WO2026010764A1 - Rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymers using phenolic coupling agents - Google Patents
Rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymers using phenolic coupling agentsInfo
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- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
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Abstract
A composition comprising a "rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer" that comprises the following properties: i) a MLRA/ML (at 125°C) value ≥ 8.0 s, and ii) a gel content ≤ 10 wt%, based on the weight of the "rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer;" and wherein the "rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer" is formed from a first composition comprising the following components: a) an ethylene/alpha-olefin/nonconjugated polyene interpolymer, and b) at least one phenolic coupling agent selected from structures b1) through b3), each as described herein.
Description
RHEOLOGY MODIFIED ETHYLENE/ALPHA-OLEFIN/NONCONJUGATED POLYENE INTERPOLYMERS USING PHENOLIC COUPLING AGENTS BACKGROUND OF THE INVENTION There is a need for ethylene/alpha-olefin/polyene interpolymers with high levels of long chain branching (LCB), and without significant crosslinking, as indicated by high MLRA/ML values and very low gel values, respectively. There is a further need for such interpolymers with high molecular weight as indicated by Mooney Viscosity (for example, ML (1+4, 125°C) ≥ 60). Such interpolymers should improve calendaring and extrusion applications, due to their reduction in melt fracture and their increase in elasticity, shear thinning, and collapse resistance during the extrusion of especially hollow parts. Further, there is a need to develop processes to generate LCB in, for example, EPDM, post-solution polymerization and solvent devolatilization, to overcome process limitations of pumping high molecular weight, highly branched polymers that have high “low-shear viscosity” values. U.S. Patent 6,437,030 discloses a process for forming a thermoplastic vulcanizate, comprising the steps of dynamically vulcanizing a rubber within a blend that comprises the rubber and a thermoplastic polymer. The step of vulcanizing is carried out by using a phenolic resin in the presence of a catalyst system, formed by combining a metal halide and a metal carboxylate. See abstract. This reference discloses, that, in general, a vulcanizing amount of phenolic curative comprises from about 1 to about 20 parts by weight, more preferably from about 3 to about 16 parts by weight, and even more preferably from about 4 to about 12 parts by weight, phenolic resin per hundred parts by weight rubber (phr) (see column 8, lines 48-53). Useful phenolic resins include SP-1044, SP-1045, SP-1055, and SP- 1056 from Schenectady International; Schenectady, N.Y (see column 5, lines 19-22). U.S. Patent 5,952.425 discloses phenolic resin curatives having a majority of dibenzyl ether linkages for the curing of unsaturated rubbers in a blend of a crystalline polyolefin and said rubber (see abstract). Typically the phenolic resin curative is used in amounts from about 0.5 to about 20 parts by weight per 100 parts by weight of unsaturated rubber, and more desirably from about 0.5 to about 14 parts by weight per 100 parts by weight of the unsaturated rubber (see column 4, line 48-55). U.S. Patent 5,750,625 discloses phenolic resin curatives used as a curative in thermo- plastic elastomers, and which are attributed with staining of painted surfaces, which physically contact the thermoplastic elastomers. When the phenolic resin curatives are esterified (for example, acetylated, tosylated, silylated or phosphorylated), before use as a
curative, the amount of staining is reduced or eliminated. See abstract. Typically the phenolic resin curative is used in amounts from about 2 to about 40 parts by weight per 100 parts by weight of rubber in the thermoplastic vulcanizate, and more desirably from about 3 to about 20 parts by weight per 100 parts by weight rubber (see column 3, line 66, to column 4, line 4). This reference discloses phenolic resins SP1045, available from Schenectady International in Schenectady, N.Y.; an acetylated SP1045; and an acetylated phenolic resin having a higher percentage of dibenzyl ether linkages than in SP1045 (see column 9, lines 26- 32). U.S. Patent 10,294,338 discloses a method for making thermoplastic vulcanizates, comprising dynamically vulcanizing an elastomer in an extrusion reactor, with a curative, in the presence of a thermoplastic resin, to form a thermoplastic vulcanizate. Process oil is added to the extrusion reactor at a first, second, and third location, where the amount of process oil introduced at the first oil injection location is less than that introduced at the second oil injection location, and where the third oil injection location is downstream of where the curative is introduced to the extrusion reactor. The thermoplastic vulcanizate comprises at least 25 wt% of oil, based on the weight of the thermoplastic vulcanizate. See abstract. Curative agents, capable of curing or crosslinking the elastomeric copolymer in the thermoplastic vulcanizate, include phenolic resins, peroxides, maleimides, and silicon- containing curatives (see column 7, lines 53-57). The phenolic resin may be employed in an amount from about 2 to about 20 phr, or from about 3 to about 15 phr, or from about 4 to about 10 phr (see column 8, lines 61-64). See also, columns 7-8, and column 11, lines 45-53 (where a phenolic resin curative is employed, a vulcanizing amount curative may comprise from about 1 to about 20 phr, or from about 3 to about 16 phr, or from about 4 to about 12 phr). U.S. Patent 4,311,628 discloses thermoplastic elastomeric compositions that comprise blends of olefin rubber and polyolefin resin, in which the rubber is cured with phenolic curative (see abstract). Typically, the quantity of phenolic curing agent, used to fully cure the EPDM rubber, is about 5 parts to 20 parts by weight phenolic curing agent per 100 parts by weight of EPDM rubber, and preferably between about 7 parts to 14 parts by weight phenolic curing agent per 100 parts by weight EPDM rubber (see column 4, lines 56-63). This reference discloses phenolic curing resins SP-1056 and SP-1045 (see, for example, Table XII). The Chemistry of Phenol-Formaldehyde Resin Crosslinking of EPDM as Studied With Low-Molecular-Weight Models: Part II. Formation of Inert Species, Crosslink Precursors
and Crosslinks, Martin Van Duin, Rubber Chemistry and Technology (1999), Vol.73, pp. 706-719, discloses the chemical structures formed using low-molecular-weight model compounds for the chemical mechanism of the resol cure of EPDM. The use of model compounds for EPDM (2-ethylidenenorbornane [ENBH] and 4-methylheptane), and for resol (2-hydroxymethylphenol [HMP] and 2,6-di(hydroxymethyl)-p-cresol) allowed the characterization of the chemical structures formed with the aid of gas chromatography/mass spectrometry (GC/MS) (see abstract). See also, The Chemistry of Phenol-Formaldehyde Resin Vulcanization of EPDM: Part. I. Evidence for Methylene Crosslinks, Martin Van Duin, Rubber Chemistry and Technology (1994), Vol.68, pp.717-727. International Publication WO2020/263681 discloses a process that exposes a neat ethylene/propylene/non-conjugated polyene terpolymer to an electron beam radiation, at a dosage from 0.2 MRad to 1.3 MRad, to form a branched ethylene/propylene/non-conjugated polyene terpolymer (b-terpolymer) having a Mooney viscosity (ML (1 +4) at 125°C) from 25 MU to 135 MU. The neat ethylene/propylene/non-conjugated polyene terpolymer (n- terpolymer) has a Mooney viscosity (ML (1 +4) at l25°C) less than 100 Mooney units (MU). See abstract and claim 1. U.S. Publication 2014/0051809 discloses highly branched compositions including: (i) from about 96 wt % to about 99.9 wt % of a metallocene catalyzed ethylene propylene diene derived units; and (ii) from about 0.1 wt.% to about 4 wt % of multifunctional monomer derived units, wherein the highly branched composition has: (a) a Mooney viscosity ML (1+4) at 125°C of about 30 to 100 MU, (b) a Mooney relaxation area MLRA of about 100 to about 1000, (c) a branching index, g’(vis) of less than about 0.9, (d) a phase angle, δ, of less than about 55 degrees at a complex modulus of 10 kPa, measured at 190°C, and (e) a degree of shear thinning greater than about 0.95, measured at 190°C. See abstract. Suitable multifunctional monomers include one or more vinyl compounds, allylic compounds, acrylate compounds, or combinations thereof (see paragraph [0155]). International Publication WO2022/115410 discloses a process of providing an ethylene/propylene/non-conjugated polyene terpolymer (EPDM) having at least 3.5 wt% non- conjugated polyene, and reacting the EPDM with a metal-Lewis acid, and forming a rheology-modified EPDM. The rheology-modified EPDM has (i) a z average molecular weight (Mz) from greater than 500,000 g/mole to 10,000,000 g/mole, (ii) a Mz/Mw from 3 to 10, (iii) a g value from 0.4 to 1.0, (iv) a z value from 1.0 to 3.5, (v) a Mooney viscosity from 50 to 150, and (vi) a tan delta value from 0.1 to less than 1.0. See abstract. Additional polymers and/or compositions are disclosed in the following references:
International Publication WO2020/263677; European Application EP1113028A1; Quantitative Assessment of the Branching Architecture of EPDM with High Content of 5- Vinyl-2-Norbornene as Third Monomer, K. Dullaert et al., Rubber Chemistry and Technology (2013), 86(4), 503-520; High Performance EPDM Polymers Based on Controlled Long Chain Branching, H. J. H. Beelen, Kautschuk Gummi Kunststoffe (1999), 52(6), 406-412; and Structural Determination of Ethylene-Propylene-Diene Rubber (EPDM) Containing High Degree of Controlled Long-Chain Branching, S. Mita et al., Journal of Applied Polymer Science (2009), 113, 2962-2972. However, as discussed above, there remains a need for ethylene/alpha-olefin/polyene interpolymers with high levels of long chain branching (LCB), and without significant crosslinking, as indicated by high MLRA/ML values and very low gel values, respectively. In addition, there is a need for such interpolymers with high molecular weight as indicated by Mooney Viscosity. There is a further need to develop processes to generate LCB in, for example, EPDM, post-solution polymerization and solvent devolatilization, to overcome process limitations of pumping high molecular weight, highly branched polymers. These needs have been met as discussed below. SUMMARY OF THE INVENTION A composition comprising a “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” that comprises the following properties: i) a MLRA/ML (at 125°C) value ≥ 8.0 s, and ii) a gel content ≤ 10 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer;” and wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is formed from a first composition comprising the following components: a) an ethylene/alpha-olefin/nonconjugated polyene interpolymer, and b) at least one phenolic coupling agent selected from structures b1) through b3), as follows: b1) , wherein each of -R1, -R2 and -R3 is independently selected from
a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3,
-CN, -C(O)H, or -C(O)NH2; and wherein -R1 and -R2 may or may not form a saturated or unsaturated fused ring; or -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; b2) , wherein m ≥ 1; -Q-,
each of -R1, -R2 and -R3, at each occurrence, is independently selected from a hydrogen, a heterohydrocarbyl, a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3, -CN, -C(O)H, or -C(O)NH2; and wherein, at each occurrence, -R1 and -R2 may or may not form a saturated or unsaturated fused ring, or -R2 and -R3 may or may not form a saturated or unsaturated fused ring, or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or b3) any combination of b1 and b2. DETAILED DRESCRIPTION OF THE INVENTION Rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymers, and methods to make the same, have been discovered. The modified interpolymers contain controlled levels of rheology-modifying branched structures in the interpolymer. It has been discovered that such modified interpolymers can be formed by coupling, for example, a desired amount of double bonds with one or more dihydroxymethyl phenols, optionally, in the presence of a Lewis acid catalyst, as illustrated, for example, in Scheme A below. The phenol and metal halide may be added to the post-reactor section of the interpolymer (for example, EPDM) manufacturing process, via a side-arm as an additive masterbatch, followed by mixing in one or more static mixers. Alternatively, these components can be melt mixed with the interpolymer in a batch or continuous mixing process, after interpolymer is produced.
