WO2013055738A1

WO2013055738A1 - Torque reducing compositions and methods of use thereof

Info

Publication number: WO2013055738A1
Application number: PCT/US2012/059461
Authority: WO
Inventors: John Volpe
Original assignee: John Volpe
Priority date: 2011-10-11
Filing date: 2012-10-10
Publication date: 2013-04-18

Abstract

This disclosure relates to compositions and methods for reducing frictional torque for wheel bearing applications. In an aspect, the disclosure also relates to bearing seal compositions capable of increasing automobile efficiency.

Description

Torque reducing Compositions and Methods of Use Thereof

CROSS-REFERNCE TO RELATED APPLICATION

[001] This application claims the benefit of U.S. Provisional Application No.

61/545,718, filed October 11, 2011, which is herein incorporated by reference in its entirety.

FIELD

[002] This disclosure relates to compositions and methods for reducing frictional torque for wheel bearing applications. In an aspect, the disclosure relates to bearing seal compositions capable of increasing automobile efficiency and methods thereof.

BACKGROUND

[003] There is a need for producing chemical compositions capable of reducing frictional torque for wheel bearing applications. There is also a need for designing mechanical parts, such as seals and bearings in the automotive industry that can be combined with torque reducing compositions in an effort to improve automotive efficiency. For example, reducing frictional torque in wheel bearing applications can result in more energy efficient automobiles capable of achieving a higher miles per gallon of gasoline standard. Compositions and methods for addressing this need are disclosed herein.

SUMMARY

[004] The disclosure provides for a polymer composition capable of reducing frictional torque in a wheel bearing, wherein said polymer composition comprises, consists of, or consists essentially of

a. at least one polymer;

b. at least one carbon filler compound;

c. at least one friction improvement compound;

d. at least one plasticizer;

e. at least one antioxidant compound; and

f. at least one cure system compound.

[005] The disclosure also provides for a polymer composition comprising, consisting essentially of, or consisting of

a. at least one polymer present in an amount of about 15% to about 40% by weight; b. at least one carbon filler compound present in an amount of about 15% to about 40% by weight;

c. at least one friction improvement compound present in an amount from about 5% to about 15% by weight;

d. at least one plasticizer present in an amount from about 5% to about 12% by weight;

e. at least one antioxidant compound present in an amount of about .1% to about 5% by weight; and

f. at least one cure system compound present in an amount of about .5% to about 5% by weight.

[006] In an aspect, the disclosure provides for a polymer composition comprising, consisting of, or consisting essentially of

• Nipol DN3350;

• N774 Carbon Black;

• N990 Carbon Black;

• IM30K;

• Dioctyl Phthalate;

• TP-759;

• Agerite Resin D;

• Struktol WB222;

• Okrin 236;

• Akrochem Antiozonant PD- 1 ;

• Stearic Acid;

• Akrochem RGT-Z Zinc Oxide; and

• Akrochem VC-40K.

[007] The disclosure also provides for a polymer composition comprising, consisting of, or consisting essentially of a bearing seal composition capable of reducing frictional torque, wherein said bearing seal composition comprises, consists of, or consists essentially of a (1) a polymer composition comprising

a. at least one polymer;

b. at least one carbon filler compound;

c. at least one friction improvement compound;

d. at least one plasticizer; e. at least one antioxidant compound;

f. at least one cure system compound; and

(2) a metal component.

[008] The disclosure also provides for a polymer composition with a hardness of about 60 to about 70 Shore A. In another aspect, the composition described herein exhibits an initial rheometer torque from about 5 to about 15 inch/pounds, a minimum rheometer torque from about 4 to about 12 inch/pounds, and a TS2 from about .75 to about 1.5 inch/pounds.

[009] The disclosure also provides for a polymer composition wherein one polymer is a nitrile polymer compound and the friction improvement compound is ΪΜ30Κ.

[0010] In an aspect the, the metal component is steel or aluminum.

[0011] Additional objects, features and advantages of the invention will be set forth in the description which follows, and in part, will be obvious from the description, or may be learned by practice of the invention. The objects, features and advantages of the invention may be realized and obtained by means of the instrumentalities and combination particularly pointed out in the appended claims

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 provides an example of a bearing seal capable of being used with compositions of the disclosure. The pink areas represent a composition according to the disclosure.

[0013] FIG. 2 provides for a composition of Formulation A.

[0014] FIG. 3 sets forth an example of the torque and curing properties associated with a composition of Formulation A.

[0015] FIG. 4 provides for an example of glass bubbles in a free state.

[0016] FIG. 5 provides for an example of glass bubbles associated with a composition of

Formulation A.

[0017] FIG. 6 provides for an example of grease compatibility specimens associated with a composition of Formulation A. In an aspect, the grease compatibility test FIG. 6 indicates that a composition disclosed herein does not rapidly degrade or become brittle in a high temperature environment. "CT" refers to the control and "WE" references the grease.

