Reactive carbonate for elastomeric articles

Abstract

This disclosure describes the preparation and use of reactive carbonates containing a metal carbonate bound to a reactive compound, wherein the reactive compound comprises a mineral binding group and a polymer reactive group connected together by a linking group. Such reactive carbonates are useful as reagents in processes for making mineral-bound elastomeric materials, and in methods for reducing cavitation in elastomer materials.

1 - 16 . (canceled) 
     
     
         17 . A process for making an elastomeric composition, the process comprising reacting a polymer with a reactive carbonate and a vulcanizing or crosslinking agent, to obtain a mineral-bound elastomeric composition,
 wherein:   the reactive carbonate comprises a metal carbonate bound to a reactive compound comprising a mineral binding group and a polymer reactive group connected together by a linking group; and the mineral-bound elastomeric composition comprises the polymer to which the metal carbonate is bound via the mineral binding group.   
     
     
         18 . The process according to  claim 17 , wherein the metal carbonate is an alkali metal carbonate or an alkaline earth metal carbonate. 
     
     
         19 . The process according to  claim 17 , wherein the metal carbonate is selected from the group consisting of a ground calcium carbonate, a precipitated calcium carbonate, and combinations thereof. 
     
     
         20 . The process according to  claim 17 , wherein the mineral binding group comprises at least one functional group selected from the group consisting of a carboxylic add, a carboxylic acid salt, a carboxylic acid derivative, an anhydride, an anhydride derivative, a phosphate, a phosphate salt, a phosphate derivative, a sulfonate, phosphoric acid and derivatives, sulfonic acid and derivatives, and combinations thereof. 
     
     
         21 . The process according to  claim 17 , wherein the polymer reactive group comprises at least one vulcanizable functional group. 
     
     
         22 . The process according to  claim 17 , wherein the polymer reactive group comprises at least one polymerizable functional group selected from the group consisting of an alkene group, an alkyne group, a halogen group, a hydroxyl group, an ester group, a lactone group, a thiol group, a thioester group, an epoxide group, an amine group, an isocyanate group, a maleimide group, an acrylate group and combinations thereof. 
     
     
         23 . The process according to  claim 17 , wherein:
 the linking group comprises a saturated or unsaturated organic group comprising 6 to 24 carbon atoms and optionally at least one atom selected from the group consisting of O, N, S and a halogen; and   the organic group connects the polymer matrix to the mineral binding group.   
     
     
         24 . The process according to  claim 17 , wherein the reactive compound is a compound of either formula (2) or (2a):
   b. (R 2 ) d -(L 2 ) c —(R 1 ) b -(L 1 )—X-Z   (2),
   wherein:   Z represents a hydrogen atom, a metal ion, or an ammonium ion;   X represents a moiety selected from the group consisting of CO 2 , PO 3 , PO 4 , SO 3 , or SO 4      L 1  independently represents a C 1-30  alkyl group, branched alkyl group, a C 1-30  alkenyl group, a branched alkenyl group, a C 3-30  alicyclic group, a C 6-30  aromatic group or a C 3-30  heteroaromatic group;   R 1  independently represents an organic group comprising a polymerizable functional group selected from the group consisting of an alkene group, an alkyne group, a halogen group, a hydroxyl group, an ester group, a lactone group, a thiol group, a thioester group, an epoxy group, an amine group, and an isocyanate group;   L 2  independently represents a C 1-30  alkylene group, a C 1-30  alkenylene group, a C 3-30  alicyclic group, a C 6-30  aromatic group or a C 3-30  heteroaromatic group;   R 2  independently represents an organic group comprising a polymerizable functional group which is branched or unbranched and selected from the group consisting of an alkene group, an alkyne group, a halogen group, a hydroxyl group, an ester group, a lactone group, a thiol group, a thioester group, an epoxy group, an amine group, and an isocyanate group;   b represents an integer of 1 to 4:   c represents an integer of 0 to 4; and   d represents an integer of 0 to 4;
 OR
   A-(X—Y—CO) m (O-B-CO) n OH   (1b)
 
 
   wherein   A is a moiety containing a terminating ethylenic bond with one or more adjacent carbonyl groups;   X is O and m is 1 to 4 or X is N and m is 1;   Y is C 1-18 -alkylene or C 2-18 -alkenylene;   B is C 2-6 -alkylene;   n is 0 to 5:   provided that when A contains two carbonyl groups adjacent to the ethylenic group, X is N.   
     
     
         25 . The process according to  claim 17 , wherein:
 the metal carbonate comprises calcium carbonate; and   the reactive compound is an unsaturated carboxylic acid or unsaturated carboxylic acid salt.   
     
     
         26 . The process according to  claim 17 , wherein the metal carbonate is calcium carbonate and the reactive compound is 9-decenoic acid. 
     
     
         27 . The process according to  claim 17 , wherein the reactive carbonate comprises a metal carbonate core at least partially covered by a layer of the reactive compound, such that the mineral binding group is bound directly to a surface of the metal carbonate core. 
     
     
         28 . The process according to  claim 17 , wherein the polymer is selected from the group consisting of an acrylonitrile-butadiene rubber, hydrogenated acrylonitrile-butadiene rubber, an ethylene propylene diene rubber, a fluorocarbon rubber, a chloropropene rubber, a silicone rubber, a fluorosilicone rubber, a polyacrylate rubber, an ethylene acrylic rubber, a styrene-butadiene rubber, a polyester urethane rubber, a polyether urethane rubber, and a natural rubber. 
     
     
         29 . The process according to  claim 17 , wherein the reacting occurs in an aqueous environment. 
     
     
         30 . The process according to  claim 17 , wherein the reacting occurs in a nonaqueous environment. 
     
     
         31 . The process according to  claim 30 , wherein the reacting occurs in the presence of a non-aqueous solvent. 
     
     
         32 . The process according to  claim 17 , wherein the reacting occurs in the presence of at least one selected from the group consisting of water, an organic solvent, a dispersant, an inorganic filler, an organic filler, a pigment, an antioxidant, a wax, a radical initiator, a coupling agent and an impact modifier. 
     
     
         33 . The process according to  claim 17 , wherein the polymer comprises a vulcanizable elastomer. 
     
     
         34 . The process according to  claim 17 , wherein the reacting does not occur in the presence of a silane or silanol. 
     
     
         35 . The process according to  claim 17 , wherein the reacting of the polymer with the reactive carbonate and the vulcanizing or crosslinking agent occurs in the presence of a non-reactive mineral selected from the group consisting of a non-reactive calcium carbonate, a talc, a diatomaceous earth, a clay and combinations thereof 
     
     
         36 . The process according to  claim 17 , wherein a proportion of metal carbonate bound in the elastomeric composition ranges from about 0.1 to about 80, or from about 1 to about 50, or from about 5 to about 30 parts per hundred rubber (PHR)r. 
     
     
         37 - 48 . (canceled)