As discussed above, a composition is provided comprising a “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” that comprises the following properties: i) a MLRA/ML (at 125°C) value ≥ 8.0 s, and ii) a gel content ≤ 10 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer;” and wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is formed from a first composition comprising component a and b as discussed above. The composition may comprise a combination of two or more embodiments, as described herein. The “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” may comprise a combination of two or more embodiments, as described herein. The first composition may comprise a combination of two or more embodiments, as described herein. Each component a and b may independently comprise a combination of two or more embodiments, as described herein. As used herein, in regard to the structures b1 and b2 of component b, R1 = R1 and R2 = R2, and so on. Also, in regard to the number of carbon atoms in a chemical substituent, the notation, for example, “C1-C10,” where “1 through 10” represents consecutive numbers from 1 to 10, refers to “from 1 to 10 carbon atoms” that may be present in the substituent. An “alkyl” group may be linear, branched, cyclic, or any combination thereof. In one embodiment or a combination of two or more embodiments, each described herein, the first composition optionally comprises at least one catalyst, as component c, and further the first composition comprises at least one catalyst, as component c. In one embodiment or a combination of two or more embodiments, each described herein, component c is selected from Lewis acids; and further selected from SnCl2, SnCl2·2H2O, or a combination thereof. In one embodiment or a combination of two or more embodiments, each described herein, component c is selected from TiCl4, BF3, SnCl4 or AlCl3. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≥ 60, or ≥ 65, or ≥ 70, or ≥ 72, or ≥ 75, or ≥ 78, or ≥ 80, or ≥ 82. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≤ 170, or ≤ 160, or ≤ 150, or ≤ 145, or ≤ 140, or ≤ 135. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene
interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≤ 135, or ≤ 130, or ≤ 125, or ≤ 120, or ≤ 115, or ≤ 110, or ≤ 105. In one embodiment or a combination of two or more embodiments, each described herein, the rheology modified interpolymer is a “rheology modified ethylene/alpha- olefin/nonconjugated diene interpolymer,” and further a “rheology modified ethylene/alpha- olefin/nonconjugated diene terpolymer,” further a rheology modified EPDM (as used herein, ethylene/propylene/nonconjugated diene terpolymer). In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a MLRA/ML value ≥ 8.2, or ≥ 8.4, or ≥ 8.6, or ≥ 8.8, or ≥ 9.0, or ≥ 9.2, or ≥ 9.4, or ≥ 9.6 s. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a MLRA/ML value ≤ 25.0, or ≤ 22.0, or ≤ 20.0, or ≤ 19.0, or ≤ 18.5, or ≤ 18.0, or ≤ 17.5, or ≤ 17.0, or ≤ 16.5, or ≤ 16.0 s. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a gel content ≤ 8.0, or ≤ 6.0, or ≤ 5.0, or ≤ 4.5, or ≤ 4.2, or ≤ 4.0, or ≤ 3.5, or ≤ 3.2, or ≤ 3.0 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer.” In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a gel content ≤ 2.8, or ≤ 2.6, or ≤ 2.4, or ≤ 2.2, or ≤ 2.0 or ≤ 1.8, or ≤ 1.6, or ≤ 1.4, or ≤ 1.2 wt%, based on the weight of the “rheology modified ethylene/alpha- olefin/nonconjugated polyene interpolymer.” In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha- olefin/nonconjugated polyene interpolymer” has a has a gel content ≥ 0, or ≥ 0.05, or ≥ 0.1 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer.” In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 0.1 rad/s (125°C), ≥ 400, or ≥ 450, or ≥ 500, or ≥ 550, or ≥ 600, or ≥ 650, or ≥ 700 kPa·s. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 0.1 rad/s (125°C), ≤ 900, or ≤ 880, or ≤ 850, or ≤ 820, or ≤ 800, or ≤ 780, or ≤ 760 kPa·s.
In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) ≥ 80, or ≥ 85, or ≥ 90, or ≥ 92, or ≥ 95, or ≥ 98, or ≥ 100, or ≥ 102, or ≥ 104. In one embodiment or a combination of two or more embodiments, each described herein, the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) ≤ 170, or ≤ 165, or ≤ 160, or ≤ 158, or ≤ 156, or ≤ 154, or ≤ 152, or ≤ 150. In one embodiment or a combination of two or more embodiments, each described herein, the ratio of the “Gel content (wt%) of the rheology modified ethylene/alpha- olefin/nonconjugated polyene interpolymer” to the “Gel content (wt%) of component a,” as thermally treated, is ≥ 1.2, or ≥ 1.4, or ≥ 1.6 and/or ≤ 5.0, or ≤ 4.5, or ≤ 4.0, or ≤ 3.5, or ≤ 3.0, or ≤ 2.5, or ≤ 2.0. Here, component a is thermally treated under the same conditions used to form the rheology modified interpolymer. In one embodiment or a combination of two or more embodiments, each described herein, the ratio of the “MLRA/ML of the rheology modified ethylene/alpha-olefin/- nonconjugated polyene interpolymer” to the “MLRA/ML of component a” is ≥ 1.80, or ≥ 2.00, or ≥ 2.20, or ≥ 2.30, or ≥ 2.40, or ≥ 2.50, or ≥ 2.60 and/or ≤ 4.20, or ≤ 4.00, or ≤ 3.80, or ≤ 3.60, or ≤ 3.40, or ≤ 3.30, or ≤ 3.20. The MLRA/ML is determined as described herein. In one embodiment or a combination of two or more embodiments, each described herein, component b is present in an amount ≥ 200 ppm, or ≥ 400 ppm, or ≥ 600 ppm, or ≥ 800 ppm, or ≥ 900 ppm, or ≥ 1000 ppm and/or ≤ 4000 ppm, or ≤ 3500 ppm, or ≤ 3000 ppm, or ≤ 2500 ppm, or ≤ 2000 ppm, or ≤ 1950 ppm, or ≤ 1900 ppm, or ≤ 1850 ppm, or ≤ 1800 ppm, based on the weight of component a. In one embodiment or a combination of two or more embodiments, each described herein, component b is present in an amount ≥ 800 ppm, or ≥ 900 ppm, or ≥ 1000 ppm and/or ≤ 1700 ppm, or ≤ 1650 ppm, or ≤ 1600 ppm, or ≤ 1550 ppm, or ≤ 1500 ppm, or ≤ 1450 ppm, or ≤ 1400 ppm, or ≤ 1350 ppm, or ≤ 1300 ppm, or ≤ 1250 ppm, or ≤ 1200 ppm, or ≤ 1150 ppm, or ≤ 1100 ppm, based on the weight of component a. In one embodiment or a combination of two or more embodiments, each described herein, component b is present in an amount ≥ 0.04 wt%, or ≥ 0.06 wt%, or ≥ 0.08 wt%, or ≥ 0.09 wt%, or ≥ 0.10 wt% and/or ≤ 0.30 wt%, or ≤ 0.20 wt%, or ≤ 0.18 wt%, or ≤ 0.16 wt%, or ≤ 0.15 wt%, or ≤ 0.14 wt%, or ≤ 0.13 wt%, based on the weight of the first composition. In one embodiment or a combination of two or more embodiments, each described
herein, for component b, structure b1, R1, R2, R3 are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl; and further selected from H or a hydrocarbyl. In one embodiment or a combination of two or more embodiments, each described herein, for component b, structure b2, the R1, R2, R3, at each occurrence, are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl; and further selected from H or a hydrocarbyl. In one embodiment or a combination of two or more embodiments, each described herein, for component b, structure b1, R1 = R3; and further R1 = R3 = H. In one embodiment or a combination of two or more embodiments, each described herein, for component b, structure b2, R1 = R3, at each occurrence; and further R1 = R3 = H, at each occurrence. In one embodiment or a combination of two or more embodiments, each described herein, for component b, structure b1, R2 is a hydrocarbyl, and further an alkyl, and further a C1-C10 alkyl, further a C1-C8 alkyl, further a C1-C6 alkyl, further a C1-C4 alkyl, further a C1-C2 alkyl, further a C1 alkyl (methyl). In one embodiment or a combination of two or more embodiments, each described herein, for component b, structure b2, R2, at each occurrence, is a hydrocarbyl, and further an alkyl, and further a C1-C10 alkyl, and further a C2-C8 alkyl, and further C4-C8 alkyl, and further a C6-C8 alkyl, and further a C8 alkyl. Also provided is a process to formed from a composition of one or more embodiments as described herein, wherein said process comprises thermally treating the first composition. In one embodiment, or a combination of two or more embodiments, each described herein, the first composition is thermally treated at a temperature ≥ 150°C, or ≥ 160°C, or ≥ 170°C, or ≥ 175°C, or ≥ 180°C, or ≥ 185°C, or ≥ 190°C, and/or at a temperature ≤ 230°C, or ≤ 225°C, or ≤ 220°C, or ≤ 215°C, or ≤ 210°C, or ≤ 205°C, or ≤ 200°C. In one embodiment or a combination of two or more embodiments, each described herein, the first composition is thermally treated in a batch mixer. In one embodiment or a combination of two or more embodiments, each described herein, the first composition is thermally treated in an extruder configuration (for example a twin screw extruder). In one embodiment or a combination of two or more embodiments, each described herein, the first composition is thermally treated in a static mixer, used in conjunction with a pumping device. In one embodiment or a combination of two or more embodiments, each described herein, the first composition is thermally treated in a batch mixer or an extruder configuration, and where the first composition is formed by adding a second composition
comprising component b, using a side-arm extruder, to a melt stream comprising component a in the batch mixer or the extruder configuration. Also provided is a composition formed from the process of one or more embodiments as described herein. Also provided is an article comprising at least one component formed from a composition of one or more embodiments as described herein. In one embodiment, or a combination of two or more embodiments, each described herein, the article is a foam, or a film, and further a foam. In one embodiment, or a combination of two or more embodiments, each described herein, the article is a wire, a cable, a footwear component, an automotive part, a profile (for example, a dense, micro-dense and/or foamed profile), a tire, a tube/hose, or a roofing membrane; and further a footwear component, an automotive part, a profile (for example, a dense, micro-dense and/or foamed profile), a tire, a tube/hose, or a roofing membrane. Component a The ethylene/alpha-olefin/nonconjugated polyene interpolymers, as described herein, comprises, in polymerized form, ethylene, an alpha-olefin, and a nonconjugated polyene. The alpha-olefin may be either an aliphatic or an aromatic compound. Alpha-olefins include, but are not limited to, C3-C20 alpha-olefins, further C3-C10 alpha-olefins, further C3-C8 alpha-olefins. In one embodiment, the interpolymer is an ethylene/propylene/nonconjugated diene interpolymer, further an EPDM. Suitable examples of nonconjugated polyenes include the C4-C40 nonconjugated dienes. Nonconjugated dienes include, but are not limited to, 5- ethylidene-2-norbornene (ENB), 5-vinyl-2-norbornene (VNB), dicyclopentadiene, 1,4- hexadiene, or 7-methyl-l,6-octadiene, and further ENB, VNB, dicyclopentadiene or 1,4- hexadiene, and further ENB or VNB, and further ENB. DEFINITIONS Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percentages are based on weight, and all test methods are current as of the filing date of this disclosure. The term "composition," as used herein, includes a mixture of materials, which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition. Any reaction product or decomposition product is typically present in trace or residual amounts.