[0018] FIG. 7 sets forth an example of the rheometer torque associated with a composition of Formulation A.

[0019] FIG. 8 sets forth an example of the tensile strength associated with a composition of Formulation A. [0020] FIG. 9 sets forth an example of the viscosity associated with a composition of Formulation A.

[0021] FIG. 10 sets forth an example of (a) rheometer cure rate properties, (b) hardness, and (c) density associated with a composition of Formulation A.

[0022] FIG. 11 sets forth an example of the tensile strength associated with a composition of Formulation A.

[0023] FIG. 12 sets forth an example of curing parameters associated with a composition of Formulation A.

[0024] FIG. 13 sets forth an example of strain parameters associated with a composition of Formulation A.

[0025] FIG. 14 sets forth an example of the rheometer torque associated with a composition of Formulation A.

[0026] FIG. 15 sets forth an example of the strain properties associated with a composition of Formulation A.

[0027] FIG. 16 provides an example of a bearing seal capable of being used with compositions of the disclosure.

DETAILED DESCRIPTION

Compositions

[0028] In an aspect, compositions of the disclosure comprise, consist essentially of, or consist of carbon filler, plasticizer, cure agent, and filler. In another aspect, the composition of the disclosure comprises, consists essentially of, or consists of a polymer, carbon filler, plasticizer, cure agent, processing aid, and filler. In another aspect, the composition of the disclosure comprises, consists essentially of, or consists of carbon filler, plasticizer, cure agent, filler, and glass microspheres.

[0029] The composition of the disclosure can also comprise, consist essentially of, or consists of the following:

• at least one carbon filler compound;

• at least one friction improvement compound;

• at least one plasticizer;

• at least one antioxidant compound; and

• at least one cure system compound. [0030] In another aspect, the composition of the disclosure comprises, consists essentially of, or consists of:

• at least one nitrile compound;

• at least one carbon filler compound;

• at least one friction improvement compound;

• at least one plasticizer;

• at least one antioxidant;

• at least one ozone protection compound;

• at least one antioxidant compound; and

• at least one cure system compound.

[0031] In another aspect, the composition of the disclosure comprises, consists essentially of, or consists of the following:

• at least one nitrile compound;

• at least one carbon filler;

• at least one plasticizer;

• at least one ether/ester plasticizer;

• at least one antioxidant;

• at least one process aid;

• at least one wax compound;

• at least one antiozonant;

• at least one lubricant, process aid, or activator;

• at least one zinc oxide compound; and

• at least one peroxide

[0032] In another aspect, the composition of the disclosure comprises, consists essentially of, or consist of the following:

• Nipol - Acrylonitrile Butadiene;

• N774 Carbon Black, N990 Carbon Black, or combinations thereof;

• Dioctyl Phthalate;

• TP-759;

• Agerite Resin D;

• Struktol WB222;

• Okrin 236; • Akrochem Antiozonant PD- 1 ;

• Stearic Acid;

• RGT-Z Zinc Oxide; and

• Akrochem VC-40K.

[0033] In another aspect, the composition of the disclosure comprises, consists essentially of, or consists of the following based on 100 parts of Nipol DN3350 polymer:

• N774 Carbon Black in a loading of about 47 parts per hundred rubber ("phr");

• N990 Carbon Black in a loading of about 60 phr;

• IM30K in a loading of about 30 phr;

• Dioctyl Phthalate in a loading of about 16 phr;

• TP-759 in a loading of about 10 phr;

• Agerite Resin D in a loading of about 1.5 phr;

• Struktol WB222 in a loading of about 3.0 phr;

• Okrin 236 in a loading of about 1.0 phr;

• Akrochem Antiozonant PD-1 in a loading of about 1.5 phr;

• Stearic Acid in a loading of about.8 phr;

• Akrochem RGT-Z Zinc Oxide in a loading of about 5.0 phr; and

• Akrochem VC-40K in a loading of about 3.36 phr.

[0034] In an aspect, any of the compositions described herein can contain glass microsphere compounds or hollow glass microspheres compounds. As an example, any of the compositions described herein can contain ΪΜ30Κ from the 3M Corporation (St. Paul, Minn.), for instance, as described in "Evaluation of 3M Performance Additives ΪΜ30Κ as a filler for FKM," by Jim Denham, Dyneon, 2008, which is herein incorporated by reference in its entirety. In an aspect, the glass microsphere compounds or hollow glass microspheres compounds are about .01 to about 100 microns, about 1 to about 50 microns; 5 to about 30 microns, about 10 to about 20 microns; about 10 microns, about 11 microns, about 12 microns, about 13 microns, about 14 microns, about 15 microns, about 16 microns, about 17 microns, about 18 microns, about 19 microns, or about 20 microns.

