WO2002020669A1 - Polyester and polyalkylene-grafted polymer composition - Google Patents

Polyester and polyalkylene-grafted polymer composition Download PDF

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Publication number
WO2002020669A1
WO2002020669A1 PCT/US2001/025330 US0125330W WO0220669A1 WO 2002020669 A1 WO2002020669 A1 WO 2002020669A1 US 0125330 W US0125330 W US 0125330W WO 0220669 A1 WO0220669 A1 WO 0220669A1
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Prior art keywords
maleimide
polymer
alkenyl
composition
poly
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PCT/US2001/025330
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French (fr)
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Xiaorong Wang
James Hall
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Bridgestone Corporation
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Publication of WO2002020669A1 publication Critical patent/WO2002020669A1/en

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G83/00—Macromolecular compounds not provided for in groups C08G2/00 - C08G81/00
    • C08G83/002—Dendritic macromolecules
    • C08G83/005—Hyperbranched macromolecules
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C08L101/005—Dendritic macromolecules
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/003—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds

Definitions

  • the present invention relates to high damping polymers with superior high-temperature stability, mechanical strength, and moldability.
  • the inventive composition is particularly useful as a soft molding material for various products.
  • Free radically-initiated polymerizations of isobutylene and maleic anhydride, as well as styrene or methyl vinyl ether and maleic anhydride, are known. Also known is imidization of a maleic anhydride with a primary amine.
  • Two or more polymers may be blended together to form a wide variety of random or structured morphologies to obtain products that offer potentially desirable combinations of characteristics. However, it may be difficult or even impossible in practice to achieve many potential combinations through simple blending. Frequently, the polymers are thermodynamically immiscible, which precludes generating a truly homogeneous product. While it is sometimes desirable to have a two-phase structure, the situation at the interface between the two phases often can lead to problems.
  • the typical case is one of high interfacial tension and poor adhesion between the two phases.
  • This interfacial tension contributes, along with high viscosities, to the inherent difficulty of imparting the desired degree of dispersion to random mixtures and to their subsequent lack of stability, giving rise to gross separation or stratification during later processing or use.
  • Poor adhesion leads, in part, to the very weak and brittle mechanical behavior often observed in dispersed blends and may render some highly structured morphologies impossible.
  • a polymer composition that has high damping capabilities while avoiding the above-mentioned problems related to blends remains desirable.
  • the present invention provides a process for forming an elastomeric polymer gel composition.
  • the process includes combining a poly(alkenyl-co-maleimide) with a maleated polyalkylene so as to form a blend. This is followed by addition of a crosslinking agent, which is allowed to react with the poly(alkenyl-co-maleimide) and maleated polyalkylene to form a polyalkenyl grafted poly(alkenyl-co-maleimide).
  • the grafted poly(alkenyl-co- maleimide) is blended with a polyester.
  • the alkeny portion of the copolymer is derived from one or more of vinyl aromatic hydrocarbons, R 1 R 2 ethylenes, and alkyl vinyl ethers
  • the present invention provides an elastomeric composition.
  • the elastomeric composition includes the just-described copolymer, a maleated polyalkylene, a crosslinking agent, and a hyper- branched polyester.
  • the present invention provides a centipede polymer composition exhibiting improved properties such as hysteresis, tensile strength, maximum elongation, tear strength, damping properties, high temperature compression set, and the like. More particularly, the grafted poly(alkenyl-co-maleimide) copolymers react with hyperbranched polyesters to improve hysteresis properties while maintaining tensile strength, tear strength, damping properties, and high-temperature compression set of the centipede polymer.
  • the following definitions apply hereinthroughout unless a contrary intention is expressly indicated:
  • maleic anhydride encompasses dicarboxylic acids, including maleic anhydride, which can form a copolymer with an alkenyl benzene, an R 1 R ethylene, or an alkyl vinyl ether, the copolymer having dicarboxylic acid units which are capable of reaction with an amine functional group;
  • maleimide encompasses the reaction product of a primary amine a maleic anhydride
  • hyperbranched means a highly branched polymer structure with a random morphology and high resistance to crystallization.
  • the polymer component includes a backbone formed by copolymerization of a maleic anhydride with at least one other monomer such as butadiene, styrene, or methyl vinyl ether.
  • the maleic anhydride units are partially imidized, and the remainder are graft reacted to a maleated polyalkylene via a crosslinking agent such as a diamine.
  • This component is blended with a hyperbranched polyester to form an elastomeric polymer gel composition with superior damping properties.
  • the elastomeric polymer gel composition contains a po!y(alkenyl-co- maleimide) having at least one maleated polyalkylene segment grafted thereto through at least one functional linkage formed by a crosslinking reaction with a grafting agent; at least one hyperbranched polyester additive, and, optionally, an extender.
  • the poly(alkenyl-co-maleimide) is a centipede polymer formed by imidizing a poly(alkenyl-co-maleic anhydride).
  • the centipede polymer has a high molecular weight spine and many relatively short side chains formed through the addition of the primary amine(s).
  • the length of the main chain usually is as long or longer than the entanglement length (which is herein defined as an order of magnitude of 100 repeating units) while the length of the side chains is smaller than the entanglement length.
  • maleic anhydride-contributed units are not reacted with primary amine and thus remain available for coupling with a maleated polyalkylene via a crosslinking agent.
  • These unreacted maleic anhydride-contributed units preferably comprise from about 0.01 to about 5 weight percent of the copolymer.
  • Suitable alkenyl contributed units include alkenyl benzene, R 1 R 2 ethylene, and alkyl vinyl ethers.
  • Preferred alkenyl benzene-contributed units of the poly(alkenyl-co- maleimide) centipede are derived from any one or combination of styrene, ⁇ - methylstyrene, p-methylstyrene, 4-phenylstyrene, m-methylstyrene, p-tert- butylstyrene, dimethylstyrene, as well as alkyl, cycloalkyl, aryl, alkaryl, and aralkyl derivatives thereof, in which the total number of carbon atoms in the combined hydrocarbon is generally not greater than 12, as well as any di- or tri-vinyl aromatic hydrocarbons.
  • Particularly preferred vinyl aromatic hydrocarbons are styrene and/or ⁇ -methylstyrene.
  • R 1 R 2 ethylene contributed units of the centipede polymer contain 3 to about 40 carbon atoms with R 1 and R 2 being defined as above.
  • R 1 and R 2 can be unsubstituted or substituted, linear or branched C1-C20 alkyl groups. If a substituted group is included, it preferably is non-reactive with the remaining components of the centipede polymers. Examples include alkoxyalkyl groups having C 1 -C 20 carbon atoms as well as -Cl, -OH, -COOH, and -CN.
  • Alkyl vinyl ether contributed units are chosen such that the alkyl group contains 1 to about 20 carbon atoms in the backbone and may be substituted or unsubstituted, linear or branched, along the backbone of the alkyl group.
  • the substituted groups such as C2-C 20 alkoxyalkyl groups, preferably are non-reactive with the remaining components of the centipede polymers.
  • Examples of unsubstituted and substituted alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, isopentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetra- decyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, cyclopropyl, 2,2-dimethylcyclopropyl, cyclopentyl, cyclohexyl, methoxymethyl, methoxyethyl, methoxypropyl, methoxybutyl
  • Poly(alkenyl-co-maleimide) and poly(alkenyl-co-maleic anhydride) encompass random and stereospecific copolymers, including copolymers having alternating alkenyl-contributed units (i.e., polymer blocks derived from an alkenyl benzene such as styrene) and maleimide- or maleic anhydride- contributed units (i.e., polymer blocks derived from a maleimide or maleic anhydride) along the backbone.
  • Such alternating structures typically are described as poly(alkenyl-a/f-maleimide) and poly(alkenyl-a#-maleic anhydride); however, these specific polymers are encompassed within the general terms poly(alkenyl-co-maleimide) and poly(alkenyl-co-maleic anhydride).
  • the poly(alkenyl-co-maleimides) are subsequently graft-reacted through a difunctional linking or grafting agent to a maleated polyalkylene to yield a maleated polymer having at least one polyalkylene segment grafted thereto through the at least one functional linkage thus formed.
  • the alkylene moiety of the polalkylene may be derived from ethylene and/or propylene.
  • a preferred polyalkylene is polypropylene.
  • the maleated polypropylene may be any of the conventional polypropylene compounds that are subsequently maleated by known methods.
  • the polypropylene grafted segment(s) have weight average molecular weights (M w ) of about 10,000 to about 10,000,000 or higher, preferably about 20,000 to about 300,000.
  • the crystallinity, or tacticity, of the polypropylene may vary from being substantially amorphous to being completely crystalline, that is from about 10- 100% crystallinity. Because of the extensive commercial use of isotactic polypropylene, the grafted polypropylene typically will be substantially crystalline, i.e., having a crystallinity of greater than about 90%. Although the polypropylene may be substantially free of ethylene, small amounts of ethylene- derived units, on the order of less than about 10% by weight, sometimes are incorporated.
  • the polypropylene contains small amounts of ethylene in copolymers known as "reactor copolymers.”
  • the grafted polypropylenes can contain minor amounts of ethylene, both as part of the ethylene-propylene segments and as polyethylene segments.
  • Polymerization conditions for the preparation of polypropylene are known.
  • Propylene can be polymerized to form isotactic polypropylene in the presence of stereospecific Ziegler-Natta catalyst systems including a transition metal compound and an organometallic compound. Suitable compounds of transition metals are those of Groups 4 to 6 and 8 of the Periodic Table of elements, preferably titanium compounds, most preferably, titanium halides.
  • Suitable organometallic compounds are those of elements of Groups 1 to 3 of the Periodic Table, especially aluminum alkyls and aluminum alkyl halides.