The term "polymer," as used herein, refers to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer includes the term homopolymer (employed to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities can be incorporated into the polymer structure), and the term interpolymer as defined hereinafter. Trace amounts of impurities, such as catalyst residues, can be incorporated into and/or within the polymer. Typically, a polymer is stabilized with very low amounts (“ppm” amounts) of one or more stabilizers. The term "interpolymer," as used herein, refers to a polymer prepared by the polymerization of at least two different types of monomers. The term interpolymer thus includes the term copolymer (employed to refer to polymers prepared from two different types of monomers) and polymers prepared from more than two different types of monomers. The term “olefin-based polymer,” as used herein, refers to a polymer that comprises, in polymerized form, 50 wt% or a majority weight percent of an olefin, such as, for example, ethylene or propylene (based on the weight of the polymer), and optionally may comprise one or more comonomers. The term "ethylene/alpha-olefin/nonconjugated polyene interpolymer," as used herein, refers to an interpolymer that comprises, in polymerized form, ethylene, an alpha-olefin, and a nonconjugated polyene. In one embodiment, the "ethylene/alpha-olefin/non-conjugated polyene interpolymer," comprises, in polymerized form, 50 wt% or a majority weight percent of ethylene (based on the weight of the interpolymer). The term "ethylene/alpha- olefin/nonconjugated diene interpolymer," as used herein, refers to an interpolymer that comprises, in polymerized form, ethylene, an alpha-olefin, and a nonconjugated diene. In one embodiment, the "ethylene/alpha-olefin/nonconjugated diene interpolymer," comprises, in polymerized form, 50 wt% or a majority weight percent of ethylene (based on the weight of the interpolymer). Note, the terms ”ethylene/alpha-olefin/nonconjugated polyene terpolymer” and “ethylene/alpha-olefin/nonconjugated diene terpolymer” are similarly defined; however, for each, the terpolymer comprises, in polymerized form, ethylene, the alpha-olefin and the polyene (or diene) as the only three monomer types. The phrase “a majority weight percent,” as used herein, in reference to a polymer (or interpolymer, or terpolymer or copolymer), refers to the amount of monomer present in the greatest amount in the polymer. The term “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer,” as used herein, refers to an ethylene/alpha-olefin/nonconjugated polyene
interpolymer that has been reacted with a composition comprising at least one phenolic coupling agent, and, optionally, at least one catalyst (for example, a Lewis acid), to increase the MLRA/ML value of the interpolymer, relative to the unreactive interpolymer. The term “Lewis acid,” as used herein, refers to a metal-based Lewis acid that acts as an electron pair acceptor to increase the reactivity of a substrate (or donor compound), for example, by forming a complex with lone-pair bearing atom(s) to activate the substrate (or donor compound) toward nucleophilic attack. Common Lewis acid catalysts are based on metals, such as aluminum, boron, silicon, and tin, as well as titanium, zirconium, iron, copper and zinc. Some examples of these catalysts include, but are not limited to, TiCl4, BF3, SnCl4, and AlCl3. The terms “thermally treating,” “thermally treated,” “thermal treatment,” and similar terms, as used herein, in reference to a first composition as discussed herein, refer to increasing the temperature of the composition by the application of heat. As an example, heat may be applied by electrical means (for example, a heating coil) and/or by radiation and/or by hot oil and/or by mechanical shearing. Note, the temperature at which the thermal treatment takes place, refers to the temperature of the “heat-applying” device. The term “extruder configuration,” as used herein, refers to one extruder, or the arrangement and number of two or more extruders used in an extrusion process. Typically, two or more extruders are arranged in a series orientation. The term “batch mixer,” as used herein, refers to a mixer, into which, the ingredients (or components) for one batch are placed, mixed, and discharged, before another batch is introduced; as opposed to continuous mixer. The term “static mixer,” as used herein, refers to an immobile unit that includes one or more stationary elements, such as, for example, baffles, blades, or elements arranged in a specific pattern, within a pipe or tube. These elements cause the fluid mass to divide and recombine, resulting in increased levels of distribution and mixing in a continuous flow, without the need for any moving parts or an external power source. The term “side arm extruder,” as used herein, refers to an extruder, for example, a single screw extruder, that is use to melt, and pump, for example, the phenolic coupling agent(s), typically in a masterbatch form, into a melt stream comprising the unmodified ethylene/alpha-olefin/nonconjugated polyene interpolymer (plus other optional components), typically at a location before one or more static mixing elements. The term “melt stream,” as used herein, refers to a composition comprising a polymer, and where the composition is in the form of a flowing melt.