[0035] In another aspect, any of the glass microsphere compounds or hollow glass microspheres compounds, such as IM30K, exhibit about 10 phr to about 60 phr for low rheomter torque. In another aspect, any of the glass microsphere compounds or hollow glass microspheres compounds, such as IM30K, exhibit about 10 phr to about 50 phr, about 15 phr to about 50 phr, about 20 phr to about 40 phr, about 25 phr to about 35 phr, or about 30 phr. [0036] In an aspect, the composition can include a peroxide in a phr range of about 3.36 to about 3.76 phr; about 3.2 phr to about 3.8 phr, about 3.4 phr to about 3.7 phr, about 3.5 phr to about 3.6 phr, and 3.55 phr to about 3.6 phr, and about 3.5 phr.

[0037] In an aspect, the composition described herein is a polymer composition. In another aspect, the composition described herein are torque reducing rubber compositions. In another aspect the disclosure provides for compositions exhibiting frictional torque reduction. The disclosure also provides for a seal coated with a composition described herein, wherein the composition coated seal exhibits reduced frictional torque on a wheel bearing. In another aspect, the disclosure provides for a seal including a composition described herein, wherein the seal exhibits reduced frictional torque on a bearing relative to an uncoated seal. In another aspect, the disclosure provides for a seal including a composition described herein, wherein the seal exhibits reduced frictional torque of about 5% to about 10%, about 5% to about 10%, about 10% to about 20%, or about 20% to about 50% on a wheel bearing relative to a control seal that does not contain a composition disclosed herein. In yet another aspect, the composition of Formulation A of Figure 2 is incorporated into a seal and the seal exhibits reduced frictional torque on a bearing relative to an a control seal that does not include a composition disclosed herein.

[0038] In an aspect, a polymer disclosed herein is present in an amount of about 2% to about 10%, about 10% to about 50% by weight, about 15% to about 40% by weight, about 20% to about 35% by weight, about 25% to about 30% by weight of the composition. In an aspect, a polymer disclosed herein is present in a loading of about of about 80 - 100 phr, about 90 - 1 10 phr, or about 100 phr.

[0039] In an aspect, a plasticizer disclosed herein is present in an amount of about 1% to about 20% by weight, about 2% to about 15 % by weight, about 5% to about 10% by weight, about 8% to about 12% by weight, about 2% by weight, about 5% by weight, about 8% by weight, about 10% by weight, or about 15% by weight of the composition. In an aspect, a plasticizer disclosed herein is present in a loading of about 20 - 50 phr, about 20 - 30 phr, about 20 phr, about 25 phr, or about 30 phr.

[0040] In an aspect, a curing agent disclosed herein is present in an amount of about .01% to about 10% by weight, about .5% to about 5% by weight, about 1% to about 5% by weight, about 2% to about 5% by weight, about .1% by weight, about .5% by weight, about 1.0% by weight, about 2.0% by weight, or about 5% by weight of the composition. In an aspect, a curing agent disclosed herein is present in a loading of about 1 - 20 phr, about 2 - 10 phr, about 2 phr, about 6 phr, or about 10 phr. [0041] In an aspect, a focused filler disclosed herein is present in an amount of about 5% to about 20% by weight, about 5% to about 15% by weight, about 10% to about 15% by weight, about 12% to about 18% by weight, about 2% by weight, about 5% by weight, about 10% by weight, about 15% by weight, or about 20% by weight of the composition. In an aspect, a plasticizer disclosed herein is in a loading of about 10 - 40 phr, about 15 - 30 phr, about 20 phr, about 28 phr, or about 30 phr.

[0042] In an aspect, a composition disclosed herein includes at least one nitrile based compound, for example, a Nipol -based compound, such as a medium-to-high-nitrile NBR ("JSR NBR N230S" manufactured by JSR Corp.); a raw carboxylated medium-to-high- nitrile NBR ("Nipol DN631 " manufactured by Nippon Zeon Co., Ltd.); a high-nitrile NBR ("JSR NBR N222S" manufactured by JSR Corp.); a medium-nitrile NBR ("JSR NBR N241 S" manufactured by JSR Corp.); a medium-nitrile NBR ("JSR NBR N240S" manufactured by JSR Corp.); a medium-nitrile NBR ("Nipol DN2850" manufactured by Nippon Zeon Co., Ltd.); acrylonitrile monomer content, a medium-nitrile NBR ("Nipol DN3350" manufactured by Nippon Zeon Co., Ltd.); a high-nitrile NBR ("JSR NBR N235S" manufactured by JSR Corp.); acrylonitrile monomer content, a high-nitrile NBR ("JSR NBR N220S" manufactured by JSR Corp.); or other nitrile-based compounds, such as those set forth in U.S. Patent No. 7,264,249, which is hereby incorporated by reference in its entirety. In an aspect, a nitrile-based compound disclosed herein is present in an amount of about 2% to about 10%, about 10% to about 50% by weight, about 15% to about 40% by weight, about 20% to about 35% by weight, about 25% to about 30% by weight of the composition. In an aspect, a nitrile based compound disclosed herein is present in a loading of about 80 - 100 phr, about 90 - 1 10 phr, or about 100 phr. In an aspect, the composition does not include a nitrile-based compound.