  • Illustrative examples include TiCI 3 and TiCI as catalysts and triethylaluminum chloride and diethyl aluminum as cocatalysts.
  • These transition metal catalyst systems can be non-supported or supported on, for example, silica gel, metal oxides and dihalides, such and MgO, MgCl 2 , ZnCI 2 , and the like. Such systems can be reacted together and can be complexed with a variety of Lewis-base electron donors.
  • Molecular weight control can be achieved by incorporating H 2 via a feed stream into the polymerization reactor. Hydrogen is added at about 0 to 30 mole% based on total monomer.
  • the polymerization reaction is preferably conducted according to the slurry method employing an inert hydrocarbon diluent or liquid propylene as the vehicle.
  • the polymerization temperature can be in the range of about 50° to about 00°C and is preferably in a range of about 60° to about 80°C.
  • Polymerization pressure is not critical and can vary widely, for example, in the range from between atmospheric pressure to 3.7 MPa. For a general review of the art, see "Olefin Polymers (Polypropylene)" in Kirk-Othmer Encyclopedia of Chem. Tech., 3rd ed., vol. 16, pp. 453-69 (J. Wiley & Sons, 1981).
  • Maleation of the polypropylene compound to maleated polypropylene is conveniently accomplished by heating a blend of polypropylene and ethylenically unsaturated carboxyl group-containing compounds, e.g., maleic anhydride, within a range of about 150° to about 400°C, often in the presence of free-radical initiators, such as organic peroxides.
  • Methods of preparing these grafted polymers are known in the art as illustrated in, e.g., U.S. Patent Nos. 3,480,580; 3,481,910; 3,577,365; 4,506,056; and 3,414,551.
  • An independent source of the description of the process can be found in Minoura, et al., J. Appl. Poly. Sci.
  • Maleation preferably is conducted with such amounts of maleic anhydride and free-radical initiators and under conditions of temperature and shearing such that free-radical sites on the polypropylene are formed substantially at the time of scission of the polypropylene chains and at the point of such scission.
  • Maleic anhydride is then grafted onto the scissioned end of one side of such broken chains. In this manner, the anhydride groups are located principally at the ends of the maleated polypropylene chains, and the substantial majority of such maleated polypropylene chains contain one site of maleation.
  • This procedure permits grafting of the maleated polypropylene at its maleated end to the poly(alkylene-co-maleimide) through use of a difunctional linking or grafting agent having two functional groups, each functional group being reactive with a maleate group on the polypropylene and with a maleate group on the poly(alkylene-co-maleimide).
  • a difunctional linking or grafting agent having two functional groups, each functional group being reactive with a maleate group on the polypropylene and with a maleate group on the poly(alkylene-co-maleimide).
  • Multiple sites of maleation can lead to grafting of the maleated polypropylene to more than one maleated centipede polymer or at more than one site of one or more maleated centipede polymers.
  • Free-radical initiators preferably are used in an amount of from about 0.01 to 1.0% (by w ), preferably, from about 0.02 to 0.5% (by wt.) and most preferably, from about 0.04 to 0.3% (by wt.) of the total polypropylene (and solvent, if used).
  • the initiator(s) is/are the first component added to the polymerization reaction.
  • the mixture is heated to a temperature at or about the known decomposition temperature of the selected free-radical initiator, concurrently with any optional mechanical shearing.
  • Maleic anhydride is subsequently added in an amount of from about 0.01 to 10% (by wt.), preferably, from about 0.1 to 5% (by wt.), and most preferably, about 0.75 to 2% (by wt.) of the total polypropylene.
  • the maleated polyalkylene contains (based upon the weight of the maleated polyalkylene) from about 0.01 to about 5% (by wt.) incorporated maleic anhydride.
  • the maleic anhydride content is from about 0.01 to about 2% (by wt.), most preferably about 0.03 to about 0.2% (by wt.).
  • Maleic anhydride may not be left in substantial amounts in the polymer without detrimental effects on the subsequent reaction of the poly(alkenyl-co-maleimide) with the maleated polyalkylene.
  • the poly(alkenyl-co-maleic anhydride) preferably contains from about 5 to 99 mole percent of maleic anhydride with the remainder being alkenyl monomer contributed units.
  • Poly(alkenyl-co-maleic anhydride) preferably contains from 20 to 60 mole percent maleic anhydride-contributed units, most preferably 40-60 mole percent maleic anhydride-contributed units, and 40-60 mole percent alkenyl monomer-contributed units.
  • the comonomers can be randomly or alternately distributed in the chain, although an alternating distribution along the polymer backbone chain is preferred for many applications.
  • the poly(alkenyl-co-maleimide) may be formed by reacting a poly(alkenyl-co-maleic anhydride) in the presence of a primary amine at a temperature of from about 100° to about 300°C and at a pressure from about slightly above vacuum to about 3.7 MPa, under substantially dry conditions.
  • the reactants are preferably dry mixed in the absence of solvents in a suitable mixing apparatus, such as a Brabender mixer. Purging the mixer with an inert gas, such as N 2 or Ar, prior to the charging of the reactants can be preferred.
  • the primary amine may be added in a single charge or by sequential partial charges into the reactor containing a charge of poly(a!kenyl- co-maleic anhydride).
  • the primary amine is charged in ratio between about 0.7 to about 1.0 moles of amine per mole of unit of maleic anhydride in the poly(alkenyl-co-maleic) anhydride, more preferably in ratio between about 0.8 to about 1.0 moles of amine per mole of units of maleic anhydride in the poly(alkenyl-co-maleic anhydride).
  • Suitable primary amines include, but are not limited to, alkyl amines, alkyl benzyl amines, alkyl phenyl amines, alkoxybenzyl amines, alkyl amino- benzoates, alkoxy aniline, and other linear primary amines containing from 1 to about 50 carbon atoms, preferably about 6 to about 30 carbon atoms in the alkyl and alkoxy substituents in these primary amines.
  • the alkyl and alkoxy substituents on these primary amines can be linear or branched, preferably linear, and saturated or unsaturated, preferably saturated.
  • Exemplary amines include hexylamine, octylamine, dodecylamine, and the like.
  • the centipede polymer may be prepared by conventional means for combining such ingredients, such as blending, milling, or internal batch mixing. A rapid and convenient method of preparation includes heating a mixture of the components to a temperature of about 50° to about 290°C.
  • the centipede polymers of this invention are preferably manufactured by mixing and dynamically heat-treating the components described above, namely, by melt-mixing.
  • any conventional, generally known equipment such as an open-type mixing roll, closed-type Banbury mixer, closed-type Brabender mixer, extruding machine, kneader, continuous mixer, etc.
  • the closed-type Brabender mixer is preferable, and mixing in an inactive gas environment, such as N 2 or Ar, is also preferable.
  • Grafting of maleated polyalkylene and poly(alkenyl-co-maleimide) is preferably carried out by addition of a grafting agent containing two or more reactive functional groups.
  • Acceptable functional groups include primary amine, secondary amine, carboxyl, formyl, hydroxyl, cyano, vinyl, alkynyl, etc.
  • a preferred grafting agent is an organic diamine, which is added to a blend of maleated polyalkylene and poly(alkenyl-co-maleimide) to partially crosslink the polyalkylene to the poly(alkenyl-co-maleimide) through the unreacted maleate functional groups.
  • Organic diamines or diamine mixtures containing two aliphatically or cycloaliphatically bound primary amino groups are preferably used as grafting agents for the process.
  • Such diamines include, for example, aliphatic or cycloaliphatic diamines corresponding to the following formula R 3 (NH 2 ) 2 wherein R 3 represents a C 2 -C 2 o aliphatic hydrocarbon, a C4-C20 cycloaliphatic hydrocarbon group, a C6-C20 aromatic hydrocarbon group, or a C4-C 2 0 N- heterocyclic ring.
  • Exemplary diamines include ethylenediamine; 1,2- and 1,3- propylene diamine; 1 ,4-diaminobutane; 2,2-dimethyl-1,3-diaminopropane; 1,6- diaminohexane; 2,5-dimethyl-2,5-diaminohexane; 1 ,6-diamino-2,2,4-trimethyl- diaminohexane; 1 ,8-diaminooctane; 1,10-diaminodecane; 1,11-diaminoun- decane; 1 ,12-diaminododecane; 1-methyl-4-(aminoisopropyl)-cyclohexyl- amine; 3-aminomethyl-3,5,5-trimethyl-cyclohexylamine; 1 ,2-bis- (aminomethyl)-cyclobutane; 1 ,2-diamino-3,6-dimethylbenz
  • Suitable polyamines for use as grafting agents include bis- (aminoalkyl) amines, preferably those having a total of from 4 to 12 carbon atoms, such as bis-(2-aminoethyl) amine, bis-(3-aminopropyl) amine, bis-(4- aminobutyl) amine, and bis-(6-aminohexyl) amine, and isomeric mixtures of dipropylene triamine and dibutylene triamine. Hexamethyl diamine, tetrameth- ylene diamine, and especially 1,12-diaminododecane are preferably used.
  • the grafted polymer composition preferably has added thereto one or more extenders such as oils and low molecular weight compounds or components.
  • Suitable extender oils include naphthenic, aromatic and paraffinic petroleum oils and silicone oils.
  • Examples of low molecular weight organic compounds or components useful as extenders are low molecular weight organic materials having a number average molecular weight (M n ) of less than 20,000, preferably less than 10,000, and most preferably less than 5,000.