The term "heteroatom," as used herein, refers to an atom other than hydrogen or carbon (for example, O, S, N or P). The term "heteroatom group" refers to a heteroatom or a chemical group containing one or more heteroatoms. The terms "hydrocarbon," "hydrocarbyl," and similar terms, as used herein, refer to a respective compound or chemical group, etc., containing only carbon and hydrogen atoms. The terms "heterohydrocarbon," "heterohydrocarbyl," and similar terms, as used herein, refer to a respective hydrocarbon," or "hydrocarbyl group, etc., in which at least one carbon atom is substituted with a heteroatom group (for example, O, S, N or P). The monovalent heterohydrocarbyl group may be bonded to the remaining compound of interest via a carbon atom or via a heteroatom. The terms "comprising," "including," "having," and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, regardless of whether the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term "comprising" may include, for example, any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term "consisting essentially of" excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term "consisting of" excludes any component, step or procedure, not specifically delineated or listed. Listing of Some Compositions and Processes A] A composition comprising a “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” that comprises the following properties: i) a MLRA/ML (at 125°C) value ≥ 8.0 s, and ii) a gel content ≤ 10 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer;” and wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is formed from a first composition comprising the following components: a) an ethylene/alpha-olefin/nonconjugated polyene interpolymer, and b) at least one phenolic coupling agent selected from structures b1) through b3), as follows:
b1) , wherein each of -R1, -R2 and -R3 is independently selected from a rocarbyl, a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3, -CN, -C(O)H, or -C(O)NH2; and wherein -R1 and -R2 may or may not form a saturated or unsaturated fused ring; or -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; b2) , wherein m ≥ 1; -Q-,
each of -R1, -R2 and -R3, at each occurrence, is independently selected from a hydrogen, a heterohydrocarbyl, a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3, -CN, -C(O)H, or -C(O)NH2; and wherein, at each occurrence, -R1 and -R2 may or may not form a saturated or unsaturated fused ring, or -R2 and -R3 may or may not form a saturated or unsaturated fused ring, or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or b3) any combination of b1 and b2. B] The composition of A] above, wherein the first composition optionally comprises at least one catalyst, as component c; and further the first composition comprises at least one catalyst, as component c. C] The composition of B] above, wherein component c is selected from Lewis acids; and further selected from SnCl2, SnCl2·2H2O, or a combination thereof. D] The composition of B] or C] above, wherein, if present, component c is present in an amount ≥ 0.01 wt%, or ≥ 0.02 wt%, or ≥ 0.03 wt%, or ≥ 0.04 wt%, or ≥ 0.05 wt% and/or ≤ 0.30 wt%, or ≤ 0.25 wt%, or ≤ 0.20 wt% or ≤ 0.15 wt%, or ≤ 0.10 wt%, based on the weight of the first composition. E] The composition of any one of A]-D] (A] through D]) above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≥ 60, or ≥ 65, or ≥ 70, or ≥ 72, or ≥ 75, or ≥ 78, or ≥ 80, or ≥ 82. F] The composition of any one of A]-E] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML
1+4, 125°C) ≤ 170, or ≤ 160, or ≤ 150, or ≤ 145, or ≤ 140, or ≤ 135. G] The composition of any one of A]-F] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≤ 135, or ≤ 130, or ≤ 125, or ≤ 120, or ≤ 115, or ≤ 110, or ≤ 105. H] The composition of any one of A]-G] above, wherein the alpha-olefin of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is a C3-C20 alpha-olefin, further a C3-C10 alpha-olefin, and further propylene, 1-butene, 1-hexene or 1- octene, further propylene, 1-butene or 1-octene, further propylene or 1-butene, further propylene. I] The composition of any one of A]-H] above, wherein the rheology modified interpolymer is a “rheology modified ethylene/alpha-olefin/nonconjugated diene interpolymer,” and further a “rheology modified ethylene/alpha-olefin/nonconjugated diene terpolymer,” further a rheology modified EPDM (as used herein, ethylene/propylene/- nonconjugated diene terpolymer). J] The composition of any one of A]-I] above, wherein the nonconjugated polyene of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is a nonconjugated diene; and further selected from 5-ethylidene-2-norbornene (ENB), 5-vinyl-2- norbornene (VNB), dicyclopentadiene, 1,4-hexadiene, or 7-methyl-l,6-octadiene, and further ENB, VNB, dicyclopentadiene or 1,4-hexadiene, and further ENB or VNB, and further ENB. K] The composition of any one of A]-J] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a MLRA/ML value ≥ 8.2, or ≥ 8.4, or ≥ 8.6, or ≥ 8.8, or ≥ 9.0, or ≥ 9.2, or ≥ 9.4, or ≥ 9.6 s. L] The composition of any one of A]-K] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a MLRA/ML value ≤ 25.0, or ≤ 22.0, or ≤ 20.0, or ≤ 19.0, or ≤ 18.5, or ≤ 18.0, or ≤ 17.5, or ≤ 17.0, or ≤ 16.5, or ≤ 16.0 s. M] The composition of any one of A]-L] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a gel content ≤ 8.0, or ≤ 6.0, or ≤ 5.0, or ≤ 4.5, or ≤ 4.2, or ≤ 4.0, or ≤ 3.5, or ≤ 3.2, or ≤ 3.0 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer.” N] The composition of any one of A]-M] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a gel content ≤ 2.8, or ≤ 2.6, or ≤ 2.4, or ≤ 2.2, or ≤ 2.0 or ≤ 1.8, or ≤ 1.6, or ≤ 1.4, or ≤ 1.2 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer.” O] The composition of any one of A]-N] above, wherein the “rheology modified
ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a has a gel content ≥ 0, or ≥ 0.05, or ≥ 0.1 wt%, based on the weight of the “rheology modified ethylene/alpha- olefin/nonconjugated polyene interpolymer.” P] The composition of any one of A]-O] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 0.1 rad/s (125°C), ≥ 400, or ≥ 450, or ≥ 500, or ≥ 550, or ≥ 600, or ≥ 650, or ≥ 700 kPa·s. Q] The composition of any one of A]-P] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 0.1 rad/s (125°C), ≤ 900, or ≤ 880, or ≤ 850, or ≤ 820, or ≤ 800, or ≤ 780, or ≤ 760 kPa·s. R] The composition of any one of A]-Q] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 100 rad/s (125°C), ≥ 4.0, or ≥ 4.2, or ≥ 4.4, or ≥ 4.6, or ≥ 4.8, or ≥ 4.9 kPa·s. S] The composition of any one of A]-R] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ, at 100 rad/s (125°C), ≤ 9.0, or ≤ 8.8, or ≤ 8.5, or ≤ 8.2, or ≤ 8.0, or ≤ 7.8, or ≤ 7.6, or ≤ 7.4, or ≤ 7.2, or ≤ 7.0 kPa·s. T] The composition of any one of A]-S] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) ≥ 80, or ≥ 85, or ≥ 90, or ≥ 92, or ≥ 95, or ≥ 98, or ≥ 100, or ≥ 102, or ≥ 104. U] The composition of any one of A]-T] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) ≤ 170, or ≤ 165, or ≤ 160, or ≤ 158, or ≤ 156, or ≤ 154, or ≤ 152, or ≤ 150. V] The composition of any one of A]-U] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a MLRA (125°C) ≥ 600, or ≥ 700, or ≥ 800, or ≥ 900, or ≥ 950 and/or ≤ 2200, or ≤ 2000, or ≤ 1800, or ≤ 1500 MU·s. W] The composition of any one of A]-V] above, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a “weight-average molecular weight / number-average molecular weight” ratio (Mw/Mn) ≥ 2.3, or ≥ 2.4, or ≥ 2.5, or ≥ 2.6 and/or ≤ 4.0, or ≤ 3.8, or ≤ 3.6, or ≤ 3.4. X] The composition of any one of A]-W] above, wherein the composition comprises a second “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” that is different from the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” in one or more properties elected from ML (1+4 at 125°C); MLRA/ML (1+4