[0043] In an aspect, a composition disclosed herein includes at least one carbon filler, for example, a carbon black compound, such as Nl 10, N121, N134, N220, N231, N234, N242, N293, N299, N315, N326, N330, N332, N339, N343, N347, N351, N358, N375, N539, N550, N582, N630, N642, N650, N683, N754, N762, N765, N774, N787, N907, N908, N990 and N99, or other carbon black compounds such as those set forth in U.S. Patent Application No. 2011/01 14240, which is hereby incorporated by reference in its entirety. In an aspect, a carbon filler used herein may have have iodine absorptions ranging from 9 to 145 g/kg and DBP number ranging from 34 to 150 cm.sup.3/100 g. In another aspect, the carbon filler may be used in an amount ranging from 10 to 150 phr or from 20 to 50 phr. In an aspect, a carbon filler compound disclosed herein is present in an amount of about 2% to about 10%, about 10% to about 50% by weight, about 15% to about 40% by weight, about 20% to about 35% by weight, about 25% to about 30% by weight of the composition. In an aspect, a carbon filler compound disclosed herein is present in a loading of about 40 - 80 phr, about 80 - 130 phr, about 90 - 1 10 phr, about 50 phr, about 60 phr, about 100 phr, about 110 phr, about 120 phr, about 130 phr.

[0044] In an aspect, a composition disclosed herein includes a friction improvement compound, such as ΪΜ30Κ. In an aspect, a friction improvement compound disclosed herein is present in an amount of about 1% to about 20% by weight, about 2% to aboutl5 % by weight, about 5% to about 10% by weight, about 8% to about 12% by weight, about 2% by weight, about 5% by weight, about 8% by weight, about 10% by weight, or about 15% by weight of the composition. In an aspect, a friction improvement component disclosed herein is present in a loading of about 20 - 50 phr, about 20 - 30 phr, about 20 phr, about 25 phr, or about 30 phr.

[0045] In an aspect, a composition disclosed herein includes at least one plasticizer, for example, Dioctyl Phthalate, TP-759, an ether 4oased plasticizer, an ester-based plasticizer, diisononyl phthalate or diisodecyl phthalate, adipates, for example dioctyl adipate, azelates and sebacates, organic phosphoric and sulfonic esters or polybutenes, or other compounds such as those set forth in U.S. Patent Application No. 2010/0273924, which is hereby incorporated by reference in its entirety. In an aspect, a plasticizer compound disclosed herein is present in an amount of about 1% to about 20% by weight, about 2% to about 15 % by weight, about 5% to about 10% by weight, about 8% to about 12% by weight, about 2% to about 5%, about 2% by weight, about 5% by weight, about 8% by weight, about 10% by weight, about 15% by weight, or about 20% by weight of the composition. In an aspect, a plasticizer disclosed herein is present in a loading of about 10 - 20 phr; about 20 - 50 phr, about 20 - 30 phr, about 10 phr, about 20 phr, about 25 phr, or about 30 phr.

[0046] In an aspect, a composition disclosed herein includes at least one antioxidant, for example, Agerite Resin D from R.T. Vanderbilt, Norwalk; polymerized l,2-dihydro-2,2,4 trimethylquinoline, or other compounds such as those set forth in U.S. Patent Application No. 2008/0048145, which is hereby incorporated by reference in its entirety. In an aspect, an antioxidant disclosed herein is present in an amount of about .1% to about 2% by weight, about .5% to about 1% by weight, about .5% to about 2% by weight, about 1% to about 2% by weight, about .1% by weight, about .2% by weight, about .5% by weight, about 1.0% by weight, or about 2.0% by weight of the composition. In an aspect, an antioxidant disclosed herein is present in a loading of about 5 - 2.0 phr, about 1 - 5 phr, about 2 - 5 phr, about 2 - 10 phr, about 1.0 phr, about 1.5 phr, or about 2.0 phr, or about 5.0 phr.

[0047] In an aspect, a composition disclosed herein includes at least one process aid, for example, Struktol WB222 or aliphatic fatty acid esters. In an aspect, the process aid disclosed herein is present in an amount of about .5% to about 2% by weight, about .5% to about 1% by weight, about .5% to about 4% by weight, about 1% to about 2% by weight, about .5% by weight, about 1.0% by weight, about 1.5% by weight, about 2.0% by weight, or about 5.0% by weight of the composition. In an aspect, a process aid disclosed herein is present in a loading of about.5 - 2.0 phr, about 1 - 5 phr, about 2 - 5 phr, about 2 - 10 phr, about 1.0 phr, about 1.5 phr, about 2.0 phr, or about 5.0 phr.