  • M n number average molecular weight
  • plasticizers namely plasticizers composed of esters including phthalic, mixed phthalic, aliphatic dibasic acid, glycol, fatty acid, phosphoric and stearic esters, epoxy plasticizers, other plasticizers for plastics, and phthalate, adipate, sebacate, phosphate, polyether, and polyester plasticizers for NBR;
  • tackifiers namely coumarone resins, coumarone-indene resins, terpene phenol resins, petroleum hydrocarbons, and rosin derivative
  • oligomers namely crown ether, fluorine-containing oligomers, polybutenes, xylene resins, chlorinated rubber, polyethylene wax, petroleum resins, rosin ester rubber, polyalkylene glycol diacrylate, liquid rubber (polybutadiene, SBR, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone oligomers, and poly( ⁇ -olefins);
  • lubricants namely hydrocarbon lubricants such as paraffin and wax, fatty acid lubricants such as higher fatty acid and hydroxy-fatty acid, fatty acid amide lubricants such as fatty acid amide and alkylene-bis- fatty acid amide, ester lubricants such as fatty acid-lower alcohol ester,
  • Suitable low molecular weight organic materials include latices, emulsions, liquid crystals, bituminous compositions, polymers, and phosphazenes.
  • One or more of these materials may be used as extenders.
  • a preferred extender is di(tridecyl)phthalate oil (DTDP) from the C.P. Hall Co., (Chicago, Illinois). Extender(s) are added to the polymer composition in the range of about 10 to about 90% (by wt.), preferably about 15 to about 75% (by wt.), and most preferably about 20 to about 60% (by wt.).
  • polyalkylene grafted poly(alkenyl-co-maleimide) After the extended, polyalkylene grafted poly(alkenyl-co-maleimide) is formed, it can be further mixed with a hyperbranched polyester.
  • the hyperbranched polyester is formed by reacting at least one carboxylic acid, at least one alcohol, and at least one anhydride, followed by the addition of at least one additional anhydride to form a polyester prepolymer. This prepolymer is cured via a crosslinking agent such as that described above to provide the hyperbranch characteristics.
  • the resultant hyperbranched polyester is added to the maleated polypropylene grafted centipede polymer in amounts between about 1 to about 50% (by wt.), preferably between about 10 and 40% (by wt), most preferably between about 15 and 45% (by wt).
  • the resulting gel has a high temperature compression set at 100°C of less that about 60%, and hysteresis values (tan ⁇ ) at 23
  • Suitable hyperbranched polyesters for use herein are compact molecules with many branches which carry a high number of terminal functional groups on each molecule. These highly branched, three dimensional molecules have a globular shape and are preferably near- gelation polymers.
  • a near-gelation polymer can be formed when the degree of interchain reaction, i.e., crosslinking, between the elastomeric molecules nears or approaches the gel point of the polymeric composition. At the gel point, a gel or insoluble polymer fraction forming in a polymeric composition first becomes observable. Theoretically, a gel corresponds to an infinite network in which polymer molecules have been crosslinked to one another to form a macroscopic molecule. The gel may then be considered one molecule.
  • a gel generally is insoluble in all solvents at elevated temperatures under conditions where polymer degradation does not occur; the non-gel portion of the polymer, often referred to as sol, remains soluble in solvents.
  • near- gelation polymers also can be referred to as near-gel polymers.
  • the gel point of the polymeric composition employed to create the near-gelation polymer preferably is determined. Several techniques are known in the art for estimating the gel point of polymeric compositions. Gel point can be determined experimentally by solvent extraction and other techniques described in P.J. Flory, Principles of Polymer Chemistry (1953), or approximated by using theoretical calculations as described in, for example, G. Odian, Principles of Polymerization, 3d ed., pp. 108-123, (1991).
  • the polymeric composition employed to create the near-gelation polymer can be referred to as the prepolymer system.
  • gel point can be discussed in terms of a variety of parameters, determining the ratio of the weight of curative to the weight of prepolymer necessary to reach the gel point can be convenient.
  • gel point can be represented by the weight of curative necessary to reach gelation, W cg , over the weight of prepolymer, W p .
  • the point of complete cure can be represented by the weight of curative necessary to reach complete cure, Wcc, divided by W p .
  • the extent of any curing reaction can be represented by the weight of curative added, W c , divided by W p .
  • the gel point of the prepolymer is determined, an appropriate amount of curative can be added and reacted with the prepolymer to achieve a near-gelation polymer.
  • the gel point preferably is approached but not exceeded, although the definition of near-gelation polymer broadly includes those reaction products of curative and prepolymer that exceed the gel point without actually reaching complete cure.
  • E is an absolute value
  • E is greater than or equal to 0 and less than or equal to about 0.5, more preferably less than about 0.2, still more preferably less than about 0.1, and even more preferably no more than about 0.05.
  • the foregoing formula involves the absolute value of a number and, therefore, the extent of the reaction (r) is a relative distance (E) both beyond and before the gel point.
  • 0.4).
  • the prepolymer used in preparing the near-gelation polymer includes at least one functional group, preferably at least 2 functional groups, more preferably between 2 and about 10 functional groups, and even more preferably between 2 and about 5 functional groups.
  • the prepolymer can be referred to as the functionalized prepolymer.
  • the functional groups can be located at the terminal end of the prepolymer, including the initiated end of the polymer, or along the backbone of the prepolymer. Therefore, crosslinking can occur anywhere on the prepolymer chain.
  • the elastomeric composition is preferably manufactured by mixing and dynamically heat-treating the components described above, namely, by melt- mixing.
  • any conventional, generally known equipment such as an open-type mixing roll, open-type Banbury mixer, closed-type Banbury mixer, closed-type Branbender mixer, extruding machine, kneader, or continuous mixer is acceptable.
  • the closed-type Brabender mixer is preferably, and mixing in an inactive gas environment, such as nitrogen or argon, is preferable.
  • the molded polymers produced from the blend of the present centipede polymer and polyester retain elastomeric characteristics and are useful in high damping applications.
  • the elastomeric composition contains from about 30 to about 60% (by wt.) centipede polymer, preferably from about 35 to about 55% (by wt.), and most preferably from about 40 to about 55% (by wt.).
  • the composition preferably contains between about 5 and 40% (by wt.) hyperbranched polyester, more preferably between about 10 and 40% (by wt.), most preferably between about 15 and 40% (by wt.).
  • the composition also contains between about 5 and 40% (by wt.) extender, more preferably between about 10 and 40% (by wt.), and most preferably between about 15 and 40% (by wt.).
  • antioxidants include 2-(2 ' -hydroxy-5 ' -methylphenyl) benzotriazole, nickel di-butyl-dithio- carbamate, zinc di-butyl-di-thiocarbamate, tris(nonylphenyl) phosphite, 2,6-di- t-butyl-4-methylphenol, and the like.
  • Exemplary conventional fillers and pigments include silica, carbon black, Ti0 2 , Fe 2 O 3 , and the like. These materials are incorporated in suitable amounts depending upon the contemplated use of the product, preferably in the range of 1-350 parts of additives or compounding ingredients per 100 parts of the polymer composition.
  • a reinforcing material may be defined as a material added to a resinous matrix to improve the strength of the polymer. Most reinforcing materials are inorganic or organic products of high molecular weight. Various examples include glass fibers, asbestos, boron fibers, carbon and graphite fibers, whiskers, quartz and silica fibers, ceramic fibers, metal fibers, natural organic fibers, and synthetic organic fibers.
  • elastomers and resins are also useful to enhance specific properties like damping properties, adhesion, and processability.
  • adhesive-like products including ReostomerTM (Riken-Vinyl, Inc.; Tokyo, Japan), hydrogenated polystyrene-(medium or high 3,4) polyisoprene- polystyrene block copolymers such as HyblerTM (Kuraray, Inc.; Osaka, Japan), polynorbornenes such as NorsorexTM (Nippon Zeon, Inc.; Tokyo, Japan), and the like.
  • ReostomerTM Raken-Vinyl, Inc.; Tokyo, Japan
  • hydrogenated polystyrene-(medium or high 3,4) polyisoprene- polystyrene block copolymers such as HyblerTM (Kuraray, Inc.; Osaka, Japan), polynorbornenes such as NorsorexTM (Nippon Zeon, Inc.; Tokyo, Japan), and the like.
  • HyblerTM
  • Damping is the absorption of mechanical energy by a material in contact with the source of that energy. Transmission of mechanical energy from, for example, a motor, engine, or power source to its surroundings desirably is damped or mitigated. Elastomeric materials often are used for this purpose. Such materials preferably are highly effective in converting this mechanical energy into heat rather than transmitting it to the surroundings. Even more preferably, this damping or conversion is effective over a wide range of temperatures and frequencies commonly found near motors, automobiles, trucks, trains, planes, and the like.
  • compositions of the present invention are favorably used in the manufacturing of any product in which some of the following properties are advantageous: a degree of softness, heat resistance, decent mechanical properties, elasticity, and/or high damping.
  • the compositions of the present invention can be used in many industry applications, in particular, in the fabrication of automotive parts, tire tread rubbers, household electrical appliances, industrial machinery, precision instruments, transport machinery, constructions, engineering, and medical instruments.
  • the composition of the present invention can be used in the fabrication of damping materials and vibration restraining materials. These uses involve connecting materials such as sealing materials, packing, gaskets, and grommets, supporting materials, such as mounts, holders, and insulators, and cushion materials, such as stoppers, cushions, and bumpers. These materials also can be used in equipment producing vibration or noise and household electrical appliances, such as in air-conditioners, laundry machines, refrigerators, electric fans, vacuums, dryers, printers, and ventilator fans. These materials also are suitable for impact absorbing materials in audio equipment and electronic or electrical equipment, sporting goods, and shoes.
  • the present invention will also be useful in any application where a superior high temperature compression set is desirable. With a compression set of less than 60% at 100°C, this composition can be used in a variety of high temperature applications. One example of this would be as coatings, especially for windows and car windshields which retain heat and cause polymers with lower service temperatures to melt.
