Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
  • C08F14/18—Monomers containing fluorine
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F214/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
  • C08F214/18—Monomers containing fluorine
  • C08F214/26—Tetrafluoroethene
  • C08F214/262—Tetrafluoroethene with fluorinated vinyl ethers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
  • C08F14/18—Monomers containing fluorine
  • C08F14/26—Tetrafluoroethene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F214/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
  • C08F214/18—Monomers containing fluorine
  • C08F214/26—Tetrafluoroethene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/14—Peroxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
  • C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms

Definitions

• This invention pertains to certain perfluoroelastomer having improved thermal resistance, to a process for their manufacture, and to the cured articles obtainable therefrom.
• Fluoroelastomer are synthetic rubbers designed for demanding service applications in hostile environments, endowed with outstanding chemical and thermal resistance.
• Perfluoroelastomers having fully fluorinated fluorinated backbones and typically based on copolymers of tetrafluoroethylene (TFE) and perfluoromethylvinylether (MVE), optionally comprising recurring units derived from cure-site containing monomers, represent in this domain top-edge class of materials, introduced into the market since late sixties.
• TFE tetrafluoroethylene
• MVE perfluoromethylvinylether
• these TFE/MVE copolymers have roughly a 60/40 to 65/35 mol/mol composition, which enables achievement of required elastomeric behaviour; such copolymers generally also comprise recurring units derived from monomers comprising curing sites and/or end groups contemplating such cure sites. Typically, peroxide curing is preferred technique used for their vulcanization and moulding.
• EP 633274 A (AUSIMONT SPA) 11 Jan. 1995 discloses thermoprocessable copolymers of tetrafluoroethylene comprising recurring units derived from perfluoromethylvinylether and from at least one additional fluoromonomer, like, notably perfluoroethylvinylether.
• WO 2007/096348 SOLVAY SOLEXIS SPA 30 Aug. 2007 discloses thermoplastic terpolymers of tetrafluoroethylene, perfluoromethylvinylether and perfluoroethylvinylether, suitable for extrusion moulding cable sheathings.
• Amorphous plastomers of tetrafluorethylene, perfluoromethylvinylether and perfluoroethylvinylether have been aso described in the past.
• U.S. Pat. No. 5,919,878 (E.I. DUPONT DE NEMOURS) 6 Jun. 1999 discloses amorphous terpolymers of TFE, MVE and perfluoroethylvinylether (EVE) suitable as thermoplastic coating.
• Similar amorphous copolymers, suitable as adhesive or coating compositions are also known from WO 99/32234 (DU PONT) 1 Jul. 1999, EP 1093485 A (DU PONT) 25 Apr. 2001, U.S. Pat. No.
• thermoplastic materials While thus terpolymers of TFE, MVE and perfluoroethylvinylether (EVE) are well-known in the art as thermoplastic materials, little or nothing is known about effects of modifying a curable perfluoroelastomer by addition of EVE for obtaining cured articles, in particular for improving thermal resistance.
• EVE perfluoroethylvinylether
• the Applicant has now surprisingly found that when combining in a curable perfluoroelastomer recurring units derived from both EVE and MVE in well-defined amounts with tetrafluoroethylene, it is advantageously possible to significantly improve performances of perfluoroelastomers, in particular at temperatures exceeding 200° C.
• the Applicant has surprisingly found that when combining recurring units derived from EVE and MVE in amounts as above described, it is advantageously possible to significantly improve performances of curable perfluoroelastomers, in particular at temperatures exceeding 200° C.
• perfluoroelastomer is intended to denote a fluoroelastomer substantially free of hydrogen atoms.
• substantially free of hydrogen atom is understood to mean that the perfluoroelastomer consists essentially of recurring units derived from ethylenically unsaturated monomers comprising at least one fluorine atom and free of hydrogen atoms [per(halo)fluoromonomer (PFM)].
• the perfluoroelastomer can comprise, in addition to recurring units derived from TFE, EVE and MVE, recurring units derived from one or more per(halo)fluoromonomer (PFM).
• PFM per(halo)fluoromonomer
• perfluoroelastomer comprises recurring units derived from a per(halo)fluoromonomer (PFM) different from TFE, EVE and MVE
• these recurring units are typically comprised in an amount not exceeding 5% moles, preferably not exceeding 3% moles, with respect to total moles of TFE, EVE and MVE.