[0048] In an aspect, a composition disclosed herein includes at least one antiozonant, for example, Akrochem Antiozonant PD-1, Okrin 236, a -isopropyl-N'-phenyl-p-phenylene Diamine (IPPD). Other suitable antiozonants products are sold under the SANTOFLEX name and are available from Flexsys, L.L.P., Akron, Ohio. Also suitable are mechanical function antiozonants, such as petroleum waxes and microcrystalline paraffinic wax sold under the name SU OLITE, also available from Crompton Knowles, or other compounds such as those set forth in U.S. Patent Application No. 2004/0143050, which is hereby incorporated by reference in its entirety. In an aspect, an antiozonant disclosed herein is present in an amount of about .1% to about 2% by weight, about .5% to about 1% by weight, about .5% to about 2% by weight, about 1% to about 2% by weight, about .1% by weight, about .2% by weight, about .5% by weight, about 1.0% by weight, or about 2.0% by weight of the composition. In an aspect, an antiozonant disclosed herein is present in a loading of about .5 - 2.0 phr, about 1 - 5 phr, about 2 - 5 phr, about 2 - 10 phr, about 1.0 phr, about 1.5 phr, about 2.0 phr, or about 5.0 phr.

[0049] In an aspect, a composition disclosed herein includes at least one lubricant, process aid, activator, aliphatic acid, or octadecanoic acid. In an aspect, the composition includes stearic acid. In an aspect, the stearic acid or at least one lubricant, process aid, activator, aliphatic acid, or octadecanoic acid is present in an amount of about .1% to about 2% by weight, about .5% to about 1% by weight, about .5% to about 2% by weight, about 1% to about 2% by weight, about .1% by weight, about .2% by weight, about .5% by weight, about 1.0% by weight, or about 2.0% by weight of the composition. In an aspect, the stearic acid or at least one lubricant, process aid, activator, aliphatic acid, or octadecanoic acid disclosed herein is present in 100 parts per 100 rubber of about .5 - 2.0, about 1 - 5, about 2 - 5, about 2 - 10, about 1.0, about 1.5, or about 2.0, or about 5.0. [0050] In an aspect, a composition disclosed herein includes a cure system, for example, Akrochem VC-40K, Di(2-tert-butylperoxyisopropyl) benzene, or other compounds such as set forth in U.S. Patent Application No. 2004/0143050, which is hereby incorporated by reference in its entirety. In an aspect, the cure system disclosed herein is present in an amount of about .5% to about 2% by weight, about .5% to about 1% by weight, about .5% to about 4% by weight, about 1% to about 2% by weight, about .5% by weight, about 1.0% by weight, about 1.5% by weight, about 2.0% by weight, or about 5.0% by weight of the composition. In an aspect, cure system disclosed herein is present in a loading of about .5 - 2.0 phr, about 1 - 5 phr, about 2 - 5 phr, about 2 - 10 phr, about 1.0 phr, about 1.5 phr, about 2.0 phr, or about 5.0 phr.

[0051] In an aspect, a composition disclosed herein exhibits a hardness of from about 40 to about 70 Shore A, from about 50 to about 70 Shore A, from about 55 to about 75 Shore A, from about 60 to about 70 Shore A, from about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, and 70 Shore A. In an aspect, the composition of the disclosure comprises, consists essentially of, or consists of consists of carbon filler, plasticizer, cure agent, and filler with a hardness of from about 40 to about 70 Shore A, from about 50 to about 70 Shore A , from about 55 to about 75 Shore A, from about 60 to about 70 Shore A , from about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, and 70 Shore A and wherein the hardness can be altered by changing the weight percent of carbon black and plasticizer.

[0052] In an aspect, the composition of the disclosure exhibits an initial rheometer torque from about 5 to about 15 inch/pounds, from about 6 to about 12 inch/pounds , from about 7 to about 10 inch/pounds, from about 8 to about 10 inch/pounds, about 6, about 7 inch/pounds, about 8 inch/pounds, about 9 inch/pounds, about 10 inch/pounds, about 1 1 inch/pounds, and about 12 inch/pounds. In another aspect, the composition of the disclosure exhibits a minimum rheometer torque from about 4 to about 12 inch/pounds, from about 4 to about 8 inch/pounds, from about 6 to about 8 inch/pounds, about 4 inch/pounds, about 5 inch/pounds, about 6 inch/pounds, about 7 inch/pounds, and about 8 inch/pounds. In yet another aspect, the composition of the disclosure exhibits a TS2 from about .75 to about 1.5 inch/pounds, from about .8 to about 1.4 inch/pounds, from about 1 to about 1.2 inch/pounds, about .8 inch/pounds, about .9 inch/pounds, about 1.0 inch/pounds, about 1.1 inch/pounds, about 1.2 inch/pounds, about 1.3 inch/pounds, and about 1.4 inch/pounds. In an aspect, the above torque values are representative of a temperature of about 360°F when evaluated by a Rheometer. [0053] In an aspect, the composition of the disclosure exhibits a tensile strength from about 900 to about 1600 psi, about 1000 to about 1500 psi, from about 1100 to about 1400 psi, from about 1200 to about 1300 psi, about 1000 psi, about 1100 psi, about 1200 psi, about 1300, about 1400 psi, and about 1500 psi.

