodiments, the crosslinking compound may have an average molecular weight from about 100 g / mol to about 10,000 g / mol, from about 100 g / mol to about 5,000 g / mol, from about 100 g / mol to about 1,000 g / mol, from about 100 g / mol to about 500 g / mol, from about 250 g / mol to about 10,000 g / mol, from about 250 g / mol to about 5,000 g / mol, from about 250 g / mol to about 1,000 g / mol, from about 250 g / mol to about 500 g / mol, from about 500 g / mol to about 10,000 g / mol, from about 500 g / mol to about 5,000 g / mol, from about 500 g / mol to about 1,000 g / mol, from about 1,000 g / mol to about 10,000 g / mol, or even from about 1,000 g / mol to about 5,000 g / mol, or any and all subranges formed from any of these endpoints.

[0065] In embodiments, the crosslinking compound may be selected from the group consisting of diamines, triamines, multifunctional amines, diols, triols, multifunctional alcohols, dithiols, thiols, multifunctional thiols, carboxylic acids, zwitterions salts, alkenes, and conjugated dienes.

[0066] In embodiments, the crosslinking compound may be a di-functional crosslinking compound. For example, in embodiments, the crosslinking compound may be defined by formula (I):wherein each R may be individually selected from a hydrogen atom or a methyl group, x may be from 4 to 120, and each Y may be individually a functional group selected from the group consisting of amines, alcohols, thiols, carboxylic acids, alkenes, and conjugated dienes. For example, in embodiments, the crosslinking compound may be defined by formula (II):wherein x may be from 4 to 120.

[0067] In embodiments in which the crosslinking compound is defined by formula (I) or formula (II), x may be from 4 to 120, from 4 to 100, from 4 to 80, from 4 to 60, from 4 to 40, from4 to 20, from 4 to 10, from 5 to 120, from 5 to 100, from 5 to 80, from 5 to 60, from 5 to 40, from5 to 20, from 5 to 10, from 6 to 120, from 6 to 100, from 6 to 80, from 6 to 60, from 6 to 40, from6 to 20, or even from 6 to 10, or any and all subranges formed from any of these endpoints.

[0068] In embodiments, the crosslinking compound may be a multi-functional crosslinking compound that includes three or more functional groups. For example, in embodiments, the crosslinking compound may be defined by formula (III):wherein each R may be individually selected from a hydrogen atom or a methyl group, each x may be from 1 to 40, and the total sum of the x units may be from 3 to 120, and each Y may be individually a functional group selected from the group consisting of amines, alcohols, thiols, carboxylic acids, alkenes and conjugated dienes. For example, in embodiments, the crosslinking compound may be defined by formula (IV):wherein each x may be from 1 to 40, and the total sum of the x units may be from 3 to 120.

[0069] In embodiments in which the crosslinking compound is defined by formula (III) or formula (IV), each x may be from 1 to 40, from 1 to 30, from 1 to 20, from 1 to 10, from 2 to 40, from 2 to 30, from 2 to 20, from 2 to 10, from 4 to 40, from 4 to 30, from 4 to 20, from 4 to 10, from 6 to 40, from 6 to 30, from 6 to 20, or even from 6 to 10, or any and all subranges formed from any of these endpoints. In embodiments in which the crosslinking compound is defined by formula (III) or formula (IV), the total sum of the x units may be from 3 to 120, from 3 to 90, from 3 to 60, from 3 to 30, from 6 to 120, from 6 to 90, from 6 to 60, from 6 to 30, from 12 to 120, from 12 to 90, from 12 to 60, from 12 to 30, from 18 to 120, from 18 to 90, from 18 to 60, or even from 18 to 30, or any and all subranges formed from any of these endpoints.

[0070] In other embodiments in which the crosslinking compound may be a multi-functional crosslinking compound that includes three or more functional groups, the crosslinking compound may be defined by formula (V):wherein n may be from 1 to 50. In embodiments in which the crosslinking compound is defined by formula (V), n may be from 1 to 50, from 1 to 40, from 1 to 30, from 1 to 20, from 1 to 10, from 1 to 5, or even from 1 to 3.