• PFM per(halo)fluoromonomers
• each of R f3 , R f4 , R f5 , R f6 is independently a fluorine atom, a C 1 -C 6 per(halo)fluoroalkyl group, optionally comprising one or more oxygen atom, e.g.
• the perfluoroelastomer also comprises recurring units derived from a bis-olefin of general formula (I) here below:
• the amount of chain units derived from these bis-olefins is generally between 0.01 and 1.0% by moles, preferably between 0.03 and 0.5 mol and even more preferably between 0.05 and 0.2% by moles with respect to the total moles of TFE, EVE and MVE recurring units.
• the perfluoroelastomer of the invention is peroxide curable, that is to say that it is susceptible of being cured with the aid of peroxide radical initiators in suitable conditions and/or in combination with appropriate ingredients.
• the perfluoroelastomer of the invention is peroxide curable, that is to say that it is susceptible of being cured with the aid of peroxide radical initiators in suitable conditions and/or in combination with appropriate ingredients.
• the perfluoroelastomer of the invention typically comprises at least one of:
• the perfluoroelastomer of the invention comprises iodine and/or bromine atoms in the chain and/or in the end position of the perfluoroelastomer chain.
• the perfluoroelastomer of the invention is free from recurring units derived from a cure-site monomer comprising a functional group of —CN type.
• the introduction of these iodine and/or bromine atoms may be performed by adding, to the reaction mixture, brominated and/or iodinated comonomers, otherwise called brominated and/or iodinated cure-site comonomers.
• the perfluoroelastomer of this embodiment typically comprises, in addition to TFE, MVE and EVE recurring units, from 0.05 to 5% moles of recurring units derived from said brominated and/or iodinated comonomers.
• Non limitative examples of said brominated and/or iodinated cure-site comonomers are notably:
• perfluoroelastomer of the invention may comprise iodine and/or bromine atoms in end-groups. These iodine and/or bromine atoms are typically introduced during manufacture of perfluoroelastomer, by polymerizing in the presence of iodinated and/or brominated chain-transfer agents.
• chain-transfer agents mention can be made of (i) alkali metal or alkaline-earth metal iodides and/or bromides and (ii) iodine and/or bromine containing fluorocarbon compounds.
• preferred iodinated and/or brominated chain-transfer agents are those of formula R f (I) x (Br) y , where R f is a (per)fluoroalkyl or a (per)fluorochloroalkyl containing from 1 to 8 carbon atoms, while x and y are integers between 0 and 2, with 1 ⁇ x+y ⁇ 2.
• R f is a (per)fluoroalkyl or a (per)fluorochloroalkyl containing from 1 to 8 carbon atoms
• x and y are integers between 0 and 2, with 1 ⁇ x+y ⁇ 2.
• the perfluoroelastomer of the invention preferably consists essentially of recurring units derived from TFE, EVE and MVE, and, optionally from the bis-olefin as above detailed, and further comprises iodine and/or bromine atoms in end-groups.
• the amount of recurring units derived from EVE is advantageously of at least 2%, preferably of at least 3%, more preferably of at least 4% by moles, with respect to total moles of TFE, EVE and MVE.
• the amount of recurring units derived from EVE is advantageously of at most 17%, preferably of at most 15%, more preferably of at most 10% by moles, with respect to total moles of TFE, EVE and MVE.
• the amount of recurring units derived from MVE is advantageously of at least 23%, preferably of at least 24%, more preferably of at least 25% by moles, with respect to total moles of TFE, EVE and MVE.
• the amount of recurring units derived from MVE is advantageously of at most 35%, preferably of at most 33%, more preferably of at most 30% by moles, with respect to total moles of TFE, EVE and MVE.
• polymer When the amount of MVE is below 23% by moles, even if the polymer further comprises recurring units derived from EVE, polymer fails to provide adequate fluoroelastomer behaviour and suitable sealing features, but rather behaves as a thermoplastomer, which is out of the scope of present invention.
• the perfluoroelastomer of the invention comprises recurring units derived from both EVE and MVE in an amount of from 26 to 42 by moles, more preferably from 28 to 40% by moles, most preferably from 28 to 37% by moles, with respect to total moles of TFE, EVE and MVE.