at 125°C); Complex Viscosity, at 0.1 rad/s, 125°C; Complex Viscosity, at 100 rad/s, 125°C; Rheology Ratio, ƞ0.1/ƞ100, 125°C; Gel content (wt%); or any combination thereof. Y] The composition of any one of A]-X] above, wherein the ratio of the “Mooney Viscosity (ML 1+4, 125°C) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “Mooney Viscosity (ML 1+4, 125°C) of component a,” is ≥ 1.05, or ≥ 1.08, or ≥ 1.10, or ≥ 1.12, or ≥ 1.15 and/or ≤ 1.50, or ≤ 1.45, or ≤ 1.40, or ≤ 1.35, or ≤ 1.30. Z] The composition of any one of A]-Y] above, wherein the ratio of the “Gel content (wt%) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “Gel content (wt%) of component a,” as thermally treated, is ≥ 1.2, or ≥ 1.4, or ≥ 1.6 and/or ≤ 5.0, or ≤ 4.5, or ≤ 4.0, or ≤ 3.5, or ≤ 3.0, or ≤ 2.5, or ≤ 2.0. Here, component a is thermally treated under the same conditions used to form the rheology modified interpolymer. A2] The composition of any one of A]-Z] above, wherein the ratio of the “rheology ratio (ƞ0.1/ƞ100, 125°C) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “rheology ratio (ƞ0.1/ƞ100, 125°C) of component a” is ≥ 2.00, or ≥ 2.05, or ≥ 2.10, or ≥ 2.15, or ≥ 2.20 and/or ≤ 4.00, or ≤ 3.80, or ≤ 3.50, or ≤ 3.20, or ≤ 3.00, or ≤ 2.80, or ≤ 2.60. B2] The composition of any one of A]-A2] above, wherein the ratio of the “Complex Viscosity (0.1 rad/s, 125°C) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “Complex Viscosity (0.1 rad/s, 125°C) of component a” is ≥ 1.60, or ≥ 1.80, or ≥ 1.90, or ≥ 2.00, or ≥ 2.02, or ≥ 2.05, or ≥ 2.08, or ≥ 2.10, or ≥ 2.12, or ≥ 2.14 and/or ≤ 3.50, or ≤ 3.00, or ≤ 2.80, or ≤ 2.70, or ≤ 2.60, or ≤ 2.50. C2] The composition of any one of A]-B2] above, wherein the ratio of the “Complex Viscosity (100 rad/s, 125°C) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “Complex Viscosity (100 rad/s, 125°C) of component a” is ≥ 0.92, or ≥ 0.93, or ≥ 0.94, or ≥ 0.96 and/or ≤ 1.30, or ≤ 1.25, or ≤ 1.20, or ≤ 1.15. D2] The composition of any one of A]-C2] above, wherein the ratio of the “MLRA/ML of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “MLRA/ML of component a” is ≥ 1.80, or ≥ 2.00, or ≥ 2.20, or ≥ 2.30, or ≥ 2.40, or ≥ 2.50, or ≥ 2.60 and/or ≤ 4.20, or ≤ 4.00, or ≤ 3.80, or ≤ 3.60, or ≤ 3.40, or ≤ 3.30, or ≤ 3.20. E2] The composition of any one of A]-D2] above, wherein the ratio of the “MLRA (125°C) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “MLRA (125°C) of component a” is ≥ 2.00, or ≥ 2.20, or ≥ 2.40, or ≥
2.60, or ≥ 2.80, or ≥ 3.00 and/or ≤ 6.00, or ≤ 5.00, or ≤ 4.80, or ≤ 4.50, or ≤ 4.20, or ≤ 4.00, or ≤ 3.80. F2] The composition of any one of A]-E2] above, wherein the composition further comprises at least an additive; and further the at least an additive is selected from fillers, pigments, UV stabilizers, anti-oxidants, processing aids, or combinations thereof, and further from UV stabilizers, anti-oxidants or combinations thereof. G2] The composition of F2] above, wherein the at least an additive is present in an amount ≥ 0.01 wt%, or ≥ 0.05 wt%, or ≥ 0.10 wt%, or ≥ 0.20 wt%, or ≥ 0.50 wt% and/or ≤ 20 wt%, or ≤ 10 wt%, or ≤ 5.0 wt%, or ≤ 2.0 wt%, or ≤ 1.0 wt%, based on the weight of the composition. H2] The composition of any one of A]-G2] above, wherein the first composition is thermally treated. A3] A process to form the composition of any one of A]-H2] above, wherein said process comprises thermally treating the first composition. B3] The composition of any one of A]-H2] above, or the process of A3] above, wherein the interpolymer of component a has a Mooney Viscosity (ML 1+4, 125°C) ≥ 40, or ≥ 45, or ≥ 50, or ≥ 55, or ≥ 58 and/or ≤ 100, or ≤ 98, or ≤ 96, or ≤ 94, or ≤ 92, or ≤ 90, or ≤ 88. C3] The composition of any one of A]-H2] or B3] above, or the process of A3] or B3] above, wherein the interpolymer of component a has an ethylene content ≥ 40, or ≥ 42, or ≥ 44, or ≥ 46, or ≥ 48, or ≥ 50, or ≥ 52, or ≥ 54 and/or ≤ 80, or ≤ 78, or ≤ 76, or ≤ 74, or ≤ 70 wt%, based on the weight of the interpolymer. D3] The composition of any one of A]-H2], B3] or C3] above, or the process of any one of A3]-C3] above, wherein the interpolymer of component a has a polyene content ≥ 0.5, or ≥ 1.0, or ≥ 1.5, or ≥ 2.0, or ≥ 2.5, or ≥ 3.0, or ≥ 3.5, or ≥ 3.8, or ≥ 4.0, or ≥ 4.2, or ≥ 4.4, or ≥ 4.6, or ≥ 4.8 and/or ≤ 10, or ≤ 9.5, or ≤ 9.0, or ≤ 8.8, or ≤ 8.6 wt%, based on the weight of the interpolymer. E3] The composition of any one of A]-H2] or B3]-D3] above, or the process of any one of A3]-D3] above, wherein the alpha-olefin of the interpolymer of component a is a C3-C20 alpha-olefin, further a C3-C10 alpha-olefin, and further propylene, 1-butene, 1-hexene or 1- octene, further propylene, 1-butene or 1-octene, further propylene or 1-butene, further propylene. F3] The composition of any one of A]-H2] or B3]-E3] above, or the process of any one of
A3]-E3] above, wherein the interpolymer of component a is an ethylene/alpha-olefin/non- conjugated diene interpolymer, and further an ethylene/alpha-olefin/nonconjugated diene terpolymer, further an EPDM. G3] The composition of any one of A]-H2] or B3]-F3] above, or the process of any one of A3]-F3] above, wherein the nonconjugated polyene of the of the interpolymer of component a is a nonconjugated diene; and further selected from 5-ethylidene-2-norbornene (ENB), 5- vinyl-2-norbornene (VNB), dicyclopentadiene, 1,4-hexadiene, or 7-methyl-l,6-octadiene, and further ENB, VNB, dicyclopentadiene or 1,4-hexadiene, and further ENB or VNB, and further ENB. H3] The composition of any one of A]-H2] or B3]-G3] above, or the process of any one of A3]-G3] above, wherein the interpolymer of component a has a MLRA/ML value ≥ 2.0, or ≥ 2.2, or ≥ 2.4, or ≥ 2.6, or ≥ 2.8, or ≥ 2.9 s and/or ≤ 7.0, or ≤ 6.8, or ≤ 6.6 or ≤ 6.4, or ≤ 6.2, or ≤ 6.0, or ≤ 5.8, or ≤ 5.6 or ≤ 5.4 s. I3] The composition of any one of A]-H2] or B3]-H3] above, or the process of any one of A3]-H3] above, wherein the interpolymer of component a has a complex viscosity ƞ at 0.1 rad/s (125°C) ≥ 200, or ≥ 220, or ≥ 240, or ≥ 260, or ≥ 280, or ≥ 290 kPa·s and/or ≤ 500, or ≤ 480, or ≤ 460, or ≤ 440, or ≤ 420, or ≤ 400, or ≤ 380, or ≤ 360 kPa·s. J3] The composition of any one of A]-H2] or B3]-I3] above, or the process of any one of A3]-I3] above, wherein the interpolymer of component a has a complex viscosity ƞ at 100 rad/s (125°C) ≥ 4.0, or ≥ 4.2, or ≥ 4.4, or ≥ 4.6, or ≥ 4.8, or ≥ 5.0 kPa·s and/or ≤ 9.0, or ≤ 8.5, or ≤ 8.0, or ≤ 7.8, or ≤ 7.6, or ≤ 7.4, or ≤ 7.2 kPa·s. K3] The composition of any one of A]-H2] or B3]-J3] above, or the process of any one of A3]-J3] above, wherein the interpolymer of component a has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) ≥ 34, or ≥ 36, or ≥ 38, or ≥ 40, or ≥ 42 and/or ≤ 78, or ≤ 76, or ≤ 74, or ≤ 72, or ≤ 70, or ≤ 68. L3] The composition of any one of A]-H2] or B3]-K3] above, or the process of any one of A3]-K3] above, wherein component a has a density ≥ 0.854, or ≥ 0.856, or ≥ 0.858, or ≥ 0.860, or ≥ 0.862, or ≥ 0.864, or ≥ 0.866, or ≥ 0.868 g/cc and/or or ≤ 0.890, or ≤ 0.885, or ≤ 0.880, or ≤ 0.875 g/cc (1 cc = 1 cm3). Density is determined according to ASTM D792. M3] The composition of any one of A]-H2] or B3]-L3] above, or the process of any one of A3]-L3] above, wherein component a has a “weight-average molecular weight / number- average molecular weight” ratio (Mw/Mn)) ≥ 2.0, or ≥ 2.1, or ≥ 2.2, or ≥ 2.3 and/or ≤ 3.5, or ≤ 3.4, or ≤ 3.2, or ≤ 3.0, or ≤ 2.8.
N3] The composition of any one of A]-H2] or B3]-M3] above, or the process of any one of A3]-M3] above, wherein the first composition comprises, as component b, two or more phenolic coupling agents. O3] The composition of any one of A]-H2] or B3]-N3] above, or the process of any one of A3]-N3] above, wherein the first composition comprises, as component b, two phenolic coupling agents. P3] The composition of any one of A]-H2] or B3]-M3] above, or the process of any one of A3]-M3] above, wherein the first composition comprises, as component b, one phenolic coupling agent. Q3] The composition of any one of A]-H2] or B3]-P3] above, or the process of any one of A3]-P3] above, wherein component b is present in an amount ≥ 200 ppm, or ≥ 400 ppm, or ≥ 600 ppm, or ≥ 800 ppm, or ≥ 900 ppm, or ≥ 1000 ppm and/or ≤ 4000 ppm, or ≤ 3500 ppm, or ≤ 3000 ppm, or ≤ 2500 ppm, or ≤ 2000 ppm, or ≤ 1950 ppm, or ≤ 1900 ppm, or ≤ 1850 ppm, or ≤ 1800 ppm, based on the weight of component a. R3] The composition of any one of A]-H2] or B3]-Q3] above, or the process of any one of A3]-Q3] above, wherein component b is present in an amount ≥ 800 ppm, or ≥ 900 ppm, or ≥ 1000 ppm and/or ≤ 1700 ppm, or ≤ 1650 ppm, or ≤ 1600 ppm, or ≤ 1550 ppm, or ≤ 1500 ppm, or ≤ 1450 ppm, or ≤ 1400 ppm, or ≤ 1350 ppm, or ≤ 1300 ppm, or ≤ 1250 ppm, or ≤ 1200 ppm, or ≤ 1150 ppm, or ≤ 1100 ppm, based on the weight of component a. S3] The composition of any one of A]-H2] or B3]-R3] above, or the process of any one of A3]-R3] above, wherein component b is present in an amount ≥ 0.04 wt%, or ≥ 0.06 wt%, or ≥ 0.08 wt%, or ≥ 0.09 wt%, or ≥ 0.10 wt% and/or ≤ 0.30 wt%, or ≤ 0.20 wt%, or ≤ 0.18 wt%, or ≤ 0.16 wt%, or ≤ 0.15 wt%, or ≤ 0.14 wt%, or ≤ 0.13 wt%, based on the weight of the first composition. T3] The composition of any one of A]-H2] or B3]-S3] above, or the process of any one of A3]-S3] above, wherein the amount of CH2OH groups (in component b) is ≥ 2.0, or ≥ 2.2, or ≥ 2.5, or ≥ 2.8, or ≥ 3.0, or ≥ 3.5 or ≥ 4.0, or ≥ 6.0, or ≥ 8.0, or ≥ 10 and/or ≤ 50, or ≤ 40, or ≤ 30, or ≤ 25, or ≤ 20, or ≤ 18, or ≤ 16, or ≤ 14, or ≤ 13 mmole CH2OH per gram of component b. Note, the amount of CH2OH can be determined using titration methods. See for example, G.A. Stenmark et al., Determination of Methylol Groups in Phenolic Resins, Analytical Chemistry, 1956, 28, 2, 260-262; incorporated herein by reference. U3] The composition of any one of A]-H2] or B3]-T3] above, or the process of any one of A3]-T3] above, wherein the molar amount of CH2OH groups (in component b) is ≥ 0.20, or ≥ 0.40, or ≥ 0.60, or ≥ 0.80, or ≥ 0.90, or ≥ 1.0 and/or ≤ 10, or ≤ 5.0, or ≤ 4.0, or ≤ 3.0, or ≤