[0071] The dynamically vulcanized composition may include at least 0.1 wt% of a crosslinking compound to ensure compatibility between the thermoplastic and the functionalized rubber. The amount of crosslinking compound may be limited (e.g., less than or equal to about 5 wt%) to maintain processability and to ensure that properties of the dynamically vulcanized composition are due to the occurrence of crosslinking of the thermoplastic, the functionalized rubber, and / or the aliphatic polyketone, not because of a relatively large amount of crosslinking compound. Accordingly, in embodiments, the dynamically vulcanized composition may comprise, based on a total weight of the dynamically vulcanized composition, about 0.1 wt% to about 5 wt% of a crosslinking compound. In embodiments, the amount of the crosslinking compound in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, greater than or equal to about 0. 1 wt%. In embodiments, the amount of the crosslinking compound in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, less than or equal to about 5 wt%, less than or equal to about 4 wt%, less than or equal to about 3 wt%, less than or equal to about 2 wt%, or even less than or equal to about 1 wt%. In embodiments, the amount of the crosslinking compound in the dynamically vulcanized composition may be, based on a total weight of the dynamically vulcanized composition, from about 0.1 wt% to about 5 wt%, from about 0.1 wt% to about 4 wt%, from about 0.1 wt% to about 3 wt%, from about 0.1 wt% to about 2 wt%, from about 0.1 wt% to about 1 wt%, or even from about 0.1 wt% to about 0.5 wt%, or any and all subranges formed from any of these endpoints.

[0072] Suitable commercial embodiments of the crosslinking compound are available under the JEFF AMINE brand from Huntsman, such as polyetheramine grade T-403 or polyetheramine grade D-400.

[0073] Other Additives

[0074] The dynamically vulcanized compositions disclosed herein may further include other additives. Other additives include conventional or commercially available plastics additives. Those skilled in the art of thermoplastics compounding, without undue experimentation, may select suitable additives from available references, for example, E.W. Flick, “Plastics Additives Database,” Plastics Design Library (Elsevier 2004).

[0075] Such additional optional other additives may be used in any amount that is sufficient to obtain a desired processing or performance property for the material or component formed therefrom. The amount should not be wasteful of the additive nor detrimental to the processing or performance of the material or article formed therefrom.

[0076] Non-limiting examples of optional other additives may include one or more of antioxidants; stabilizers nucleating agents; colorants (e.g., pigments and / or dyes); inorganic mineral fillers; mineral oils; flame retardants; glass beads, glass flakes, and glass fibers; impact modifiers; micas; slip and anti-blocking agents; ultraviolet light absorbers; waxes; and combinations thereof. In embodiments, the antioxidant may comprise N,N’-hexane-l,6-diylbis(3- (3,5-di-tert-butyl-4-hydroxyphenylpropionamide)). In embodiments, the stabilizer may comprise calcium phosphate.

[0077] Suitable commercial embodiments of the antioxidant are available under the IRGANOX brand from BASF, such as grade 1098. Suitable commercial embodiments of the stabilizer are available under the EPSOLUTE brand from Budenheim, such as grade Cl 3-09. Suitable commercial embodiments of the flame retardant are available under the EXOLIT brand from Clariant, such as grade OP 1230.

[0078] Method for Preparing Dynamically Vulcanized Compositions

[0079] In embodiments, the dynamically vulcanized composition described herein may be made with a batch process or continuous process.

[0080] In embodiments, the components of the dynamically vulcanized composition, including the thermoplastic, the functionalized rubber, the aliphatic polyketone, and the crosslinking compound, may be added to an extruder (27 MM Leistritz Twin Extruder (L / D 60)) and blended. In embodiments, the blending (e.g., in the barrel of the extruder) may be carried out at a temperature from 150 °C to 270 °C.