  • Example 1 Preparation of Hyperbranched Polyester A hyperbranched polyester was synthesized in a 1 liter glass kettle fitted with a Dean-Stark trap and magnetic stirring. 84.4 g ethylhexanoic acid, 41.1 g pentaerythritol, and 44.2 g phthalic anhydride (Aldrich; Milwaukee, Wisconsin) were mixed in the flask and heated. All materials melted and mixed at 220°C, and water, formed as a byproduct, was driven off as the temperature was raised to 260°C. When water evolution slowed, the mixture was heated to 280°C under vacuum for 4 hours, followed by addition of 1 ,2,4- benzene tricarboxylic anhydride (Aldrich). The reaction mixture was reheated to 280°C for 2 hours under vacuum.
  • Aldrich 1 ,2,4- benzene tricarboxylic anhydride
  • the product was a soft, elastomeric polymer.
  • An Rheometry Dynamic Analysis temperature sweep showed a tan ⁇ peak of 2.6 at 35°C and a tan ⁇ of 1.5-2.6 from 25° to 145°C.
  • Example 2 Preparation of Hyperbranched Polyester 54.5 g pentaerythritol, 57.7 g ethylhexanoic acid, 59.2 g phthalic anhydride, 12 g UMEXTM 110TS maleated iso-polypropylene with an acidity of 7 mg KOH/g (SANYO Chemical; Osaka, Japan), and 1 g 1 ,2,4-benzene tricarboxylic anhydride were added to the glass kettle described in Example 1. After 1 hour at 260°C, the evolution of water had slowed. Another 57.7 g ethylhexanoic acid was added and reaction continued 3 hours at 260°C. Reaction was continued for 8 additional hours at 260°C under vacuum. A soft elastomeric polymer was formed.
  • Example 3 Preparation of the Polypropylene-Grafted Centipede Polymer To a 6 L kneader-extruder (Jaygo, Inc.) equipped with sigma blades was added 1.252 kg lsoban-10TM poly(maleic anhydride-a#-isobutylene) (Kuraray Co.), and 0.989 kg octylamine (99%, BASF) at 54°C. Mixing was started with a blade speed of 25 rpm and screw speed of 40 rpm for 5 minutes, then the temperature of the mixer was adjusted to rise to 190°C at a rate of about 3°C/minute. Mixing was further continued for 2 more hours isothermally at 190°C.
  • Examples 4-6 Preparation of High Damping Gels
  • a charge of 35 g of the product of Example 3 was added to a Brabender mixer ( ⁇ 55 g capacity) equipped with a roller blade and
  • the mixer was initially set to 160°C and 60 rpm. After 3 minutes,
  • Example 5 For Example 5, the procedure from the preceding paragraph was repeated. After 3 minutes, a charge of 10.5 g of the product from Example 2 and a charge of 4.5 g DTDP were added the mixer. The material was further mixed at those conditions for 27 minutes, then agitation was ceased and the mixture was removed from the mixer.
  • Example 6 the procedure of Example 4 was repeated except for a minor change in the charges of the materials and the total mixing time.
  • Example 2 were added to the mixer. The total mixing time was 45 minutes.
  • the products were soft and thermo- reversible gels.
  • the materials from Examples 4-6 exhibited excellent damping properties with good balanced tensile strength and thermostabilities.
  • all materials shown in the table were thermally recyclable at 160°C and have a service temperature up to 100°C.

Abstract

A process for forming an elastomeric polymer gel composition includes blending a maleated polyalkylene and a poly(alkenyl-co-maleimide) followed by addition of a crosslinking agent that is allowed to react with the copolymer and maleated polyalkylene to form a polyalkyenyl-grafted copolymer. The grafted copolymer is further blended with a hyperbranched polyester.

Description

POLYESTER AND POLYALKYLENE-GRAFTED POLYMER COMPOSITION
BACKGROUND OF THE INVENTION
The present invention relates to high damping polymers with superior high-temperature stability, mechanical strength, and moldability. The inventive composition is particularly useful as a soft molding material for various products.
Free radically-initiated polymerizations of isobutylene and maleic anhydride, as well as styrene or methyl vinyl ether and maleic anhydride, are known. Also known is imidization of a maleic anhydride with a primary amine. Two or more polymers may be blended together to form a wide variety of random or structured morphologies to obtain products that offer potentially desirable combinations of characteristics. However, it may be difficult or even impossible in practice to achieve many potential combinations through simple blending. Frequently, the polymers are thermodynamically immiscible, which precludes generating a truly homogeneous product. While it is sometimes desirable to have a two-phase structure, the situation at the interface between the two phases often can lead to problems. The typical case is one of high interfacial tension and poor adhesion between the two phases. This interfacial tension contributes, along with high viscosities, to the inherent difficulty of imparting the desired degree of dispersion to random mixtures and to their subsequent lack of stability, giving rise to gross separation or stratification during later processing or use. Poor adhesion leads, in part, to the very weak and brittle mechanical behavior often observed in dispersed blends and may render some highly structured morphologies impossible. A polymer composition that has high damping capabilities while avoiding the above-mentioned problems related to blends remains desirable.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a process for forming an elastomeric polymer gel composition. The process includes combining a poly(alkenyl-co-maleimide) with a maleated polyalkylene so as to form a blend. This is followed by addition of a crosslinking agent, which is allowed to react with the poly(alkenyl-co-maleimide) and maleated polyalkylene to form a polyalkenyl grafted poly(alkenyl-co-maleimide). The grafted poly(alkenyl-co- maleimide) is blended with a polyester. The alkeny portion of the copolymer is derived from one or more of vinyl aromatic hydrocarbons, R1R2ethylenes, and alkyl vinyl ethers
In another aspect, the present invention provides an elastomeric composition. The elastomeric composition includes the just-described copolymer, a maleated polyalkylene, a crosslinking agent, and a hyper- branched polyester.
The present invention provides a centipede polymer composition exhibiting improved properties such as hysteresis, tensile strength, maximum elongation, tear strength, damping properties, high temperature compression set, and the like. More particularly, the grafted poly(alkenyl-co-maleimide) copolymers react with hyperbranched polyesters to improve hysteresis properties while maintaining tensile strength, tear strength, damping properties, and high-temperature compression set of the centipede polymer. The following definitions apply hereinthroughout unless a contrary intention is expressly indicated:
"vinyl aromatic hydrocarbon" and "alkenyl benzene" are used interchangeably;
"maleic anhydride" encompasses dicarboxylic acids, including maleic anhydride, which can form a copolymer with an alkenyl benzene, an R1R ethylene, or an alkyl vinyl ether, the copolymer having dicarboxylic acid units which are capable of reaction with an amine functional group;
"maleimide" encompasses the reaction product of a primary amine a maleic anhydride;
"R1R2ethylene" as used herein encompasses monomers of the generalormula R1R2=CH2 where R1 and R2 independently are H or substituted or unsubstituted C1-C20 alkyl groups; poly(alkenyl-co-maleimide) includes poly(alkenylbenzene-co- maleimide), poly(R1R2ethylene-co-maleimide), and poly(alkyl vinyl ether-co- maleimide); and
"hyperbranched" means a highly branched polymer structure with a random morphology and high resistance to crystallization.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferably, the polymer component includes a backbone formed by copolymerization of a maleic anhydride with at least one other monomer such as butadiene, styrene, or methyl vinyl ether. The maleic anhydride units are partially imidized, and the remainder are graft reacted to a maleated polyalkylene via a crosslinking agent such as a diamine. This component is blended with a hyperbranched polyester to form an elastomeric polymer gel composition with superior damping properties.
The elastomeric polymer gel composition contains a po!y(alkenyl-co- maleimide) having at least one maleated polyalkylene segment grafted thereto through at least one functional linkage formed by a crosslinking reaction with a grafting agent; at least one hyperbranched polyester additive, and, optionally, an extender.
The poly(alkenyl-co-maleimide) is a centipede polymer formed by imidizing a poly(alkenyl-co-maleic anhydride). The centipede polymer has a high molecular weight spine and many relatively short side chains formed through the addition of the primary amine(s). The length of the main chain usually is as long or longer than the entanglement length (which is herein defined as an order of magnitude of 100 repeating units) while the length of the side chains is smaller than the entanglement length.
At least a portion of the maleic anhydride-contributed units are not reacted with primary amine and thus remain available for coupling with a maleated polyalkylene via a crosslinking agent. These unreacted maleic anhydride-contributed units preferably comprise from about 0.01 to about 5 weight percent of the copolymer. Suitable alkenyl contributed units include alkenyl benzene, R1R2ethylene, and alkyl vinyl ethers.
Preferred alkenyl benzene-contributed units of the poly(alkenyl-co- maleimide) centipede are derived from any one or combination of styrene, α- methylstyrene, p-methylstyrene, 4-phenylstyrene, m-methylstyrene, p-tert- butylstyrene, dimethylstyrene, as well as alkyl, cycloalkyl, aryl, alkaryl, and aralkyl derivatives thereof, in which the total number of carbon atoms in the combined hydrocarbon is generally not greater than 12, as well as any di- or tri-vinyl aromatic hydrocarbons. Particularly preferred vinyl aromatic hydrocarbons are styrene and/or α-methylstyrene.
R1R2ethylene contributed units of the centipede polymer contain 3 to about 40 carbon atoms with R1 and R2 being defined as above. Either or both of R1 and R2 can be unsubstituted or substituted, linear or branched C1-C20 alkyl groups. If a substituted group is included, it preferably is non-reactive with the remaining components of the centipede polymers. Examples include alkoxyalkyl groups having C1-C20 carbon atoms as well as -Cl, -OH, -COOH, and -CN.