• Preferred perfluoroelastomers of the invention are those consisting essentially of:
• More preferred perfluoroelastomers of the invention are those consisting essentially of:
• the preparation of the fluoroelastomer of the invention may be performed by copolymerizing the monomers in aqueous emulsion, according to methods that are well known in the art, in the presence of radical initiators (for example alkali metal or ammonium persulfates, perphosphates, perborates or percarbonates), optionally in combination with ferrous, cuprous or silver salts, or salts of other readily oxidizable metals.
• radical initiators for example alkali metal or ammonium persulfates, perphosphates, perborates or percarbonates
• ferrous, cuprous or silver salts or salts of other readily oxidizable metals.
• Surfactants of various types are usually also present in the reaction medium, among which fluorinated surfactants are more particularly preferred.
• the polymerization reaction to obtain the perfluoroelastomer may be performed in bulk or in suspension, in an organic liquid in which a suitable radical initiator is present, according to well-known techniques.
• the polymerization reaction is generally performed at temperatures of between 25 and 150° C., at a pressure of up to 10 MPa.
• the preparation of the perfluoroelastomer is preferably performed as a microemulsion of perfluoropolyoxyalkylenes, as notably described in U.S. Pat. No. 4,789,717 (AUSIMONT SPA [IT]) 6 Dec. 1988 and U.S. Pat. No. 4,864,006 (AUSIMONT SPA [IT]) 5 Sep. 1989.
• the perfluoroelastomer of the present invention are typically cured via peroxide vulcanization.
• the peroxide-mediated vulcanization can be performed according to known techniques, via the addition of suitable peroxide capable of generating radicals by thermal decomposition.
• Curable composition comprising the perfluoroelastomer of the invention thus typically comprises at least one peroxide, preferably at least one organic peroxide.
• Said peroxide is typically used in amount of 0.05 to 10%, preferably of 0.5 to 5% by weight relative to the perfluoroelastomer.
• dialkyl peroxides for instance di-tert-butyl peroxide and 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane; dicumyl peroxide; dibenzoyl peroxide; di-tert-butyl perbenzoate; bis[1,3-dimethyl-3-(tert-butylperoxy)butyl]carbonate.
• Curable compound comprising the perfluoroelastomer of the invention can generally comprise additional ingredients, preferably selected from the group consisting of:
• vulcanization coagents in an amount generally of between 0.5% and 10% and preferably between 1% and 7% by weight relative to the perfluoroelastomer;
• b′ optionally, a metallic compound, in an amount of between 1% and 15% and preferably between 2% and 10% by weight relative to the polymer, preferably chosen from oxides and hydroxides of divalent metals, for instance Mg, Zn, Ca or Pb, optionally combined with a salt of a weak acid, for instance stearates, benzoates, carbonates, oxalates or phosphites of Ba, Na, K, Pb or Ca;
• c′ optionally, acid acceptors of metal non-oxide type such as 1,8-bis(dimethylamino)naphthalene, octadecylamine, etc.
• thickening fillers preferably carbon black, silica, semicrystalline fluoropolymers consisting of TFE homopolymers or copolymers of TFE with one or more monomers containing at least one unsaturation of ethylenic type, in an amount of from 0.01 mol % to 10 mol % and preferably from 0.05 mol % to 7 mol %; pigments, antioxidants, stabilizers and the like.
• vulcanization coagents mention can be notably made of triallyl cyanurate; triallyl isocyanurate (TAIC); tris(diallylamine)-s-triazine; triallyl phosphite; N,N-diallylacrylamide; N,N,N′,N′-tetraallylmalonamide; trivinyl isocyanurate; 2,4,6-trivinyl-methyltrisiloxane, and bis-olefins of formula (I) as above detailed.
• perfluoroelastomers comprising recurring units derived from cyano (—CN) containing monomers
• aromatic polyamines compounds and/or organotin compounds can be used as vulcanization coagents.
• Y being —O—, —S—, —SO 2 —, —CH 2 —, —C(O)—, —C(CF 3 ) 2 —, —C(CH 3 ) 2 —, —(CH 2 ) n —, —(CF 2 ) n —, n being an integer from 0 to 5.
• organotin compounds mention can be notably made of those of formula Ar′ x SnY 4-x , wherein Ar′ is an aromatic group, optionally comprising condensed rings, Y is an organic group comprising a carbon-carbon double bond, preferably an allyl, allenyl, propargyl group, and x is an integer from 0 to 3.
• silica fillers are those preferred for achieving improved thermal resistance.