[0054] In an aspect, the composition of the disclosure exhibits an elongation from about 300 to about 450, about 325 to about 400, from about 350 to about 375, about 300, about 325, about 350, about 375, and about 400.

[0055] In an aspect, the composition of the disclosure exhibits a 100% modulus from about 200 to about 300 psi, about 225 to about 275 psi, from about 240 to about 260 psi, from about 200 psi, about 225 psi, about 250 psi, about 275 psi, and about 300 psi.

[0056] In another aspect, the composition of the disclosure exhibits a specific gravity from about 1.0 to about 1.3 g/cm³, from about 1.1 to about 1.2 g/cm³, from about 1.12 to about 1.16 g/cm³, from about 1.14 to about 1.15 g/cm³, about 1.12 g/cm³, about 1.13 g/cm³, about 1.14 g/cm³ , about 1.15 g/cm³, and about 1.16 g/cm³ .

Bearing Seal

[0057] In an aspect, the disclosure provides for a bearing seal comprising, consisting essentially of, or consisting of a composition disclosed herein. In another aspect, the disclosure provides for the seal of Figure 1 comprising, consisting essentially of, or consisting of a composition disclosed herein. A composition disclosed herein may be coated onto a seal or embedded into the seal. For example, the color-coated pink internal areas of the seal are made from a composition disclosed herein and color-coated gray outmost areas of the seal represents the metal insert.

[0058] In an aspect, the insert in the bearing seal is metal, aluminum, steel, stainless steel, cold-roll steel, or iron. The seal may be constructed in a wide range of sizes. The diameter of the seal can be from about 1 to about 20 inches, from about 2 to about 10 inches, from about 2 to about 8 inches, from about 2 to about 6 inches, from about 3 to about 5 inches, from about 5 inches or more, or from about 15 inches or more and, in an aspect, the width of the bearing seal can be from about .1 to about 2 inches, from about .1 to about .5 inches, from about .2 to about .4 inches, from about .1 to about .2 inches, from about 1 to about 15 inches, from about .1 inches or more, from about .2 inches or more, from about .5 inches or more, or from about 1 inches or more. In an aspect, the seal is round or oval.

[0059] In an aspect, the disclosure provides for a multi lip seal comprising, consisting of, or consisting essentially one or more axial lips, one or more radial lips, and an outside diameter with a metal and/or a rubber gasket. In another aspect, the disclosure provides for a multi lip seal comprising, consisting of, or consisting essentially a composition disclosed herein together with one or more axial lips, one or more radial lips, and an outside diameter with metal and rubber gasket. In an aspect, a seal disclosed herein is used to prevent or treat contamination into the bearing or the retention of grease in the bearing while maintaining the lowest possible bearing torque.

[0060] The disclosure also provides for a composition comprising, consisting of, or consisting essentially of a rubber compound disclosed herein, an axial lip, a radial lip, and an outside diameter. In an aspect, the axial lip functions to exclude contamination and/or an interference fit to prevent contamination and minimize frictional torque. In an aspect, the radial lip prevents, reduces, or minimizes grease retention, an interference fit to minimize frictional torque, and is designed to accommodate internal bearing pressure relief. In an aspect, the rubber gasket portion is designed to prevent, reduce, or minimize for

contamination exclusion and corrosion.

[0061] In another aspect, the compositions disclosed herein provide for compressive stress relaxation improvement with microspheres. In addition to reducing frictional torque, microspheres in a rubber compound have the ability to improve the compressive stress relaxation properties ("CSR"). For instance, according to ASTM D-6147 Test Method for Vulcanized Rubber and Thermoplastic Elastomers-Determination of Force Decay (Stress Relaxation) in Compression " [w]hen a constant strain is imposed on rubber, the force necessary to maintain that strain is not constant but decays with time; the phenomenon is called force decay (stress relaxation). Conversely, when rubber is subjected to a constant stress, an increase in the deformation takes place in time; this behavior is called creep. These phenomena are of practical significance in rubber articles, such as seals and gaskets."