Alkyl vinyl ether contributed units are chosen such that the alkyl group contains 1 to about 20 carbon atoms in the backbone and may be substituted or unsubstituted, linear or branched, along the backbone of the alkyl group. The substituted groups, such as C2-C20 alkoxyalkyl groups, preferably are non-reactive with the remaining components of the centipede polymers.
Examples of unsubstituted and substituted alkyl groups (i.e., R1 and R2 from the R1R2ethylene contributed unit; and alkyl from the alkyl vinyl ether contributed) include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, isopentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetra- decyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, cyclopropyl, 2,2-dimethylcyclopropyl, cyclopentyl, cyclohexyl, methoxymethyl, methoxyethyl, methoxypropyl, methoxybutyl, methoxypentyl, methoxyhexyl, methoxyheptyl, methoxyoctyl, methoxynonyl, methoxydecyl, ethoxymethyl, ethoxyethyl, ethoxypropyl, ethoxybutyl, ethoxypentyl, ethoxyhexyl, ethoxy- heptyl, ethoxyoctyl, ethoxynonyl, ethoxydecyl, propoxy methyl, propoxyethyl, propoxypropyl, propoxybutyl, propoxypentyl, propoxyhexyl, propoxyheptyl, propoxyoctyl, propoxynonyl, propoxydecyl, butoxybutoxymethyl, butoxyethyl, butoxypropyl, butoxybutyl, butoxypentyl, butoxyhexyl, butoxyheptyl, butoxy- octyl, butoxynonyl, butoxydecyl, pentyloxymethyl, pentyloxyethyl, pentyloxy- propyl, pentyloxybutyl, pentyloxypentyl, pentyloxyhexyl, pentyloxyoctyl, pentyl- oxynonyl, pentyloxydecyl, hexyloxymethyl, hexyloxyethyl, hexyloxypropyl, hexyloxybutyl, hexyloxypentyl, hexyloxyhexyl, hexyloxyheptyl, hexyloxyoctyl, hexyloxynonyl, hexyloxydecyl, heptyloxymethyl, heptyloxyethyl, heptyloxy- propyl, heptyloxybutyl, hexyloxypentyl, heptyloxyhexyl, heptyloxyheptyl, heptyloxyoctyl, heptyloxynonyl, heptyloxydecyl, octyloxymethyl, octyloxyethyl, octyloxypropyl, octyloxy butyl, octyloxypentyl, octyloxyhexyl, octyloxyheptyl, octyloxynonyl, octyloxyoctyl, decyloxymethyl, decyloxyethyl, decyloxypropyl, decyloxybutyl, decyloxypentyl, decyloxyhexyl, decyloxyheptyl, 1-methylethyl, 1-methylpropyl, 1-methylbutyl, 1-methylpentyl, 1 -methyl hexy 1, 1-methylheptyl, 1-methyloctyl, 1-methylnonyl, 1-methyldecyl, 2-methylpropyl, 2-methylbutyl, 2- methylpentyl, 2-methylhexyl, 2-methylheptyl, 2-methyloctyl, 2,3-dimethylbutyl, 2,3,3-trimethylbutyl, 3-methylpentyl, 2,3-dimethylpentyl, 2,4-dimethylpentyl, 2,3,3,4-tetramethylpentyl, 3-methylhexyl, 2,5-dimethylhexyl, and the like. Preferred alkenyl monomers for forming the poly(aIkenyl-co-maleic anhydride) are styrene, methyl vinyl ether, and/or isobutylene.
Poly(alkenyl-co-maleimide) and poly(alkenyl-co-maleic anhydride) encompass random and stereospecific copolymers, including copolymers having alternating alkenyl-contributed units (i.e., polymer blocks derived from an alkenyl benzene such as styrene) and maleimide- or maleic anhydride- contributed units (i.e., polymer blocks derived from a maleimide or maleic anhydride) along the backbone. Such alternating structures typically are described as poly(alkenyl-a/f-maleimide) and poly(alkenyl-a#-maleic anhydride); however, these specific polymers are encompassed within the general terms poly(alkenyl-co-maleimide) and poly(alkenyl-co-maleic anhydride). The poly(alkenyl-co-maleimides) are subsequently graft-reacted through a difunctional linking or grafting agent to a maleated polyalkylene to yield a maleated polymer having at least one polyalkylene segment grafted thereto through the at least one functional linkage thus formed. The alkylene moiety of the polalkylene may be derived from ethylene and/or propylene. A preferred polyalkylene is polypropylene.
The maleated polypropylene may be any of the conventional polypropylene compounds that are subsequently maleated by known methods. The polypropylene grafted segment(s) have weight average molecular weights (Mw) of about 10,000 to about 10,000,000 or higher, preferably about 20,000 to about 300,000.
The crystallinity, or tacticity, of the polypropylene may vary from being substantially amorphous to being completely crystalline, that is from about 10- 100% crystallinity. Because of the extensive commercial use of isotactic polypropylene, the grafted polypropylene typically will be substantially crystalline, i.e., having a crystallinity of greater than about 90%. Although the polypropylene may be substantially free of ethylene, small amounts of ethylene- derived units, on the order of less than about 10% by weight, sometimes are incorporated. Furthermore, in certain instances, the polypropylene contains small amounts of ethylene in copolymers known as "reactor copolymers." Thus, the grafted polypropylenes can contain minor amounts of ethylene, both as part of the ethylene-propylene segments and as polyethylene segments. Polymerization conditions for the preparation of polypropylene are known. Propylene can be polymerized to form isotactic polypropylene in the presence of stereospecific Ziegler-Natta catalyst systems including a transition metal compound and an organometallic compound. Suitable compounds of transition metals are those of Groups 4 to 6 and 8 of the Periodic Table of elements, preferably titanium compounds, most preferably, titanium halides. Suitable organometallic compounds are those of elements of Groups 1 to 3 of the Periodic Table, especially aluminum alkyls and aluminum alkyl halides. Illustrative examples include TiCI3 and TiCI as catalysts and triethylaluminum chloride and diethyl aluminum as cocatalysts. These transition metal catalyst systems can be non-supported or supported on, for example, silica gel, metal oxides and dihalides, such and MgO, MgCl2, ZnCI2, and the like. Such systems can be reacted together and can be complexed with a variety of Lewis-base electron donors.
Molecular weight control can be achieved by incorporating H2 via a feed stream into the polymerization reactor. Hydrogen is added at about 0 to 30 mole% based on total monomer. The polymerization reaction is preferably conducted according to the slurry method employing an inert hydrocarbon diluent or liquid propylene as the vehicle. The polymerization temperature can be in the range of about 50° to about 00°C and is preferably in a range of about 60° to about 80°C. Polymerization pressure is not critical and can vary widely, for example, in the range from between atmospheric pressure to 3.7 MPa. For a general review of the art, see "Olefin Polymers (Polypropylene)" in Kirk-Othmer Encyclopedia of Chem. Tech., 3rd ed., vol. 16, pp. 453-69 (J. Wiley & Sons, 1981).
Maleation of the polypropylene compound to maleated polypropylene is conveniently accomplished by heating a blend of polypropylene and ethylenically unsaturated carboxyl group-containing compounds, e.g., maleic anhydride, within a range of about 150° to about 400°C, often in the presence of free-radical initiators, such as organic peroxides. Methods of preparing these grafted polymers are known in the art as illustrated in, e.g., U.S. Patent Nos. 3,480,580; 3,481,910; 3,577,365; 4,506,056; and 3,414,551. An independent source of the description of the process can be found in Minoura, et al., J. Appl. Poly. Sci. 1625 (1969). The use of heat and/or physical shearing optionally with the free-radical initiators, in such equipment as extruders, masticators, and the like, to accomplish simultaneously a controlled degradation in molecular weight of the polypropylene along with the free-radical grafting of the maleic anhydride can be desirable in some circumstances.
Maleation preferably is conducted with such amounts of maleic anhydride and free-radical initiators and under conditions of temperature and shearing such that free-radical sites on the polypropylene are formed substantially at the time of scission of the polypropylene chains and at the point of such scission. Maleic anhydride is then grafted onto the scissioned end of one side of such broken chains. In this manner, the anhydride groups are located principally at the ends of the maleated polypropylene chains, and the substantial majority of such maleated polypropylene chains contain one site of maleation. This procedure permits grafting of the maleated polypropylene at its maleated end to the poly(alkylene-co-maleimide) through use of a difunctional linking or grafting agent having two functional groups, each functional group being reactive with a maleate group on the polypropylene and with a maleate group on the poly(alkylene-co-maleimide). Multiple sites of maleation can lead to grafting of the maleated polypropylene to more than one maleated centipede polymer or at more than one site of one or more maleated centipede polymers.
Free-radical initiators preferably are used in an amount of from about 0.01 to 1.0% (by w ), preferably, from about 0.02 to 0.5% (by wt.) and most preferably, from about 0.04 to 0.3% (by wt.) of the total polypropylene (and solvent, if used). Preferably, the initiator(s) is/are the first component added to the polymerization reaction. The mixture is heated to a temperature at or about the known decomposition temperature of the selected free-radical initiator, concurrently with any optional mechanical shearing. Maleic anhydride is subsequently added in an amount of from about 0.01 to 10% (by wt.), preferably, from about 0.1 to 5% (by wt.), and most preferably, about 0.75 to 2% (by wt.) of the total polypropylene.