[0081] Blending (also known as compounding) devices are well known to those skilled in the art and generally include means of feeding, especially at least one hopper for pulverulent materials and / or at least one injection pump for liquid materials; high-shear blending means, for example a co-rotating or counter-rotating twin-screw extruder, usually comprising a feed screw placed in a heated barrel (or tube); an output head, which gives the extrudate its shape; and means for cooling the extrudate, either by air cooling or by circulation of water. The extrudate is generally in the form of rods continuously exiting the device and able to be cut or formed into granules. However, other forms may be obtained by fitting a die of desired shape on the output die.

[0082] Dynamically Vulcanized Compositions

[0083] As described herein, the inclusion of the aliphatic polyketone and the crosslinking compound improves the compatibility between the thermoplastic and the functionalized rubber, thereby improving flexibility (e.g., improved tensile elongation at break) while improving chemical resistance (e.g., improved gel content).

[0084] In embodiments, the thermoplastic may form a thermoplastic matrix to ensure the dynamically vulcanized composition achieves an improved chemical resistance. At least one of the functionalized rubber and the aliphatic polyketone may form particles that are dispersed in the thermoplastic matrix. In such embodiments, the particles of the functionalized rubber or the aliphatic polyketone may have a particle size distribution D50, as measured by atomic force microscopy, less than or equal to about 20 microns, less than or equal to about 15 microns, less than or equal to about 12 microns, less than or equal to about 10 microns, less than or equal to about 8 microns, or even less than or equal to about 5 microns. In embodiments, the functionalizedrubber may form a functionalized rubber matrix and at least one of the thermoplastic and the aliphatic polyketone may form particles that are dispersed in the functionalized rubber matrix. In such embodiments, the particles of the thermoplastic or the aliphatic polyketone may have a particle size distribution D50, as measured by atomic force microscopy, less than or equal to about 20 microns, less than or equal to about 15 microns, less than or equal to about 12 microns, less than or equal to about 10 microns, less than or equal to about 8 microns, or even less than or equal to about 5 microns.

[0085] In embodiments, the thermoplastic may form a continuous phase or a co-continuous phase with the functionalized rubber. In embodiments, the dynamically vulcanized composition may include multiple regions within the composition. In embodiments, the dynamically vulcanized composition may include at least two regions selected from the group of functionalized rubber particles dispersed in the thermoplastic matrix, thermoplastic particles dispersed in the functionalized rubber matrix, and a co-continuous phase of the thermoplastic and the functionalized rubber.

[0086] In embodiments, the dynamically vulcanized composition may comprise an improved tensile elongation at break, which is indicative of improved flexibility. For example, in embodiments, the dynamically vulcanized composition may have a tensile elongation at break, as measured in accordance to ASTM D638 at 23 °C, that is greater than the tensile elongation at break of a similar composition that is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and a crosslinking compound. In embodiments, the dynamically vulcanized composition may comprise a tensile elongation at break greater than or equal to 3%, greater than or equal to 5%, greater than or equal to 7%, or even greater than or equal to 10%.

[0087] In embodiments, the dynamically vulcanized composition may comprise an improved gel content, which is indicative of improved chemical resistance. For example, in embodiments, the dynamically vulcanized composition may have a gel content, as measured through mass retention after a four hour exposure to xylene at reflux, that is greater than the gel content of a similar composition that is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and acrosslinking compound. In embodiments, the dynamically vulcanized composition may comprise a gel content greater than or equal to 90 wt%, greater than or equal to 92 wt%, greater than or equal to 94 wt%, greater than or equal to 96 wt%, or even greater than or equal to 98 wt%. In embodiments, the dynamically vulcanized composition may comprise a gel content of 100 wt%.

[0088] In embodiments, the dynamically vulcanized composition may exhibit a threshold level of flame retardancy, with or without the addition of a flame retardant additive. For example, in embodiments, the dynamically vulcanized composition may have a flammability rating of V-0 at a thickness of 3.2 mm, as measured in accordance with UL-94.