Methods

[0062] The disclosure provides for a method of reducing torque by applying a composition described herein to a bearing seal. In an aspect, the torque reducing seal bearing is depicted in Figure 1. In an aspect, the bearing seal composition is used in an automobile and may be used together with other friction reducing compounds or components as recognized in the art.

[0063] The disclosure also provides for a method of increasing the energy efficiency or improving the miles per gallon of an automobile, motorcycle, or other motor-based machines by utilizing a bearing seal coated or combined with a composition described herein. A bearing seal coated or combined with a composition described herein may also be used in conjunction with energy efficient automobiles, motorcycle, or other motor-based machines, such as electric or hybrid gas/electric vehicles. The disclosure also provides for a wheel including the seal described herein.

[0064] In an aspect, the seal or composition disclosed herein is used in a class of light weight vehicles. In another aspect, the seal or composition disclosed herein is used together with a hub/bearing or bal/bearing mechanism.

[0065] In an aspect, the compounds or compositions disclosed herein can be used in the automotive, machinery, or aerospace industry. In another aspect, the compounds or compositions disclosed herein can be used together with a seal, bearing seal, or multi-lip outboard hub bearing seal. In another aspect, the compounds or compositions disclosed herein can be used together with the hub bearing seal of Figure 1. In an aspect, a composition described herein can also be used together with other bearing seals, for example, such as those in U.S. Patent No. 7,942,584, which is herein incorporated in its entirety.

[0066] In an aspect, the compositions described herein are produced by utilizing a mixer, such as a Banbury mixer. In an aspect, the compositions described herein may be prepared by the process set forth in Example 1. In another aspect, the procedure of Example 1 can be modified by changing the order in which the ingredients are added, the duration time of the mixing, the temperatures used throughout the mixing operation, the removal from the mixer for a separate milling operation, and the re-mixing (2^nd 3^rd or 4^th passes) of the steps.

[0067] In an aspect, the compounds are produced during a molding process and evaluated based on milling, pre-forming, molding, and trimming the product.

Kit;

[0068] Also provided is a kit comprising, consisting of, or consisting essentially of a composition, seal, or bearing as disclosed herein.

[0069] The kit may also include instructions for describing procedures associated with the disclosed methods. In yet another aspect, the kit comprises instructions for using a composition as described herein for reducing torque or increasing the energy efficiency of a vehicle. In another aspect, the kit includes a seal as described in Figure 1.

Examples

Example 1 [0070] This example describes a method for mixing a compound disclosed herein using the following procedure:

1. Set Banbury mixer to 70 rpm, turn on cooling water.

2. Load polymer, lower ram and mix for approximately 20 seconds.

3. Raise ram, add additive compounds, add about ½ of the ΪΜ30Κ, add about ½ of

plasticizer, and about ½ of carbon blacks. Lower ram.

4. At 1.5 minutes, raise ram, sweep and lower ram.

5. At 3 minutes, raise ram, add remaining amount of the ΪΜ30Κ, add remaining amount of the plasticizer, and add remaining amount of the of carbon blacks, sweep and add cure compound.

6. At 4.5 minutes, raise ram, sweep and add cure compound. Lower ram.

7. At 5 minutes, raise ram and sweep. Lower ram.

8. At 5.5 minutes drop batch.

[0071] In an aspect, Formulation A of Figure 2 is prepared by the above method. In another aspect, the above procedure can be assembled in a custom mixer or may be scaled-up or down in a preparation process.

Example 2

[0072] This example describes a method for testing the physiochemical properties of compositions disclosed herein:

[0073] After preparation of the compositions described herein, such as by the method above, the physiochemical properties of the compositions are characterized.

[0074] The initial rheometer torque, minimum rheometer torque, and TS2 are

characterized by Rheometer. The tensile strength, elongation properties, modulus properties, hardness properties, and specific gravity are also tested. The reducing of torque and other physiochemical properties are also evaluated by water spray testing, grease compatibility testing, both high and low temperature testing, mud spray testing, and oil compatability testing.

[0075] Figures 4 - 15 represent examples of physiochemical properties associated with a composition of Formulation A of Figure 2.

Example 3

[0076] This example describes a method for evaluating compressive stress relaxation improvement with microspheres using the compositions disclosed herein: [0077] Using an Instron model 3335 Tensometer and Instron supplied software that mimics the protocol of ASTM D-6147 Test Method for Vulcanized Rubber and

Thermoplastic Elastomers-Determination of Force Decay (Stress Relaxation) in

Compression, molded buttons are deflected 25% for 24 hours at Room Temperature in order to measure the CSR. NBR Buttons containing the microspheres are compared to a similar NBR without microspheres with a 30% reduction in the CSR. This reduction improves the sealing capabilities of O-rings and gaskets type materials.