The maleated polyalkylene contains (based upon the weight of the maleated polyalkylene) from about 0.01 to about 5% (by wt.) incorporated maleic anhydride. Preferably, the maleic anhydride content is from about 0.01 to about 2% (by wt.), most preferably about 0.03 to about 0.2% (by wt.). Unreacted polyalkylene and minor amounts of reaction byproducts, such as decomposed free-radical products, also are present in the reaction mix. These byproducts are substantially removed by known methods, e.g., sparging with N2 or washing with water. Maleic anhydride may not be left in substantial amounts in the polymer without detrimental effects on the subsequent reaction of the poly(alkenyl-co-maleimide) with the maleated polyalkylene.
The poly(alkenyl-co-maleic anhydride) preferably contains from about 5 to 99 mole percent of maleic anhydride with the remainder being alkenyl monomer contributed units. Poly(alkenyl-co-maleic anhydride) preferably contains from 20 to 60 mole percent maleic anhydride-contributed units, most preferably 40-60 mole percent maleic anhydride-contributed units, and 40-60 mole percent alkenyl monomer-contributed units. The comonomers can be randomly or alternately distributed in the chain, although an alternating distribution along the polymer backbone chain is preferred for many applications.
The poly(alkenyl-co-maleimide) may be formed by reacting a poly(alkenyl-co-maleic anhydride) in the presence of a primary amine at a temperature of from about 100° to about 300°C and at a pressure from about slightly above vacuum to about 3.7 MPa, under substantially dry conditions. The reactants are preferably dry mixed in the absence of solvents in a suitable mixing apparatus, such as a Brabender mixer. Purging the mixer with an inert gas, such as N2 or Ar, prior to the charging of the reactants can be preferred. The primary amine may be added in a single charge or by sequential partial charges into the reactor containing a charge of poly(a!kenyl- co-maleic anhydride). Preferably the primary amine is charged in ratio between about 0.7 to about 1.0 moles of amine per mole of unit of maleic anhydride in the poly(alkenyl-co-maleic) anhydride, more preferably in ratio between about 0.8 to about 1.0 moles of amine per mole of units of maleic anhydride in the poly(alkenyl-co-maleic anhydride).
Suitable primary amines include, but are not limited to, alkyl amines, alkyl benzyl amines, alkyl phenyl amines, alkoxybenzyl amines, alkyl amino- benzoates, alkoxy aniline, and other linear primary amines containing from 1 to about 50 carbon atoms, preferably about 6 to about 30 carbon atoms in the alkyl and alkoxy substituents in these primary amines. The alkyl and alkoxy substituents on these primary amines can be linear or branched, preferably linear, and saturated or unsaturated, preferably saturated. Exemplary amines include hexylamine, octylamine, dodecylamine, and the like.
The poly(alkenyl-co-maleimide), prior to grafting with maleated polyalkylene, preferably has Mw of between about 10,000 and 500,000 and even more preferably between about 150,000 and 450,000. The centipede polymer may be prepared by conventional means for combining such ingredients, such as blending, milling, or internal batch mixing. A rapid and convenient method of preparation includes heating a mixture of the components to a temperature of about 50° to about 290°C. The centipede polymers of this invention are preferably manufactured by mixing and dynamically heat-treating the components described above, namely, by melt-mixing. As for the mixing equipment, any conventional, generally known equipment such as an open-type mixing roll, closed-type Banbury mixer, closed-type Brabender mixer, extruding machine, kneader, continuous mixer, etc., is acceptable. The closed-type Brabender mixer is preferable, and mixing in an inactive gas environment, such as N2 or Ar, is also preferable.
Grafting of maleated polyalkylene and poly(alkenyl-co-maleimide) is preferably carried out by addition of a grafting agent containing two or more reactive functional groups. Acceptable functional groups include primary amine, secondary amine, carboxyl, formyl, hydroxyl, cyano, vinyl, alkynyl, etc. A preferred grafting agent is an organic diamine, which is added to a blend of maleated polyalkylene and poly(alkenyl-co-maleimide) to partially crosslink the polyalkylene to the poly(alkenyl-co-maleimide) through the unreacted maleate functional groups.
Organic diamines or diamine mixtures containing two aliphatically or cycloaliphatically bound primary amino groups are preferably used as grafting agents for the process. Such diamines include, for example, aliphatic or cycloaliphatic diamines corresponding to the following formula R3(NH2)2 wherein R3 represents a C2-C2o aliphatic hydrocarbon, a C4-C20 cycloaliphatic hydrocarbon group, a C6-C20 aromatic hydrocarbon group, or a C4-C20 N- heterocyclic ring. Exemplary diamines include ethylenediamine; 1,2- and 1,3- propylene diamine; 1 ,4-diaminobutane; 2,2-dimethyl-1,3-diaminopropane; 1,6- diaminohexane; 2,5-dimethyl-2,5-diaminohexane; 1 ,6-diamino-2,2,4-trimethyl- diaminohexane; 1 ,8-diaminooctane; 1,10-diaminodecane; 1,11-diaminoun- decane; 1 ,12-diaminododecane; 1-methyl-4-(aminoisopropyl)-cyclohexyl- amine; 3-aminomethyl-3,5,5-trimethyl-cyclohexylamine; 1 ,2-bis- (aminomethyl)-cyclobutane; 1 ,2-diamino-3,6-dimethylbenzene; 1 ,2- and 1 ,4- diaminocyclohexane; 1,2-, 1,4-, 1,5-, and 1 ,8-diaminodecalin; 1-methyl-4- aminoisopropyl-cyclohexylamine; 4,4'-diamino-dicyclohexyl; 4,4'-diamino- dicyclohexyl methane; 2,2'-(bis-4-aminocyclohexyl)-propane; 3,3'-dimethyl- 4,4'-diaminodicyclohexyl methane; 1 ,2-bis-(4-aminocyclohexyl)-ethane;
3,3l,5,5'-tetramethyl-bis-(4-aminocyclohexyl)-methane and -propane; 1 ,4-bis- (2-aminoethyl)-benzene; benzidine; 4,4'-thiodianiline; S.S'-dimethoxy- benzidine; 2,4-diaminotoluene, diaminoditolylsulfone; 2,6-diaminopyridine; 4- methoxy-6-methyl-m-phenylenediamine; diaminodiphenyl ether; 4,4'-bis(o- toluidine); o-phenylenediamine; o-phenylenediamine, methylenebis(o- chloroaniline); bis(3,4-diaminophenyl)sulfone; diaminodiphenylsulfone; 4- chloro-o-phenylenediamine; m-aminobenzylamine; m-phenylenediamine; 4,4'- C-ι-C6-dianiline; 4,4'-methylene-dianiline; aniline-formaldehyde resin; trimethylene glycol di-p-aminobenzoate; bis-(2-aminoethyl)-amine, bis-(3- aminopropyl-amine, bis-(4-aminobutyl)-amine; bis-(6-aminohexyl)-amine, and isomeric mixtures of dipropylene triamine and dibutylene triamine. Mixtures of these diamines may also be used.
Other suitable polyamines for use as grafting agents include bis- (aminoalkyl) amines, preferably those having a total of from 4 to 12 carbon atoms, such as bis-(2-aminoethyl) amine, bis-(3-aminopropyl) amine, bis-(4- aminobutyl) amine, and bis-(6-aminohexyl) amine, and isomeric mixtures of dipropylene triamine and dibutylene triamine. Hexamethyl diamine, tetrameth- ylene diamine, and especially 1,12-diaminododecane are preferably used. The grafted polymer composition preferably has added thereto one or more extenders such as oils and low molecular weight compounds or components. Suitable extender oils include naphthenic, aromatic and paraffinic petroleum oils and silicone oils. Examples of low molecular weight organic compounds or components useful as extenders are low molecular weight organic materials having a number average molecular weight (Mn) of less than 20,000, preferably less than 10,000, and most preferably less than 5,000. Although there is no particular limitation to the material that may be employed, the following is a list of exemplary appropriate materials: 1) softening agents, namely aromatic naphthenic and paraffinic softening agents for rubbers or resins;
2) plasticizers, namely plasticizers composed of esters including phthalic, mixed phthalic, aliphatic dibasic acid, glycol, fatty acid, phosphoric and stearic esters, epoxy plasticizers, other plasticizers for plastics, and phthalate, adipate, sebacate, phosphate, polyether, and polyester plasticizers for NBR;
3) tackifiers, namely coumarone resins, coumarone-indene resins, terpene phenol resins, petroleum hydrocarbons, and rosin derivative; 4) oligomers, namely crown ether, fluorine-containing oligomers, polybutenes, xylene resins, chlorinated rubber, polyethylene wax, petroleum resins, rosin ester rubber, polyalkylene glycol diacrylate, liquid rubber (polybutadiene, SBR, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone oligomers, and poly(α-olefins); 5) lubricants, namely hydrocarbon lubricants such as paraffin and wax, fatty acid lubricants such as higher fatty acid and hydroxy-fatty acid, fatty acid amide lubricants such as fatty acid amide and alkylene-bis- fatty acid amide, ester lubricants such as fatty acid-lower alcohol ester, fatty acid-polyhydric alcohol ester and fatty acid-polyglycol ester, alcoholic lubricants such as fatty alcohol, polyhydric alcohol, polyglycol and polyglycerol, metallic soaps, and mixed lubricants; and, 6) petroleum hydrocarbons, namely synthetic terpene resins, aromatic hydrocarbon resins, aliphatic hydrocarbon resins, aliphatic cyclic hydrocarbon resins, aliphatic or alicyclic petroleum resins, aliphatic or aromatic petroleum resins, polymers of unsaturated hydrocarbons, and hydrogenated hydrocarbon resins.