[0089] As exemplified in the Examples section below, the dynamically vulcanized compositions described herein comprising the reaction product of a thermoplastic, a functionalized rubber, an aliphatic polyketone, and a crosslinking compound have improved flexibility (e.g., improved tensile elongation at break) and improved chemical resistance (e.g., improved gel content).

[0090] Methods of Forming Articles from Dynamically Vulcanized Compositions

[0091] In embodiments, an article formed from the dynamically vulcanized compositions disclosed herein may be formed by at least one of injection molding, compression molding, blow molding, profile and sheet extrusion. In embodiments, the method for preparing a dynamically vulcanized composition disclosed herein may further comprise injection molding the dynamically vulcanized composition to form an article.

[0092] The article may be formed into any shape for further processing or for the intended end use. For example, in embodiments, the dynamically vulcanized composition may be immediately cooled down and pelletized after exiting the extruder. The pellets resulting from extrusion may be subjected to further processing, such as injection molding, blow molding, compression molding, or profiled extrusion, to convert the pellets to the final article.

[0093] Articles Formed from Polycarbonate Compositions

[0094] As discussed herein, the dynamically vulcanized compositions disclosed herein may be used to form any article that requires both improved flexibility and improved chemical resistance.The dynamically vulcanized compositions are especially useful for forming articles in the automotive, industrial robotics, and chemical industries industry, such as hoses and vibration dampeners industries, such as hoses and vibration dampeners.EXAMPLES

[0095] Non-limiting examples of various embodiments of the disclosed invention are provided.

[0096] Table 1 shows sources of ingredients used to form example dynamically vulcanized compositions El to E9 and comparative dynamically vulcanized compositions Cl and C2.

[0097] Table 1

[0098] Table 2 below shows the formulations (in wt%) used to form and the elongation at break and gel content of Examples El and E2 and Comparative Examples Cl and C2.

[0099] Table 2

[0100] As shown in Table 2, Examples El and E2, dynamically vulcanized compositions including a thermoplastic (NHU 3508), a functionalized rubber (HYTEMP AR212HR), an aliphatic polyketone (M630S) and a crosslinking compound (JEFF AMINE T-403), had a greater tensile elongation at break and a greater gel content as compared to Comparative Example Cl, a composition including a thermoplastic, a functionalized rubber, and a crosslinking compound and lacking an aliphatic polyketone, and as compared to Comparative Example C2, a composition including a thermoplastic, a functionalized rubber, and an aliphatic polyketone, and lacking a crosslinking compound.

[0101] Referring now to FIGS. 1 -4, all examples showed a thermoplastic continuous phase with functionalized rubber or functionalized rubber / aliphatic polyketone dispersed phases. As shown in FIGS. 1 and 2, respectively, Examples El and E2 had smaller and discrete functionalized rubber domains, indicating compatibilization between the thermoplastic and the functionalized rubber. As shown in FIGS. 3 and 4, respectively, Comparative Examples Cl and C2 had larger functionalized rubber domains.

[0102] As indicated by Examples El and E2 and Comparative Examples Cl and C2, the inclusion of the aliphatic polyketone and the crosslinking compound improves the compatibility between the thermoplastic and the functionalized rubber, thereby improving flexibility and chemical resistance of the dynamically functionalized composition.

[0103] Referring now to FIGS. 5-7, Example E2 was submitted for UL-9420 mm vertical burn testing, in accordance with ASTM D-3801, and evaluated with a target of V-0 performance at 3.2 mm thickness. Example E2 achieved a non-rating at 3.2 mm thickness. Despite the non-rating, Example E2 showed char formation and relatively slow burn characteristics. It took almost all of the 10 second contact time during the initial flame contact for the example to catch on fire. The sample then proceeded to burn through 60 seconds and became engulfed in flames. While not wishing to be bound by theory, addition of flame retardant additives to the dynamically vulcanized composition may help achieve a V-0 rating. Moreover, the inherent flame retardancy of the thermoplastic may help reduce the loading level of the flame retardant additive needed to achieve a V-0 rating.