2.0, or ≤ 1.8, or ≤ 1.6, or ≤ 1.5, or ≤ 1.4, or ≤ 1.3 mmole CH2OH per 100 gram of component a. V3] The composition of any one of A]-H2] or B3]-U3] above, or the process of any one of A3]-U3] above, wherein for component b, structure b1, R1, R2, R3 are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl; and further selected from H, or a hydrocarbyl. W3] The composition of any one of A]-H2] or B3]-V3] above, or the process of any one of A3]-V3] above, wherein for component b, structure b2, the R1, R2, R3, at each occurrence, are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl; and further selected from H, or a hydrocarbyl. X3] The composition of any one of A]-H2] or B3]-W3] above, or the process of any one of A3]-W3] above, wherein for component b, structure b1, R1 = R3; and further R1 = R3 = H. Y3] The composition of any one of A]-H2] or B3]-X3] above, or the process of any one of A3]-X3] above, wherein for component b, structure b2, R1 = R3, at each occurrence; and further R1 = R3 = H, at each occurrence. Z3] The composition of any one of A]-H2] or B3]-Y3] above, or the process of any one of A3]-Y3] above, wherein for component b, structure b1, R2 is a hydrocarbyl, and further an alkyl, and further a C1-C10 alkyl, further a C1-C8 alkyl, further a C1-C6 alkyl, further a C1- C4 alkyl, further a C1-C2 alkyl, further a C1 alkyl (methyl). A4] The composition of any one of A]-H2] or B3]-Z3] above, or the process of any one of A3]-Z3] above, wherein for component b, structure b2, R2, at each occurrence, is a hydrocarbyl, and further an alkyl, and further a C1-C10 alkyl, and further a C2-C8 alkyl, and further C4-C8 alkyl, and further a C6-C8 alkyl, and further a C8 alkyl. B4] The composition of any one of A]-H2] or B3]-A4] above, or the process of any one of A3]-A4] above, wherein for component b, structure b2, Q, at each occurrence, is a -CH2-. C4] The composition of any one of A]-H2] or B3]-A4] above, or the process of any one of A3]-A4] above, wherein for component b, structure b2, Q, at each occurrence, is a -CH2-O- CH2-. D4] The composition of any one of A]-H2] or B3]-C4] above, or the process of any one of A3]-C4] above, wherein component b is selected from structure b1. E4] The composition of any one of A]-H2] or B3]-C4] above, or the process of any one of A3]-C4] above, wherein component b is selected from structure b2. F4] The composition of any one of A]-H2] or B3]-C4] above, or the process of any one of
A3]-C4] above, wherein component b is selected from structure b3. G4] The composition of any one of A]-H2] or B3]-F4] above, or the process of any one of A3]-F4] above, wherein component c is present, and the weight ratio of component b to component c is ≥ 0.8, or ≥ 0.9, or ≥ 1.0 and/or ≤ 3.0, or ≤ 2.5, or ≤ 2.0. H4] The composition of any one of A]-H2] or B3]-G4] above, or the process of any one of A3]-G4] above, wherein component a is present in an amount ≥ 98.00 wt%, or ≥ 98.50 wt%, or ≥ 99.00 wt%, or ≥ 99.20 wt%, or ≥ 99.50 wt%, or ≥ 99.80 wt% and/or < 100 wt%, or ≤ 99.90 wt%, ≤ 99.88 wt%, or ≤ 99.86 wt%, based on the weight of the first composition. I4] The composition of any one of A]-H2] or B3]-H4] above, or the process of any one of A3]-H4] above, wherein the sum of component a and component b is present in an amount ≥ 99.00 wt%, or ≥ 99.20 wt%, or ≥ 99.50 wt%, or ≥ 99.60 wt%, or ≥ 99.70 wt%, or ≥ 99.80 wt%, or ≥ 99.90 wt% and/or ≤ 100 wt%, or ≤ 99.99 wt%, or ≤ 99.98 wt%, or ≤ 99.96 wt%, based on the weight of the first composition. J4] The composition of any one of A]-H2] or B3]-I4] above, or the process of any one of A3]-I4] above, wherein the first composition further comprises a polymer, different from component a in one or more features, such as comonomer type; comonomer content; ML (1+4) @ 125°C; MLRA/ML; Complex Viscosity, at 0.1 rad/s, 125°C; Complex Viscosity, at 100 rad/s, 125°C; Rheology Ratio, ƞ0.1/ƞ100, 125°C; or any combination thereof. K4] The composition of any one of A]-H2] or B3]-J4] above, or the process of any one of A3]-J4] above, wherein the first composition comprises ≤ 10 ppm, or ≤ 5.0 ppm, or ≤ 2.0 ppm, or ≤ 1.0 ppm, or ≤ 0.5 ppm, or ≤ 0.2 ppm, or ≤ 0.1 ppm of a propylene homopolymer, or a propylene/ethylene copolymer (majority wt% propylene), or a propylene/alpha-olefin copolymer (majority wt% propylene), based on the weight of the first composition; and further the first composition does not comprise a propylene homopolymer, or a propylene/ethylene copolymer, or a propylene/alpha-olefin copolymer. L4] The composition of any one of A]-H2] or B3]-K4] above, or the process of any one of A3]-K4] above, wherein the first composition comprises ≤ 10 ppm, or ≤ 5.0 ppm, or ≤ 2.0 ppm, or ≤ 1.0 ppm, or ≤ 0.5 ppm, or ≤ 0.2 ppm, or ≤ 0.1 ppm of a metal carboxylate (for example, a zinc carboxylate, a stannous carboxylate, or a combination thereof), based on the weight of the first composition; and further the first composition does not comprise a metal carboxylate. M4] The composition of any one of A]-H2] or B3]-L4] above, or the process of any one of A3]-L4] above, wherein the first composition comprises ≤ 10 ppm, or ≤ 5.0 ppm, or ≤ 2.0 ppm, or ≤ 1.0 ppm, or ≤ 0.5 ppm, or ≤ 0.2 ppm, or ≤ 0.1 ppm of a peroxide, based on the
weight of the first composition; and further the first composition does not comprise a peroxide. N4] The composition of any one of A]-H2] or B3]-M4] above, or the process of any one of A3]-M4] above, wherein the first composition comprises ≤ 10 ppm, or ≤ 5.0 ppm, or ≤ 2.0 ppm, or ≤ 1.0 ppm, or ≤ 0.5 ppm, or ≤ 0.2 ppm, or ≤ 0.1 ppm of a “phenolic resin that is acetylated, tosylated, silylated or phosphorylated,” based on the weight of the first composition; and further the first composition does not comprise a “phenolic resin that is acetylated, tosylated, silylated or phosphorylated.” O4] The composition of any one of A]-H2] or B3]-N4] above, or the process of any one of A3]-N4] above, wherein the first composition is not subject to E-beam radiation. P4] The composition of any one of A]-H2] or B3]-O4] above, or the process of any one of A3]-O4] above, wherein the first composition is thermally treated in a batch mixer. Q4] The composition of any one of A]-H2] or B3]-O4] above, or the process of any one of A3]-O4] above, wherein the first composition is thermally treated in an extruder configuration (for example a twin screw extruder). R4] The composition of any one of A]-H2] or B3]-O4] above, or the process of any one of A3]-O4] above, wherein the first composition is thermally treated in a static mixer, used in conjunction with a pumping device. S4] The composition of any one of A]-H2] or B3]-O4] above, or the process of any one of A3]-O4] above, wherein the first composition is thermally treated in an batch mixer or an extruder configuration, and where the first composition is formed by adding a second composition comprising component b, using a side-arm extruder, to a melt stream comprising component a in the batch mixer or the extruder configuration; and further the second composition is added at a location before one or more static mixing elements. T4] The composition of any one of A]-H2] or B3]-S4] above, or the process of any one of A3]-S4] above, wherein the first composition is thermally treated at a temperature ≥ 150°C, or ≥ 160°C, or ≥ 170°C, or ≥ 175°C, or ≥ 180°C, or ≥ 185°C, or ≥ 190°C, and/or at a temperature ≤ 230°C, or ≤ 225°C, or ≤ 220°C, or ≤ 215°C, or ≤ 210°C, or ≤ 205°C, or ≤ 200°C. A5] A composition formed from the process of any one of A3]-T4] above. B5] An article comprising at least one component formed from the composition of any one of A]-H2], B3]-T4] or A5] above. C5] The article of B5] above, wherein the article is a foam or a film, and further a foam.