Claims

THE CLAIMS

Claim 1. A polymer composition capable of reducing frictional torque in a wheel bearing, wherein said polymer composition comprises

a. at least one polymer;

b. at least one carbon filler compound;

c. at least one friction improvement compound;

d. at least one plasticizer;

e. at least one antioxidant compound;

f. at least one cure system compound; and

wherein said polymer composition exhibits a hardness of between 60 - 70 Shore A .

Claim 2. The polymer composition according to claim I, wherein said at least one polymer is a nitrile polymer compound.

Claim 3. The polymer composition according to claim I, wherein said friction

improvement compound is ΪΜ30Κ.

The polymer composition according to claim 1, wherein

a. the at least one polymer is a nitrile polymer compound;

b. the at least one carbon filler compound is a carbon black compound; c. the at least one friction improvement compound is a glass microsphere

compound; and

d. the at least one plasticizer is a Dioctyl Phthalate compound.

Claim 5. The polymer composition according to claim 1, wherein said polymer composition comprises

a. at least one polymer present in an amount of about 15% to about 40% by weight;

b. at least one carbon filler compound present in an amount of about 15% to about 40% by weight;

c. at least one friction improvement compound present in an amount from about 5% to about 15% by weight; d. at least one plasticizer present in an amount from about 5% to about 12% by weight;

Claim 6. The polymer composition of claim 1, wherein said polymer composition further comprises at least one peroxide.

Claim 7. The polymer composition of claim 1, wherein said polymer composition has an initial rheometer torque from about 5 to about 15 inch/pounds, a minimum rheometer torque from about 4 to about 12 inch/pounds, and a TS2 from about .75 to about 1.5 inch/pounds .

Claim 8. A polymer composition comprising the following

• Nipol DN3350;

• N774 Carbon Black, N990 Carbon Black, or combinations thereof;

• IM30K;

• Dioctyl Phthalate;

• TP-759;

• Agerite Resin D;

• Struktol WB222;

• Okrin 236;

• Akrochem Antiozonant PD- 1 ;

• Stearic Acid;

• Akrochem RGT-Z Zinc Oxide; and

• Akrochem VC-40K.

Claim 9. The polymer composition of claim 8, wherein said polymer composition has an initial rheometer torque from about 5 to about 15 inch/pounds, a minimum rheometer torque from about 4 to about 12 inch/pounds, and a TS2 from about .75 to about 1.5 inch/pounds.

Claim 10. The polymer composition of claim 8, wherein said polymer composition has a hardness value from about 60 to 70 Shore A.

Claim 1 1. A bearing seal composition capable of reducing frictional torque, wherein said bearing seal composition comprises

(1) a polymer composition comprising

a. at least one polymer;

b. at least one carbon filler compound;

c. at least one friction improvement compound;

d. at least one plasticizer;

e. at least one antioxidant compound;

f. at least one cure system compound; and

(2) a metal component;

wherein said bearing seal composition is capable of reducing frictional torque in a wheel bearing.

Claim 12. The bearing seal composition of claim 1 1, wherein said friction improvement compound is ΪΜ30Κ.

Claim 13. The bearing seal composition of claim 11, wherein said polymer composition comprises

e. at least one antioxidant compound present in an amount of about .1% to about 2% by weight; and

Claim 14. The bearing seal composition of claim 1 1, wherein said metal component is steel or aluminum.

Claim 15. A method of reducing frictional torque in a wheel bearing composition comprising combining

(1) a polymer composition comprising

a. at least one polymer;

b. at least one carbon filler compound;

c. at least one friction improvement compound;

d. at least one plasticizer;

e. at least one antioxidant compound;

f. at least one cure system compound; and

(2) a metal component;

wherein said polymer/metal composition forms a wheel bearing and said wheel bearing reduces frictional torque.

Claim 16. The method according to claim 15, wherein said friction improvement compound is ΪΜ30Κ.

Claim 17. The method according to claim 15, wherein said polymer composition comprises a. at least one polymer present in an amount of about 15% to about 40% by weight;

Claim 18. The method according to claim 15, wherein said metal/polymer composition has an initial rheometer torque from about 5 to about 15 inch/pounds, a minimum rheometer torque from about 4 to about 12 inch/pounds, and a TS2 from about .75 to about 1.5 inch/pounds.

Claim 19. The method according to claim 15, wherein said metal/polymer composition has a hardness from about 60 to 70 Shore A.

Claim 20. The method according to claim 15, wherein said polymer composition comprises

• Nipol DN3350;

• N774 Carbon Black, N990 Carbon Black, or combinations thereof;

• IM30K;

• Dioctyl Phthalate;

• TP-759;

• Agerite Resin D;

• Struktol WB222;

• Okrin 236;

• Akrochem Antiozonant PD- 1 ;

• Stearic Acid;

• Akrochem RGT-Z Zinc Oxide; and

• Akrochem VC-40K.