[0104] Table 3 below shows the formulations (in wt%) used to form and the elongation at break of Examples E3 to E9.

[0105] Table 3

[0106] Table 3 cont.

[0107] As shown in Table 3, Examples E5, E7, and E8, dynamically vulcanized compositions including a thermoplastic (NHU 3508), a first functionalized rubber (HYTEMP AR212HR), a second functionalized rubber (BLENDEX 338, PARALOID EXL-2314, and LOTADER AX8900, respectively), an aliphatic polyketone (M630F), and a crosslinking compound (JEFFAMINE T- 403), had a greater tensile elongation at break as compared to Examples E3 and E4, dynamically vulcanized compositions including a thermoplastic, a functionalized rubber (HYTEMP AR212HR), an aliphatic polyketone, and a crosslinking compound and lacking a second functionalized rubber. While Examples E6 and E9 included a second functionalized rubber (ELVALOY HP441 and FINE-BLEND SAG 002, respectively), these dynamically vulcanized compositions had a lesser tensile elongation at break as compared to Examples E3 and E4. As indicated by Examples E3 to E9, addition of a second functionalized rubber used in conjunction with a first functionalized rubber may improve the flexibility of the dynamically vulcanized composition as compared to a dynamically vulcanized composition that lacks a second functionalized rubber.

[0108] Every document cited herein is incorporated herein by reference in its entirety unless otherwise specified. The citation of any document is not to be construed as an admission that it is prior art with respect to any invention disclosed or claimed herein. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0109] It will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

Claims

CLAIMSWhat is claimed is:

1. A dynamically vulcanized composition comprising the reaction product of, based on a total weight of the dynamically vulcanized composition: a thermoplastic; a functionalized rubber; about 0.5 wt% to about 20 wt% of an aliphatic polyketone; and about 0.01 wt% to about 5 wt% of a crosslinking compound.

2. The dynamically vulcanized composition of claim 1, wherein the thermoplastic comprises polyamide, polyester, polyimide, polyphenylene sulfide, polyphenylene ether, polycarbonate, polystyrene, or any combination thereof.

3. The dynamically vulcanized composition of any one of the preceding claims, wherein the dynamically vulcanized composition comprises, based on the total weight of the dynamically vulcanized composition, about 30 wt% to about 70 wt% of the thermoplastic.

4. The dynamically vulcanized composition of any one of the preceding claims, wherein the thermoplastic has a melt flow rate (5.0 kg at 316 °C) in the range of about 40 g / 10 min to about 750 g / 10 min,5. The dynamically vulcanized composition of any one of the preceding claims, wherein the functionalized rubber comprises a functionalized acrylic rubber, methacrylate rubber, acrylic acid rubber, methacrylic acid rubber, acrylonitrile-styrene-acrylate, ethylene propylene diene rubber, ethylene acrylic acid rubber, butadiene rubber, isoprene rubber, styrene-butadiene rubber, styrene- ethylene-butadiene rubber, a functionalized nitrile rubber, or any combination thereof.

6. The dynamically vulcanized composition of any one of the preceding claims, wherein the functionalized rubber is hydrogenated.

7. The dynamically vulcanized composition of any one of the preceding claims, wherein the functionalized rubber includes a pendant functional group selected from the group consisting of epoxides, sulfur-containing groups, carboxyls, amides, maleic anhydride, maleic acid, alkenes, and alkynes.

8. The dynamically vulcanized composition of any one of the preceding claims, wherein the functionalized rubber comprises a first functionalized rubber and a second functionalized rubber, the second functionalized rubber comprising acrylonitrile butadiene styrene, a core shell polymer of epoxy functional acrylic shell and butyl acrylate core, ethylene-acrylic ester-glycidyl methacrylate terpolymer, or any combination thereof.

9. The dynamically vulcanized composition of any one of the preceding claims, wherein the dynamically vulcanized composition comprises, based on the total weight of the dynamically vulcanized composition, about 30 wt% to about 70 wt% of the functionalized rubber.