D5] The article of B5] above, wherein the article is a wire, a cable, a footwear component, an automotive part, a profile (for example, a dense, micro-dense and/or foamed profile), a tire, a tube/hose, or a roofing membrane; and further a footwear component, an automotive part, a profile (for example, a dense, micro-dense and/or foamed profile), a tire, a tube/hose, or a roofing membrane. TEST METHODS Mooney Viscosity and Mooney Relaxation Area (MLRA) (Neat Interpolymers and Rheology Modified Interpolymers) Mooney Viscosity was measured using ASTM D1646, with a one minute preheat time and a “four minute” rotor operation time, followed by a two minute relaxation time. The instrument was an Alpha Technologies Mooney Viscometer 2000. The conditions used for the neat interpolymer samples and for the for the rheology modified interpolymer samples were (ML 1+4 @ 125°C). About a 7-14 gram sample size was used. The Mooney Relaxation Area (MLRA) data was obtained from the Mooney Viscosity measurement, where the test sample was relaxed after the rotor was stopped. At the end of the Mooney Viscosity test, the rotation of the disk was stopped within 0.1 seconds. Collection of relaxation data typically began one second after the rotor was stopped, and continued for at least two minutes after the rotor was stopped. The MLRA value reported is the integrated area under the Mooney torque relaxation time curve, from 1 second to 120 seconds (MLRA (1’ + 4’ + 2’)). The MLRA value indicates the degree of elasticity of a polymer, and can be regarded as a stored energy term. Higher MRLA values indicate that, after the removal of an applied strain, the test sample stores more energy and requires more time to relax (that is, to dissipate the stored energy). Polymers with more elasticity (for example, those with a more long chain branched (LCB) structure, typically exhibit higher MLRA values compared to less elastic polymers (for example, those having a less long chain branched structure). The MLRA is reported in Mooney Unit - seconds (MU·s). The term “MLRA / ML ratio," as used herein, is the “Mooney Relaxation Area - to - the Mooney Viscosity” ratio, and this notation is an abbreviated form for “MLRA / ML(1 + 4) @ 125°C.” The MLRA/ML ratio indicates the degree of melt elasticity of a polymer and is directly proportional to the degree of melt elasticity. The MLRA/ML ratio is reported in seconds (s). Rubber Process Analyzer (RPA) (Neat Interpolymers and Rheology Modified Interpolymers)
Dynamic viscoelastic properties were measured per ASTM D6204, with a rotorless oscillating shear rheometer (that is a rubber process analyzer (RPA)). An RPA frequency sweep was performed at 125°C, using a 7% strain for the neat and rheology modified interpolymer samples, using an Alpha Technologies RPA 2000. The test sample was cut out with a Cutter 2000R. The sample size was between 5 and 7 grams. The test sample was considered to be of proper size (116 to 160% of the test cavity volume) when a small bead of the interpolymer was extruded uniformly around the periphery of the dies as they were closed. The sample was placed between two pieces of MYLAR film. A frequency sweep was performed as discussed above. The angular frequency range was from 0.1 rad/s to 100 rad/s. The stress response was analyzed in terms of amplitude and phase, from which, the storage shear modulus (G’), loss shear modulus (G”), complex viscosity (η*), tan delta (that is a phase angle δ), and complex shear modulus G* were calculated. Modulus values were reported in kilopascal (kPa), phase angle was reported in degrees, and viscosity was reported in kPa·s. The properties recorded were complex viscosity (η*) at 0.1 rad/s and 100 rad/s and rheology ratio. The “rheology ratio” (or “RR”), was calculated as the ratio of the complex viscosity at 0.1 rad/s, and 125°C, to the complex viscosity at 100 rad/s, and 125°C; RR equals ƞ0.1/ƞ100, at 125°C. Gel Content The gel content (insoluble fraction) produced by crosslinking, during the rheology modification, was determined by extracting the rheology modified interpolymer with xylene (certified ACS grade, CAS: 1330-20-7), which was purchased from Fisher Scientific. See ASTM D2765-16, Standard Test Methods for Determination of Gel Content and Swell Ratio of Crosslinked Ethylene Plastics, ASTM International, West Conshohocken, PA, 2016, www.astm.org. The xylene extraction sample holder was prepared by cutting a piece of 120-mesh, stainless steel mesh, measuring approximately 80 mm by 40 mm (3.0 in. by 1.5 in.). The mesh was folded, in half, to form a square measuring approximately 40 mm (1.5 in.) for each side. The two sides of this square were closed to form an open mesh pouch, by folding the mesh at the edges and stapling the folds. The open sample holder was weighed to four decimal places (W1). For each rheology modified interpolymer, 0.3 grams of the interpolymer (cut into approximately 3 mm3 pieces) was placed into a prepared open mesh pouch. The open mesh pouch and interpolymer, contained therein, were weighed to four decimal places (W2). The
open side of the mesh pouch was then folded over and stapled shut, to create a closed mesh pouch, which was weighed to four decimal places (W3). The closed mesh pouch containing the rheology modified interpolymer, was suspended in 4 liters of refluxing xylene, containing 40 grams of an antioxidant (2,2’- methylene-6-tertiary butyl phenol) and boiling chips, The refluxing continued for 12 hours. At the end of 12 hours, the closed mesh pouch was removed from the xylene, and immediately dried in a vacuum oven at 150°C, with a nitrogen flow of approximately 5 PSI, for 12 hours. At the end of 12 hours, the dried closed pouch was weighed to four decimal places (W4), for a determination of the gel content of the rheology modified interpolymer. Each rheology modified interpolymer was run in duplicate, and the average result was reported as weight percent of gel content (Gel content (wt%)). The gel content of each rheology modified interpolymer was calculated as follows: Extract content (wt%) = (W3-W4)/(W2-W1) x 100%], where W1 = weight of the mesh pouch, sealed on three sides, one side open; W2 = weight of the mesh pouch and the interpolymer (before extraction), and where the mesh was sealed on three sides (2 sides stapled), with one side open; W3 = weight of the mesh pouch and the interpolymer (before extraction), and where the mesh was sealed on all sides to create a closed pouch; W4 = weight of the closed mesh and interpolymer after extraction and drying. Gel content (wt%) = 100 - Extract (wt%). Gel Permeation Chromatography (GPC) The chromatographic system consists of a PolymerChar GPC-IR (Valencia, Spain) high temperature GPC chromatograph, equipped with an internal IR5 infra-red detector (IR5). The autosampler oven compartment is set at 160º Celsius, and the column compart- ment is set at 150º Celsius. The columns are four AGILENT “Mixed A” 30 cm, 20-micron linear mixed-bed columns. The chromatographic solvent is 1,2,4-trichlorobenzene, which contained 200 ppm of butylated hydroxytoluene (BHT). The solvent source is nitrogen sparged. The injection volume is 200 microliters, and the flow rate is 1.0 milliliters/minute. Calibration of the GPC column set is performed with 21 narrow molecular weight distribution polystyrene standards, with molecular weights ranging from 580 to 8,400,000, and which are arranged in 6 “cocktail” mixtures, with at least a decade of separation between individual molecular weights. The standards are purchased from Agilent Technologies. The polystyrene standards are prepared at 0.025 grams in 50 milliliters of solvent, for molecular weights equal to, or greater than, 1,000,000, and at 0.05 grams in 50 milliliters of solvent, for
molecular weights less than 1,000,000. The polystyrene standards are pre-dissolved at 80° Celsius, with gentle agitation, for 30 minutes then cooled, and the room temperature solution is transferred cooled into the autosampler dissolution oven (equilibrated at 160°C) for 30 minutes. The polystyrene standard peak molecular weights are converted to polyethylene molecular weights using Equation 1 (as described in Williams and Ward, J. Polym. Sci., Polym. Let., 6, 621 (1968)): ^ = ^ ^ ^^^^^^^^^^^^ × ^^^^^^^^^^^^^^ (EQ 1), where M is the to 1.0. A fifth order
polynomial is used to points. The total plate count of the GPC column set is performed with decane which was introduced into a blank sample via a micropump controlled with the PolymerChar GPC-IR system. The plate count for the chromatographic system should be greater than 18,000 for the four Agilent “Mixed A” 30 cm, 20-micro linear mixed-bed columns. Samples are prepared in a semi-automatic manner with the PolymerChar “Instrument Control” Software, wherein the samples are weight-targeted at 2 mg/ml, and the solvent (contained 200 ppm BHT) was added to a pre nitrogen-sparged, septa-capped vial, via the PolymerChar high temperature autosampler. The samples are dissolved for 3 hours at 160º Celsius under “low speed” shaking. The calculations of Mn(GPC), Mw(GPC), and Mz(GPC) are based on GPC results using the internal IR5 detector (measurement channel) of the PolymerChar GPC-IR chromatograph according to Equations 2-4, the PolymerChar GPCOne™ software, the baseline-subtracted IR chromatogram at each equally-spaced data collection point (i), and the polyethylene equivalent molecular weight obtained from the narrow standard calibration curve for the point (i) from Equation 1. ^^(^^^) = ∑^ ^^^ ^ (EQ 2 ^^^^ ), 3), 4).
In order to monitor the deviations over time, a flowrate marker (decane) was introduced into each sample, via a micropump controlled with the PolymerChar GPC-IR
system. This flowrate marker (FM) is used to linearly correct the pump flowrate (Flowrate(nominal)) for each sample, by RV alignment of the respective decane peak within the sample (RV(FM Sample)), to that of the decane peak within the narrow standards calibration (RV(FM Calibrated)). Any changes in the time of the decane marker peak are then assumed to be related to a linear-shift in flowrate (Flowrate(effective)) for the entire run. After calibrating the system, based on a flow marker peak, the effective flowrate (with respect to the narrow standards calibration) is calculated from Equation 5. Processing of the flow marker peak was done via the PolymerChar GPCOne™ software. Acceptable flowrate correction is such that the effective flowrate should be within +/-0.5% of the nominal flowrate. Flowrate(effective) = Flowrate(nominal) * (RV(FM Calibrated) / RV(FM Sample)) (EQ 5). EXPERIMENTAL Commercial Polymers and Reagents Commercial polymers and reagents are listed below in Tables 1 and 2, respectively. Table 1: Commercial EPDM Polymers (Component a) Mooney (1+4') @ Ethylene Content, ENB Content, E 125 C, MU wt% (ASTM wt% (ASTM Densi 3 SAMPL o ty (g/cm ) 900) D6047) (ASTM D792 Source (ASTM D1646) D3 ) NORDEL IP 4785HM Hydrocarbon 85 68 4.9 0.880 Dow* Rubber NORDEL IP 4760P Hydrocarbon 60 67.5 4.9 0.880 Dow Rubber NORDEL 6565 XFC EPDM 65 55 8.5 0.862 Dow Each wt% based on the weight of the EPDM. *The Dow Chemical Company Table 2: Commercial Phenolic Coupling Agents and Catalyst Abbreviation Chemical Description Source Phenolic Coupling Agents (Component b) DMC 2,6-di(hydroxymethyl)-p-cresol (12 mmole CH OH per one Sigma-Aldrich 2 gram DMC) Heat reactive resin (phenolic resin with octyl groups), SP-1045 methylol content 9.5-11 wt% (3.1 – 3.5 mmole per one gram phenolic resin), Akrochem density 1.04 Catalyst (Component c) SnCl2·2H2O Tin(II) chloride dihydrate Sigma-Aldrich Note, MW (CH2OH) = 31.034 g/mol. Preparation of Rheology Modified Interpolymer Batch Mixer Modification – (40 grams) – see Table 3
Samples of the EPDM (40 g) were modified on a RS5000 Batch Mixer from Rheometers Services Inc.. The small bowl, with roller blade rotors, suitable for mixing batches up to 45 g, was used. After initial fluxing of the base polymer (EPDM) for a minute (200oC, 5 rpm), the remaining ingredients in the formulation were loaded in the mixer, as discussed below, at a low speed (5 rpm) for about 1-2 minutes. Following incorporation of all other ingredients, a rotor speed of 50 rpm and a bowl temperature of 200°C were used, unless noted otherwise. The mixing was continued for an additional six minutes. After mixing, the batch was collected on a glass reinforced TEFLON sheet, and pressed into a flat ‘patty’ (approximate 0.25” thickness) on a compression molder Carver Hydraulic Press (duration of compression 3-5 minutes, pressure approx.20,000 psi, temperature 20-25oC). The flat ‘patty’ was cooled to ambient temperature. Depending on the individual ingredient, different methods of addition to the batch mixer were used. The EPDM pellets or crumb were directly added. The phenolic coupling agent, and the catalyst, if used, were each weighed on a film formed from the base resin (EPDM) and then rolled by hand (used nitrile gloves) to form a “burrito-shaped” encapsulant. The EPDM film had a thickness of approx.1-2 mm, and was prepared by compression molding 20-30 grams of the EPDM at 100-120°C, at a pressure of approx.20,000 psi, for 3 minutes. This rolled encapsulant was then added to the mixer. The amount of EPDM in Table 3 includes the amount of the EPDM used to form the film for the encapsulant. Results The Mooney Viscosity and the rheological properties for each rheology modified interpolymer, prepared in the Batch mixer, are shown in Table 3. The gel content of some of the rheology modified interpolymers are also shown in Table 3. The control, first compositions A and D were not thermally treated, but tested as is. Control, first composition B was thermally treated in the batch mixer as discussed above. Tables 4A and 4B provide the ratios of some properties of the rheology modified interpolymers, relative to the noted respective control interpolymers. As seen in Table 3, Examples R1 and R3 had significant MLRA/ML values (≥ 9.7 s), indicating the formation of LCB within the interpolymer. These examples also had low gel levels (≤ 1.1 wt%), indicating very little gel formation or crosslinking took place during the modification process. Example RE (no optional catalyst) had a low MLRA/ML value (5.0 s), indicating that little LCB formed during the modification process. Example RF had a high MLRA/ML value of 15.0 s, but also had a high gel content of 15.2 wt%, indicating that too much crosslinking took place during the modification.