Other appropriate low molecular weight organic materials include latices, emulsions, liquid crystals, bituminous compositions, polymers, and phosphazenes. One or more of these materials may be used as extenders. A preferred extender is di(tridecyl)phthalate oil (DTDP) from the C.P. Hall Co., (Chicago, Illinois). Extender(s) are added to the polymer composition in the range of about 10 to about 90% (by wt.), preferably about 15 to about 75% (by wt.), and most preferably about 20 to about 60% (by wt.).
After the extended, polyalkylene grafted poly(alkenyl-co-maleimide) is formed, it can be further mixed with a hyperbranched polyester. The hyperbranched polyester is formed by reacting at least one carboxylic acid, at least one alcohol, and at least one anhydride, followed by the addition of at least one additional anhydride to form a polyester prepolymer. This prepolymer is cured via a crosslinking agent such as that described above to provide the hyperbranch characteristics. The resultant hyperbranched polyester is added to the maleated polypropylene grafted centipede polymer in amounts between about 1 to about 50% (by wt.), preferably between about 10 and 40% (by wt), most preferably between about 15 and 45% (by wt). The resulting gel has a high temperature compression set at 100°C of less that about 60%, and hysteresis values (tan δ) at 23°C greater than about 0.5, more preferably greater than about 0.8.
Suitable hyperbranched polyesters for use herein are compact molecules with many branches which carry a high number of terminal functional groups on each molecule. These highly branched, three dimensional molecules have a globular shape and are preferably near- gelation polymers. A near-gelation polymer can be formed when the degree of interchain reaction, i.e., crosslinking, between the elastomeric molecules nears or approaches the gel point of the polymeric composition. At the gel point, a gel or insoluble polymer fraction forming in a polymeric composition first becomes observable. Theoretically, a gel corresponds to an infinite network in which polymer molecules have been crosslinked to one another to form a macroscopic molecule. The gel may then be considered one molecule. A gel generally is insoluble in all solvents at elevated temperatures under conditions where polymer degradation does not occur; the non-gel portion of the polymer, often referred to as sol, remains soluble in solvents. For present purposes, near- gelation polymers also can be referred to as near-gel polymers. When forming a near-gelation polymer, the gel point of the polymeric composition employed to create the near-gelation polymer preferably is determined. Several techniques are known in the art for estimating the gel point of polymeric compositions. Gel point can be determined experimentally by solvent extraction and other techniques described in P.J. Flory, Principles of Polymer Chemistry (1953), or approximated by using theoretical calculations as described in, for example, G. Odian, Principles of Polymerization, 3d ed., pp. 108-123, (1991). The polymeric composition employed to create the near-gelation polymer can be referred to as the prepolymer system.
Although gel point can be discussed in terms of a variety of parameters, determining the ratio of the weight of curative to the weight of prepolymer necessary to reach the gel point can be convenient. Thus, gel point can be represented by the weight of curative necessary to reach gelation, Wcg, over the weight of prepolymer, Wp. Likewise, the point of complete cure can be represented by the weight of curative necessary to reach complete cure, Wcc, divided by Wp. In general, therefore, the extent of any curing reaction can be represented by the weight of curative added, Wc, divided by Wp. For present purposes, extent of reaction, r, can be repre- sented by Wc over Wp. Therefore, the extent of gelation, rg, is rg = Wcg Wp, and the extent of complete cure rcc = Wcc/Wp.
Once the gel point of the prepolymer is determined, an appropriate amount of curative can be added and reacted with the prepolymer to achieve a near-gelation polymer. When selecting an appropriate amount of curative, the gel point preferably is approached but not exceeded, although the definition of near-gelation polymer broadly includes those reaction products of curative and prepolymer that exceed the gel point without actually reaching complete cure. Thus, the weight ratio employed to create a near-gelation polymer preferably is based on E = | (r - rg)/ rg I where E is the relative distance to the gel point while r and rg are defined as above. Since E is an absolute value, E is greater than or equal to 0 and less than or equal to about 0.5, more preferably less than about 0.2, still more preferably less than about 0.1, and even more preferably no more than about 0.05. The foregoing formula involves the absolute value of a number and, therefore, the extent of the reaction (r) is a relative distance (E) both beyond and before the gel point. For example, where the gel point of a particular polymeric composition is about 0.5 parts of curative per part of prepolymer, a near-gel polymer can be obtained by reacting the polymeric composition with about 0.3 or about 0.7 parts of curative per part of the prepolymer (thus, E = |(0.3 - 0.5) / (0.5)| = 0.4 or E = |(0.7 - 0.5) / (0.5)| = 0.4).
The prepolymer used in preparing the near-gelation polymer includes at least one functional group, preferably at least 2 functional groups, more preferably between 2 and about 10 functional groups, and even more preferably between 2 and about 5 functional groups. For present purposes, the prepolymer can be referred to as the functionalized prepolymer. The functional groups can be located at the terminal end of the prepolymer, including the initiated end of the polymer, or along the backbone of the prepolymer. Therefore, crosslinking can occur anywhere on the prepolymer chain.
The elastomeric composition is preferably manufactured by mixing and dynamically heat-treating the components described above, namely, by melt- mixing. As for the mixing equipment, any conventional, generally known equipment such as an open-type mixing roll, open-type Banbury mixer, closed-type Banbury mixer, closed-type Branbender mixer, extruding machine, kneader, or continuous mixer is acceptable. The closed-type Brabender mixer is preferably, and mixing in an inactive gas environment, such as nitrogen or argon, is preferable. In summary, the molded polymers produced from the blend of the present centipede polymer and polyester retain elastomeric characteristics and are useful in high damping applications. The elastomeric composition contains from about 30 to about 60% (by wt.) centipede polymer, preferably from about 35 to about 55% (by wt.), and most preferably from about 40 to about 55% (by wt.). The composition preferably contains between about 5 and 40% (by wt.) hyperbranched polyester, more preferably between about 10 and 40% (by wt.), most preferably between about 15 and 40% (by wt.). The composition also contains between about 5 and 40% (by wt.) extender, more preferably between about 10 and 40% (by wt.), and most preferably between about 15 and 40% (by wt.).
Frequently, adding other known additives to the compositions can be desirable. Stabilizers, antioxidants, conventional fillers, reinforcing agents, reinforcing resins, pigments, fragrances, and the like are examples of some such additives. Specific examples of useful antioxidants and stabilizers include 2-(2'-hydroxy-5'-methylphenyl) benzotriazole, nickel di-butyl-dithio- carbamate, zinc di-butyl-di-thiocarbamate, tris(nonylphenyl) phosphite, 2,6-di- t-butyl-4-methylphenol, and the like. Exemplary conventional fillers and pigments include silica, carbon black, Ti02, Fe2O3, and the like. These materials are incorporated in suitable amounts depending upon the contemplated use of the product, preferably in the range of 1-350 parts of additives or compounding ingredients per 100 parts of the polymer composition. A reinforcing material may be defined as a material added to a resinous matrix to improve the strength of the polymer. Most reinforcing materials are inorganic or organic products of high molecular weight. Various examples include glass fibers, asbestos, boron fibers, carbon and graphite fibers, whiskers, quartz and silica fibers, ceramic fibers, metal fibers, natural organic fibers, and synthetic organic fibers. Other elastomers and resins are also useful to enhance specific properties like damping properties, adhesion, and processability. Examples of other elastomers and resins include adhesive-like products including Reostomer™ (Riken-Vinyl, Inc.; Tokyo, Japan), hydrogenated polystyrene-(medium or high 3,4) polyisoprene- polystyrene block copolymers such as Hybler™ (Kuraray, Inc.; Osaka, Japan), polynorbornenes such as Norsorex™ (Nippon Zeon, Inc.; Tokyo, Japan), and the like. The foregoing materials are equally applicable to the instant centipede polymer compositions.
Damping is the absorption of mechanical energy by a material in contact with the source of that energy. Transmission of mechanical energy from, for example, a motor, engine, or power source to its surroundings desirably is damped or mitigated. Elastomeric materials often are used for this purpose. Such materials preferably are highly effective in converting this mechanical energy into heat rather than transmitting it to the surroundings. Even more preferably, this damping or conversion is effective over a wide range of temperatures and frequencies commonly found near motors, automobiles, trucks, trains, planes, and the like.
The compositions of the present invention are favorably used in the manufacturing of any product in which some of the following properties are advantageous: a degree of softness, heat resistance, decent mechanical properties, elasticity, and/or high damping. The compositions of the present invention can be used in many industry applications, in particular, in the fabrication of automotive parts, tire tread rubbers, household electrical appliances, industrial machinery, precision instruments, transport machinery, constructions, engineering, and medical instruments.
The composition of the present invention can be used in the fabrication of damping materials and vibration restraining materials. These uses involve connecting materials such as sealing materials, packing, gaskets, and grommets, supporting materials, such as mounts, holders, and insulators, and cushion materials, such as stoppers, cushions, and bumpers. These materials also can be used in equipment producing vibration or noise and household electrical appliances, such as in air-conditioners, laundry machines, refrigerators, electric fans, vacuums, dryers, printers, and ventilator fans. These materials also are suitable for impact absorbing materials in audio equipment and electronic or electrical equipment, sporting goods, and shoes. The present invention will also be useful in any application where a superior high temperature compression set is desirable. With a compression set of less than 60% at 100°C, this composition can be used in a variety of high temperature applications. One example of this would be as coatings, especially for windows and car windshields which retain heat and cause polymers with lower service temperatures to melt.