10. The dynamically vulcanized composition of any one of the preceding claims, wherein the aliphatic polyketone has a melt flow rate greater than or equal to about 1 g / 10 min, as measured in accordance to ASTM DI 238 at 240 °C and a weight of 2.16 kg.

11. The dynamically vulcanized composition of any one of the preceding claims, wherein the aliphatic polyketone has a melt flow rate less than or equal to about 300 g / 10 min, as measured in accordance to ASTM D1238 at 240 °C and a weight of 2.16 kg.

12. The dynamically vulcanized composition of any one of the preceding claims, wherein the crosslinking compound is selected from the group consisting of diamines, triamines, multifunctional amines, diols, triols, multifunctional alcohols, dithiols, thiols, multifunctional thiols, carboxylic acids, zwitterions salts, alkenes, and conjugated dienes.

13. The dynamically vulcanized composition of claim 12, wherein the crosslinking compound has an average molecular weight greater than or equal to about 100 g / mol.

14. The dynamically vulcanized composition of any one of the preceding claims, wherein the crosslinking compound is a di-functional crosslinking compound.

15. The dynamically vulcanized composition of claim 14, wherein the crosslinking compound is defined by formula (I):wherein each R is individually selected from a hydrogen atom or a methyl group, x is from 4 to 120, and each Y is individually a functional group selected from the group consisting of amines, alcohols, thiols, carboxylic acids, alkenes, and conjugated dienes.

16. The dynamically vulcanized composition of claim 15, wherein the crosslinking compound is defined by formula (II):wherein x is from 4 to 120.

17. The dynamically vulcanized composition of any one of claims 1 to 13, wherein the crosslinking compound is a multi-functional crosslinking compound that includes three or more functional groups.

18. The dynamically vulcanized composition of claim 17, wherein the crosslinking compound is defined by formula (III):wherein each R is individually selected from a hydrogen atom or a methyl group, each x is from 1 to 40, and the total sum of the x units is from 3 to 120, and each Y is individually a functional group selected from the group consisting of amines, alcohols, thiols, carboxylic acids, alkenes, and conjugated dienes.

19. The dynamically vulcanized composition of claim 18, wherein the crosslinking compound is defined by the formula (IV):wherein each x is from 1 to 40, and the total sum of the x units is from 3 to 120.

20. The dynamically vulcanized composition of claim 17, wherein the crosslinking compound is defined by formula (V):wherein n is from 1 to 50.

21. The dynamically vulcanized composition of any one of the preceding claims, wherein the thermoplastic forms a thermoplastic matrix and at least one of the functionalized rubber and the aliphatic polyketone forms particles that are dispersed in the thermoplastic matrix.

22. The dynamically vulcanized composition of claim 21, wherein the particles of the at least one of the functionalized rubber and the aliphatic polyketone have a particles size distribution D50 less than about 20 microns.

23. The dynamically vulcanized composition of any one of the preceding claims, wherein the functionalized rubber forms a functionalized rubber matrix and at least one of the thermoplastic and the aliphatic polyketone forms particles that are dispersed in the functionalized rubber matrix.

24. The dynamically vulcanized composition of any one of the preceding claims, wherein the dynamically vulcanized composition has a tensile elongation at break, as measured in accordance to ASTM D638 at 23 °C, that is greater than the tensile elongation at break of a similar composition that is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and a crosslinking compound.

25. The dynamically vulcanized composition of any one of the preceding claims, wherein the dynamically vulcanized composition has a gel content, as measured through mass retention after a four hour exposure to xylene at reflux, that is greater than the gel content of a similar compositionthat is identical to the dynamically vulcanized composition with an exception that the similar composition does not include at least one of an aliphatic polyketone and a crosslinking compound.

26. The dynamically vulcanized composition of any one of the preceding claims, wherein the dynamically vulcanized composition has a flammability rating of V-0 at a thickness of 3.2 mm, as measured in accordance with UL-94.

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