• silica fillers silica having a pH value, determined according to the DIN ISO 787-9 standard, higher than 7, and/or silica having hydrophobic behaviour are preferred.
• the use of these silica fillers in fluoroelastomer is notably described in WO 2008/003634 (SOLVAY SOLEXIS SPA [IT];) 10 Jan. 2008 and in WO 2008/003635 (SOLVAY SOLEXIS SPA [IT];) 10 Jan. 2008.
• carbon black fillers In cases wherein improved water vapour resistance, especially at high temperature, is sought, carbon black fillers, and more particularly, those carbon black fillers having CTAB of 25 to 35 m 2 /g are preferred; these fillers are notably described in WO 2008/003636 (SOLVAY SOLEXIS SPA [IT];) 10 Jan. 2008.
• the invention also pertains to cured articles made from the perfluoroelastomer of the invention.
• the cured articles of the invention are typically manufactured by a process comprising:
• the curable perfluoroelastomer composition is molded and simultaneously vulcanized using techniques such as injection-moulding or compression-moulding, or alternatively by extrusion-moulding.
• temperatures at which the vulcanizing-moulding are not particularly limited, temperatures of between about 50° C. and about 250° C. and preferably between about 100° C. and about 220° C. are generally used.
• the vulcanized shaped pre-formed sealing articles can be subjected to a subsequent thermal post-treatment step.
• This treatment is generally performed in suitable heating devices, generally electric ovens or convection ovens.
• the thermal post-treatment is generally performed for a time from at least two minutes to 36 hours, preferably from 30 minutes to 24 hours and more preferably from 1 hour to 12 hours.
• Temperature of such post-treatment is not particularly limited; it is generally understood that this post-treatment (elsewhere known as post-cure) is typically carried out at temperatures between 150 and 350° C., preferably between 200 and 300° C.
• Fluoroelastomers described below have been formulated with or without additives/ingredients mentioned in the below embedded tables; addition of said additives/ingredients has been carried out following compounding procedures described in ASTM D 3182 standard; cured specimens have been prepared following procedure described in same standard.
• M 100 is the stress in MPa for an elongation of 100%
• T.S. is the stress at break in MPa
• E.B. is the elongation at break in %.
• Shore A (3′′) hardness (HDS) has been determined according to ASTM D2240—Type A Durometer standard at 25° C.
• Compression set has been determined on type 214 O-rings according to ASTM D329 and D1414 standards.
• Reactor was thus heated to set-point temperature of 80° C.; then 18 g of 1,4-diiodoperfluorobutane (C 4 F 8 I 2 ) were added, followed by a monomers mixtures having following composition: tetrafluoroethylene (TFE) 45% moles, perfluoroethylvinylether (EVE) 10% moles, perfluoromethylvinylether (MVE) 45% until a final pressure of 20 bar (2 MPa), 0.31 g of ammonium persulfate (APS) and 8.6 g of CH 2 ⁇ CH—(CF 2 ) 6 —CH ⁇ CH 2 , fed in 20 portions each 5% increase in conversion.
• TFE tetrafluoroethylene
• EVE perfluoroethylvinylether
• MVE perfluoromethylvinylether
• APS ammonium persulfate
• reactor was loaded with a monomers mixture having following composition: TFE 45% moles; EVE 15% moles; MVE 40% moles, for reaching set-point pressure of 20 bar relative, which was maintained feeding a mixture having following composition: TFE 55% moles; EVE 12% moles; MVE 33% moles.
• CS % 38 38 37 36 65 (1) Mooney viscosity (2 + 9) at 121° C.; (2) bis-olefin of formula: CH 2 ⁇ CH—(CF 2 ) 6 —CH ⁇ CH 2 ; (3) LUPEROX ® 101XL: neat liquid 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane; (4) Carbon black MT N 990 (5) Austin black 325 filler, commercially available from Coal Fillers Incorporated; (6) Carried out on post-cured specimens; vulcanizing-moulding and post-curing conditions: Cure: 20 min at 175° C.; post-cure: (8 + 16)h at 290° C. (7) CS on #214 O-ring.
• TAICROS ® TAIC liquid triallylisocyanurate commercially available from Evonik; (10) Carried out on post-cured specimens; vulcanizing-moulding and post-curing conditions: Cure: 20 min at 160° C.; post-cure: (8 + 16) h at 230° C. (7) CS on #214 O-ring.

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