The present invention will be described in more detail with reference to the following non-limiting examples. EXAMPLES
Example 1 : Preparation of Hyperbranched Polyester A hyperbranched polyester was synthesized in a 1 liter glass kettle fitted with a Dean-Stark trap and magnetic stirring. 84.4 g ethylhexanoic acid, 41.1 g pentaerythritol, and 44.2 g phthalic anhydride (Aldrich; Milwaukee, Wisconsin) were mixed in the flask and heated. All materials melted and mixed at 220°C, and water, formed as a byproduct, was driven off as the temperature was raised to 260°C. When water evolution slowed, the mixture was heated to 280°C under vacuum for 4 hours, followed by addition of 1 ,2,4- benzene tricarboxylic anhydride (Aldrich). The reaction mixture was reheated to 280°C for 2 hours under vacuum.
The product was a soft, elastomeric polymer. An Rheometry Dynamic Analysis temperature sweep showed a tan δ peak of 2.6 at 35°C and a tan δ of 1.5-2.6 from 25° to 145°C.
Example 2: Preparation of Hyperbranched Polyester 54.5 g pentaerythritol, 57.7 g ethylhexanoic acid, 59.2 g phthalic anhydride, 12 g UMEX™ 110TS maleated iso-polypropylene with an acidity of 7 mg KOH/g (SANYO Chemical; Osaka, Japan), and 1 g 1 ,2,4-benzene tricarboxylic anhydride were added to the glass kettle described in Example 1. After 1 hour at 260°C, the evolution of water had slowed. Another 57.7 g ethylhexanoic acid was added and reaction continued 3 hours at 260°C. Reaction was continued for 8 additional hours at 260°C under vacuum. A soft elastomeric polymer was formed.
Example 3: Preparation of the Polypropylene-Grafted Centipede Polymer To a 6 L kneader-extruder (Jaygo, Inc.) equipped with sigma blades was added 1.252 kg lsoban-10™ poly(maleic anhydride-a#-isobutylene) (Kuraray Co.), and 0.989 kg octylamine (99%, BASF) at 54°C. Mixing was started with a blade speed of 25 rpm and screw speed of 40 rpm for 5 minutes, then the temperature of the mixer was adjusted to rise to 190°C at a rate of about 3°C/minute. Mixing was further continued for 2 more hours isothermally at 190°C. Then, 0.562 kg PO1015™ maleated polypropylene, Exxon Chemical; Houston, Texas) was added to the mixer. Mixing was continued for another 30 minutes, followed by addition of 23 g dodecane diamine (98%, Aldrich). After 15 minutes, 1.397 kg DTDP was added and the temperature was adjusted to 160°C. After another 2 hours, the final product was then extruded through a A inch (0.63 cm) die. The final product contained 33% DTDP and was a thermoreversible elastomer.
Examples 4-6: Preparation of High Damping Gels For Example 4, a charge of 35 g of the product of Example 3 was added to a Brabender mixer (~55 g capacity) equipped with a roller blade and
N2 purging. The mixer was initially set to 160°C and 60 rpm. After 3 minutes,
15 g of the product from Example 1 was added to the mixer. The material was further mixed at those conditions for 17 minutes; then, agitation was ceased and the mixture removed form the mixer.
For Example 5, the procedure from the preceding paragraph was repeated. After 3 minutes, a charge of 10.5 g of the product from Example 2 and a charge of 4.5 g DTDP were added the mixer. The material was further mixed at those conditions for 27 minutes, then agitation was ceased and the mixture was removed from the mixer.
For Example 6, the procedure of Example 4 was repeated except for a minor change in the charges of the materials and the total mixing time. In this example, 35 g of the product of Example 3 and 15 g of the product of
Example 2 were added to the mixer. The total mixing time was 45 minutes.
Example 7: Physical Testing
The products of examples 3-6 were molded into sheets and cylinder buttons at ~160°C. Ring samples were cut from these sheets for tensile measurements. The details of the physical properties of the final materials are listed in Table 1. Table 1 : Physical Properties of Polymer Compositions
Figure imgf000021_0001
As can be seen in the table, the products were soft and thermo- reversible gels. The materials from Examples 4-6 exhibited excellent damping properties with good balanced tensile strength and thermostabilities. Finally, all materials shown in the table were thermally recyclable at 160°C and have a service temperature up to 100°C.

Claims

We claim:
1. A method for forming an elastomeric composition comprising: A. providing a blend of i. a copolymer that includes maleimide units and units derived from one or more of: a. a vinyl aromatic hydrocarbon, b. R1R2ethylene, in which R1 and R2 independently are selected from hydrogen or substituted or unsubstituted Ci to C20 alkyl groups having from 1 to 40 carbon atoms, and c. an alkyl vinyl ether, wherein the alkyl group is linear or branched, substituted or unsubstituted, having from 1 to about 40 carbon atoms, and ϋ. a maleated polyalkylene; and iii. a crosslinking agent; B. allowing said crosslinking agent to react with the poly(alkenyl- co-maleimide) and maleated polyalkylene to form a maleated polyalkylene-grafted poly(alkenyl-co-maleimide); C. combining the grafted copolymer with a hyperbranched polyester to provide the elastomeric composition; and D. optionally, adding an extender to the elastomeric composition to form an extended elastomeric composition having a tan δ of at least 0.5.
2. A polymer gel composition comprising: a. a copolymer including maleimide and alkenyl units, b. a crosslinking agent, c. a maleated polyalkylene, d. a hyperbranched polyester, and e. optionally, an extender.
3. The method of claim 1 wherein step C includes mixing 10 to 90% (by wt.) of said elastomeric composition with a total amount of 90 to 10% (by wt.) of said extender.
4. The method of any of claims 1 and 3 or the composition of claim 2 wherein said elastomeric composition comprises from 30 to 60 weight percent of said copolymer, 5 to 40 weight percent of said hyperbranched polyester, and 5 to 40 weight percent of said extender.
5. The method of any of claims 1 and 3 to 4 wherein said vinyl aromatic hydrocarbons are selected from one or more of styrene, α-methyl- styrene, p-methylstyrene, 4-phenylstyrene, m-methylstyrene, o-methyl- styrene, p-tert-butylstyrene, and dimethylstyrene.
6. The method of any of claims 1 and 3 to 5 wherein R1 and R2 of said R1R2ethylene and said alkyl groups of said alkyl vinyl ether independently are methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, isopentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, cyclopropyl, 2,2- dimethylcyclopropyl, cyclopentyl, cyclohexyl, methoxy methyl, methoxyethyl, methoxypropyl, methoxybutyl, methoxypentyl, methoxyhexyl, methoxyoctyl, methoxynonyl, ethoxydecyl, ethoxymethyl, ethoxyethyl, ethoxypropyl, ethoxy- butyl, ethoxypentyl, ethoxyhexyl, ethoxyheptyl, ethoxyoctyl, ethoxynonyl, ethoxydecyl, propoxymethyl, propoxyethyl, propoxypropyl, propoxybutyl, propoxypentyl, propoxyheptyl, propoxyoctyl, propoxynonyl, propoxydecyl, butoxymethyl, butoxyethyl, butoxypropyl, butoxybutyl, butoxypentyl, butoxy- hexyl, butoxyheptyl, butoxyoctyl, butoxynonyl, butoxydecyl, pentyloxymethyl, pentyloxyethyl, pentyloxypropyl, pentyloxybutyl, pentyloxypentyl, pentyoxy- hexyl, pentyloxyoctyl, pentyloxynonyl, pentyloxydecyl, hexyloxymethyl, hexyl- oxyethyl, hexyloxypropyl, hexyloxybutyl, hexyloxypentyl, hexyloxyhexyl, hexyl- oxyheptyl, hexyloxyoctyl, hexyloxy nonyl, hexyloxydecyl, heptyloxymethyl, heptyloxyethyl, heptyloxypropyl, heptyloxybutyl, hexyloxypentyl, heptyloxy- hexyl, heptyloxyheptyl, heptyloxyoctyl, heptyloxynonyl, heptyloxydecyl, octyl- oxymethyl, oxtyloxyethyl, octyloxypropyl, octyloxybutyl, octyloxypentyl, octyl- oxyhexyl, octyloxyheptyl, octyloxyoctyl, oxtyloxynonyl, decyloxymethyl, decyl- oxyethyl, decyloxypropyl, decyloxybutyl, decyloxypentyl, decyloxyhexyl, decyl- oxyheptyl, 1-methylethyl, 1-methylpropyl, 1-methylbutyl, 1-methylpentyl, 1- methylhexyl, 1 -methyl heptyl, 1-methyloctyl, 1 -methyl nonyl, 1-methyldecyl, 2- methylpropyl, 2-methylbutyl, 2-methylpentyl, 2-methylhexyl, 2-methy I heptyl, 2- methyloctyl, 2,3,3-trimethylbutyl, 3-methylpentyl, 2,3-dimethylpentyl, 2,4- dimethylpentyl, 2,3,3,4-tetramethylpentyl, 3-methylhexyl, or 2,5-dimethylhexyl.
7. The method of any of claims 1 and 3 to 6 or the composition of any of claims 2 and 4, wherein the alkylene-contributed groups of said maleated polyalkylene are at least one of ethylene and propylene.
8. The method of any of claims 1 and 3 to 7 or the composition of any of claims 2, 4, and 7 wherein the maleimide units of said copolymer are formed by reacting units derived from a maleic anhydride with a primary amine.
9. The method of any of claims 1 and 3 to 8 or the composition of any of claims 2, 4, and 7 to 8 wherein said hyperbranched polyester is a near gelation polymer formed by reacting a polyester prepolymer and a cross- linking agent, said hyperbranched polymer having a physical state relative to the gelation point of a crosslinked polymer defined by 0 < (r-rg)/rg< 0.5 where r is the weight ratio of said crosslinking agent to said polyester prepolymer and rg is the weight ratio of said crosslinking agent to said polyester prepolymer at the gelation point of the crosslinked polymer.
10. The method of any of claims 1 and 3 to 9 wherein steps A and B are carried out in the absence of solvent.
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