Table 3: First Compositions (wt. parts) – Batch Mixer and Rheology Modified Interpolymers A B D First Composition Control – Control- C Co E 1 2 3 F (no TT)* (TT)** (E-Beam)*** ntrol – (no TT)* Comp. Inv. Inv. Inv. Comp. NORDEL 4785 Comp. a 100 100 100 99.9 99.85 99.8 99.4 NORDEL 6565 Comp. a 100 99.8 DMC 0.1 0.1 0.1 0.1 (ppm)A (1001) (1002) (1002) (1002) [mmole of CH2OH per 100 g Comp. a] [1.2] [1.2] [1.2] [1.2] SnCl2.2H2O 0.05 0.1 0.1 SP-1045 0.6 (ppm)A (6036) [mmole of CH2OH per 100 g Comp. a] [1.9 – 2.1] Total wt. parts 100 100 100 100 100 100 100 100 100 Rheology Mod. Interpolymer RA RB RC RD RE R1 R2 R3 RF ML (1+4) @ 125°C, MU 86 81 120 66 93 102 NM 83 126 MLRA/ML, s 3.1 5.5 14.9 6.0 5.0 9.7 NM 15.6 15.0 MLRA (125°C) MU·s 267 446 1788 396 465 989 - 1295 1890 Complex Viscosity, @ 0.1 rad/s, 125°C, kPa·s 304 421 721 348 473 720 754 747 727 Complex Viscosity, @ 100 rad/s, 125°C, kPa·s 7.0 6.4 7.2 5.2 6.9 6.9 6.9 5.0 7.0 Rheology Ratio, ƞ0.1/ƞ100, 125°C 43.5 66.1 100.1 66.9 68.6 104.3 109.3 149.4 103.9 Gel content, wt% NM 0.5 0.5 NM NM 0.9 NM 1.1 15.2 *No TT = No Thermal Treatment. **TT = Thermally Treated. ***E-beam at 0.7 MRad. NM = Not measured. For R2, the MLRA/ML value and the gel content value should be similar to the respective values for R1. A)The “ppm” amount of the phenol or phenolic resin, are each based on the weight of the EPDM (component a). For DMC, the [mmole of CH2OH per 100 g Comp. a] = {[(amt. of DMC) x (12 mmol/g DMC)] / amt. Comp. a] x 100}. For SP-1045, the [mmole of CH2OH per 100 g Comp. a] = {[(amt. of SP-1045) x (3.1 or 3.5 mmol/g SP-1045)] / amt. Comp. a] x 100}.
Table 4A: Ratio of Properties of Rheology Modified Interpolymers Relative to Properties of a Control RA Ratio* R1 R2 RE RF ML (1+4) @ 125°C 86 ML(R_) / ML(RA) 1.19 - 1.08 1.47 MLRA/ML, s 3.1 [MLRA/ML of R_] / [MLRA/ML of RA] 3.13 - 1.61 4.84 MLRA 267 [MLRA of R_] / [MLRA of RA] 3.70 - 1.74 7.08 Complex Viscosity, @ 0.1 rad.s-1, 125°C, [Complex Visc. (0.1 rad.s-1) R_] / [Comp -1 Pa·s 304 lex Visc. (0.1 rad.s ) RA] 2.3 1.56 k 7 2.48 2.39 Complex Viscosity, @ 100 rad.s-1, 125°C, -1 -1 kPa·s 7.0 [Complex Visc. (100 rad.s ) R_] / [Complex Visc. (100 rad.s ) RA] 0.99 0.99 0.99 1.00 Rheology Ratio, ƞ0.1/ƞ100, 125°C 43.5 [ƞ0.1/ƞ100 (R_)] / [ƞ0.1/ƞ100 (RA)] 2.40 2.51 1.58 2.39 *Each ratio relative to RA, except the ratio for the “Gel Content,” shown below, which is relative to RB. Note, [Gel content (R1)] / [Gel content (RB)] = 1.8, and [Gel content (RF)] / [Gel content (RB)] = 30.4. Table 4B: Ratio of Properties of Rheology Modified Interpolymers Relative to Properties of a Control RD control Ratio* R3 ML (1+4) @ 125°C 66 ML(R3) / ML(RD) 1.26 MLRA/ML, s 6.0 [MLRA/ML of R3] / [MLRA/ML of RD] 2.60 MLRA 396 [MLRA of R3] / [MLRA of RD] 3.27 Complex Viscosity, @ 0.1 rad.s-1, 125°C, kPa·s 348 [Complex Visc. (0.1 rad.s-1) R3] / [Complex Visc. (0.1 rad.s-1) RD] 2.15 Complex Viscosity, @ 100 rad.s-1, 125°C, kPa·s 5.2 [Complex Visc. (100 rad.s-1) R3] / [Complex Visc. (100 rad.s-1) RD] 0.96 Rheology Ratio, ƞ0.1/ƞ100, 125°C 66.9 [ƞ0.1/ƞ100 (R3)] / [ƞ0.1/ƞ100 (RD)] 2.23 *Each ratio relative to RD.
Claims
CLAIMS 1. A composition comprising a “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” that comprises the following properties: i) a MLRA/ML (at 125°C) value ≥ 8.0 s, and ii) a gel content ≤ 10 wt%, based on the weight of the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer;” and wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” is formed from a first composition comprising the following components: a) an ethylene/alpha-olefin/nonconjugated polyene interpolymer, and b) at least one phenolic coupling agent selected from structures b1) through b3), as follows: b1) , wherein each of -R1, -R2 and -R3 is independently selected from a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3,
-CN, -C(O)H, or -C(O)NH2; and wherein -R1 and -R2 may or may not form a saturated or unsaturated fused ring; or -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; b2) , wherein m ≥ 1; -Q-, at
each of -R1, -R2 and -R3, at each occurrence, is independently selected from a hydrogen, a heterohydrocarbyl, a hydrocarbyl, -Br, -Cl, -I, -OH, -SH, -NO2, -NH3, -CN, -C(O)H, or -C(O)NH2; and wherein, at each occurrence, -R1 and -R2 may or may not form a saturated or unsaturated fused ring, or -R2 and -R3 may or may not form a saturated or unsaturated fused ring, or -R1, -R2 and -R3 may or may not form a saturated or unsaturated fused ring; or b3) any combination of b1 and b2.
2. The composition of claim 1, wherein the first composition optionally comprises at least one catalyst, as component c.
3. The composition of claim 2, wherein component c is selected from Lewis acids.
4. The composition of any one of claims 1-3, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Mooney Viscosity (ML 1+4, 125°C) ≥ 60.
5. The composition of any one of claims 1-4, wherein the rheology modified interpolymer is a rheology modified EPDM.
6. The composition of any one of claims 1-5, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a complex viscosity ƞ at 0.1 rad/s (125°C) from 400 to 900 kPa·s.
7. The composition of any one of claims 1-6, wherein the “rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” has a Rheology Ratio (ƞ0.1/ ƞ100, 125°C) from 80 to 170.
8. The composition of any one of claims 1-7, wherein the ratio of the “Gel content (wt) of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “Gel content (wt%) of component a,” as thermally treated, is from 1.2 to 5.0; wherein component a is thermally treated under the same conditions used to form the rheology modified interpolymer.
9. The composition of any one of claims 1-8, wherein the ratio of the “MLRA/ML of the rheology modified ethylene/alpha-olefin/nonconjugated polyene interpolymer” to the “MLRA/ML of component a,” each measured at 125oC, is from 1.80 to 4.20.
10. The composition of any one of claims 1-9, wherein component b is present in an amount from 200 ppm to 4000 ppm, based on the weight of component a.
11. The composition of any one of claims 1-10, wherein component b is present in an amount from 0.08 wt% to 0.17 wt%, based on the weight of the first composition.
12. The composition of any one of claims 1-11, wherein for component b, structure b1, R1, R2, R3 are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl; and wherein for structure b2, the R1, R2, R3, at each occurrence, are each independently selected from H, a hydrocarbyl or a heterohydrocarbyl.
13. The composition of any one of claims 1-12 wherein for component b, structure b1, R1 = R3; and wherein for structure b2, R1 = R3, at each occurrence.
14. The composition of any one of claims 1-13, wherein for component b, structure b1, R2 is a hydrocarbyl; and wherein for structure b2, R2, at each occurrence, is a hydrocarbyl.
15. A process to form the composition of any one of claims 1-14, said process comprising treating the first composition.
16. The process of claim 15, wherein the first composition is thermally treated in a static mixer; used in conjunction with a pumping device.
17. The process of claim 15, wherein the first composition is thermally treated in a batch mixer or an extruder configuration, and where the first composition is formed by adding a second composition comprising component b, using a side-arm extruder, to a melt stream comprising component a in the batch mixer or the extruder configuration 18. A composition formed from the process of any one of claims 15-17. 19. An article comprising at least one component formed from the composition of any one of claims 1-14 or 18. 20. The article of claim 19, wherein the article is a wire, a cable, a footwear component, an automotive part, a profile (for example, a dense, micro-dense and/or foamed profile), a tire, a tube/hose, or a roofing membrane.
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